Chennai Petroleum Corporation Limited

(A group company of Indian Oil)

REFIERY – III

PLANT-207

ONCE-THROUGH HYDROCRACKER UNIT

(OHCU)

OPERATING MANUAL

Date Prepared by Checked by Reviewed by Approved by

March-13

C.Ravichandran Anil Sahni P.Kannan S.T.Kalaimani

 OPERATING MANUAL REV. No 03
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1. GEERAL IFORMATIO

1.1 Introduction
1.2 History
1.3 Process technology and licensor

2. PROCESS DESCRIPTIO

2.1 Feed & Reaction section

2.2 Recycle gas loop
2.3 Fractionation section
2.4 Light ends recovery section
2.5 Make up gas compression section

3. CHEMICAL REACTIOS

3.1 Hydrocarbon group types

3.2 Reactions occurring in OHCU reactors
3.3 Catalyst chemistry

4. CATALYST HADLIG

4.1 Catalyst Type

4.2 Catalyst Loading and unloading
4.3 Sulphiding of fresh catalysts.
4.4 Catalyst safety hazards and first aid

5. PROCESS VARIABLES

5.1 Feed effects

5.2 Hydrogen effects
5.3 Catalyst effects
5.4 Reaction section operation effects
5.5 Fractionation and LER operation effects
5.6 Effects of Reactor and

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Distillation sections interactions

6. START UP, SHUT DOW AD

AD EMERGECY PROCEDURES

6.1 Initial start-up

6.2 Shutdown procedure.
6.3 Emergency procedures

7. SPECIAL EQUIPMET

7.1 Reactors
7.2 RGC
7.3 Feed filter
7.4 Make-up gas compressor

8. SAFETY I HYDROCRACKER

9. CORROSSIO I HYDROCRACKER

10. ISPECTIO AD MAITEACE

11. TROUBLE SHOOTIG OPERATIO

12. IMPROVEMETS I HYDROCRACKER OPERATIO

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TABLE INDEX:

TABLE DESCRIPTIO PAGE

3.1 Design Feed Specification

3.2 Make-Up Hydrogen Quality
3.3 Injection Water Quality
3.4 Product Yields: Start-of-Run and End-of-Run
3.5 Product Quality - SOR
3.6 Product Quality - EOR
3.7 Product Properties
3.8 Process Condition For Reactor
3.9 Battery Limit Condition
5.1 Feed Source
5.2 Back Wash Oil Consumption
5.3 Back Wash Oil Filter Timer
5.4 Feed Furnace 207F-1 Interlocks
5.5 Reactor Effluent Cooling
7.1 Catalyst Shape and Quantity
7.2 Catalyst Density
7.3 Catalyst Specification and loading: 207R-1
7.4 Catalyst Specification and loading: 207R-2
7.5 Catalyst Safety Hazards and First Aid
8.1 Operating Variables Vs Catalyst Life
8.2 Effects of Increasing Process Variables
on Product Characteristics
9.1 Offsite Facilities
9.2 The underground utility services
11.1 Reactor Pressurization Limitations (MPT)
11.2 Expected CAT Vs Maximum Heating Rate
11.3 Chopper and Control Valve stroke checking
11.4 Emergency procedure – tabular format

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12.1 Gas Requirements For Regeneration

13.1 RGC Startup Procedure
13.2 RGC over Speed Cam Lift, Governor Lift

TABLE DESCRIPTIO PAGE

13.3 RGC Speed Vs Steam Consumption

13.4 RGC Steam Correction Aspects
13.5 RGC Set Values
13.6 CW Passivation Chemical Levels
13.7 Sulphiding Check List
13.8 DMDS Volume
14.1 Backwash Oil Consumption
14.2 Filter Timer Setup
14.3 207K-2 MUGC Cause & Matrix Effect
14.4 Turbine Pump Casing Design And Turbine Data
15.1 Chemical Consumption
15.2 Lube Oil Specification
18.1 Exchanger Data
18.2 Air Cooler Data
18.3 Pumps Data
18.4 Operating Condition 207K-2 (H2 Case and N2 Case)
18.5 Columns and Vessels Data
18.6 207F-1 Feed Furnace data
18.7 207F-2 Fractionator Furnace data
19.1 207G-3A/B Feed Pump Interlocks
19.2 207K-2A/B/C MUGC Interlocks
19.3 207K-1 RGC Inter locks
19.4 207G-5A/B Amine Pump Interlocks
19.5 207F-1 Feed Furnace Trip Logic
19.6 207F-2 Fractionator Furnace Interlocks
19.7 Auto Depressurizing System for 207R-1
19.8 Auto Depressurizing System for 207R-2
19.9 Feed Filter 207T-1 Logic
19.10 General Safety Logic
19.11 Safety MOVs.Trip Logic

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19.12 Logic for Pumps with Auto Cut-in (or) Cut-out

20.1 PSV details
22.1 ISBL / OSBL tie-ups

TABLE DESCRIPTIO PAGE

22.1 ISBL / OSBL tie-ups

24.1 Design Utility Condition for OHCU
24.2 Raw Water Quality
24.3 DM Water Quality
24.4 Cooling Water Quality
24.5 Boiler Feed Water Quality
26.1 Actual Process Values - OHCU
26.2 OHCU Design Values (SOR and EOR)
26.3 Quality Control Logic Charts
29.1 Design Reactor Loading: Volume Fractions
29.2 Feed-to-Products Volume Expansion Factors
29.3 Engineering Unit Conversions

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OTE:

In this manual, all operating procedures and technical data are based on
CLG documents and equipment vendors’ documents. Operating
procedures and process parameter values may be reviwed based on the
experience.

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CHAPTER – 1

GEERAL IFORMATIO

1.1 ITRODUCTIO

Crude oil is subjected to refining process to convert the oils to high value products such as
transportation fuels, chemicals, lubricants and so forth. The simplified flow diagram of a
refinery operation is shown in Fig 1.1.The crude oil is first fractionated by distillation and
different fractions are subsequently upgraded by a variety of processes. One such process is
“HYDROCRACKIG" which uses preferably Gas Oils as its feed stock with boiling range
3000 C to 5800 C from Vacuum distillation & Visbreaker. The place of the Hydrocracker in our
refinery is shown in Fig1.1

Hydrocracking is a catalytic refining process that converts heavy, high boiling feedstock to
smaller, lower boiling products through carbon bond breaking, accompanied by simultaneous or
sequential hydrogenation. Hydrocracking is a process of considerable flexibility because it
allows the conversion of a wide range of feedstocks to a variety of products of superior quality.

Other catalytic processes besides Hydrocracking are Hydrotreating (Sulphur, Nitrogen &
Oxygen), Reforming, and Alkylation & Isomerization.

1.2 HISTORY

Hydrocracking is one of the oldest hydrocarbon conversion process. First commercial

Hydrocracking process was practiced at Germany in 1927.

Newly developed catalytic-cracking process (Single & Two Stage) proved more economical for
converting heavy fraction into gasoline in 1960's and became commercial reality.

Several factors like development of Zeolite catalyst over amorphous catalyst, Nickel or nickel
tungsten on silica alumina, Demand & Requirement of automobile fuel of superior quality (High
octane in Gasoline, Low sulphur in Diesel, High freeze point in Jet fuel etc), etc. made rapid
growth and development in Hydrocracking process in 1970’s.

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Due to continuous development, different process flow configurations have arised based on
the feed quality, desired product pattern, conversion level and capacity viz single-stage (or) two-
stage and once-through (or) recycle modes.

1.3 EED FOR HYDROCRACKIG I CPCL

Stringent market demand on Quality & Cost in the present MDPM scenario and the high
demand on middle distillates call upon the Indian Refineries to opt conversion of Heavy stocks
into light and middle distillates. In view of this, Hydrocracker has made made entry into Indian
refineries.

1.4 PROCESS TECHOLOGY and LICESOR

Many types of patented Hydrocracking process have developed and offered for License by major
Oil companies. CPCL opted the license of “ISOCRACKING" developed by Chevron Lummus
Global LLC “CLG" USA. It is so called "ISOCRACKING" because of predominant yield of the
"iso" component.

Hence CPCL has chosen “Once-through Hydrocracker” for partial conversion of the feed into
products which is a extremely versatile catalytic-process, processing heavy feed stock in the
presence of Hydrogen & Catalyst, yielding lighter products & middle distillates and prepare feed
to FCCU.

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CHAPTER – 2

PLOT PLA

PLOT PLA IS AVAILABLE I THE ECLOSED FOLDER

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CHAPTER – 3

DESIG CODITIOS
DESIG FEED SPECIFICATIOS
Table 3.1

Feed specifications SR VGO VB VGO

CDU/VDU
Feedstock Sources VBU
BH/PG Crude

Distillation (º C), ASTM- D-1160

Start 320 300
10% 380 324
30% 415 378
50% 440-460 402
70% 490 435
90% 540 473
End Point, Max. 585 500
API Gravity 20.8-34.8 20.7
specific- Gravity 0.825-0.929 0.93
Asphaltenes, Wt %, Max. 0.010 0.020
Iron, PPM 0.0 5
Nitrogen, ppm wt. 1000 2000
Sulphur, Wt % 2.8 5.0
Kinematic- Viscosity at 50ºC, cst 46.3
Kinematic- Viscosity at 100ºC, cst 9.6
Kinematic- Viscosity at 200ºC, cst 0.6-1.65
Kinematic- Viscosity at 250ºC, cst 0.4-1.1
CCR, Wt % 0.6 1.0
Nickel + Vanadium, PPM 1.0 9

MAKE-UP HYDROGE QUALITY

Table 3.2
Hydrogen Purity, Mole % 99.5 (Min.)
CO + CO2, Mole 20 PPM (Max.)
Nitrogen, Mole 50 PPM (Max.)
Water, Mole 50 PPM (Max.)
Chlorine + Chlorides, Mole 1 PPM (Max.)
Methane, Mole % Balance

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IJECTIO WATER QUALITY

Table 3.3

H2S, PPM 1000 (Max.)

NH3, PPM 1000 (Max.)
Oxygen Content, ppb (Wt) 15 (Max.)
Chloride Content, PPM (Wt) 50 (Max.)
Acidity, pH 7.5 (Min.)
Nonvolatile Residue, PPM (Wt) 2 (Max.)

ESTIMATED PRODUCT YIELDS AD ISPECTIOS – SOR and EOR

Feed: 90% SR VGO, 10% VB VGO

Total Feed Rate = 1.85 MMTPA (112% of Design) 249.2 m3/hr
Total Feed Rate = 37,400 BPSD
Chemical Hydrogen Consumption = 256 Nm3/m3 of feed for SOR,
262 Nm3/m3 of feed for EOR
Chemical Hydrogen Consumption = 1,520 SCFB, for SOR,
1,550 SCFB, for EOR

Product Yields: Start-of-Run and End-of- Run

Table3.4
Start-of-Run End-of- Run
Products
Wt % LV % Wt % LV %
H2S 3.21 3.21
NH3 0.13 0.13
C1 0.25 0.45
C2 0.39 0.66
C3 0.67 1.23 1.00 1.83
iC4 0.73 1.20 1.21 2.0
nC4 0.73 1.16 1.10 1.75
Light Naphtha 3.40 4.7 3.60 4.97
Heavy Naphtha 5.10 6.21 5.10 6.20
Kerosene 23.69 27.07 23.60 26.89
Diesel 21.75 23.99 20.02 22.03
Bottoms 42.43 46.33 42.42 46.24
C5 + 96.37 108.3 94.75 106.32
Total 102.48 111.89 102.51 111.90
Note: Yields are expressed as percentages of fresh feed.

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PRODUCT QUALITY - SOR:

Table 3.5

Cut Light Heavy Kerosene / Diesel UCO

aphtha aphtha ATF
Cut Points, ºC 95 95–130 130-260 260-370 370+
API Gravity 79.0 54.0 42.5 36.5 34.8
Density @15°C 670-675 763-768 812-817 820-870 850-855
ASTM, °C D 86 D 86 D 86 D 86 D 1160
ST 23 102 142 229 337
10 36 107 161 268 394
50 49 114 193 302 473
90 79 128 238 348 548
EP 91 147 266 376 562
95 370
Sulphur, PPM <5 <5 10 (max.) 10 (max.) <50 (max.)
Mercaptan Sulphur, PPM 10 (max.) 10 (max.)
Nitrogen, PPM <1 <1
Paraffins, LV %
66 30
(Estimated)
Naphthenes, LV %
32 62
(Estimated)
Aromatics, LV %
2 8 22
(Estimated)
Flash Point, °C 38 (Min.) 35 (Min)
Smoke Point, mm 21
Cetane Index (D 613) 55 (Min)
Freeze Point, °C (-)51
Pour Point, °C 3 (Max)
Viscosity @ 40°C, cst
Viscosity @ 100ºC, cst 2 to 5 4.2
Viscosity @ -20ºC, cst 8
Water, PPM 500 (Max)
Metals, PPM < 0.1
Octane Number, Estimated
RONC/MONC 75/76 64/62
RVP, kg/cm2 0.8 (Max.) 0.8 (Max.)

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PRODUCT QUALITY – EOR

Table 3.6

Cut Light Heavy Kerosene / Diesel UCO

aphtha aphtha ATF
Cut Points, ºC 95 95–130 260-370 370+
API Gravity 79.0 54.0 130-260 36.5 34.8
Density @15°C 670-675 763-768 42.5 820-870 850-855
812-817
ASTM, °C D 86 D 86 D 86 D 86 D 1160
ST 23 102 142 229 337
10 36 107 161 268 394
50 49 114 193 302 473
90 79 128 238 348 548
EP 91 147 266 376 562
Sulphur, PPM <5 <5
Mercaptan Sulphur, PPM 10 (max.) 10 (max.) 10 (max.) 10 (max.) <50 (max.)
Nitrogen, PPM <1 <1 <1 (max.)
Paraffins, LV % 66 30
(Estimated)
Naphthenes, LV % 32 62
(Estimated)
Aromatic-s, LV % 2 8 22
(Estimated)
Flash Point, °C 38 (min.) 35 (min)
Smoke Point, mm 21
Cetane Index (D 613) 55 (min)
Freeze Point, °C (-)51
Pour Point, °C 3 (max)
Viscosity @ 40°C, cst 2 to 5
Viscosity @ 100ºC, cst 4.2
Viscosity @ -20ºC, cst 8
Water, PPM 500 (max)
Metals, PPM <0.1
Octane Number,
Estimated RONC/MONC 75/76 64/62
2
RVP, kg/cm 0.8 (max.) 0.8 (max.)
Note: Yields are expressed as percentages of fresh feed.

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PRODUCT PROPERTIES

Table 3.7

LPG
H2S, Mole. PPM Nil
Copper Strip Corrosion (1 hour @ 38°C ) No. 1 (max.)
Mercaptan Sulphur, wt ppm 5 (max.)
nC5 / iC5, Mole % 1 (max.)
Free Water Nil
Vapor Pressure @ 65°C, KSC (g) 16.8 (min.)
Vaporization @ 2°C & Atm. Pressure, % 95 (min.)
Ethane and Lighter, Wt % 2 (max.)
Unsaturated HC 1 Wt % (max.)

CLPS OFF-GAS
H2S, Mole. PPM 20
Ammonia, mole ppm 5.0
H2, Mole % 70.5 – 79.2
C1 Mole % 14.4 – 20.3
C2 Mole % 3.2 – 4.9
C3 Mole % 1.4 – 2.0
IC4 Mole % 0.5 – 0.8
NC4 Mole % 0.4 – 0.6
C5 + Mole % 0.1 – 0.4
H2O Mole % 0.5 %
Chloride Content 1 ( max)

FUELGAS (LER OFF-GAS)

H2S, mole ppm 27 –30
Ammonia, mole ppm -
H2O, Mole % 0.8
C1 Mole % 32.2 – 34.8
C2 Mole % 27.6 – 32.6
C3 Mole % 9.5 – 10.7
IC4 Mole % 0.1
NC4 Mole % -
C5 + Mole % 0.9 – 1.0
H2 Mole % 19.7 – 29.0

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LIGHT APHTHA
ASTM Distillation ( D 86) 0C
Start 23
5% 29
10% 36
30% 42
50% 49
70% 66
90% 79
95% 84
End Point, Max. 91
0 3
Density @ 15 C, kg/m 670 - 375
0
TBP Cut Point, C 95
PONA 66/0/32/2
Sulphur Content, ppm <5
Mercaptan Sulphur, ppm 10 (max)
Nitrogen Content, ppm <1
RONC/MONC 75/76
Metals Content 0
RVP, KSC (a) 0.8 max

HEAVY APHTHA

Start 102
5% 106
10% 107
30% 111
50% 114
70% 119
90% 128
95% 133
End Point, Max. 147
Density @ 150C, kg/m3 763-768
TBP Cut Point, 0C 95-130
PONA 30/0/62/8
Sulphur Content, ppm <5
Mercaptan Sulphur, ppm 10 (max)
Nitrogen Content, ppm <1
RONC/MONC 64/62
Metals Content 0
RVP, KSC (a) 0.8 max

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PRODUCT AVIATIO SUPERIOR

TURBIE FUEL KEROSEE
TEST
Density @ 150C, kg/m3 775-830 812-817
TBP Cut Point, 0C 130-260 130-260
Start 142 142
5% 154 154
10% 161 161
30% 176 176
50% 193 193
70% 212 212
90% 238 238
95% 249 249
End Point, Max. 266 266
Flash Point, 0C, Abel 38 (min) 35 (min)
Sulphur Content, ppm 10 (max) 10 (max)
Cu strip Corrosion (2 Hr @ 1000C) No.1 No.1
Freezing Point, 0C -51
Silver strip Corrosion -
Aromatic- Content, Volume % 22
Naphthalene Content, Volume % 3
Mercaptan Sulphur, ppm 3
Water Tolerance, MI 1
Viscosity @ -200C, cst 8
Smoke point, mm 21 21 (min)
Colour Say bolt 10 (min)

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HIGH SPEED DIESEL

Density @ 150C, kg/m3 820-870

TBP Cut Point, 0C -
Start 229
5% 257
10% 268
30% 287
50% 302
70% 320
90% 348
95% 360
End Point, Max. 376
Cetane Number (ASTM D 613) 55 (min) EOR
Flash Point, 0C, Abel 35 ( min)
Sulphur Content, ppm <10 ( max)
Pour Point, 0C 3 (max)
Kinematics- Viscosity @ 400C 2-5
Water Content, vppm 500 (max)

UCOVERTED OIL

Density @ 150C, kg/m3 850-855

TBP Cut Point, 0C -
Start 337
5% 378
10% 394
30% 437
50% 473
70% 511
90% 548
95% 557
End Point, Max. 562
Sulphur Content, wppm <50 (max)
Nitrogen Content,wppm <1
Kinematic- Viscosity @ 400C 4.2
CCR Content, Wt % <0.1

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Metals Content, wppm <0.1

PROCESS CODITIO FOR REACTOR

Table 3.8

1.85 (249.2 m3/hr)

Fresh Fed Rate, MMTPA(112% design) 37,400 BPSD

LHSV, 1/hr 0.8

Gross Conversion, Vol. % 54

5 years
Total Catalyst Life,
(With one Regeneration)
Reactor Pressure, KSC (g)
207R-1 207R-2
SOR/EOR
Inlet 172.5/176.0 167.4/167.4

Outlet 169.0/169.0 163.9 / 163.9

H2 Partial Pressure, KSC (a) 145 135

Reactor Temperature, 0C
207R-1 207R-2
SOR/EOR

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Inlet 378/396 378/396

Outlet 411/429 411 / 429

Maximum 440 440

Minimum 310 310

Gas to Oil Ratio at Reactor Inlet,
845 845
Nm3/m3
Number of Reactors 1 1

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BATTERY LIMIT CODITIO

Table 3.9 ICOMIG STREAM

Pressure
Stream Phase Source Temp. 0 C
Kg/cm2
SR VGO
Hot L Crude Unit 12 170
Cold L Storage 12 80
VB VGO L VBU 12 170
Make Up H2 V H2 Unit 20 40
Wash Water L DM Water 8 ambient
Lean Amine L Amine, Regeneration 12 40
Caustic 15% L Crude Unit 4 40

OUTGOIG STREAM

Pressure Temp.
Stream Phase Source
Kg/cm2 0
C
Fuel Gas V 207C-25 4 40
LPG L 207C-41 14 40
Light Naphtha
Storage (MS / LN) L 207E-30 7 40
HGU feed tank L 207E-30 4 40
HGU hot feed L 207G-24A/B 8 55
Heavy Naphtha
CRU hot feed L 207C-44 5 161
CRU tank L 207E-31 5 40
Storage (HSD / HN) L 207E-31 7 40
Kerosene / ATF L 207E-17 6 40
Diesel L 207C-36 6 40
UCO
FCCU storage L 207E-21 7 80
FCCU / IFO L 207E-21 / bypass 9 150
CLPS vapor V 207C-12 30 40
Sour water L 207C-13 5 40
Sour gas V 207C-13, C-6, C-43 6 40, 66, 50
Rich Amine L 207C-6 6 66
Hydrogen Bleed V 207C-7 6 62
Spent Caustic L 207C-43 6 50
Slop L Various 6 40-80

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CHAPTER – 4

PFD AND P&ID

PFDs. & PCDs. ARE ATTACHED AT THE ED OF THIS MAUAL

AD

P&IDs. ARE AVILABLE I AEXURE – I

OF THE
OPERATIG MAUAL.

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CHAPTER – 5

PROCESS DESCRIPTIO
5.1 FEED & REACTIO SECTIO
5.1.1 FEED SOURCES: CPCL OHCU receives VGO feed from the four different sources as
follows

Table 5.1: FEED SOURCES

SL FLOW RATE Battery limit

No. FEED (SOR) condition Remarks
SOURCE m3/hr Pressure Temp
Kg/cm2 °C
1. Hot VGO from 111.9 to 0 12.0 170 CDU-3 ISBL VGO 201 FI-3104
refinery-3 Via
207FV—1406
2. Hot VGO from 111.9 to 0 12.0 170 As CDU-2 VGO pump
refinery-2 Via 15G-26A/B can not cope up the
207FV--1407 pressure requirement to supply
VGO to OHCU, new booster
pump 320G-5A/B is installed in
CDU-2; CDU-2 ISBL VGO
flow 15F-444.
3. Cold VGO from 111.9 max. 12.0 80 207G-1A/B supplies cold feed
OHCU cold feed from offsite tanks 207D-1 / D-2;
tanks 207D-1 / these tanks have tie-ups to
D-2 Via receive VGO from CDU-2 &
207FV-1404 CDU-3; Vacuum distillates from
CDU-1 and DAO from PDA unit
(LEB).
Note: VBVGO tie-up to these
tanks is not provided, to avoid
gum formation due to
polymerization of unsaturates
in cold storage.
4. Hot VB VGO 25.5 max. 12.0 170 Ref.-3 VBU LVGO and HVGO
from ref.3 VBU are mixed together; VBU ISBL
via combined VGO line 201FI-3506,
207FV-1402 TI-3502.

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5.1.2 FEED BLEDIG

The blending control system aids to:
- Mix VBVGO with straight-run VGO in an adjustable but constant proportion,
(limited to maximum10% VBVGO)

- Mix CDU-2 VGO with CDU-3 VGO in an adjustable but constant proportion.
Proportion could range from 100% CDU-2 VGO to 100% CDU-3 VGO.

- Preferentially feed hot VGO and supplement cold VGO (from tanks) to maintain a constant
‘VBVGO to total VGO’ ratio (if the hydro cracker demands more VGO than is available from
the hot streams).

The reactor feed surge drum level controller 207LIC-1601 maintains a constant level and NPSH
for the reactor feed pumps 207G-3A/(B) by adjusting the total of the four component feeds. The
level controller output signal “K” represents the total flow.

The operator can set the percentage of hot VBVGO (207FK-1402) in the total feed. The
operator-set percentage is represented by signal “F” .The remainder of the total feed will come
from the other three feed sources (cold VGO from storage, hot VGO from CDU-3, and hot VGO
from CDU-2. The total of these three streams is automatically calculated as “K*(1-F)” and
becomes the set point of the sequence flow controller 207FIC-1403.

If the operator sets the %VBVGO target to 10%, the VBVGO flow controller 207FIC -1402 will
receive a set point signal representing 10% of the total flow required, and the sequence flow
controller 207FIC-1403 representing total non-VB VGO, will receive a set point signal
representing 90% of the total flow required. The feed surge drum level controller 207LIC1601
proportionally adjusts both flow set point signals. The sequence flow controller 207FIC-1403
first tries to satisfy the demand for non-VBVGO by bringing in hot VGO. The output signal
“K2” represents the total flow of hot (non-VB) VGO.

The operator can set the percentage of hot VGO from the CDU-3 versus the existing CDU-2
(207FK-1407). The percentage is represented by signal “F2” on the PCD. If the operator sets the
% CDU-3 VGO target to 60%, the hot VGO from the CDU-3 flow controller FIC1406 will
receive a set point signal representing 60% (K2*F2) of the total non-VB flow required, and the
hot VGO from the CDU-2 flow controller 207FIC-1407 will receive a set point signal
representing 40% [K2*(1-F2)] of the total non-VB flow required. Both flow set point signals
are proportionally adjusted by the sequence flow controller 207FIC-1403. If the demand for non-
VBVGO is greater than can be met by the hot streams, sequence flow controller 207FIC-1403
output “A” reaches 100% and output “B” will be used to bring-in cold-VGO from storage.

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Let’s look at how the controls respond to some upset situations:

- If the VBVGO flow is lost (or if the control valve goes wide open), the reactor feed
surge drum level will temporarily drop until the level controller 207LIC-1601 responds by
increasing the flow of non-VBVGO. The ratio will no longer be controlled, but the total feed rate
and feed surge drum level will be maintained.

- If the flow of one of the hot non-VBVGO streams is lost (or if the control valve goes wide
open), the measured flow to the sequence flow controller 207FIC-1403 will temporarily drop
until it can respond by increasing the flow of the other hot non-VB VGO stream flow rate. The
ratio would no longer be controlled, but the total hot non-VB VGO feed flow would be
maintained. If that was not sufficient, the sequence flow controller 207FIC-1403 would then
move to output “B” and bring in cold VGO from storage.

5.1.3 FEED PREHEAT

The temperature of the feed flowing to the feed filters is controlled. The combined feed stream at
131°C is preheated first in shell side of the Oil-feed /Kerosene exchanger 207E-1 to 148°C and
then in shell side of the Oil feed/Diesel exchanger to 168°C. The temperature controller
207TIC1413 bypasses hot Diesel around the tube side of the exchanger 207E-2. Opposite acting
valves (One valve opens as the other closes) 207TV-1413A in tube inlet and 207TV1413B in
tube bypass are used for rangeability.

5.1.4 FEED FILTER SYSTEM: Make - FUJI Filter Mfg. Co. Ltd., Japan.

Feed filter 207T-1 is used to filter the oil feed and remove solids and particulates which would
otherwise lie down on the first Rx. top bed catalyst, leading to premature plugging of the top bed.
The filter consists of 4 banks, each bank having 10 stations. Each station consists of 12 filter &
elements of mesh size 20µm. The filter is capable of removing solids particles of size 20µm and
above. The design solid loading to the filter is 20-40 ppm under normal operation (200 ppm under
upset situation).

A differential pressure indicator 207PDI-1505 is used to measure the degree of plugging of the
feed filters. When a differential pressure of 2.0 Kg/cm2 is reached, filter back flushing is actuated.
And timer set up i.e., after 360 min. or individual bank (207FI 1402,1403, 1404, 1405 ) flow fall
below 15 m3/hr is also actuate the back flushing sequence. Design backwash flow is 30 m3/hr.
Each bank is back flushed in sequence with a slipstream of filtered feed taken from the outlet of
the feed filter until all banks have been back flushed and the pressure drop has returned to normal.
Maximum allowable ∆P across filter is 2.7 Kg/cm2 (normal flow direction).

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Table: 5.2 BACKWASH OIL COSUMPTIO

Flow rate 30 m3/hr

Time 30 sec./ one station backwash
5.5 min./ one bank (10 stations)
22 min./ total (4 banks)
00.25 m3/station
Backwash oil volume 02.50 m3/ bank
10.00 m3/ total

FILTER OPERATIO:
1.Mode selection at control panel:
Select one of the following modes:
- Auto back wash mode (by preset timer or preset ∆P)
- Manual mode (1 particular bank can be selected from any of the four banks)
- Off ('maintenance mode')

2.Set up the timers: Table 5.3:

TIMER NAME ADJUSTABLE RANGE DESIGN SET TIME
Back wash auto 1-12 hours 6 hours
T0 start delay
Delay (backwash 0.5-10 seconds 1 second
T1
start signal)
T2 Backwash timer 10-180 seconds 30 seconds

3. Backwash steps (as per instrument control):

3.1 Getting input signal:
Backwash sequence will start (on getting the input signal) under the following conditions:
a. Signal from 'adjustable electronic timer, when time is up.
b. Signal from PDAH of 207PDI-1505 (∆P across the filter), 2.0 Kg/cm2
c. Signal upon manual order (at manual mode in control panel).
d. Low flow to the individual bank

3.2 Backwashing each station:

a. Close inlet line b. Open drain line (solenoid operated)

3.3 T2 time up (refer timer set up table above)

3.4 Backwash finish

a. Close drain line b. Open inlet line (solenoid operated)

3.5 ext station backwash starts (return to the step 3.2 above).

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5.1.5 BACKWASH OIL SURGE DRUM

Backwash oil from the feed filter 207T-1 is received in the 'Backwash oil surge drum 207C-39
vapors flashed in the drum goes to flare, as the vessel floats with the flare header (0.2 kg/cm2).

207LI-3405
- Gives start signal to Backwash oil pump 207G-31A/B – primary pump as selected in field,
(A or B) at 30% level of the drum.
207LI-3402
- Gives start signal to Backwash oil pump 207G-31A/B - secondary pump as selected in field,
at 60% level of the drum.
- Stop signal to both the pumps 207G-31A & B, at 5% level of the drum.
207LI-3401
- Gives signal to stop backwash operation of feed filter, when drum level becomes high (90%).

5.1.6 REACTOR FEED SURGE DRUM 207C-1

Feed surge drum 207C-1

- aids in mixing of different feed fractions,
- provides surge time of about 20 minutes, at design feed rate,
- provides NPSH and spillback facility to Rx.feed pumps 207G-3A/B
-
Filtered VGO feed is received in feed surge drum 207C-1 at 168°C. The reactor feed surge drum
level is maintained by a level controller 207LIC-1601 which adjusts the total flow of the four
feed streams from off plot. The drum pressure of 5.7 ksc is maintained by N2 blanketing using a
split-range pressure controller 207PIC-1602. When the pressure drops, N2 is brought in and
when the pressure goes up above the set value, N2 is vent to flare.

5.1.7 REACTOR FEED PUMPS 207G-3A/B

Reactor Feed Pump 207G-3A/B is a high-pressure (9 stages) centrifugal pump driven by an HT

motor (full load 244 amps). The pump boosts the oil feed from 5.7 Kg/cm2 to 185.7 Kg/cm2 to
enable the oil feed to flow through the high pressure reaction section. The pump design
temperature (seal design temperature 225° C) MAWT of 167°C limits the VGO feed preheat in
207E-1 and 207E-2. Total oil feed rate to the reactor is set by a flow controller 207FIC-1801.
Minimum flow controllers 207FIC-1704 / FIC--1710 recycle part of the pump discharge-flow
back to the feed surge drum 207C-1 and ensure minimum flow (130 m3/hr) through the pump at
all times, thus preventing mechanical damage. Feed flow controller 207FIC-1801 is provided
with low flow alarm (130 m3/hr). In case of feed pump 207G-3A/B failure, an automatic-
chopper valve 207FBV-1802 (flow less than 90 m3/hr) will close, to prevent backflow of high-
pressure hydrogen and oil through the pump to the low pressure feed system. For additional
protection, stop check valves on the discharge of each pump plus a stop check valve on the pump
common discharge line are provided.

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207G-3A/B is provided with dedicated lube oil circulating system (to bearings) – pl.refer
‘Special-equipment section” of this manual for more details. Hot UCO to 207G-3A/B line is
provided to keep the spare pump in warm – up condition to facilitate taking the spare pump on
line any time as required.

5.1.8 RECYCLE GAS RATE:

The make-up plus recycle “gas-to-oil” ratio should be held at the recommended value (Design
850 Nm3/hr) by adjusting recycle compressor speed (precise control is not required, so speed
manipulation is adequate). At reduced feed rates, a minimum gas rate 1,50,000 Nm3/hr should
be maintained to enhance reactor flow distribution (by maintaining feed velocity) and to assist in
reactor temperature control (by providing a heat sink). Infact the designer recommends
maintaining the same recycle gas rate even at reduced feed rates, in order to ensure better
distribution of the reactor feed across the catalyst bed.

Recycle gas rate = 850 Nm3 (minimum) for every m3 of VGO feed

For 225.0 m3/hr of feed (100% design), recycle gas rate = 1, 91,250 Nm3/hr

For 249.2 m3/hr of feed (112% design), recycle gas rate = 2, 11,820 Nm3/hr

5.1.9 REACTOR FEED FURACE

Oil feed mixes with recycle gas (coming from RGC discharge via 207E-7) and gets heated up to
the reaction temperature, in Rx.feed/effluent exchanger 207E-3A/B (176°C to 356°C) and in
Furnace 207F-1 (356°C to 378°C). Temperature controller 207TIC--1803 controls the furnace
inlet temperature by varying the oil bypass rate around tube side of the Rx.feed/effluent
exchanger 207E-3A/B. A second temperature controller 207TIC--1971 controls 207F-1 COT,
that is 207R-1 I/L temperature, using the furnace firing system. These controllers prevent small
variations in the reactor outlet temperature from having an impact on the reactor inlet
temperature. Also, they help to ensure the target ∆T of 22ºC minimum across the feed furnace,
in order to provide for the capability to quickly reduce the Rx. inlet temperature in case of an
emergency, by pulling furnace fires.

207F-1 is a box type natural draft furnace with the feed going through 2 passes. Tube metallurgy
is SS-316L. It is to be noted unlike conventional furnaces, 207F-1 is not provided with any pass
flow control valves or block valves instead, the furnace pass inlets and outlets are designed to be
symmetrical, which is aid for uniform pass O/L temperatures.

The temperature controller 207TIC-1910 at the furnace outlet adjusts the furnace firing to
maintain the desired reactor inlet temperatures. Temperature indicators 207TI-1805/1806 and
207TI-1807/1808 are located at the outlet of each pass to monitor temperature difference
between the pass outlets. This could indicate any flow maldistribution and potential coking

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problems. In addition, skin temperature indicators 207TXI-1821-1832 / 207TXI-1841-1852

(12 per pass) are located at various points in the furnace to monitor radiant section skin
temperatures. As 207F-1 handles explosive gas (H2 and Hydrocarbon) at high temperature and
pressure, in close proximity to fire the skin temperatures should be kept as low as possible
(design skin temp is 551 deg C). Draft gauges 207PI-1801A/B indicates whether there is a
positive draft through the furnace. The damper located at the top of the furnace stack is adjusted
(207 HV-1801) to vary airflow and ensure that a proper draft is induced and an appropriate
amount of excess air is available.

Table 5.4 FEED FURACE 207F-1 ITERLOCKS:

Sl. Inter
ACTUATED BY VALUES ACTIO UPO
no. lock no
1. I-1801 FT/FALL-1802 90 m3/hr Closes Main FG
-207F-1 coil flow Low Low UV-1803
FT/FALL-2202 84189 Nm3/hr
-Recycle gas flow Low Low
2. I-1802 PSLL-1804 Closes Main FG
2
-207F-1 Main fuel gas pr. 0.1 kg/ cm UV-1803
Low Low
3. I-1803 Emergency trip switches 1.Closes
-207 HS-1801A – provided at Main FG UV-1803
control panel Pilot gas UV-1802
-207 HS-1801B – provided in field - 2.Opens stack damper
(15 meter away from furnace) HV-1801
4. I-1804 207PAH-1897/1898/1899 2 mm of H20 Full opens stack
-207F-1 Arch pr. High damper HV-1801
5. I-1805 207PAHH-1897/1898/1899 Closes main FG
-207F-1 Arch pr. High High 5 mm of H20 UV-1803
( 2/3 logic)
6. I-3501 207FALL-3588A BFW 25 m3/hr Closes main FG
(to F1 steam generation coil) UV-1803
flow Low
7. - 207FHS-2201 - Start up bypass for
207F-1

5.1.10 REACTOR COTROL AD MOITORIG

207F-1 O/L oil-gas mixture at 378ºC enters first reactor 207R-1. In the reactors the exothermic
Hydrocracking and Hydrtreating reactions taking place in presence of Ni3S2 catalyst, result in a
large heat release that increases the temperature of the reactants. This increased temperature
further increases the rate of reaction. This heat release therefore results in temperature rise across
each bed. (max allowable temp difference across the each bed is 30o C).

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In order to control this temperature rise and, likewise, the rate of reaction, a series of reactor
temperature controllers is provided to control the temperature profile through the reactors:
First Rx . 2nd bed I/L - 207TIC-1911
First Rx. 3rd bed I/L - 207TIC-1941
Second Rx. 1st bed I/L - 207TIC-2003
Second Rx. 2nd bed I/L - 207TIC-2021

Temperature control is accomplished by manipulating the flow of “cold” quench gas that is
introduced between the catalyst beds in each reactor. The temperature O/L at each bed is around
411ºC, which may vary slightly depending upon the reaction rate in each bed. The bed O/L is
quenched using quench gas to 378ºC.

In order to measure the temperatures in the reactors, thermocouples are placed in the catalyst
beds. Except for the top of the top catalyst bed, eight thermocouples are positioned 45 degrees
apart at the same height in the top and bottom of each bed (16 totals per bed). Optionally, the
average of the eight readings at top level average temperature (LAT) or the highest among the
eight or select the any one thermocouples can be sent the signal to the reactor bed temperature
controllers (quench gas) 207TIC-1911/1941/2003/2021.

An inter-reactor effluent/fractionator feed exchanger 207E-6 is removes some heat from the
207R-1 effluent. The tube O/L (207R-2.feed) temperature is controlled by bypassing a portion of
the fractionator feed around the shell-side of exchanger 207E-6. The bypass is controlled by
opposite acting control valves, 207TV-2002A is shell I/L and TV-2002B in shell B/P (one valve
opens as the other closes). This control system minimizes disturbances to the fractionator feed
system while providing for good control of the exchanger tube O/L temperature. The 207R-2
inlet temperature is controlled by a temperature controller 207TIC-2003, which adjusts the
quench flow to the first reactor effluent, at the tube out let of 207E-6.

In addition to providing temperature control, the temperatures measured at the top and bottom of
each bed in each reactor can be used to monitor reaction progress and to indicate the location
and extent of possible channeling of reactants. Temperatures measured at different heights but at
the same circumferential position (i.e. temperature difference across a bed) indicate the extent of
reaction in the bed. Temperatures measured at the same height but at different circumferential
positions in the bed can indicate the location and extent of possible maldistribution of reactants.
For example, a liquid-poor region may experience a higher temperature rise because slower
moving liquid has more time to react and will liberate more heat (local hot spot).Additionally,
there are three separate skin thermocouples (207TXI-1906/1907/1910) located on the outside of
the reactor at the top and bottom of each bed.

Pressure drop across each reactor and separately the top catalyst bed of the first reactor is
monitored using differential pressure indicators (First Rx.PDI-1903, First Rx.first bed
207PDI-1904, Second Rx.207PDI-2003). Maximum allowable DP is 7 kg/ cm2 for the each

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reactor. Note that interpretation of first Rx.top bed pressure drop must be done carefully. The
low-pressure lead of the top bed DP transmitter (207PDI-1904) is tied into the quench line.
There is a pressure drop through the quench line whenever quench is used. As such, the
differential pressure transmitter will read artificially low except when the quench rate is zero.
Therefore, comparisons of pressure drop over time must be done at similar quench gas rates.

5.1.11 REACTOR EFFLUET COOLIG

The 207R-2 effluent consists of
- product oil
- unreacted H2
- gases formed due to - Hydrocracking & Hydrotreating
a. NH3 formed due to denitrification,
b. H2S formed due to desulphurisation,
c. Steam formed due to reduction of oxygen-atom
containing Hydrocarbon molecules.

Reactor effluent is cooled in a series of exchangers from 411 OC to 55 OC as follows:

Table: 5.5: Reactor Effluent cooling
EXCHAGER SHELL SIDE TUBE SIDE
Number Type Heat duty FLUID TEMP C O
FLUID TEMP OC
MMKcal/hr IN OUT IN OUT
nd
207E-3A/B Breach-lock 45.6 2 Rx. 411 279 Rx. feed 176 356
Shell & tube effluent
nd
207E-4 Breach-lock 14.1 CLPS liquid 162 257 2 Rx. 279 233
Shell & tube effluent
207E-5 Breach-lock 5.3 BFW (MPS - - 2nd Rx. 233 213
Shell & tube generation) effluent
nd
207E-7 Breach-lock 6.6 2 Rx. 213 190 Recycle gas 84-116 185
Shell & tube effluent
207E-8 Breach-lock 14.3 CLPS liquid 54 162 2nd Rx. 190 136
Shell & tube effluent
207E-9A-H Air cooler 19.9 Air - - 2nd Rx. 127 55
effluent

In Rx. feed / effluent exchanger 207E-3A/B, Rx. feed O/L temperature is controlled by
regulating 207TV-1803 in the tube B/P line. 207TV-2102A & B (opposite acting control valves)
provided in 207E-4 shell I/L & B/P lines control the temperature of CLPS liquid coming out of
the exchanger shell. MP steam is generated in 207E-5. Steam generated from this exchanger
joins with the MPS from other steam generators and the steam drum before being superheated in

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207F-2 convection coil. 207E-5 Steam-side PSV O/L is connected to the flare, considering the
tube rupture case. The reactor effluent steam generator level is controlled by a “three-element”
boiler feed water (BFW) system (level to flow cascade with steam feed forward). Including the
flow controller (207FIC--2102) prevents BFW supply pressure from upsetting the level and
“linearizes” the BFW valve. Including the steam flow feed forward provides quick manipulation
of the BFW flow (based on the known mass balance), independent of the slower feedback action
of the level controller (207LIC-2101). Tube O/L effluent temperature is indicated by
207TI-2106.

A 3-way valve 207 HV-2201 is used to bypass part of the recycle gas going through 207E-7 tube
side. 207E-7 recycle gas O/L at 185 OC (207TI-2206) goes and joins the oil feed going to 207E-
3A/B. Rx.effluent from 207E-7 is cooled in 207E-8 by the CLPS liquid going through the shell
side, to 136 O C (207TI-2202). The effluent is finally cooled in the Air cooler 207E-9 to 55 OC.
Of the 8 fans in 207E-9A-H, 4 fans 2079A, 9C, 9E & 9G are provide with variable speed
arrangement and emergency power backup. 207E-9 O/L temperature (207TI-2306, 55 oC)
controlled by using the variable speed arrangement. All the fin cooler motors are provided with
vibration trips. The fans stop switches are available in the ground floor near 207G-3A.

5.1.12 WATER IJECTIO FACILITIES

Condensate (water) is injected at the inlet of the reactor effluent air cooler on continuous flow
control (207FV-3304, 6.0 m3/hr. for the design feed rate)). Because of the injection water
pumps 207G-4A/B are positive-displacement type pumps (constant volume characteristic), a
pressure-controlled (207PIC-3303) spillback is provided. (The net flow can be throttled only if
the pump discharge pressure is controlled). A chopper valve will close on low-low flow at
4 m3/hr to prevent backflow of high-pressure gas on loss of the water injection pumps.

Fractionator reflux drum sour water from 207G-10A/B is collected in the injection water drum,
through the 207LV-3304. 207G-10A/B discharge excess water is sent on pressure control
(207PIC-3304) to the sour water degasser. Drum pressure is controlled by a split-range make-up
(N2) / bleed-off (flare) pressure-controller (207PIC-3302). The level in the injection water drum
is controlled (207LIC-3301) by manipulating the valve on the stream from the pumps. On
low-low level, a chopper valve precludes high-pressure reactor effluent from flowing to the
low-pressure water injection drum.

5.2 RECYCLE GAS LOOP

5.2.1 REACTOR EFFLUET AIR COOLER

Temperature 550C (207TC-2306) in the Cold High Pressure Separator (CHPS) is achieved by
manipulating the reactor effluent air cooler variable-speed fans.

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5.2.2 COLD HIGH PRESSURE SEPARATOR

The oil level in the CHPS 207C-2 is controlled by a liquid level controller (207LIC-2401A/B).
Two parallel high pressure letdown valves are included, one in operation and the other a spare.

The low-low level (20%) shutdown function trips the level controller into manual and drives the
output signal to close the outlet valve. For added safety, a solenoid valve arrangement between
the valve positioner and the valve actuator is vented to close the oil outlet valve.

The level of the water phase is detected and controlled by an interface level controller
(207LIC-2404A/B). Two parallel high-pressure letdown valves are provided, one operating and
the other as a spare. The low-low level (10%) shutdown function trips the level controller into
manual and drives the output signal to close the outlet valve. For added safety, a solenoid valve
arrangement between the valve positioner and the valve actuator is vented to close the water
outlet valve.

The relief valve for the high pressure loop is located on the CHPS (shown on the P&IDs). The
set pressure (161.5 Kg/cm2)of this pilot-operated relief valve is 5% greater than the normal
operating pressure (154 Kg/cm2) of the CHPS. When this set pressure (161.5 Kg/cm2) is
exceeded, the relief valve will lift and begin depressuring the system.

5.2.3 HIGH PRESSURE H2S ABSORBER AD LEA AMIE SYSTEM

CHPS vapour goes through HP centrifugal separator 207C-3. A level controller 207LIC-2501
automatically drains any liquid that accumulates in the separator. A fast-acting controller with a
level “gap” along with a limited sized, tight-shutoff control valve helps avoid hydrogen blow-
through. The separator gas is sent for amine absorption to the HP amine absorber 207C-4. Lean
amine from offplot ARU, comes through 207FV-3001 gets preheated in LP steam 207E-10 and
is received in the lean amine surge drum 207C-5 the level is controlled by 207LIC-3001. Lean
amine from 207C-5 is pumped by 207G-5A/B through 207FV--3103 and the chopper valve
207FBV-3104 to HP H2S absorber 207C-4. The lean amine flow to the absorber (223.5 m3/hr.)
is set to achieve the allowable 50 ppm H2S in recycle gas. A chopper valve FBV-3104 will close
on low-low flow (40 m3/ hr) or 207C-4 level high at 70%, or 207G-5A/B trip, to prevent
backflow of high- pressure gas on loss of the Lean amine charge pumps 207G-5A/B. if the level
comes low the PLC tag 207PALL 2505 (6%) will deenergise the solenoid and shut the
207LIC-2504 A/B.

The temperature of the lean amine must be maintained 5°C greater than the feed vapor
temperature (207TDC-3003) to prevent any condensation of the vapor on contacting the lean
amine. This is critical in preventing foaming in the absorber. A differential temperature
measurement (207TD-2504) is provided (with a low alarm) for monitoring. This differential
temperature cannot be used directly in the temperature difference controller (207TDC-3003)
because of the excessive time lag/dead time between the absorber and the HP lean amine

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preheater 207E-10 bypass control valve. Instead, the lean amine temperature is measured
immediately downstream of the preheater to provide quick feedback. The controlled
temperature difference may have to be adjusted periodically to account for any variation in heat
loss from the preheater to the absorber.

Steam pressure to the HP lean amine preheater 207E-10 is held constant by a pressure controller
(207PIC-3002). In addition, a temperature control system is provided which desuperheats the
steam. The pressure controller (207PIC-3002) and temperature controller (207TIC-3005)
combine to limit the steam temperature to avoid degradation of the lean amine, which can create
by-products that promote fouling, corrosion, foaming, and pumping difficulties. HP H2S
absorber 207C-4 rich amine level is controlled by the high-pressure letdown control valve(s)
207LV-2504A/B, with one in operation and the other as a dedicated spare. The pressure drop
across the trays, measured by a differential pressure indicator 207PDI-2503 (max 0.25 kg/cm2) is
the best indicator to detect foaming in the absorber.

A full line size hand controlled bypass of the H2S absorber 207 HV-2502 is provided for startup.
The bypass can also be used during normal operation to help reduce foaming problems by
reducing the velocity through the absorber. If the 207PDI 2503 attain the maximum value
gradually open the 207 HIC 2502 fully and do oil skimming. After oil skimming slowly close
the 207 HIC 2502 and see the 207PDI 2503.

207G-5A/B are protected by a low-flow spillback system (130 m3/hr). The low flow controller
207FIC-3101/3102 is operated with a “low set point” so that its control valve is normally closed.

The high-pressure lean amine surge drum pressure (5 kg/cm2) is controlled by a split-range
pressure controller 207PIC-3001 (on falling pressure, N2 is brought in on rising pressure, N2 is
vented to flare).

5.2.4 RECYCLE COMPRESSOR KO DRUM 207C-7

A level controller 207LIC-2601 automatically drains any liquid that accumulates in the KO
drum. The system is designed to avoid hydrogen blow-through. A high-level trip (alarm at 71%
and trip value at 79%) will shut off the recycle compressor to prevent liquid from reaching the
recycle compressor. Two out of three levels (207LI-2603A, LI-2604A and LI-2605A) must
indicate a high level before a shutdown trip signal is sent to the recycle compressor.

5.2.5 RECYCLE GAS COMPRESSOR 207K-1

207 HC-2703 is used to adjust compressor turbine speed to set the recycle gas rate to the reactor
section.

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The recycle gas compressor circulates the recycle gas through the high pressure system. One part
of compressor discharge gets heated by the reactor effluent in 207E-7 and joins the Rx.oil feed
going to 207E-3. The other part goes as quench gas to reactor beds as already described.
Antisurge flow controller 207 UIC-2702 fixes the spillback flow (207FI-2705) to 207E-9, to
avoid “surge”, an unstable condition of widely oscillating flow rates that will damage the
machine. There is almost no flow through the spillback line during normal plant operation.

5.2.6 COLD LOW PRESSURE SEPARATOR 207C-9

The oil level is controlled by a level-to-flow cascade control system (207LIC-2801 to

207FIC-2801). This takes advantage of the surge volume in the CLPS to provide as smooth a flow
as possible to the product stripper.

An interface level controller (207LIC-2802) will automatically send any accumulated sour water
to the water degasser.

5.2.7 CLPS VAPOR H2S ABSORBER 207C-11

The lean amine to the CLPS vapor H2S absorber is on flow control (207FIC-2901), and is set to
achieve the desired degree of H2S (20ppm max allowable) removal from the CLPS overhead
vapor.

Control of the rich amine level (207LIC-2901) in the bottom of the absorber is achieved by
manipulating the rich amine control valve 207LV-2901. Rich amine is sent to the Rich amine
flash drum 207C-5. A differential pressure indicator (207PDI-2902) across the packing is used
to detect foaming. A controller (207PIC-2901) on the overhead line maintains the absorber
pressure.

The temperature of the lean amine must be maintained at least 5°C greater than the feed vapor
temperature to prevent any condensation of the vapor on contacting the lean amine. (This is
critical in preventing foaming in the absorber). A differential temperature measurement
(207TDI-2902) is provided for monitoring. The differential temperature control system
(207TDC-3003) provided for the high pressure H2S absorber will also protect the CLPS vapor
H2S absorber. (The vapor temperature to the CLPS vapor absorber should always be lower than
that to the high pressure H2S absorber because of the flash between the CHPS and CLPS.)

5.2.8 RICH AMIE FLASH DRUM 207C-5

Pressure is maintained on the flash drum by a backpressure controller (207PIC-3201, 6 kg/cm2)

on the sour gas line. Level is controlled (207LIC-3201) by adjusting the flow to the offplot
amine section.

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5.2.9 CLPS VAPOR KO DRUM 207C-10

Any accumulated liquid is removed from the KO drum by a level controller (207LIC-2902) and
sent to the rich amine flash drum. Normal operating pressure (37.5 kg/cm2) is determined
offplot at the PSA unit. Excess pressure is relieved first to fuel gas and then to the relief system
by a sequence-type, split-range pressure controller (207PIC-2903).

5.2.10 REACTOR SYSTEM PRESSURE

Reactor system pressure is controlled at the suction of the recycle gas compressor by
manipulating the net flow of make-up hydrogen to the reactor section. The controller
207PIC-2702 set point should be adjusted periodically to achieve the desired pressure (172.5
kg/cm2) at the inlet of the first reactor. A high-set point pressure control loop is included on the
recycle gas compressor suction line to ensure that pressure does not exceed the set pressure of
the reactor loop PSV (installed on the CHPS overhead piping). This will minimize releases
through the safety valve on the CHPS (set value 161.6 kg/cm2).

A release in this service creates a large load on the relief system, and safety valves are notorious
for not resetting properly. The set point should be higher than that of the main reactor loop
pressure controller so that no recycle gas is normally vented.

The pressure controller 207PIC-2601 is configured as a sequence-type split range controller.

It first opens the “A” valve to the fuel gas system. A flow control override (500 Nm3/hr) is
provided to limit the amount of recycle (hydrogen) gas that can be sent to the fuel gas system. If
the “A” valve becomes limited, the pressure controller PIC-2601 would then begin to open the
“B” valve to flare.

In an emergency, emergency dump valves 207 HBV-2601 and 207 HBV-2602 can be opened in
either automatic or manual to begin depressuring the high pressure loop. Two depressuring
systems are provided in parallel. The restriction orifices set the depressuring rate (21 Kg/cm2 per
minute). The hand switches (207 HS-2601/A) operate the quarter-turn, block valves to open or
close the path to the orifices. The two depressuring installations join in a common line to the
relief header. A downstream pressure indicator (PI-2602) with high (0.25 Kg/cm2 and high-high
(0.50 Kg/cm2) DCS alarms alert panel man of potential over pressuring of the flare header, if
any.

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5.3 FRACTIOATIO SECTIO

5.3.1 PRODUCT STRIPPER 207C-14

The stripper feed temperature is controlled by the hot reactor effluent / CLPS liquid exchanger
temperature controller 207TIC--2102. The superheated high-pressure (10.5 kg/cm2)
stripping steam rate is controlled by a flow controller (207FIC-9002). The feed temperature and
stripping steam rate are adjusted as required to achieve the target concentration of H2S in the
bottoms product.

A level controller 207LIC-4003 maintains the product stripper level by manipulating the flow of
the product stripper bottoms to the fractionator. A low-low level (7 %) in the stripper will
switch the fractionator furnace to firing on pilots only. Flow control 207FIC--4201 will start the
emergency circulation of the product fractionator bottoms from the fractionator bottoms pump to
the fractionator furnace 207F2 inlet to maintain a minimum safe flow (130 m3/hr) to the furnace.

Stripper overhead temperature is maintained by manipulating reflux flow. The temperature set
point 207TIC 4003 is adjusted as required to control the heavy ends in the unstabilized naphtha
stream. The TIC cascades to the set point of 207FIC 4001, which by flow control to the stripper,
controls the overhead temperature. Also, the temperature must always be set above the water
dew point (146°C) to provide smooth stripper operation and to protect the packing from
corrosion.

Product stripper pressure is controlled (207PIC 4101) by manipulating the flow (207FIC-4001)
of overhead vapor to the LER section. The product stripper must operate at a high enough
pressure (14 Kg/cm2) so the overhead vapor can flow to the light ends recovery section (the
control valve must not be allowed to go wide open).

Product stripper reflux drum inlet temperature is controlled 207TIC 4101 (67°C) by
manipulating the speed of the overhead condenser fans. The temperature can be adjusted to vary
the split between the net overhead vapor and liquid. Water boot interface level is controlled
(207LIC-4104) by manipulating the sour water stream to the water degassing drum.

Manipulating the flow controller controls product stripper reflux drum level 207LI 4101 on the
(product stripper) unstabilized naphtha stream to the LER section. Incorporating the flow
controller allows the level controller LIC-4101 to be tuned for “flow smoothing.” This takes
advantage of the surge volume in the reflux drum to provide a smooth flow of unstabilized
naphtha.

5.3.2 PRODUCT FRACTIOATOR FEED FURACE 207F-2

Combined fractionator feed temperature is controlled by manipulating the furnace firing

controls. The temperature set point 207TIC 4209 is adjusted as required to control the desired

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fractionator flash zone temperature 360ºC. The effluent temperature 207TI 4203 to 4207From
each pass is monitored to ensure the flow distribution is uniform through the four passes.
(Valves on the inlet to each pass can be adjusted if poor distribution is suspected.). Design skin
temp at radiation zone is 5350 C, and at convection zone is 4270 C.

To prevent furnace coking or high tube temperatures in the event of a low flow rate 130 m3/hr,
an emergency circulation flow controller 207FIC 4201 is provided. If a low flow occurs, the
controller routes some of the fractionator bottoms to the furnace inlet to maintain the minimum
safe flow rate130 m3/hr at which normal furnace firing can take place. A low-low flow switch
will shut off the furnace firing system if the sum of the flows through the fractionator furnace
drops below a specified low limit.

Draft pressure gauges are placed to monitor the draft in the furnace at various zones. There are
12 skin point thermocouples 207TXI-4220 to 4260 per pass to monitor tube skin temperatures.
The furnace damper is adjusted with a hand controller 207 HIC-4201 to vary air flow, draft and
an appropriate amount of excess air is available.

5.3.3 PRODUCT FRACTIOATOR 207C-16

Superheated high pressure stripping steam is flow controlled 207FIC-4305 into the column.
Overflash flow rate (20% of the feed rate) is measured with an external overflash meter. Flash
zone pressure 207PI-4304 and temperature 207TI-4309 are monitored to control the diesel
quality. Delta temperature should be 5 to 7ºC. The pressure drop (207PDI-4301/4302/4303)
across each section of the rectification section is monitored. A high/erratic- pressure drop would
indicate flooding.

5.3.4 FRACTIOATOR OVERHEAD SYSTEM

Fractionator overhead temperature is maintained by manipulating reflux flow 207FIC 4301. The
temperature set point 207TIC 4302 (98 to 100ºC) is adjusted as required to control the heavy
ends in the unstabilized naphtha stream. The temperature sensor is located below the top tray to
give better control in the presence of light gases (especially at startup). Additionally, it is
important to maintain a minimum overhead temperature (98ºC) to prevent condensation of water
and consequent unstable operation of the fractionator. Fractionator reflux drum inlet temperature
(55ºC) is controlled by 207TIC 4502 by manipulating the speed of the overhead condenser fans.
The temperature can be adjusted to control the degree of sub cooling of the reflux drum liquid.
207LIC 4503 control the water boot interface level by routing the sour water either to injection
water drum or to sour water degasser drum.

Fractionator reflux drum level is controlled by manipulating the flow controller (207FIC-4601)
on the (fractionator) Unstabilised naphtha stream to the LER section. Incorporating the flow
controller allows the level controller (207LIC 4501) to be tuned for “flow smoothing.” This

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takes advantage of the surge volume in the reflux drum to provide a smooth flow of unstabilised
naphtha.

The fractionator overhead vapor is totally condensed in the fractionator overhead condenser.
The condenser is elevated above the reflux drum and drains by gravity through the control valve
shown at the outlet of the condenser (the condenser drain valve). An equalizing line connects
the fractionator overhead vapor line with the reflux drum vapor space. The control valve in the
equalizing line is normally wide open. Thus, fractionator and reflux drum pressures are
essentially the same.

A sequence-type, split-range pressure controller (207PIC-4501) is used. Normally, the condenser

drain valve is throttling and the equalizing line control valve is wide open. Throttling the
condenser drain valve backs liquid up into the overhead condenser tubes, resulting in a liquid
level in the overhead condenser. This reduces the tube area available for condensation. When
the condenser drain valve is wide open there should be no level in the overhead condenser,
which corresponds to maximum heat exchanger tube surface area exposed to the overhead vapor,
and therefore corresponds to maximum rate of condensation of the overhead vapor stream.

Fractionator pressure control is achieved by manipulating the level in the overhead condenser.
The pressure controller (207PIC 4501) automatic-ally positions this level so that the rate of
vapor condensation matches the rate of vapor coming from the fractionator, thus holding the
pressure constant. On increasing fractionator pressure, the condenser drain valve would open
slightly, reducing the level in the overhead condenser and increasing the condensation of the
overhead vapor (increased tube surface area). Conversely, on decreasing fractionator pressure,
the condenser drain valve would close slightly, increasing the level in the overhead condenser
and reducing the condensation of the overhead stream (decreased tube surface area).

As mentioned previously, the equalizing line control valve is wide open in normal operation, and
the pressure in the column is equal to the pressure in the reflux drum. However, if the pressure
controller (PIC-4501) had to open the drain valve wide, and the pressure continued to rise, the
pressure controller would then begin to close the equalizing line valve. If column pressure
continued to rise, the equalizing line control valve would eventually completely close, forcing all
overhead vapors through the overhead condenser. The further increase in pressure is controlled
by pressure controller (207PIC 4502) which set point 0.900kg/cm2 is higher than the
fractionator’s pressure controller (PIC-4501) set point 0.850 kg/cm2 which would vent the no
condensed overhead vapor to the relief system.

5.3.5 KEROSEE STRIPPER 207C-18

The kerosene side cut rate from the fractionator is manipulated (207LIC-4701) to control
kerosene stripper bottoms level. The kerosene product draw rate is on flow control
(207FIC-4702). The draw rate is adjusted to control the end point 2660 C specification of the
kerosene stream. The reboiler heat input (duty) is ratioed to kerosene draw rate to ensure the

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adequate removal of light ends from the kerosene product in order to meet the kerosene flash
point (min 38ºC) specification. The duty of the reboiler is calculated from the temperature

difference across the reboiler (diesel pumparound side), the diesel pumparound flow rate, and
the diesel heat capacity. The ratio controller (207FFC-4701) adjusts the amount of diesel
pumparound bypassed around the reboiler to maintain the operator set duty/product ratio.
Opposite acting valves (one valve opens as the other closes) are used for positive control and
range ability.

5.3.6 DIESEL STRIPPER 207C-19

The diesel side cut rate from the fractionator is manipulated (207LIC-4901) to control diesel
stripper bottoms level. The diesel product draw rate is on flow control (207FIC-5101). The draw
rate is adjusted to control the end point specification 3760 C of the diesel stream. The stripping
steam rate is ratioed (207FFC-4901) to diesel draw rate. This control system was configured to
ensure adequate removal of light ends from the diesel product in order to meet diesel flash point
specifications (min 35ºC).

5.3.7 KEROSEE PUMPAROUD

A flow controller (207FIC-4801) sets kerosene pumparound flow rate. Pumparound heat
removal duty is also controlled to increase stability of the fractionator operation. The duty is
calculated from the temperature drop, the flow rate, and the heat capacity of the kerosene
pumparound stream. The duty controller (207FIC-4802) manipulates the speed of the Kerosene
pumparound air cooler fans. Stop switches are available near 207G3A pump.

5.3.8 DIESEL PUMPAROUD

A flow controller (207FIC-5003) sets diesel pumparound flow rate. Pumparound heat removal
duty is also controlled to increase stability of the fractionator operation. The duty is calculated
from the temperature drop, the flow rate, and the heat capacity of the diesel pumparound stream.
The duty controller (207FIC-5004) manipulates the amount bypassed around the diesel
pumparound steam generator. Opposite acting valves (one valve opens as the other closes) are
used for positive control and range ability. The diesel pumparound steam generator level is
controlled by a “three-element” BFW system.

5.3.9 FRACTIOATOR BOTTOMS

Fractionator bottoms level is controlled by manipulating the bottoms flow to the FCC unit. A
level-to-flow cascade is used to facilitate “flow smoothing” level control. In flow smoothing
control, the level controller (207LIC-4301) is tuned to take advantage of the fractionator bottoms
surge volume to provide as smooth a flow as possible to the FCC unit. The fractionator bottoms

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level controller (207LIC-4301) is a sequence-type, split-range controller. The level controller

first sends the bottoms to the FCC unit as hot feed (207FIC-5203). If that path becomes blocked
or limited, the level controller (207LIC 4301) then sends the unconverted oil to FCC unit storage

(Cold UCO) (207FIC-5202). the fractionator bottoms steam generator level is controlled by a
“three-element” BFW system. The cold UCO temperature 80-1000 C is controlled
(207TIC-5203) by manipulating fin fan 207E-21A/B motor speed. The temperature of the hot
feed to the FCC unit is controlled by 207TIC-5204 by adding a portion of the stream through the
unconverted oil air cooler.

5.4 LIGHT EDS RECOVERY SECTIO

5.4.1 DE ETHAISER 207C-20

The level in the deethanizer reflux drum is controlled by manipulating the flow of reflux (feed)
to the column. Incorporating the flow controller (207FIC-5601) in the level loop facilitates
tuning the level controller (207LIC-5601) for “flow smoothing.” This takes advantage of the
surge volume in the reflux drum to provide a smooth flow reflux to the deethanizer. The water
drawoff pot is provided with an interface level glass that indicates (207LI-5501) the water level
in the pot. The water is manually drained to the water degasser. The water level in the
deethanizer reflux drum is controlled by an interface level controller (207LIC-5602) on the sour
water to the sour water degasser drum.

A temperature controller (207TIC-5512) in tray-2 is used to control the amount of light impurity
in the bottom stream. The temperature controller manipulates a heat flow controller on the
deethanizer reboiler. Reboiler heat flow to the reboiler is calculated by multiplying the
temperature drop of the fractionator bottoms through the reboiler by its flow rate and heat
capacity. The portion of the fractionator bottoms flow (heat) that bypasses the reboiler is
controlled by opposite acting control valves (one valve opens as the other closes). This control
system (207FIC-5561) minimizes disturbances to the fractionator bottoms stream, while
providing for wide adjustability in the reboiler duty. The same control system is used on the
debutanizer reboiler and the naphtha splitter reboiler.

Deethanizer bottoms level is controlled by manipulating the flow controller (207FIC-5502) on

the deethanizer bottoms to the debutanizer. Incorporating the flow controller in the level loop
facilitates tuning the level controller (207LIC-5502) for “flow smoothing.” Thus, the level
controller can take advantage of the deethanizer bottoms surge capacity to provide a smooth
flow to the debutanizer.

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5.4.2 SPOGE OIL ABSORBER 207C-22

Heavy naphtha sponge oil is sent to the sponge oil absorber on flow control (207FIC 5801). The
level in the sponge oil absorber reflux drum is controlled by manipulating the flow of reflux
(feed) to the column. Incorporating the flow controller (207FIC 5802) in the level loop
facilitates tuning the level controller (207LIC 5802) for “flow smoothing.” The bottoms level in
the sponge oil absorber is controlled by a level controller (207LIC 5701) that sets the flow
controller (207FIC 5701) on the sponge absorber bottoms sent to the deethanizer reflux drum.
Incorporating the flow controller in the level loop facilitates tuning the level controller for “flow
smoothing.”

5.4.3 DEBUTAIZER 207C-27

The level in the debutanizer reflux drum is controlled by manipulating the flow of LPG to the
caustic- washer. Cascading the flow controller (207FIC-6001) to the level loop facilitates tuning
the level controller (207LIC-6001) for “flow smoothing.”. Reflux can be adjusted to control the
back-end specification on the LPG stream.The water level in the debutanizer reflux drum is
controlled by an interface level controller (207LIC-6002) on the sour water to the sour water
degasser.

A temperature controller (207TIC-5904) on a tray near the bottom of the column is used to
control the amount of light impurity in the bottom stream. The temperature controller
manipulates a heat flow controller (207FIC-5903) on the debutanizer reboiler. Reboiler heat
flow is calculated by multiplying the temperature drop of the diesel pumparound stream through
the reboiler by its flow rate and heat capacity. The portion of the diesel pumparound flow (heat)
that bypasses the reboiler is controlled by opposite acting control valves (one valve opens as the
other closes). This control system (207FIC-5903) minimizes disturbances to the pumparound
stream, while providing for wide adjustability in the reboiler duty. The same control system is
used on the deethanizer reboiler and the naphtha splitter reboiler.

Debutanizer bottoms level is controlled by manipulating the flow controller (207FIC-5902) on

the debutanizer bottoms to the naphtha splitter. Incorporating the flow controller in the level
loop facilitates tuning the level controller (207LIC-5901) for “flow smoothing.” Thus, the level
controller can take advantage of the debutanizer bottoms surge capacity to provide a smooth
flow to the naphtha splitter. On low-low level (10%), a tight shutoff chopper valve will close to
prevent blow-through to the naphtha splitter. The debutanizer overhead vapor is totally
condensed in the debutanizer overhead condenser. Column pressure (10.4 kg/cm2) is controlled
(207PIC-6001) using the same technique as described for the fractionator.

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To prevent over pressuring the equipment, the reflux drum is equipped with a vent line to flare
with high pressure controller (207PIC-6003), the set point should be slightly higher
(10.5 kg/cm2) than the normal operating pressure in the reflux drum. This will avoid excessive
venting, yet still prevent popping of the reflux drum safety valve.

5.4.4 APHTHA SPLITTER 207C-29

The level in the naphtha splitter reflux drum is controlled by manipulating the flow of light
naphtha either hot, to the H2 unit, or cold, to storage. Incorporating the flow controller
(207FIC6201) in the level loop facilitates tuning the level controller (207LIC-6201) for “flow
smoothing.” Reflux is on flow control. Reflux can be adjusted to control the end point
specification (90ºC) on the light naphtha stream.

A temperature controller (207TIC-6103) on a tray 2 near the bottom of the column is used to
control temperature 130-135ºC to control the amount of light impurity in the bottoms stream.
The temperature controller manipulates a heat flow controller (207FIC-6102) on the debutanizer
reboiler. Reboiler heat flow is calculated by multiplying the temperature drop of the fractionator
bottoms stream through the reboiler by its flow rate and heat capacity. The portion of the
fractionator bottoms flow (heat) that bypasses the reboiler is controlled by opposite acting
control valves (one valve opens as the other closes). Fractionator bottoms flow (heat) to the
reboiler is controlled by opposite acting control valves. This control system minimizes
disturbances to the fractionator bottoms stream, while providing for wide adjustability in the
reboiler duty. The same control system is used on the deethanizer reboiler and the debutanizer
reboiler.

Naphtha splitter bottoms level is controlled by manipulating the flow controller (207FIC-6301)
on the naphtha splitter bottoms stream. Incorporating the flow controller in the level loop
facilitates tuning the level controller (207LIC-6101) for “flow smoothing.” Thus, the level
controller can take advantage of the naphtha splitter bottoms surge capacity to provide a smooth
flow to the MS reformer. The naphtha splitter overhead vapor is totally condensed in the naphtha
splitter overhead air cooler 207E 29 A/B. Column pressure (1.25kg/cm2) is controlled
(207PIC 6201) using the same technique as described for the fractionator. The fin fan stop
switches are at fan area and near by 207G-3A, start switch is only at fan area.

To prevent over pressuring the equipment, the reflux drum is equipped with a vent line to relief
and a high pressure controller (207PIC-6202). The set point should be slightly higher
(1.3kg/cm2) than the normal operating pressure in the reflux drum. This will avoid excessive
venting, yet still prevent popping of the reflux drum safety valve (3.5 kg/cm2).

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5.4.5 LPG TREATIG

LPG from 207G21A/B is initially caustic-washed to remove H2S traces any and water-washed
to wash out any caustic carry over. The caustic circulation from 207G23A/B is added to LPG
thro a manual valve and indicated by 207FI 6402. The caustic and LPG mixing is thro the static
mixture its pressure drop is around 200 MMWC (207PDI 6402). Then LPG flow thro the wash
water drum 207C40 and finally flows to R/D via coalescer. A backpressure (11 kg/cm2)
controller 207PIC 6601 keeps the whole system liquid packed. Water from the water washer
flows to the sour water degasser through the interface level 207LIC-6601.

5.4.6 FUEL GAS H2S ABSORBER 207C-25

A level controller (207LIC-6801) automatically drains any liquid that accumulates in the
separator. The lean amine to the H2S absorber is on flow control (207FIC 6801), and is set to
achieve the desired degree of H2S removal (20-30 ppm) from the fuel gas.

The temperature of the lean amine must be maintained 5°C hotter than the feed vapor
temperature (36ºC) to prevent any condensation of the vapor on contacting the lean amine.
(This is critical in preventing foaming in the absorber.) A safe temperature difference is
maintained by (207TDC-6801) manipulating the heat input in the fuel gas lean amine preheater
using a bypass. Steam pressure to the fuel gas lean amine preheater is held constant by a pressure
controller (207PIC-6701). In addition, a temperature control system is provided which
desuperheats the steam. The pressure controller and temperature controller (207TIC-6706)
combine to limit the steam temperature to avoid degradation of the lean amine, which can create
by-products that promote fouling, corrosion, foaming, and pumping difficulties.

Control (207LIC-6801) of the rich amine level in the bottom of the fuel gas H2S absorber is
achieved by manipulating the letdown control valve. The pressure drop across the trays,
measured by a differential pressure indicator (207PDI-6803), is the best indicator to detect
foaming in the absorber. A full line size hand controlled bypass of the H2S absorber is provided
for startup. The bypass can also be used during normal operation to help reduce foaming
problems by reducing the velocity through the absorber. Pressure controller 207PIC 6806 in the
fuel gas H2S absorber is control the fuel gas absorber pressure at 10.4 kg/cm2.

5.5 MAKE-UP HYDROGE COMPRESSIO SECTIO

Reactor section pressure (measured at the suction of the recycle compressor) is controlled by
manipulating the set point of the pressure controller (207PIC-6904) at the discharge of the make-
up hydrogen compressor. 207PIC-6904 is the slave to the master controller (207PIC-2702),
which is on the suction to the recycle compressor. 207PIC-2702 controls the set point of
207PIC-6904 to achieve the target pressure. This pressure-to-pressure control cascade provides

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better control compared to a simple pressure controller because of the time lag/dead time
involved.

The make-up compressor discharge pressure controller (207PIC-6904) then manipulates the
make-up compressor spillback valve. Spillback manipulation is necessary because the make-up
hydrogen compressors are positive-displacement type compressors (constant volume
characteristic); the net flow cannot be throttled directly. Thus, the net flow of hydrogen (to the
reactor section) is determined as 100% capacity minus the portion spilled back.

A suction pressure override is also provided, (normally 0.5 kg/cm2 lower than available
hydrogen header pressure). It protects the compressor from high rod loading that can be caused
by high differential pressure on a reciprocating compressor as a result of high discharge pressure
or low suction pressure. If a low suction pressure is measured, the suction pressure controller
(207PIC-6903) will take over control of the spillback valve to increase spillback flow (increase
suction pressure) and reduce the differential pressure.

The hydrogen make-up compressors are reciprocating compressors with discrete steps of
unloading. The operator manually adjusts the degree of compressor unloading (207HS-7002/7102/
7202) to keep the spillback valve in a good working range.

The first-stage suction drum is provided with a level controller (207LIC-6901) to automatically
drain any accumulated liquid. In addition, this drum is provided with a high-high level (100%)
shutdown that will shut all compressor trains running at the time. The second- and third-stage
suction drum shutdowns will shut the corresponding train only.

A high-pressure controller (207PIC-6902) on the make-up hydrogen from the hydrogen plant is
provided to help protect the make-up compressor suction from high pressure.

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CHAPTER-6

CHEMICAL REACTIOS
6.1 HYDROCARBO GROUP TYPES
Hydrocarbons are classified into four major groups according to the types of carbon-carbon
bonds they contain. The four major groups are Paraffins, Naphthenes, aromatics, and olefins.
Each group is described below.

Paraffins (alkanes) are straight chain or branched-chain hydrocarbons without any rings or
double bonds. Straight-chain Paraffins are called normal Paraffins and are responsible for the
waxy character of many petroleum stocks. Normal Paraffins, although having good burning
properties, have very high freeze points and very high pour points, so they make poor jet or
diesel fuels. Although they have a very high viscosity index, which is necessary for a high
quality lube oil, their very high pour points make them unsuitable for lube base stocks.
Branched-chain Paraffins are called isoparaffins. They make excellent high smoke point, low
freeze point jet fuel. Likewise, they make excellent diesel fuel, having low pour points with
high Cetane number. They also retain much of the high viscosity index character of their normal
paraffin cousins, but can have very low pour points, so they can make excellent lube base stock.
H
H C H
H H H H H

H H H H H H H C C C C C C H

H C C C C C C H H H H H
H C H H C H
H H H H H H H H
Normal Paraffin
Is o p a ra ffin

aphthenes (cyclic alkanes) are saturated ring compounds they do not contain any unsaturated
(benzene-like) rings. The simplest Naphthenes is cyclohexane. It’s structure is six carbon atoms
in a ring, each atom bonded to two hydrogen atoms. In VGOs or hydroprocessed VGOs,
Naphthenes are typically six-membered rings. Five-membered rings are also present but in
much lower concentration. Naphthenes have intermediate API gravities and burning properties.

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The great majority of molecules in mineral oil-based lube oils contain one or more Naphthenes
rings plus one or more paraffinic (alkyl) chains. This class of compounds is called alkyl
Naphthenes.

H H
H H
C C
H H
C C
H H
C C
H H
H H
N a p h th e n i c C o m p o u n d
( C yc l o h e xa n e )

Aromatics contain one or more unsaturated six-member carbon rings. An unsaturated ring
contains the equivalent of three double bonds. If some of the rings share two or more carbon
atoms, they are called condensed rings or polycyclic or polynuclear aromatics. In Hydrocracker,
aromatics are generally “saturated” (hydrogen added) to form Naphthenes. However, at higher
temperatures, this trend can be shifted and aromatics can form from Naphthenes by giving up
hydrogen.

H H

H C C H
H C C C
H C H C C H
C C C
H C C C
C C H C
H C H C
H C H
H
H
Aro m atic C om p ound (B enzene) Polycyclic Aromatic
(Phenanthrene)

As a group, aromatics have higher carbon-to-hydrogen ratios than any other group. They have
relatively low API gravities and tend to produce smoke when burned, so they make poor jet fuel.
They also have lower cetane numbers, so they make poor diesel fuel. Low molecular weight
aromatics have good antiknock properties, however, so they make excellent high octane
gasoline. Large, condensed aromatic ring structures like pyrene or coronene are believed to be
typical precursors to coke formation on catalyst surfaces, which can lead to catalyst deactivation.

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Olefins (alkenes) are reactive molecules, which contain one or more double bonds in an
otherwise paraffinic structure. Due to their highly reactive character, olefins do not occur
naturally in crude oil. Olefins can be formed as reaction intermediates during hydrocracking, but
the combination of their reactivity plus the environment in a typical hydroprocessing reactor
(high hydrogen partial pressure) is usually sufficient to saturate any olefins before they exit the
reactor.

H H
H
C C C C H
H
H H H
Olefin (Butene)

Heteroatomic compounds are usually hydrocarbons containing nitrogen or sulphur atoms.

Although a VGO may contain as much as 3% S and 3000 PPM N present as heteroatoms, a
hydrocracker will almost completely desulphurize and denitrify the product.

Heteroatomic Compounds
H H H H
C C C C

C C C C
H N H H S H
H

Pyrrole Thiophene

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6.2 REACTIOS OCCURIG I THE OHCU REACTORS

6.2.1 HYDROTREATIG REACTIOS

6.2.1.1 DESULPHURIZATIO:

The feedstock is desulphurized by hydrogenating sulphur-containing compounds to form

hydrocarbons and H2S. The H2S is subsequently removed from the reactor effluent, leaving only
the hydrocarbons in the product. Typical desulphurisation reactions convert thiols or thiophenes
to straight-chain or branched paraffins and H2S. The heat of reaction for desulphurisation is
about 560 kcal/Nm3 (60 Btu/SCF) of hydrogen consumed. Since desulphurisation is a primary
reaction, this heat release contributes appreciably to the total heat liberated in the reactor.

R C CH R

HC CH + 4H 2 Catalyst CH3 CHCH 2CH3+ H2S

S
Thiophene Branched Paraffin

R CH SH + H2 Catalyst R CH2 R + H 2S

Thiol Straight-Chain
Paraffin

6.2.1.2 DEITRIFICATIO:

Nitrogen is removed from the feedstock by hydrogenating nitrogen-containing compounds to

form ammonia and hydrocarbons. The ammonia is subsequently removed from the reactor
effluent, leaving only the hydrocarbon in the product. Typical hydrotreating reactions with
nitrogen compounds include hydrogenation of pyridines to form paraffins and ammonia,
quinolines to form aromatics and ammonia, and pyrroles to form paraffins and ammonia. The
heat of reaction of the denitrification reactions is about 660 kcal/Nm3 (70 Btu/SCF) of hydrogen
consumed.
Catalyst (i3S2)
R-CH2CH2CH2NH2 + H2 R-CH2CH2CH3 + NH3

Amine Paraffin Ammonia

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6.2.1.3 OLEFI SATURATIO:

Hydrogenation of olefins is one of the most rapid of the reactions taking place. Therefore,
essentially all olefins are saturated very early in the reactor system. The heat of reaction for
these reactions is about 1320 kcal/Nm3 (140 Btu/SCF) of hydrogen consumed. Because the
olefin content of the Hydrocracker feed is significant and because the saturation reactions are
rapid and release a large quantity of heat, care should be taken to control the temperature in the
first bed.
Catalyst (i3S2)
CH2CH=CH2 + H2
R CH2CH2CH3
R

Olefin Paraffin

6.2.1.4 AROMATIC- SATURATIO:

Some of the aromatics in the feed are hydrogenated to Naphthenes. Aromatic saturation
accounts for a significant portion of both the total hydrogen consumption and the total heat of
reaction. Heats of reaction vary from about 380-750 kcal/Nm3 (40-80 Btu/SCF) of hydrogen
consumed, depending on the type of aromatic being saturated. In general, higher pressures and
lower temperatures result in a greater degree of aromatic saturation.

H H H H
H H
C C H C C
H
R C C H + 3H 2 R C C
H
C C C C

H H H H H
H

Aromatic Naphthene

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6.2.2 HYDROCRACKIG REACTIOS:

Hydrocracking is a way to reduce the boiling range and remove heteroatom (mainly sulphur and
nitrogen) from the feedstock VGO. Hydrocracking of large hydrocarbon molecules into smaller
molecules occurs in nearly all processes carried out in the presence of excess hydrogen. The heat
release from the Hydrocracking reactions contribute appreciably to the total heat requirement
paraffinic molecules must be cracked into smaller molecules. The following is a generalized and
simplified equation of the Hydrocracking reaction taking place
Catalyst (Ni3S2)

CnH2n+2 + (x-1) H2 x C n/xH2n/x +2 + Heat,

Where x = no. of fragments ( low carbon no. paraffin molecules),

cracked from the high carbon no. paraffin molecule.
The following is a brief explanation of the chemical transformations taking place in the reaction
stage:
In the reactors, sulphur and nitrogen are removed from the feedstock. In general, the carbon
skeleton of the feed molecule is not altered by heteroatom removal; however, the boiling point of
the molecule decreases by 27-54°C for sulphur compounds and up to 104°C for nitrogen
compounds. Alkyl aromatics also react in the reaction stage to give three types of products:
• Aromatic- saturation to give a naphthene.
• Aromatic- dealkylation to give a paraffin and aromatic.
• Aromatic- condensation to give a polycyclic aromatic.

The amounts of each type of product depend on processing conditions (temperature, catalyst,
and hydrogen partial pressure) and feed composition.Operating conditions and catalyst
composition are important factors in determining the product properties and yields. If highly
branched naphtha is desired, isomerization should be emphasized (for example, by low reactor
temperature and high ratio of acid/hydrogenation activity in the catalyst). If mid-distillate
production is desired, product stabilization should be emphasized (with higher hydrogenation
activity to prevent over cracking).

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6.3 CATALYST CHEMISTRY

In order to hydrotreat and hydrocrack the feed, it must be processed in reactors containing
several types of catalysts. These catalysts provide a surface on which the reactions can occur
and help promote the rate of reaction. Hydrocracking catalysts are dual functional, which means
that they have both acid cracking sites and metal hydrogenation sites. The metal hydrogenation
sites provide olefin intermediates and saturate olefin products. They saturate some of the
aromatic- rings and prevent the accumulation of coke on the acid sites by hydrogenating coke
precursors. The acid cracking sites provide the carbonium ion intermediates and the
isomerization activity that result in the dominance of isoparaffins products. More acidic
catalysts produce a lighter yield distribution of higher iso-to-normal ratio products. Higher
hydrogenation activity catalysts produce more saturated products with a heavier yield
distribution.
The design of the hydrocracker is based on the use of a multiple catalyst system which provides
the optimum severity for the removal of feed impurities and conversion to distillate fractions.
The catalysts are also graded by size, shape, and reactivity to allow operations which minimize
the potential for premature pressure drop buildup. Refer to Tables in chapter-7 for the catalyst
loading profile.

6.3.1 CATALYST DEACTIVATIO

During hydrocracker operation, the catalysts will gradually deactivate or foul, losing their ability
to promote the desired reactions. Fouling results from carbonaceous deposits on the catalyst and
by metal deposits from trace contaminants in the feed which block access of the feed molecules
to the reaction sites. Catalysts deactivated by carbonaceous deposits (coke) can be regenerated,
but catalysts deactivated by trace metal contaminants are not regenerable. Some of these
contaminants can be volatile Ni and V in high end point feeds or in residuum entrainment
containing both metals and asphaltenes. Also, some contaminants could originate from feed
additives such as silicon and sodium or from corrosion products such as iron sulfide. For the
CPCL design, most of the first bed of the first reactor is devoted to demetallation catalyst. This
catalyst is designed to remove metals from the feed and thus protect the hydrotreating and
hydrocracking catalysts from metal contamination.

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To offset the loss of reaction sites, the reactor temperature must be increased. Higher
temperatures raise the rate of reaction at the remaining sites so that hydrocracking and
hydrotreating remains at the desired level. The rate at which temperature must be increased to
compensate for loss of catalyst activity is called the "fouling rate." The fouling rate is initially
high, levels off, and finally increases again near the end of a run. The shape for this temperature
versus time curve is the result of simultaneous coke and contaminants fouling during a run.

Fouling due to contaminants can be minor or major, depending on the contaminant type and
concentration. It can be minimized by removing contaminants from the feed. In this case
fouling will be attributed mainly to coke fouling. Initial high fouling rates occur until an
equilibrium layer of heavy oil and coke builds up on the catalyst. This initial period may take 1
to 4 weeks, depending on feed and operating conditions. It is necessary to raise catalyst
temperatures gradually during this period in order to control catalyst fouling caused by coking
within acceptable levels. A faster temperature increase than recommended would result in
excessive catalyst fouling due to high coke formation caused by the very active fresh catalyst.
This would reduce both subsequent catalyst activity and overall run length.

Following this period, the catalyst will deactivate very slowly as some additional coke formation
occurs. Maintaining high hydrogen pressure is essential to minimize the coke fouling.

6.3.2 CATALYST SULPHIDIG

Fresh catalyst as well as regenerated catalyst needs to be sulphided so that the optimum catalyst
stability and activity can be obtained before oil feed is introduced. The sulphiding process
consists of catalyst pretreatment with a sulphiding agent in the presence of hydrogen. When
heated and passed over the catalyst, the sulphiding agent breaks down into H2S which reacts
with the metal oxides on the catalyst, thereby generating active metal sites (metal sulfides).
The reactions taking place during sulphiding are as follows:

(1) Cracking of DMDS (The Sulphiding Agent):

CH3-S-S-CH3 + 3H2 → 2CH4 + 2H2S
This occurs at temperatures between 218–232ºC for DMDS.

(2) Conversion
of metal oxide to metal sulfide:
2H2S + 3NiO + H2 → Ni3S2 + 3H2O

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Initial sulphiding is best accomplished at as low a temperature as possible. This is usually at the
minimum temperature needed to generate H2S from the sulphiding agent. There is a temperature
rise associated with each reaction. The first temperature rise accompanies the decomposition of
DMDS to H2S and methane. This reaction goes to completion within the top of the first catalyst
bed. The second temperature rise accompanies the reaction of the just-formed H2S with the
metal oxides. In this reaction, the limiting reactant, H2S, is consumed within several inches of
bed depth. As each section of catalyst bed becomes completely sulphided, the reaction front
moves down the reactor. The temperature wave associated with this reaction moves with the
reaction front and can be monitored using the bed TIs of the reactor.

6.3.3 CATALYST REGEERATIO:

Catalyst regeneration is performed to restore catalyst activity lost due to the gradual
accumulation of coke on the catalyst. Catalyst activity lost due to metals poisoning (nickel,
vanadium, iron) cannot be restored. The regeneration process is a controlled burn of the
accumulated coke (the oxidation phase), followed by the reduction of metal sulfates on the
catalyst using low concentrations of hydrogen (the reduction phase). If the controlled reduction
were eliminated, the metal sulfates would be reduced when hydrogen is brought in for the
subsequent sulphiding operation. The highly exothermic reaction (sulfates to sulfides) would
quickly be out of control because of the high hydrogen concentration, and the catalyst would
most likely be damaged. The regeneration is completed by sulphiding the catalyst. Catalyst
regeneration consists primarily of burning off accumulated coke on the catalyst during the
oxidation phase:

4C + 2H2 4CO2 + 2H2O

During the oxidation phase, a flow-controlled amount of oxidation gas is sent to the reactors. A
ratio controller (FFC-6904) is used to control the % oxygen in nitrogen concentration at the
reactor inlet. Inert (nitrogen) recycle gas is brought to the suction of the make-up hydrogen
compressor on pressure control. The ratio controller measures this flow and adjusts airflow to
keep the ratio constant. Control of the make-up compressor discharge pressure is achieved by
spilling back around the compressor. For safety reasons, the air control valve will automatically
shut on high oxygen concentration at the inlet of the make-up compressor or on low-low flow of
inert recycle gas. Reactor loop pressure control is achieved by venting to the atmosphere.

During the oxidation phase, an unwanted side reaction takesplace, where some of the sulphur
(in the catalyst molecule) is also gets oxidised, to yield nickel sulphate, nickel oxide and sulphur
oxide.
i3S2 + 4O2 iSO4 + 2iO + SO2

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In the reduction phase, the nickel sulphate is eliminated to prevent temperature runaway during
subsequent sulphiding. Since some of the sulphur is retained as nickel sulphide, the subsequent
sulphiding uses less DMDS than used for sulphiding of fresh catalyst

3iSO4 + 10H2 i3S2 + SO2 + 10H2O

During the reduction phase, a flow-controlled amount of reduction gas is sent to the reactors.
Inert (nitrogen) recycle gas is brought to the suction of the make-up hydrogen compressor on
pressure control. A flow controller is used to manually control the % hydrogen in nitrogen
concentration at the reactor inlet. Control of the make-up compressor discharge pressure is
achieved by spilling back around the compressor. Venting to the atmosphere is not necessary for
reactor loop pressure control because all the hydrogen is consumed and the reactor loop is a
closed system.

• More details about catalyst regeneration are available in Chapter-12.

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CHAPTER – 7

CATALYST
7.1 CATALYST TYPE AD QUATITY:
Details of Catalyst type and required catalyst amounts are given in the following table.
Table 7.1.: Catalyst shape and Quantity

Diameter Total requirement for R-1 and R-2

Catalyst Type Shape
mm Kg m3 Drums
Demetallization and
Grading
ICR 122ZSB Sphere ~4.23 16,130 37.3 203
Hydrotreating
ICR 134SAQ Asym quad 2.82 *2.31 75,022 82.2 551
Hydrocracking
ICR 126 Cylinder 2.54 113,348 116.0 667
ICR 126N Cylinder 1.59 12,525 12.8 74
ICR 126L Cylinder 2.12 69,547 73.10 438
Support
ICR 114ZF Trilobe ~4.23 7,075 8.0 50
otes:
1. A 5% contingency over quantities shown above should be ordered to ensure complete
loading.
2. Typical net catalyst weights per drum and estimated loaded densities are:

Table 7..2: Catalyst density

Catalyst Kg per drum Loaded densities, kg/m3
ICR 134SAQ 136.1 912
ICR 126 170.1 976
ICR 126L 158.8 950
ICR 126N 170.1 976
ICR 114ZF 136.1 897
ICR 122ZSB 79.4 432
Alcoa T 162 --- 2,160
Gross drum weights are ~22kg heavier than net weights.

3. Loading requirement is based on

- 150mm layer catalyst above support screen for each bed of each reactor.
- Support catalyst to 150mm above top of cone in bottom bed of each reactor
- All beds loaded to within 150mm of the bubble cap tray.

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4. Volume shown as loaded be dense method for : ICR 134SAQ, ICR 126, ICR126L,
ICR 126N. Volume shown as loaded by sock method for ICR 122ZSB & ICR 114ZF.

5. Fill bottom dump pipe Alcoa T162 or equal.

6. Interbed catalyst dump pipe may be filled with 6.3mm ceramic balls.

7. Catalyst weights are based on updated loading information and slightly from those in EDP.

7.2 CATALYST LOADIG PATTER:

Before giving the reactor man entry check inside atmosphere for safe entry. Check all the
internals for it's intact. Clean out any debris if any present inside. Before loading catalyst the
reactor walls and internals should be visually inspected for water. Catalyst must not be loaded if
there is any sign of water.

Catalyst loading considerations:

Dry conditions are necessary for catalyst storage and loading. During the catalyst loading, the
catalyst must not be exposed to steam, rain, fog, cooling tower mist, etc. catalyst should not be
exposed to atmospheric air for long periods of time. A plastic or canvas covered “doghouse "
covering the top of the reactor will provide sufficient protection to permit catalyst loading during
mildly adverse conditions. At any case catalyst contact with water should be avoided.
Hydrocracker unit catalyst loading pattern details are as given below:

Table 7.3: Catalyst specification and Loading - 207R-1:

Catalyst Layer size Loading Required Required Loaded Catalyst Drum Catalyst
method depth (m) vol. (m3) density weight kg weight drums
Kg/m3 Kg
Outage 0.15
ICR 122ZSB 1/6 " Sock 3.55 37.3 432 16130 79.4 203
ICR 114ZF 3/16" Sock 0.15 1.6 897 1415 136.1 10
Outage 0.15
ICR 134SAQ 1/9*1 Dense 5.00 52.6 912 47968 136.1 352
/11"
ICR 114F 3/16* Sock 0.15 1.6 896 1415 136.1 10
Outage 0.15
ICR 134SAQ 1/9*1 Dense 1.24 13.1 912 1896 136.1 88
/11"
ICR 126 1/10" Dense 4.44 46.7 976 45586 170.1 268
ICR 114ZF 3/16" Sock 0.15 1.6 896 1415 136.1 10
Support balls ¼" Sock

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In the reactors, the grading and support catalyst will be sock loaded, while the active
catalyst i.e. ICR 134SAQ, ICR126, ICR126L and ICR126N will be dense loaded.

Dense loading provides the following benefits:

1. Denser loading of catalyst compared to sock loading.
2. Even catalyst distribution across the reactor, thus reducing the chances of channeled flow
after startup.
Catalyst loading must be interrupted periodically to inspect the bed and to check the bed catalyst
densities. The catalyst bed should be leveled across the entire reactor. The catalyst must be
carefully loaded to limit the amount of free fall through the loading sock, as rough handling will
cause breakage and produce fines. Typically a 150mm conduit attached to the loading hopper
outlet is used to guide the catalyst through the manway in the reactor internals to the dense
loader and to prevent damage to the catalyst as it fall. A conduit made from sections of metal
pipe with a flexible nylon or dacron sock attached at the bottom to connect with the loader is
preferred. The conduit must run full of catalyst without any free fall to prevent unnecessary
catalyst attrition and achieve the maximum catalyst loading rate. Alternatively, flexible conduits,
such as heavy-walled fiberglass hose or rip stop polyethylene hose, can be used.

Loading procedure for R-1:

Loading bed o: 3

1. Remove the catalyst dump pipe from the reactor internals above the bed to prevent
interference with catalyst loading.
2. Place chalk marks along the wall of bed no.3 about 150mm above the bottom cone. If
possible, also mark the demarcation between the ICR126L and ICR134 SAQ loading point. If it
isn't possible to reach the reactor wall at this location, load the estimated weights of the catalyst.
3. Fill the bottom dump pipe ¼ inch. Alcoa T162 alumina balls or equivalent. Fill the reactor to
flush with the bottom support cone with inert ¼ inch. balls. Alcoa T162 or equivalent should be
used.
4. Sock load the bottom of bed no.3 with ICR 114ZF up to chalk mark.
5. Dense load bed no.3 with ICR 126 as called for min the loading diagram. Inspect the bed
several times during the dense loading to check for levelness and compactness. Now simply
switch to ICR 134SAQ and continue loading.in any case, it is more important to keep the loading
sock full of catalyst breakage than it is to get the catalyst transition from ICR 126 to ICR
134SAQ at exactly the right level. On the last bed inspection, place several chalk marks 150mm
below the interbed distributor tray to aid in "topping off" bed no.3.
6. During "topping off" operation, load the catalyst in the area adjacent to the reactor wall first
since this is the most difficult are to reach. Fill in the center portion and level the bed to 150mm
+ or – 25mm below distributor tray.
7. When loading of the bottom bed is completed, clean catalyst dust from the internals
8. Check the catalyst support screen above the loaded for intact.

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Loading bed no.2

1. Remove the catalyst dump pipe from the reactor internals above the bed to prevent
interference with catalyst loading.
2. Fill the catalyst drainpipe with 1/4inch Alcoa T162 alumina balls to a level ~0.6m below
the top of the drainpipe. Place a disposal flow restictor on top of the drainpipe, that is cut in to
four 900 wedges to allow it to flow out of catalyst during catalyst dumping. Continue to fill the
drainpipe with 1/4inac Alcoa 162 alumina balls to level ~0.3m below the top of the drainpipe.
Place another disposal; flow restrictor on the drainpipe filling at the this level. Continue to fill
the drainpipe with 1/14 inch Alcoa T162 alumina balls until it is full.
3. Place chalk mark along the wall of bed no.2 about 150mm above the catalyst support
screen.
4. Sock load a 150mm layer of ICR 114ZF on top of the catalyst support screen.
5. Dense load the reminder of bed no.2 with the active catalyst (134SAQ).
6. Top the bed off to 150mm = or – 25mm below the distributor tray.

Loading bed no.1

Repeat the steps in a similar fashion to loading bed-2. ICR 114ZF and ICR 122ZSB are loaded
for the depth of 150mm and 3550 mm respectively.

Loading procedure for 207R-2:

R-2 catalyst quantities are given in the below table:

Table 7.4: Catalyst specification and loading - 207R-2:

Catalyst Layer Nominal Loading Required Required Loaded Catalyst Drum Catalyst
size method depth (m) vol. (m3) desity weight weight drums
3
Kg/m kg Kg
Outage 0.15
ICR 126 1/10" Dense 6.60 69.4 976 67,762 170.1 399
ICR 126N 1/12" Dense 1.22 12.8 976 12,525 170.1 74
ICR 126L 1/16" Dense 0.36 3.8 950 35,97 158.8 23
ICR 114ZF 3/16" Sock 0.15 1.6 896 14,15 136.1 10
Outage 0.15
ICR 126L 1/16" Dense 6.60 69.4 950 65,950 158.8 415
ICR 134SAQ 1/9*1/11" Dense 1.58 16.6 912 15,158 136.1 111
ICR 114F 3/16" Sock 0.15 1.6 896 14,15 136.1 10
Support balls ¼" Sock
207R-2 all beds catalyst is loaded using similar procedure as described for 207R-1.

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207R1 207R2

3.66m 3.66m
X-Area=10.52m2 X-Area=10.52m2
Outage Outage

ICR 122ZSB (Sock) ICR 126 (Dense)

ICR 114ZF (Sock)

Outage
ICR 126N (Dense)

ICR 134SAQ (Dense)

ICR 114ZF (Sock) ICR 126L (Dense)

Outage
ICR 114ZF (Sock)
Outage
ICR 134SAQ (Dense)

ICR 126L (Dense)

ICR 126 (Dense) ICR 134SAQ (Dense)

ICR 114ZF (Sock) ICR 114ZF (Sock)

Support Balls Support Balls

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 CHAPTER – 8

PROCESS VARIABLES
This section describes the effects of changing key process variables on reaction and fractionation
section operation. Specifically, the variables discussed in this section are listed below.

1 Feed Effects
2 Hydrogen Effects
3 Catalyst Effects
4 Reaction Section Operation Effects
5 Fractionation and Light Ends Sections Operation Effects
6 Effects of Reaction and Distillation Section Interactions

Process variables should not be discussed without first determining the basis for changing these
variables. All changes should be made to achieve an objective. The apparent objective of
operating the Isocracker is to convert feed to on specification products. The actual objective is to
maximize benefits to the refinery. The important factors involved in achieving this objective are

• Safety
• Value of Feed and Products
• Cost of Hydrogen
• Cost of Catalyst
• Cost of Utilities
• Replacement Cost of Equipment

A change in one process variable is likely to affect several of the others. A change which would
appear to help achieve the prime objective may be detrimental overall. Thus, it is important to
understand the interactions among the various process variables to determine the overall effect a
change would have on refinery operation. Many of the variables discussed in this section have an
effect on the catalyst performance. To help understand how the catalyst performance can be
affected, a brief review of catalyst kinetics follows.

On each catalyst pellet there are millions of what are called “active sites.” On these active sites,
the feed is converted to products. As the catalyst temperature is increased, the active sites work
faster and upgrade more feed to products. If some active sites become inactive (through catalyst
fouling), then a higher catalyst temperature is needed to get the same conversion of feed to
products from the remaining active sites.

Thus, if the operation of the Isocracker is to be changed, there are two things to consider with
respect to the catalyst. First, what is the catalyst average temperature (CAT) required to get the
desired conversion and upgrading at the new conditions? Second, what is the fouling rate
(°C/month the CAT must be increased to achieve desired product specifications) of the catalyst

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at the new conditions? The figures at the end of this section illustrate the effect of process
variables on CAT requirements. The catalyst life can be estimated from the actual CAT, the
expected fouling rate, and the predicted end-of-run (EOR) CAT.

8.1 Feed Effects

The Isocracker has the flexibility to process feeds with a range of properties. However, varying
design feed properties can have a large impact on the operation of the unit. For this reason, the
feed stream specifications shown in Table were provided to ensure that catalyst life is not
reduced unintentionally by processing feedstocks which are more difficult than the design
feedstock.

8.1.1 Feed Properties

The properties of the feed to the reactor have a significant effect on:
• Catalyst Life
• Required CAT
• Hydrogen Consumption
• Product Yields and Properties
• Reactor Performance

The properties of the feed blend should be held within the limits of the design specifications
shown in Table. The effects of feed properties are discussed in the following paragraphs.

8.1.2. Feed Boiling Range

The feed is a mixture of many different sized molecules. The composition of the feed mixture is
dependent on the crude oil used and the operating conditions of the upstream units. The primary
function of the Hydrocracker is to crack the large molecules (VGO-sized) to smaller molecules
(naphtha, kerosene, diesel-sized).

As the feed boiling range increases, the levels of nitrogen, polycyclic aromatics (PCA),
asphaltenes, and metals increase. A higher feed nitrogen level and higher PCA level require a
higher CAT. High PCA, asphaltene, and metal levels increase the fouling rate of the catalyst.
Therefore, increasing the feed boiling range shortens the run span by increasing both the
required CAT and the fouling rate.

8.1.3 Feed Nitrogen

Feed nitrogen is a temporary catalyst poison. Nitrogen tends to exist as basic compounds in the
feed. The sites on the catalyst that crack the feed are acidic. The nitrogen is adsorbed on the
acidic active sites, thus neutralizing their effectiveness to crack the feed. The remaining

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unaffected active sites must crack more feed to compensate for the neutralized sites. Thus, with
a higher level of feed nitrogen, a higher CAT is required to achieve a desired conversion.

If the feed nitrogen is lowered, some of the nitrogen neutralizing the active sites will desorbs;
however, nitrogen desorption is very slow in comparison to nitrogen adsorption. Thus, if the
feed nitrogen is lowered, the new equilibrium amount of nitrogen adsorbed on the active sites
may not be reached for several days. In some extreme cases where the feed nitrogen is
drastically reduced, the new equilibrium may not be reached for several weeks.

8.1.4 Feed Asphaltenes and Metals

Feed asphaltenes and heavy metal content must be limited to very low levels to prevent rapid
catalyst deactivation. The contribution of each to catalyst deactivation is discussed below.

Asphaltenes are hydrogen-deficient, condensed-ring molecules which boil well over 550°C.
Because of their structure and large size, they are difficult to crack and saturate and may
polymerize on the catalyst surface as carbonaceous deposits. With proper operation of upstream
units, asphaltene content of the Isocracker feed should be well below 100 ppm. But even short-
term poor operation of upstream units could result in high asphaltene levels in the Hydrocracker
feed (over 100 ppm) and cause catalyst coking and fouling.

Heavy metals, particularly nickel and vanadium, in addition to alkalis (such as sodium) and
alkaline earths (such as calcium and magnesium) are deposited on the catalyst and irreversibly
destroy its activity. These metals are found predominately in asphaltenes; however, they are
sometimes present in other molecular forms. Like asphaltenes, excessive metals reach the
catalyst in the feed through poor operation of the upstream units.

Metals concentrations as low as 1 ppm can have a significant effect on fouling due to pore
mouth plugging. Although the catalyst pellets look solid, each is full of tiny pores that oil and
hydrogen molecules can enter and then react within the pellet. Oil feed and hydrogen molecules
can react all the way into the center of the catalyst pellet. Metals, however, are too large to fit
inside the catalyst pores so they react on the outside of the pellet. Thus, when metals are
deposited on the catalyst surface, they not only foul the active sites on the outside of the catalyst,
but also block feed from reaching the active sites inside the pores. Consequently, even small
amounts of feed metals can foul the catalyst very quickly.

Iron carried in with the feed can be a troublesome contaminant. It may be chemically combined
with the heavy hydrocarbon molecules, or it may exist as suspended particulate matter. In either
case, it not only deactivates the catalyst through pore mouth plugging, as described above, but
also plugs the catalyst interstices such that excessive pressure drop may develop. Normally this
plugging would appear as crust at the top of the first-stage reactor. The feed filters are intended
to reduce the amount of iron particulates (e.g., scale) reaching the catalyst beds to minimize
plugging from this source.

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The first bed of the reactor is filled with a large-size demetallation catalyst, ICR 122ZSB. Its
large size and oval shape will distribute particulate matter over several meters of catalyst depth,
reducing the chance of formation of a crust at the top of the reactor. In addition, its porosity
makes it an effective depository for feed metals, protecting the more active catalyst in the lower
beds.

8.1.5 Polycyclic Aromatics

Polycyclic aromatics (PCAs) are catalyst coke precursors. These large multi-ring aromatic
compounds tend to dehydrogenate on the catalyst, ultimately forming coke. Consequently, the
amount of these compounds in the feed has a significant effect on catalyst activity and fouling
rate.

Characterization of PCAs in hydrocarbon streams is an involved exercise in chemical

characterization. Chevron has developed a simple characterization value that roughly correlates
with PCA content and with feed processing characteristics. This polycyclic index (PCI) is
determined by a simple UV absorption measurement technique. It is useful to track this value in
the Isocracker feed as an index to how difficult the feed is to process.

8.1.6 Feed Sulfur

Isocracker metallurgy and corrosion allowances were based on a specific sulfur content in the
feed. Extended operation on combined feeds with higher than design feed sulfur content would
shorten the useful life of the reactor and other equipment in the plant. Running high sulfur feeds
may increase the H2S content of the recycle gas, decrease hydrogen partial pressure, and reduce
overall catalyst performance.

8.1.7 Feed Chlorides

The salt (inorganic water-soluble compounds such as NaCl, MgCl, etc.) content of the feed
determines how rapidly salt builds up at the top of the first-stage reactor. If a salt crust builds
up, reactor pressure drop will increase, and can rise to the point where pressure drop may limit
the feed rate to the unit and require a shutdown. In addition to causing catalyst plugging,
excessive organic and inorganic chlorides may cause fouling and stress corrosion cracking in the
feed/effluent heat exchangers. Chlorides can also combine with ammonia produced in the
reactors to form ammonium chloride which may plug and corrode reactor effluent exchangers
and coolers. Desalted oil feeds may still contain trace amounts of organic and inorganic
chlorides and should be analyzed frequently to ensure that the specified maximum chloride level
of 1 ppm is not exceeded.

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8.1.8 Feed Oxygen

There is evidence that oxygenated compounds cause reactor bed plugging, furnace tube fouling,
and heat exchanger fouling. Care should be taken in the operation of feed tankage and
blanketing of the feed surge drum to exclude oxygen from the feed.

8.1.9 Upstream Processing

Operation of the Isocracker can be significantly affected by the performance of upstream units.
As mentioned above, it is extremely important that the crude desalter achieve consistent salt
removal to minimize the effect of these contaminants on the Isocracker. It is also important that
upstream units operate to minimize the Isocracker feed end point and distillation tails. Catalyst
poisons such as asphaltenes, metals, and nitrogen increase exponentially with boiling point. The
initial portion of the feed distillation should also be carefully controlled. Excessive amounts of
diesel-boiling range material in the feed (called overlap) will increase the product diesel pour
point.

Furthermore, a portion of the feed to the Isocracker comes from tankage. The condition of the
tanks and their nitrogen blanketing should be monitored frequently to minimize oxygen
contamination of the VGO. In addition, particulates (both corrosion products and coke) tend to
accumulate in tanks.

8.1.10 Feed Rate

During normal operation, the Isocracker will process a blend of 90% straight run (SR) VGO,
which can be a mixture of hot and cold (from tankage) VGO and 10% Visbreaker (VB) VGO at
a total feed rate of 222.5 m3/hr. The mechanical equipment is designed with the flexibility to
handle 40% turndown, so if feed is temporarily unavailable (due to problems in the crude units,
for example), reduced feed rates to the Isocracker are mechanically feasible.

When it is desired to change the feed rate to the Isocracker, the interaction between CAT,
conversion, and feed rate should be considered. To maintain conversion for an increased fresh
feed rate, the reaction temperature must be increased to compensate for the increased feed rate.
Figure 8-5 shows the changes in CAT required for different feed rates and conversion levels.
Figure 8-6 shows how changing the feed rate and conversion level affects catalyst fouling rate.
Note that the conversion is based on conversion below a temperature that Chevron has defined
as T*. T* is a useful and consistent “cut point” to use to track conversion because it is a
characteristic of a particular feed, in contrast to being a cut point defined by the design and
operation of equipment.

One potential scenario that can affect the first-stage feed rate is the loss of hot feed from
upstream units. If there is no hot feed available, the rate of the vacuum distillates from storage
should be increased so that the total cold feed rate is 111 m3/hr (50% of the design feed rate).

71
The bypasses on the feed preheat exchangers may need to be adjusted to limit the temperature of
the feed to the feed filters. With the proper adjustments in CAT, it is possible to continue
operation at the reduced flow rate. Note that for this example the CAT must be adjusted not
only for the reduction in feed rate, but also for changes in feed quality.

8.2 Hydrogen Effects

Hydrogen is the key ingredient in Hydrocracking. To promote the Hydrocracking reactions, it is
important to keep the hydrogen partial pressure and temperature in the range in which the
desired reactions occur. This section discusses the effects of make-up hydrogen purity,
hydrogen partial pressure, and recycle gas rate on Hydrocracking reactions.

8.2.1 Hydrogen Partial Pressure

Hydrogen partial pressure has an important effect on catalyst activity and fouling rate. An
increase in hydrogen partial pressure suppresses the coke fouling of the catalyst and maintains
low nitrogen levels in the products. Thus, the hydrogen partial pressure should be maximized
within the mechanical limits of the reactor system to maximize run length. Figure 8-7 can be
used to understand the effects of hydrogen partial pressure on catalyst fouling.

In addition to decreasing fouling rates, increasing the hydrogen partial pressure causes more
aromatic molecules to be converted to naphthenic molecules. This improves the smoke point
and cetane number of the products.

The hydrogen partial pressure can be increased by:

• Increasing Bleed Gas Rate

• Increasing Make-Up Hydrogen Purity
• Increasing Recycle Gas Purity
• Increasing Total System Pressure (Operate as close as is practical to the relief valve set
pressure located on the CHPS).
• Decreasing CHPS Temperature

The process design was based on an average hydrogen partial pressure of 145 kg/cm2 (a) for the
first reactor and 135 kg/cm2 (a) for the second stage. Reactor average hydrogen partial pressure
is difficult and tedious to calculate in the field (a material balance around the reactors is
required, which implies that a test run is first performed). Consequently, the reactor inlet
hydrogen partial pressure is normally used for monitoring operating plants. Reactor average
hydrogen partial pressure is 95-98% of the reactor inlet hydrogen partial pressure.

This simplified approach is more than adequate to characterize hydrogen partial pressure effects
on operation and catalyst life.

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8.2.2 Make-Up Hydrogen Rate

Most of the hydrogen fed to the Isocracker is consumed chemically. A small amount is
physically dissolved in the products from the reactors and later flashes out in the low pressure
separators and in the distillation and the gas recovery facilities. A very small amount leaks out;
some through flanges and valve packing leaks, some through compressor shaft seals, and even
some by diffusion through steel walls. Hydrogen may also be intentionally bled from the high
pressure loop to control the buildup of light hydrocarbons, such as methane, in the recycle gas,
which could lower hydrogen purity and decrease hydrogen partial pressure. Although the unit
will normally maintain the design concentration of recycle gas hydrogen without taking a bleed,
it is preferred to use the bleed valve for reactor loop pressure control as described below.

Make-up hydrogen is fed to the reaction section as required on pressure control of the high
pressure loop. Maximizing total system pressure by operating as close as practical to the CHPS
relief valve set pressure will help maximize hydrogen partial pressure.

8.2.3 Make-Up Hydrogen Purity

Make-up hydrogen from the off plot hydrogen unit consists of a mixture of hydrogen and
methane. Methane is also produced in the hydrocracking reaction. The hydrogen is consumed
in the hydrocracking reactions and lost in the other ways described above. The methane
concentration builds to an equilibrium concentration in the recycle gas such that the amount
dissolved in the reactor effluent plus any bleed or leakage equals the amount coming in with the
make-up hydrogen plus any methane formed in the reactors. Since methane does not dissolve as
readily as other light hydrocarbons in heavier hydrocarbon streams, the concentration of
methane in the recycle gas will be large relative to its concentration in the make-up gas. The
result is reduced hydrogen partial pressure in the reactors. Thus, to maintain the desired
hydrogen partial pressure and minimize the amount of impurities fed to the system, the purity of
the make-up hydrogen should be kept at the design value (99.5 mole % H2). If the make-up
hydrogen purity falls below the design value, a bleed may be required to maintain an acceptable
hydrogen partial pressure.

8.2.4 Recycle Gas Rate

Recycle gas has four major functions listed below:

1. Maintaining high hydrogen partial pressure in the reactors. Without the excess
hydrogen in the recycle gas, the hydrogen concentration (partial pressure) would be very low in
each reactor because most of the make-up hydrogen is consumed by reaction.

2. Providing a heat sink for the high heat of reaction in the catalyst beds. The reaction of
hydrogen with the feed is highly exothermic, several times the design heat duty of each of the

73
reactor feed furnaces. The overall temperature rise from this heat release is held in control by
using quench gas; however, the quench gas can only be added between reactors and between
catalyst beds. Keeping a high gas rate (make-up gas plus recycle gas) in the reactor limits
temperature rise in a catalyst bed (30°C maximum across any single bed) by spreading the
effects of heat release over a larger mass flow.

3. Distributing reactants over the catalyst. The two-phase reaction mixture of hydrogen-rich
gas and oil is difficult to distribute evenly across the catalyst in the reactor. A high recycle gas
rate helps to evenly distribute flow across the reactor by keeping the pressure drop through the
beds in an optimum range. Good distribution is essential to avoid hot spots in the catalyst
caused by low flow or stagnant conditions which fail to effectively carry away the heat of
reaction.

3. Minimizing recracking of products by carrying them out of the reactor before they can
recrack. The Hydrocracking reactions take place in the oil-soaked pores of the catalyst.
The cracked products are carried away from the reaction sites in two ways:

• By vaporizing into the gas stream.

• By trickling over the catalyst with the liquid which eventually leaves the reactor.

Any cracked product which remains in the liquid is likely to recrack, degrading to a less valued
product. A high recycle gas rate helps to vaporize products and carry them out of the reactor
before they can “overcrack.”

All four effects of recycle gas discussed above are favored by high recycle gas rates. These
effects all help minimize catalyst fouling.

The recycle gas rate should be adjusted to meet all the following limits:

• 188,000 Nm3/Hr Total Gas Rate to the First-Stage Reaction Section (at 222.5 m3/Hr Oil Feed)
• 30°C Maximum Temperature Rise Across Any Single Catalyst Bed

Please note that these gas rates were calculated to satisfy the minimum of 845 Nm3 (inclusive of
quench flow) of reactor inlet gas per m3 of fresh feed. If the feed rate is increased above
225.5m3/hr, the gas rates should be raised to meet the above criteria. If the feed rate is lowered
below the design rate, the gas rates should be maintained at 100% to maintain good distribution
in the reactors.

In addition to affecting the reactors, the recycle gas rate can also affect the performance of other
equipment. Equipment that can be affected by changes in the feed gas rate include the feed /
effluent exchangers, reactor feed furnaces, and interconnecting piping. Decreases in the feed gas
flow rates will result in lower velocities through this equipment. This will result in lower heat
transfer coefficients and may lead to coking in the furnaces and fouling in the exchangers.

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8.2.5 Recycle Gas Purity

The hydrogen purity or hydrogen concentration of the recycle gas has a direct influence on the
reactor hydrogen partial pressure. A high recycle gas purity yields high hydrogen partial
pressures and minimizes catalyst fouling. The design purity of the recycle gas is approximately
90.7 mole % H2 at SOR and 85.6 mole % H2 at EOR. The recycle gas purity depends mainly on
the make-up hydrogen purity and the yield of methane in the reactors. A gas bleed, CHPS
temperature, and hydrogen consumption also have an effect. Taking a bleed, which results in an
increase in the make-up hydrogen rates, lowers the methane content of the recycle gas and
improves hydrogen partial pressure. Lowering the CHPS temperature will improve purity
because more light hydrocarbons will condense out of the recycle gas and because less hydrogen
dissolves at lower temperatures. Lowering the CHPS pressure will reduce the recycle purity.
Hydrogen consumption is dependent on catalyst temperature and target conversion and cannot
be controlled independently.

8.3 Catalyst Effects

The following section discusses the effects of various catalyst types and temperatures on
hydrocracking performance. Hydrocracking catalysts are usually cylindrical or shaped
(e.g., asymmetric quadrilobe) pellets of highly porous materials. The types and characteristics of
the catalyst are discussed below and in the catalyst specifications given in chapter-7 , Catalyst.

8.3.1 Catalyst Type

The type of catalyst used effects the performance and product yield structure of the unit. The
catalysts loaded in this Isocracker have the following purposes:

• ICR 122ZSB is a roughly 4 to 5 mm spherical catalyst. It provides size grading for removal
of any particulates that have not been removed by the feed filter. It also removes organically
bound metals (usually nickel and vanadium) from the feed so as to protect the more active
catalyst downstream. It has essentially no activity for the removal of sulfur or nitrogen, nor does
it do any hydrocracking.

• ICR 134 is a catalyst that is designed to do the maximum amount of sulfur and nitrogen
removal. It does little hydrocracking.

• ICR 126 is a catalyst that is designed to do deep desulfurization and denitrification as well as
accomplishing hydrocracking with good selectivity to mid-distillate fuels of superior quality.
Two different sizes of this catalyst are selected for this design. A smaller sized catalyst gives the
best activity, but also results in a larger pressure drop through the reactor. In this design, the
smaller size is used in the first reactor; there is capacity for more pressure drop because of the
large size of the ICR 122ZSB that is used in the first bed. In the second reactor, the larger sized

75
catalyst is used throughout. At SOR conditions, this selection of catalyst sizes results in the
same pressure drop in the first and second reactor.

8.3.2 Catalyst Temperature

Catalyst temperature is a measure of how hard the catalyst is working. As the temperature
increases, the catalyst cracks more and makes lighter products. This shift is shown in the
difference between SOR and EOR yields. At a fixed temperature with all other variables
unchanged, the catalyst will produce a nearly constant product slate; however, over a period of
time (weeks or months), the catalyst will slowly “foul,” that is, become coked-up with reaction
by-products and feed impurities. The coke that forms on the catalyst will cause part of the
catalyst to become useless. The catalyst temperature must be raised to enable the remaining
active catalyst to work harder and compensate for lost activity. The rate of temperature rise to
compensate for fouling is called the fouling rate.

In addition to raising temperature to compensate for catalyst fouling, temperature changes may
be required to compensate for changes in:
• Feed Properties
• Feed Rate
The temperature increases required for these changes are not a measure of fouling; they are an
indication that the catalyst is doing a tougher job. Therefore, fouling can be measured most
accurately when running the same feed at the same conversion level at various times during a
catalyst run. Frequent changes in feed properties and operating conditions make it difficult to
measure the fouling rate. In addition to affecting the product slate, catalyst temperature also has
an effect on product qualities. For a given conversion, a higher catalyst temperature will usually
result in a lower smoke point kerosene product and a lower cetane index diesel product. This is
a result of the equilibrium shift to aromatic molecules from naphthenic molecules at higher
temperatures. Having more aromatics decreases kerosene smoke point and diesel cetane index.

8.3.3 Catalyst Life

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Both stages of the Isocracker are designed to have a catalyst life of more than 2 years to first
regeneration. The table below summarizes the effects of changing each of the process variables on
catalyst life.
Table 8.1: Operating Variables vs Catalyst Life

Variables Change Effect on Catalyst Life

Feed Rate Increase Decrease
Conversion Increase Decrease
Hydrogen Partial Pressure Increase Increase
Make-Up Gas Purity Increase Increase
Reactor Pressure Increase Increase
Recycle Gas Rate Increase Increase
Recycle Gas Purity Increase Increase

8.4 Reaction Section Operation Effects

There are several additional variables which affect the operation of the reaction section besides
the effects of feed, hydrogen, and catalyst already discussed.

8.4.1 Cold High Pressure Separator Pressure

The relief valve for the high pressure loop is located on the CHPS overhead line. The set
pressure (161.5 Kg/cm2) (pressure above which the relief valve will open and begin to
depressure the unit) of this pilot operated valve is 105% of normal operating pressure
(154 Kg/cm2). To avoid unnecessarily popping the relief valve, the CHPS pressure should never
be operated above 95% of the relief valve set point. This margin allows for some tolerance in the
relief valve spring setting, and also time for operator response if the system pressure starts to
build. Once the relief valve opens, it may not reset properly and the released gases will cause an
unnecessary load on the flare system and waste hydrogen.

At SOR when the catalyst beds and equipment are clean, or at low feed rates, the pressure drop
through the reactor loop will be low. In this case, the reactors will be operating well below their
mechanical design limits even when the CHPS is operating at the normal pressure.

The pressure control for the reactor loop is based on setting the recycle compressor suction
pressure such that the CHPS operates at the normal maximum pressure allowed by the CHPS
relief valves. This is done by varying the make-up hydrogen rate. When the equipment and
catalyst fouls as the run progresses, the reactor inlet pressures will increase. The recycle
compressor discharge pressure (and differential pressure across the compressor) should be

increased to compensate for the higher pressure drop. If the mechanical design pressure for the
reactors is reached, it will be necessary to lower the pressure controller on the CHPS overhead to
stay below the reactor design pressure limit.

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The reactor loop pressure should be held as high as possible, as limited by CHPS relief valve
setting and reactor design pressure. This will ensure operation at as high a hydrogen partial
pressure as possible. Maintaining a high hydrogen partial pressure will decrease catalyst fouling
rate, increase catalyst life, and improve product smoke point and cetane number.

8.4.2 Cold High Pressure Separator Temperature

The CHPS temperature 550C is controlled by adjusting the speed of the fans operating in the
reactor effluent air cooler (207E9). Lowering separator temperature will:

• Increase the recycle gas purity.

• Lower the recycle compressor horsepower requirement.
• Make the separation of oil from water in the separator more difficult.

Usually water will separate easily from the oil in the separator. Because oil-water separation is
not expected to be a problem, the separator temperature should be kept as low as possible by
running all of the fans in the air cooler. If some fans have to be shut down, turn off those which
are not on the emergency power system.

8.4.3 Cold Low Pressure Separator Pressure

The pressure in the CLPS (207C9) is only variable within a narrow range. The upper limit of the
controlled pressure range is dictated by the relief set pressure (41.8 Kg/cm2) on the CLPS. The
low pressure limit (28 Kg/cm2) is set by the pressure required to send the net offgas to the PSA
unit for H2 recovery. Within this pressure range, lower pressures are favored because they allow
more dissolved gases to flash off, reducing the required fractionator overhead condenser duty
and maximizing recovered hydrogen.

8.4.4 Injection Water Rate

To prevent deposition of ammonium bisulfide and ammonium chloride in the reactor effluent air
cooler (207E9), water is injected in the effluent vapor line upstream of the air cooler inlet. The
ammonium bisulfide and ammonium chloride readily dissolve in the injection water and are
removed from the system in the CHPS sour water stream. The design quantity of injection water
(5480 kg/hr) is required to limit ammonium bisulfide concentration in the sour water to 11 wt %
(12 wt % maximum limit). The hydrocracker cannot run very long if the injection water pump
fails because the ammonium salts will rapidly plug the air cooler. If the water injection cannot
be restarted within 1 day, the unit should be shut down until water injection can be established.
In the meantime, all possible efforts should be made to restart the injection water, while close

monitoring of loop pressure drop should be initiated to determine if tubes have become plugged
with ammonium sulfide deposits.

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When the oil feed rate is reduced, the gas rate is maintained at 100% to help maintain good
distribution in the reactors. Likewise, for ease of operation and to ensure uniform injection
water flow, the injection water rate is maintained at 100% even when the oil feed rate is reduced.

8.4.5 Reactor Temperature Profile

Hydrocracking reactions release a large amount of heat , causing the catalyst temperature to rise.
The higher temperature promotes the cracking reactions, thereby releasing even more heat. This
sequence of events must be controlled to prevent the temperature from approaching the reactor
design temperature. The primary function of the quench system is to control the extent of
reaction (rate of heat release) and the temperature rise across each bed. The quench controllers
monitor the temperature at the top of each bed and regulate the flow of quench gas above each
bed. The bed heights are chosen to give approximately equal heat release per bed, provided each
bed is operated at the same average temperature.

Four important terms should be defined before further discussion of reactor temperature profiles:

• Level Average Temperature (LAT)

• Bed Average Temperature (BAT)
• Catalyst Average Temperature (CAT)
• Temperature Profile

The LAT is the simple arithmetic average for a set of eight thermocouples at one level in a
catalyst bed. The BAT is the simple arithmetic average of the bed inlet and outlet LATs. The
CAT is the weighted average of the BATs. Each individual BAT is weighted by the volume
fraction of the total active catalyst in that bed. The temperature profile describes the BATs for
the whole reactor. There are three types of profiles:

• A flat temperature profile means that the BATs are equal.

• An ascending profile means that each successive BAT is higher than the bed above.

• A descending profile means that each successive BAT is lower than the bed above. This
profile is rarely used (or achievable).

BAT, CAT, and temperature profiles are all used to monitor reactor performance. The CAT
determines how hard the catalyst is working and the temperature profile describes how the work
is distributed over the reactor. A flat profile will cause the catalyst work to be evenly distributed
in the reactor, which maximizes the catalyst life and liquid yields. A rising profile will cause
less burden on the upper beds and more burden on the lower beds. As a result, the upper beds

foul slower and the lower beds foul faster than normal. The overall effect is a somewhat reduced
catalyst life compared to when running a flat profile.

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Some refiners choose to run a rising profile because in some cases the reduced utilities costs are
worth more than the increased catalyst costs. A rising profile saves utilities for two reasons:
• The reaction heat release is not quenched as hard so the recycle compressor flow rate (which
includes quench gas) decreases, and hence its horsepower goes down.

• The increased difference between reactor inlet and outlet temperatures enables the
feed/effluent exchangers to transfer more heat, allowing the furnace firing rate to be reduced.

Please note that running a rising profile does not affect the amount of heat contained in the
reactor effluent it just makes it available at a higher temperature because of the reduced quench
gas flow. In effect, less heat is wasted in the effluent cooler. The heat saved is transferred in the
feed/effluent exchanger to reduce furnace firing rate.

The feed/effluent exchangers can deliver extra heat to the reactor feed by closing the bypass.
The feed furnace firing rate will automatically cut back to hold reactor inlet temperature. When

adjusting the bypass rate to recover more heat from the reactor effluent, remember that the
reactor feed furnace should have a minimum temperature rise of 22°C. This minimum
temperature rise gives the operators the capability of quickly reducing reactor inlet temperature
by shutting down the furnace in case of emergency.

8.5 Fractionation and Light Ends Sections Operation Effects

The following section is a discussion of the effects of changing the controllable process
variables on product stripper, product fractionator, sidecut strippers, deethanizer, debutanizer,
and naphtha splitter operation. Table 8-1 summarizes these effects. In order to more fully
understand the effects various changes in operation can have, a brief description of important
distillation terms and a general discussion on distillation itself are given below.

Generally stated distillation is an operation intended to separate a stream with two or more
different types of molecules into two or more product streams, based on volatility differences
among the different types of molecules. Refinery distillation is especially complex because the
refinery products that have to be separated contain thousands of different types of molecules. It
is extremely important to operate the distillation section accurately because the product yields
and product performance (flash point, pour point, etc.) are determined by the way that the
fractionator is operated.

8.5.1 Distillation Terms

Cut Point : Cut point is a common and very useful concept utilized for fractionator
performance analysis. All of the product yields specified in the Engineering Design Package are

80
defined between certain cut points. The information needed to calculate the cut points at which
a fractionator is operating are the product volumetric flow rates and product true boiling point
distillations.

Rectification and Stripping: A distillation column can be divided into a rectification section
(trays above the feed inlet) and a stripping section (trays below the feed inlet). Each section has
its own specific function. In the rectification section, high boiling components are removed
from the upflowing vapor stream by contact with a downflowing liquid stream. In the stripping
section, low boiling components are removed from the downflowing liquid stream by contact
with upflowing vapor or stripping gas.

This exchange of high boiling and low boiling components is essential to the distillation process
and is what distinguishes a distillation column from a flash drum. The ability of a distillation
column to separate low-boiling molecules from high-boiling molecules depends on three major
factors:

1) Number of trays.

2) Ratio of downflowing liquid to upflowing vapor (L/V) in the rectification section. Ratio of
upflowing vapor or stripping gas to downflowing liquid (V/L) in the stripping section.

3) The relative tendency of the products to vaporize (relative volatility).

Since Factors 1 and 3 are out of the control of operations, the internal column flows (L/V and
V/L ratios) are the single most effective variables that can be adjusted to affect separation
quality.

Overflash: The overflash in the fractionator is a measure of the extent of “overvaporization” of

the fractionator feed as it enters the flash zone. If a perfect split of distillate products and
fractionator bottoms were possible with a single stage flash, then the furnace heat input would be
adjusted to just vaporize all the products and no overflash would be necessary. However, to
sharply separate the fractionator bottoms from the bottom sidecut to meet product specifications,
the heater must supply additional heat to vaporize additional feed so that the excess can be
condensed and provide the countercurrent liquid flowing back down to the flash zone. Overflash
liquid is the “overflashed” vapor from the flash zone that has condensed and is traveling back
down to the flash zone.

Pumparounds: A pumparound stream is withdrawn from the column as a bubble point liquid,
used to heat cooler streams, then returned to the column several trays higher as a subcooled

liquid. The trays between the pumparound drawoff and pumparound return are called the
pumparound zone. When the subcooled liquid stream contacts the hot dew point vapors rising

81
through the pumparound zone, condensation occurs. The rate of the vapor stream leaving the
pumparound zone will be less than it was on entering. Pumparounds are used to condense
products within the column rather than in the overhead system. This allows the heat of
condensation to be removed at high temperatures where it can be used to more effectively
transfer heat to other streams. Internal condensation of products can also limit column diameter
above the pumparound zone since vapor traffic is reduced. Offsetting these benefits is a
reduction in top reflux. This drops the ratio of downflowing liquid to upflowing vapor (L/V) in
the rectifying zone above the pumparound, causing the amount of heavy molecules to increase in
the overhead product.

Reboilers: Reboilers are used to add heat to column bottoms. The added heat partially
vaporizes the column bottoms oil. This vapour then strips light molecules out of the bottom
product. In the kerosene stripper, deethanizer, debutanizer, and naphtha splitter, a portion of the
column products are reboiled to provide a vapor stream that strips light molecules from the
downflowing liquid. The performance of the columns depends on the ratio of the vapor to the
downflowing liquid. When the V/L ratio is higher, more light molecules are stripped from the
column bottoms product.

As the lighter molecules are removed by stripping, the temperature of the downflowing liquid
rises. The temperature rise across the column is a rough indication of the stripping V/L.

Steam Stripping: Steam stripping is used in the diesel sidecut stripper and the bottom of the
fractionator. The stripping steam generates stripping vapor by lowering the partial pressure of
the hydrocarbons in the downflowing liquid which causes the liquid to vaporize. The
downflowing hydrocarbon liquid supplies the heat of vaporization and consequently becomes
cooler. The temperature drop across the stripping zone of a steam stripped column is a rough
indicator of the stripping V/L.

Product Specification Limits: The yields of most refinery products are limited by certain
quality specifications. For example, kerosene cannot be allowed to contain too many light,
volatile molecules or else its flash point will be too low. Diesel fuel cannot be allowed to
contain too many heavy molecules or else its pour point will be too high. If profitability requires
high diesel production, it will be critically important to recover as many suitable molecules from
the fractionator feed, without compromising the product specifications.

The keys for making onspecification products are to sharpen the rectifying performance of the
column (by increasing L/V) to exclude too-heavy molecules and to sharpen the stripping
performance of the column (by increasing V/L) to exclude too-light molecules. After sharp

splits are established, product yield can be increased by dropping some of the next lighter
product, by pulling some of the next heavier product, or both.

Dropping Effects: Dropping” is a term operators use to describe moving lighter molecules
down the column. This involves lowering a sidecut flow controller set point to produce less of a
product. The overall effect of this move is to allow the back end of a lighter product to pass

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down the column and become the front end of the next heavier product. If that product is flow
controlled, its back end will be displaced further down the column to become the front end of the
next heavier product.

The effect of “dropping” is to lighten products starting with the stream whose rate is reduced and
continuing downward through the column. “Dropping” puts the front-end dependent
specifications (e.g., flash point) of all the affected streams at risk because the bulk composition
gets lighter. “Dropping” will also increase the rectifying L/V in each of the affected rectifying
zones because the downflowing liquid rates go up while the upflowing vapor rate is unchanged.
Finally, “dropping” will cause the draw temperatures of all affected products to decrease.

Pulling Effects: “Pulling” is a term operators use to describe moving heavier molecules up the
column. This involves raising a sidecut flow controller set point to produce more of a product.
The overall effect of the move is to allow the front end of the next heavier product to be pulled
up the column and become the new back end of the next lighter product. If the product below is
flow-controlled, it will reach further down the column to “pull” up the front end of the next
heavier product to satisfy the set point of its flow controller.

The effect of “pulling” is to heavy up products starting with the stream whose rate is increased
and continuing downward through the column. “Pulling” will also decrease the rectifying L/V

in each of the affected rectifying zones because the downflowing liquid rates are reduced while
the upflowing vapor rate is unchanged. “Pulling” puts the back-end dependent specifications
(e.g., kerosene freeze point, or diesel pour point) of all affected streams doubly at risk because
the bulk composition gets heavier and because the rectifying performance is degraded due to
lower L/V. Finally, “pulling” will cause the draw temperatures of all affected products to
increase.

8.5.2 Effects of Process Variables on Distillation Section Operation

Table shows the effects of increasing a distillation section process variable (listed along the
top of the chart) on the properties of each product, on the second-stage feed rate, on the
fractionator reflux rate, and on the fractionator overflash rate (listed on the left side of the chart).
A blank entry means that increasing the process variable has no significant effect on the selected
product property.

8.5.2.1 Product Stripper

The product stripper is designed to separate H2S, LPG, and some naphtha from the heavier oils.
The bottoms liquid, which contains less than 1 ppm H2S, feeds the rest of the fractionation
section. The overhead product is sent to the light ends recovery section. Process variables
affecting the performance of the product stripper include overhead pressure, feed temperature,
overhead temperature, and stripping steam rate.

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In the product stripper, removal of heavy molecules from the overhead (rectification) takes place
in the packed bed above the feed inlet. In the packed beds below the feed inlet, light molecules
are stripped from the stripper bottoms product (stripping).

8.5.2.1.1 Product Stripper Overhead Pressure

The product stripper normally operates at a pressure of 14.1 kg/cm2 (g) so that the overhead
remains at a high enough pressure to be sent to the light ends recovery section without further
compression.

If the pressure of the product stripper is increased, vapor flows (and returning liquid flows) in
the rectification and stripping sections will decrease. Raising the column pressure (while the
overhead temperature controller set point is constant) will allow fewer heavy molecules to be
present in the overhead vapor and there will be a lower yield of overhead. At a constant
temperature, less feed flashes on the feed tray so the required heat removal (via the overhead
reflux) is less. More light ends stay in the flashed feed liquid, so the light ends content of the
bottoms increases. It is best to operate the product stripper at the lowest reasonable pressure that
will allow the overhead to be sent to the light ends recovery section.

8.5.2.1.2 Product Stripper Feed Temperature

The stripper feed temperature (248 oC) is controlled by the temperature controller around E-4.
An increase of feed temperature will cause the temperatures in the product stripper to increase.
The overhead temperature controller will increase the reflux to maintain the desired overhead
temperature. A higher L/V in the rectification section will improve the removal of the heavier
molecules from the overhead.

If the feed temperature decreases, the temperature and vapor flows in the product stripper will
decrease. This will lower the V/L ratio in the stripping section and the stripping steam rate will
have to be increased to strip the lighter gases out of the bottoms product. The overhead
temperature will have to be increased to prevent condensation of the additional water.

8.5.2.1.3 Product Stripper Overhead Temperature

The stripper overhead temperature controller controls the cut point between the overhead light
ends recovery section feed and the fractionator feed. Raising the set point of the overhead
controller raises the cut point of the overhead product and increases the amount of overhead
product. The overhead temperature of the product stripper (146 oC) is maintained above the
water dew point to prevent water condensation.

8.5.2.1.4 Product Stripper Stripping Steam Rate

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The purpose of the stripping steam is to strip the lighter gases out of the bottoms product by
lowering the hydrocarbon partial pressure. The stripping steam rate (design is 3653 kg/hr.
approximately 14.65 kg/m3 of feed) was set to strip the H2S and LPG out of the fractionator
feed.
Increasing the stripping steam rate increases the vapor traffic going up the product stripper,
which raises the capacity to strip light gases from the bottoms liquid by increasing the stripping
section V/L ratio. Stripping steam also affects the amount of feed that vaporizes on the feed tray
and the hydrocarbon dew point (temperature at which the overhead vapors will condense) of the
overhead temperature controller. More stripping steam lowers the hydrocarbon partial pressure
(at a constant total pressure) so the overhead product cut point increases (opposite to raising
pressure) and the overhead product rate increases. More feed is flashed on the feed tray, so the
reflux rate increases for heat balance. In summary, increasing the stripping steam results in less
light ends in the bottoms liquid for three reasons:

1) More light ends in the bottoms are removed at the feed tray due to a higher percentage
flashed.
2) Overhead cut point increases.
3) Higher V/L in the stripping section.

8.5.2.2. Product Fractionator

The product fractionator is designed to recover the desired products from the reaction section
effluent liquid. In normal operation, naphtha is recovered from the overhead; kerosene and
diesel are drawn as sidecuts; fractionator bottoms liquid is sent to the FCC or storage. Process
variables affecting the recovery of these products are feed temperature, column pressure,
overflash rate, stripping stream rate, pumparound heat removal, and sidecut stripper operation.
Discussions of each of these product fractionator process variables follow.

8.5.2.2.1 Product Fractionator Overhead Pressure

Pressure in the column is controlled by varying the position of the control valve in the overhead
line. The control valve restricts the flow of liquid from the air cooler and causes it to back up

into the air cooler. The air cooler, therefore, is operated in a partially flooded mode. The
amount of condensation is controlled by the amount of “unflooded” area. The “flooded” area
will subcool the liquid. The column pressure is then controlled by changing the area available
for condensation. At a steady overhead flow rate, restricting the flow of liquid will reduce the
area for condensation, thereby raising the column pressure. Opening the control valve will
increase the area for condensation and lower column pressure.

A pressure equalizing line between the column overhead and the reflux drum is used to maintain
a smooth flow of liquid (which flows due to hydraulic head only) and to prevent backflow
should the column pressure decrease.

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Finally, under low cooling demand, the air cooler could become completely flooded. At this
point, pressure control is lost. An outlet temperature controller is added to prevent excessive
subcooling of the liquid. It reduces the cooling available in the air cooler, which allows the
pressure control valve to open. This allows the air cooler to partially drain and restores pressure
control to the column.

Pressure is an important variable in determining the product fractionator feed heater duty. For a
fixed product fractionator column distillate yield and overflash rate, reducing the column
pressure reduces the heat input requirements of the heater. At a fixed furnace duty, reducing the
column pressure can improve the product fractionator column distillate yield by increasing the
overflash rate to give better separation. However, lowering column pressure increases the vapor
velocity in the column, which can lead to column flooding. It is best to operate the fractionator
at the lowest pressure, as limited by flooding, which still provides adequate pressure for the
products to flow off plot. The design overhead pressure is 0.8 kg/cm2 (g).

The following describes what happens to the products if column overhead pressure is increased.
Increasing the fractionator overhead pressure causes the overhead cut point to decrease which, in
turn, causes the naphtha rate to the light ends section to decrease. The rates of the products
drawn off as side cuts will remain the same because they are controlled by flow controllers with
a set flow rate. The fractionator bottoms level will increase because of the lighter material
dropping down the column. The composition of the three side cuts will become lighter (lower
start point and end point) due to dropping effects. The product qualities that are dependent on the
front end of the product cut (flash point) will become worse because of the lighter material
dropping down the column. Cold properties of the product (pour point, freeze point) will
become better because these properties are primarily dependent on the back end of the product
cut which has gotten lighter.

8.5.2.2.2 Product Fractionator Feed Temperature

The feed to the product fractionator is heated in the fractionator feed furnace to produce at least
10% overflash. The temperature of the fractionator feed is controlled by the fractionator furnace
firing. The normal operating temperature is 359°C. At a given column pressure, the amount of
feed that vaporizes in the fractionator flash zone is determined by the feed temperature. The
overflash rate (20% of the feed rate) determines the sharpness of separation between the diesel
sidecut and the product fractionator bottoms (see below).

As the feed temperature is increased, more of the feed vaporizes resulting in higher vapor flows
up the column and a higher fractionator reflux rate. The increased reflux rate and liquid traffic
in the rectification section will result in higher L/Vs. Consequently, the individual products will
have decreased end points. The product cold properties (pour point and freeze point) will
improve.

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8.5.2.2.3 Overflash Rate

The column overflash rate (50m3/hr) determines the back end tail of the diesel sidecut.
Increasing the overflash increases traffic on the trays below the diesel draw, which improves
rectification. This improved rectification minimizes the amount of higher end point molecules
which reach the diesel draw tray. Thus, the end point of the diesel is reduced, and its pour point
is improved, thereby allowing more diesel to be drawn.

The increased heat input to the fractionator from increasing the overflash rate is removed in the
circulating reflux and the overhead condenser. The overflash rate can be increased up to
flooding or heat removal limits in order to maximize distillate yields. For a fixed pumparound
duty, the column overflash rate also determines the vapor and liquid traffic on all trays above the
flash zone. This sets the degree of rectification of the kerosene and diesel products.

8.5.2.2.4 Product Fractionator Stripping Steam Rate

Stripping steam (3425 kg/hr) is fed to the product fractionator below Tray 1. Increasing the
stripping steam rate can improve the recovery of distillate products by reducing the amount of
lighter boiling products in the fractionator bottoms. At a constant set point of the overhead
temperature controller, more stripping steam will result in increased naphtha product due to

lower hydrocarbon partial pressure in the overhead. All of the initial and final cut points of the
products will increase. The cold product properties (pour point and freeze point) will get worse
because the FBP of the sidecuts have gotten heavier. The flash points of all products will
improve because the IBP of all cuts has gotten heavier. Note, however, that high steam rates
increase the condenser duty in the column overhead, the amount of sour water produced as
condensate, and can lead to column flooding by increasing column vapour trafic.

Decreasing the stripping steam rate will reduce steam consumption, overhead condenser duty,
and condensate production; however, the amount of the lighter boiling distillate products in the
fractionator bottoms will increase. Also, an insufficient stripping steam rate can lead to weeping
and poor column performance in the stripping section (Trays 1-11). The optimal stripping steam
rate is based on operating experience (design value is 3425 kg/hr) balancing product recovery
and sharpness of separation with steam and sour water disposal costs.

8.5.2.2.5 Product Fractionator Overhead Temperature

The fractionator overhead temperature (98 to 100ºC) is controlled by the fractionator overhead
condenser. Additionally, a temperature controller, located below Tray 50, adjusts the amount of
fractionator reflux to achieve the desired cut point between naphtha and kerosene. If the
naphtha/kerosene cut point shifts, all other cut points will shift in the same direction if the
sidecut flow rate set points are not changed. For instance, increasing the fractionator overhead
temperature results in a reduced reflux rate and an increased product naphtha rate. All of the
product initial and final cut points will increase because L/V in the product rectification section

87
has decreased and there is less cooling in the column. The flash point of all products will
improve but the cold properties (pour point and freeze point) will get worse.

8.5.2.2.6 Product Fractionator Heat Removal and Pumparound Rates

The product fractionator relies on the overhead condenser system and the two circulating reflux
systems (pumparound) for heat removal. While each of these systems is controlled separately,
the proper balance of heat removal among these systems is necessary to prevent flooding while
maximizing rectification for best product yields. During initial operation, the design duties of the
heat removal systems should be used to operate the product fractionator. As experience
develops and operational needs change, the heat removal distribution among these systems can
be tailored to specific operating requirements.

The fractionator column overhead is condensed in an air cooler, and then goes to the fractionator
reflux drum. The naphtha is drawn on level control of the reflux drum. Part of the naphtha is
returned as overhead reflux to Tray 50 of the fractionator. The reflux is used to control the
temperature of the column overhead. This determines the cut point between the naphtha and
kerosene. Kerosene pumparound is drawn (165 oC, 200 m3/hr) from Chimney Tray CT-3 and is
returned (110 oC) above Chimney Tray CT4 of the fractionator after it is cooled in the BFW

preheater and air cooler. The heat removal by this pumparound reduces both the liquid and
vapor traffic above Tray 42 and cools the rising flash zone vapor. Consequently, the
rectification ability above a pumparound is reduced as the pumparound rate is increased.
Decreasing the rectification above the kerosene pumparound will result in increasing the naphtha
and kerosene end points.

The diesel pumparound is drawn (270o C, 270 m3/hr) from Chimney Tray CT1 and returned
(210 oC) above Chimney Tray CT2. This stream is used to reboil the kerosene side stripper and
the debutanizer, and then generate steam; the temperature control on the exit of the steam
generator determines the temperature of the pumparound when it returns to the fractionator. As
with the kerosene pumparound, the rectification ability above it is reduces as the pumparound
rate is increased. Decreasing the rectification above the diesel pumparound will result in
increasing the kerosene and diesel end points but allows for enough duty to reboil the kerosene
side stripper and the debutanizer.

The pumparound duty controls the fractionation above the return trays by controlling the liquid
and vapor traffic in that section of the product fractionator. Increasing the circulating reflux heat
removal reduces vapor and liquid traffic and results in decreased rectification above the
circulating reflux. Reducing the circulating reflux heat removal increases vapor and liquid
traffic and results in better rectification above the circulating reflux but allows additional heat to
be lost in the fractionator overhead condenser.

8.5.2.2.7 Product Fractionator Sidecut Stripper Operation

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There are two sidecut strippers associated with the fractionator. The top sidecut is kerosene,
which is drawn from CT3 above 39 of the fractionator and reboiled in the kerosene stripper. The
second sidecut is diesel, which is drawn from Chimney Tray CT-1 above Tray-25 of the
fractionator and is steam stripped in the diesel stripper. The purpose of the sidecut strippers is to
remove the lightest components from the product draw. Without stripping, all of the sidecuts
would have flash points close to ambient temperature. These light molecules are removed in the
strippers by being reboiled or stripped from the product. The process variables affecting the
performance of the distillation section as related to the sidecut strippers include production rates
and reboiler duties.

8.5.2.2.8 Sidecut Production Rates

The production rates of kerosene and diesel can be controlled by adjusting the flow rates of the
product liquid drawn off the bottom of each respective stripper. At a fixed plant feed rate, a
change in a sidecut rate is usually balanced by a move of one or more of other variables such as:
• The Production Rate of Another Sidecut
• Fractionator Heat Removal
• Fractionator Overflash Rate
• Reactor CAT

The following scenario describes what might occur in the column if the kerosene draw rate is
increased. If the kerosene draw is increased while the other product draw rates remain constant,
the effect will be to “pull” the front end of the light diesel cut into the kerosene and the front end
of the fractionator bottoms into the diesel. The temperature of all the trays below the kerosene
draw, including the pumparound draw trays, will increase. The pumparound return liquids

temperature is controlled by temperature controllers that adjust the kerosene pumparound air
cooler operation or the diesel pumparound steam generator. If the pumparound return liquid
temperature controller is not adjusted, the pumparound heat removal will increase. This will
reduce vapor and liquid traffic and hurt rectification above the pumparound.

Increasing the kerosene draw rate (with no other changes) will also result in less overflash into
the flash zone. This will adversely affect the diesel heavy end tail as well as heavy up the entire
diesel cut. There will be an increase in the cut point between the diesel and fractionator bottoms.
The column bottoms level will begin to drop. At this point, the column will be out of material
balance (i.e., more distillate products being drawn than are entering the column). This will
require that either the diesel draw rate be reduced to compensate for the increase in kerosene, or
that the column overhead temperature be lowered to reduce naphtha carried overhead, also
compensating for the increase in kerosene.

8.5.2.2.9 Kerosene Stripper Reboiler Duties

The kerosene stripper removes light molecules from the kerosene draw by reboiling them in the
kerosene reboiler and returning them to the product fractionator. The kerosene is reboiled by the

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heat from diesel pumparound liquid. If the production rate of kerosene varies, it is very
important to adjust the reboiler duty so that adequate stripping is achieved. The duty is adjusted
by varying the amount of pumparound oil bypassing the reboiler. The stripper has automatic
ratio controller that adjusts the bypass flow around the reboiler depending on the product flow
rate.

The reboiler duties of the stripper can be varied to adjust the flash point and IBP of the sidecut
product. Increasing the kerosene stripper reboiler duty will increase the amount of vapor
flowing upward through the stripper. The increased V/L ratio will increase the removal of the
light boiling molecules from the product resulting in increased kerosene IBP. The extra heat
input is carried back to the product fractionator where it will be removed as incremental
overhead condenser duty, leading to a higher reflux rate. This will give a higher L/V on
Trays 43-50 to improve rectification of the naphtha (lower end point).

The extra vapor generated by increasing the reboiling rate increases the required overhead
condenser duty and increases the top reflux.
Design
Draw rate 84.2 m3/hr
Draw temperature 75 oC
Reboiler heat duty 2.3 MM KCal/hr

8.5.2.2.10 Diesel Stripper Steam Rate

Super heated MP Stripping steam liquid (V/L). This results in a sharper IBP of the diesel
product. in the diesel stripper removes the light molecules from the diesel draw. Increasing the

stripping steam rate increases the stripping capacity by increasing the ratio of upflowing vapor to
downflowing liquid.

The extra vapor generated by increasing the stripping steam rate increases the required overhead
condenser duty and increases the top reflux. High stripping steam rates can lead to flooding of
the stripper and the section of the product fractionator above the stripper return due to high vapor
traffic. High stripper steam rates could cause the diesel water content to be too high.

Design
Draw rate 75.0 m3/hr
Draw temperature 278 oC
Stripping steam flow 1827 kg/hr

8.5.2.3 Deethanizer and Sponge Oil Absorber

The deethanizer is designed to remove C2, H2S, and other light gases from the LPG/naphtha
stream before the LPG and naphtha is separated in the debutanizer. The column and sponge oil
absorber were designed for high C3 recovery into LPG with almost complete removal of H2S
from the bottoms product (stabilizer feed). An important variable affecting C3 recovery is the

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heavy naphtha sponge oil rate (10 to 12 m3/hr) and its composition. Other process variables
affecting the performance of the deethanizer include column pressure, feed temperature, Tray-2
temperature, and sponge oil operation.

8.5.2.3.1 Deethanizer Column Pressure

The pressure of the deethanizer (12 kg/cm2) is controlled by the pressure controller at fuel gas
absorber outlet. Sour gas from the deethanizer reflux drum is routed to the sponge oil absorber.
Pressure is an important variable in column performance because it has a significant impact on
vapor flow rates in the column.

If the column pressure is increased, vapor flows (and returning liquid flows) in the rectification
and stripping sections will decrease. Raising column pressure, while the temperature controller
set point is constant, allows fewer heavy molecules to be present in the overhead vapor to satisfy
the dew point requirement. Consequently, C3 content of the overhead will decrease and the
amount of overhead offgas will also decrease. Higher C3 recovery in the deethanizer will
increase LPG production. Furthermore, at constant feed temperature, less feed flashes on the top
tray so more light ends stay in the flashed feed liquid. The light ends content of the bottoms
increases which will result in increased H2S content and vapor pressure of the LPG product.

8.5.2.3.2 Deethanizer Feed Temperature

The feed to the column passes through the deethanizer overhead condenser. Hydrocarbon enters
the column at a fairly constant temperature (40oC), as the condenser uses cooling water as its
condensing media.

8.5.2.3.3 Deethanizer Tray 2 Temperature

The temperature of Tray 2 (86 oC) of the deethanizer is sensitive to the C2 and H2S content of the
bottoms product. This design controls the temperature of Tray 2 using a temperature to reboiler
duty cascade control arrangement. The duty controller sets the amount of fractionator bottoms
going through the reboiler to maintain the operator set Tray 2 temperature. If the temperature on
Tray 2 is increased while column pressure is held constant, more heavy molecules will end up in
the overhead vapor causing an increase in C3 losses and a decrease in LPG recovery. Less light
molecules will also be carried to the debutanizer which lowers LPG vapor pressure.

8.5.2.4 Sponge Oil Absorber

Deethanizer overhead vapor enters the sponge oil absorber as feed at the bottom of two packed
beds. Heavy naphtha from the naphtha splitter bottoms is fed to the overhead of the sponge
absorber and is refluxed back to the sponge absorber on reflux drum level control. This addition
of heavy naphtha is necessary because the column has primarily light, noncondensable gases
such as H2S and C2 in its overhead stream such that it cannot generate enough liquid reflux.

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Sponge oil rate (10 to 12 m3/hr) is an important variable that affects LPG recovery because it
serves as column reflux. A higher sponge oil rate leads to a higher L/V ratio to help in the
removal of heavy molecules, mainly C3, from the deethanizer overhead vapor. More sponge oil,
however, also means more light gases such as H2S and C2 will be carried to the debutanizer
leading to an increase in H2S content and vapor pressure of the LPG.

In addition to the rate of sponge oil sent to the column, the composition of the sponge oil itself is
another important variable affecting C3 recovery. If the heavy naphtha cut becomes heavier, it
will be more effective at removing light gases in the sponge oil absorber, which will result in
lower C3 and C4 losses and a higher LPG rate.

8.5.2.5 Debutanizer

The main objective of the debutanizer is to separate LPG from the naphtha product. Process
variables affecting the performance of the debutanizer include column pressure, Tray 5
temperature, and reflux rate. In this column, removal of heavy molecules from the overhead
(rectification) takes place on Trays 23-44 and removal of light components from the naphtha
product takes place on Trays 1-22.

8.5.2.5.1 Debutanizer Column Pressure

Column pressure (10.7 kg/cm2) is controlled in the overhead line near the inlet of the reflux
drum. Raising the column pressure allows fewer heavy molecules to be present in the overhead
liquid draw. This decreases the rate and C5 content of the LPG, which in turn results in an
increased light naphtha product rate. Almost all H2S entering the debutanizer is recovered in the
overhead product. Since there are fewer heavy molecules in the LPG, the amount of H2S relative
to the amount of hydrocarbon molecules has increased (assuming constant feed H2S
concentration). This increases the H2S concentration in the LPG and, with the reduction of
heavy molecules, increases its vapor pressure. Furthermore, at a constant feed temperature,
increasing column pressure results in less feed flashing on the feed tray. More light ends will
reach the column bottom which raises the light naphtha vapor pressure.

8.5.2.5.2 Debutanizer Tray 5 Temperature

The temperature of Tray 5 (166 oC) of the debutanizer is sensitive to the butane content in the
bottoms stream. This design controls the temperature of Tray 5 using a temperature to reboiler
duty cascade control arrangement. The duty controller sets the amount of diesel pumparound
going through the reboiler to maintain the operator set Tray 5 temperature.

If the temperature on Tray 5 is increased while column pressure is held constant, more heavy
molecules will end up in the overhead draw causing an increase in C5 content of the LPG. This
loss of heavy material will reduce the light naphtha product rate.

8.5.2.5.3 Debutanizer Reflux Rate

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The debutanizer reflux rate is held constant by flow control (11 m3/hr). Increasing the reflux
rate will increase L/V in the rectification section and improve the removal of high boiling
components from the vapor stream above the feed tray. The C5 content and rate of the LPG will
decrease and cause an increase in light naphtha rate.

8.5.2.6 aphtha Splitter

The main objective of the naphtha splitter is to separate the light naphtha (C5-95ºC) from the
heavy naphtha product. Process variables affecting the performance of the naphtha splitter
include column overhead pressure, Tray 2 temperature, and reflux rate. In this column, removal
of heavy molecules from the overhead (rectification) takes place on Trays 21-36 and removal of
the light components from the heavy naphtha product takes place on Trays 1-20.

8.5.2.6.1 aphtha Splitter Column Pressure

Column pressure is controlled on the overhead line near the inlet of the reflux drum. Raising
the column pressure allows fewer heavy molecules to be present in the overhead liquid draw.
This decreases the rate and C7 content of the light naphtha product, which in turn, results in an
increased heavy naphtha product rate. Increasing the column pressure at a constant feed
temperature also results in less feed flashing on the feed tray. More C6 will reach the column
bottoms, increasing the C6 content in the heavy naphtha product.

8.5.2.6.2 aphtha Splitter Tray-2 Temperature

The temperature of Tray 2 (130 oC) of the naphtha splitter is sensitive to the C6 content in the
bottoms stream. This design controls the temperature of Tray 2 using a temperature to reboiler
duty cascade control arrangement. The duty controller sets the amount of fractionator bottoms
going through the reboiler to maintain the Tray 2 temperature set by the operator.

If the temperature on Tray 2 is increased while column pressure is held constant, more heavy
molecules will end up in the overhead draw, resulting in an increased C7 content of the light
naphtha product. This loss of heavy material will reduce the heavy naphtha product rate.

8.5.2.6.3 aphtha Splitter Reflux Rate

The naphtha splitter reflux rate (51 m3/hr) is held constant by flow control. Increasing the reflux
rate will increase L/V in the rectification section and improve the removal of higher boiling
components from the vapor stream above the feed tray. The C7 content and rate of the light
naphtha will decrease and cause an increase in heavy naphtha rate.

8.6 Effects of Reactor and Distillation Sections Interactions

The following section discusses the effects of reactor and distillation section interactions.

8.6.1 Hydrocracker Feed and Product Assays

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Hydrocracker feed and products are mixtures of many different hydrocarbons. The distribution
of boiling points for the mixtures can be determined with a true boiling point (TBP) assay. The
TBP distribution for the fresh feed is at a much higher boiling point than for the products. The
feed is cracked by the catalyst in the reactors into a lighter distribution, as reflected by the
product TBP distributions occurring at lower boiling points. If the reactors crack more, the
product assays will shift towards lower boiling temperatures; if the reactors crack less, the
product assays will shift towards higher boiling temperatures.

The reactor effluent provides the feed to the distillation section. The operating variables of the
distillation section define the product assays and cut points. The main cut points are set as
follows:

• The light naphtha/heavy naphtha cut point is set by the overhead temperature controller of
the naphtha splitter which resets the flow rate controller of the reflux. Less net light naphtha
results from a lower temperature set point (more reflux is needed).

• The kerosene/diesel cut point is set by the kerosene product draw rate.

• The fractionator bottoms cut point is set by the diesel product draw rate.

The product cut assays are also affected by distillation operations as follows:

• The light naphtha end point and cut point depend on the amount of reflux to the naphtha
splitter (i.e., overhead column temperature). Increasing the reflux will reduce the light naphtha
heavy end tail.

• The heavy naphtha start point depends on the naphtha splitter reboiler duties. The difference
between the start point and the cut point on the front end of an assay is also known as a tail.
Increasing the naphtha splitter reboiler duty will reduce the light end tail and lower product
vapor pressure.

• The kerosene end point depends mostly on the L/V on Trays 26-39. Changes in operation
which increase the amount of heat going up the column, such as reducing pumparound duty or
increasing fractionator feed furnace duty, will reduce the heavy end tail.

• The diesel start point depends primarily on the kerosene stripper reboiler duty. Increasing
the reboiler duty will reduce the light end tail and improve the flash point.

• The diesel end point depends mostly on the L/V on Trays 12-25. Changes in operation
which increase the amount of heat going up the column, such as increasing the fractionator
furnace duty, will reduce the heavy end tail and improve the diesel pour point.

94
• The fractionator bottoms start point depends primarily on the stripping steam rate to the
bottom of the fractionator.

8.6.2 Fractionator Level Control

The objective in fractionator level control is to maintain a controllable level in the fractionator
while providing a stable feed to the FCC or tankage. Complications arise in an Isocracker
fractionation system because the fractionator is not fed a constant blend of products. The
relative proportions of naphtha, diesel, and bottoms vary depending on how much cracking is
taking place in the reactors. The Isocracker was designed to convert 54% of the feed to distillate
products. During normal operation as much hot feed (150 oC) as it can accept will be sent to the
FCC. Any additional fractionator bottoms will be sent through the air cooler (90 oC) to tankage.

For short-term fluctuations in fractionator level, the fractionator level can be maintained by
adjusting the diesel draw. If the fluctuation is due to a change in reactor feed content (for
example, the “new” feed is easier to crack), longer term changes to reactor operation will have to
be made.

Process Evaluation and Planning

To maintain the desired product quality and catalyst life, periodic feed stream analyses and
process performance evaluations should be made. Data obtained from these analyses and
evaluations are used to monitor catalyst activity and may be used to project remaining catalyst
life.

Feed Stream Inspections

The catalysts used in this process are sensitive to certain chemical substances, which act as
catalyst poisons. Lists for allowable quantities of these trace substances in the various feed
streams to ensure adequate catalyst life is attached. The methods which should be used when
performing analyses for these substances are presented in the Analytical Manual. Some feed
stream properties, such as nickel and vanadium content, asphaltenes, and end point, have limits
which should not be exceeded if design yields, product properties, and catalyst life are to be
achieved.

Sample Schedules

95
Tables for recommended sample schedule during startup, test run, and normal operation and for
sample schedule during catalyst sulfiding are given below. The tables list stream properties to
be measured, the test method to be used, and frequency of analysis. The sample analyses are
intended to provide necessary detailed information on plant operation and should be adhered to
after initial startup. Most of the inspections required during normal operation are the same as for
startup, except that the frequency of sampling is reduced. To obtain the maximum amount of
useful information for plant performance evaluation, samples for all the analyses on a given
stream should be drawn at the same time. The test methods are explained in detail in the
Analytical Manual.

Performance Test Run

As per the license agreements, a test run was performed at the beginning of the unit’s operation.
Process Engineering had developed a table of instrument readings, corrections required, and
frequency to generate a material balance around the plant.

The analyses and operating data had provided the necessary data to:

• Obtain an accurate material balance around the reaction section

• Measure the product yields and hydrogen consumption

• Determine the reaction section operating parameters necessary to interpret the test run
results.

96
97
98

ote:

1. The words in the cells indicate the directional change in the rate or property for an
increase in the indicated controller set point, assuming all other controllers are working and
no abnormal conditions or equipment limits are hit.

2. A blank cell indicates that little or no change is expected.

3. Increasing fractionator stripping steam raises product cut points (opposite to raising
pressure), but also increases L/V in each rectifying section (similar to raising feed
temperature). The opposing effects on end point may cancel.

4. Increasing naphtha and/or kerosene draw rate leads to higher temperatures on diesel
pump-around draw tray, resulting in more pumparound heat removal and less top reflux.

99
 CHAPTER – 9

UDER GROUD SYSTEM & DRAWIG

9.1 REFIERY-3 OFFSITE FACILITIES
Table 9.1
Flow rate D/C Pressure Auto cut in
SERVICE PUMPS 3 Destination
m /hr. Kg/cm2 a / cut out

Oily Water 47-GM-103 A/B/C ETP I, II, III

100 7.0 YES
Sewer
47-GM-104 A/B/C 10 3.0 NO Floor wash
Contaminated ETP I, II, III
Rain Water 47-GM-102 A/B/C/D Canal
System 250 7.0 YES
Fire water
OWS
ETP I, II, III
47-GM-105 A/B/C Canal
Storm Water 400 3.0 NO
47-GM-105 D/E Fire water
(diesel driven) CRWS

Combined OWS stream passes through a channeling arrangement before entering OWS
sump before it can be pumped to destinations as detailed in the table.

Combined CRWS stream also passes through a channeling arrangement and can be routed
to OWS, CRWS or Storm Water Reservoir by operating on the Sluice Gates located
upstream of channeling arrangement.

CRWS sump is provided with a floor wash pump for removing bottom sludge.

Increasing degree of contamination:

Storm Water  Contaminated Rain Water  Oily Water
(But it is possible that all become equally contaminated)

Increasing order of capacity handled / load:

Oily Water  Contaminated Rain Water  Storm Water

100
Table 9.2: The underground utility services

OSBL OSBL
Service Description ISBL Destination
connectivity Destination
OWS Oily Water Sewer MHO- OWS offsite sump
CRWS Contaminated Rain MHC-2A,
CRWS offsite sump
Water Sewer MHC-04
AS Amine Sewer ---------- Amine sump 207C-51 Rich amine to
ARU
CS Caustic Sewer MHO- OWS offsite sump
CBD Closed Blow Down SLOP CBD sump 207C-52 Slop
WCR Pump Bearing Cooling Pump Coolant Sump Blow down to
(U/G) Water return 207C-57 Cooling tower

9.2 ISBL UDERGROUD SERVICES OF OHCU

The underground services of OHCU are divided into five areas for ease of identifying and
clearing blockages.

9.2.1 SEALIG ARRAGEMET I OWS AD CRWS PITS (ISBL)

Type 16 without sealing wall inside: This is common to both OWS and CRWS

Vent Vent Vent

Seal

Flow direction of Oily Water or Contaminated Water

Note:
• Depth of the pit increases from pit to pit.
• Seal is achieved by the inlet bend, which normally avoids a backward flow.
• Vents are provided to remove vapours as well as facilitate flow

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Type 16 (with sealing inside wall) pit: Only for CRWS

Vent Vent Vent

This backward flow of oil is prevented

Note:
• Depth of the pit increases from pit to pit.
• Seal is achieved by the inside wall, which normally avoids a backward flow.
• Vents are provided to remove vapours as well as facilitate flow.

9.2.2 OWS: Ref Fig II

Salient features:

OWS underground system is provided with Clean Out Points (flanged) which are
located sufficiently elevated to clear any blockage. Clean Out flanges are suitably
sized to connect firewater hoses.

Originally OWS ISBL final outlet was connected to Offsite CRWS MHC-6C. It was
corrected later by introducing a new MHO- in the Offsite along the north of OHCU.

Slope from MHO-05 to MHO-04 (normal flow direction is from MHO-05 to 04) and
slope from MHO-14 to MHO-13 (normal flow direction is from MHO-14 to 13) is
very little or nil. It was observed at the time of thoroughness checking that water flow
took place in the reverse direction in both cases. . This should be borne in mind while
troubleshooting.

Vents should be observed for blockage / flow of gases and cleaned from time to time.

Streams connected to OWS:

• Drain from Vessels and Columns
• Drain from Pumps, Heat Exchangers, Coolers, Condensers

• Caustic from 207G-32

• DMDS from 207G-30, 207C-38

102
9.2.3 CRWS: Ref Fig III

This is the most important underground system because of its high load bearing
capacity especially during water stagnation times (rains / flooding). CRWS
contents can be routed to OWS or Storm Water reservoir by operating the Sluice
gates at the Offsite.

Inside Surface drains contaminated or otherwise, flow eventually to CRWS

through Catch Basins.

Condensate from Steam supply / Condensate recovery stations and steam trap
outlet are routed to CRWS through Catch Basins.

In the CRWS drawing Fig III, Catch Basins are indicated as Alphabets with
arrows leading to respective CRWS pits.

9.2.4 CBD: Ref Fig IV A & IV B

CBD underground Clean Out Points are provided with flushing oil connections,
which can be used on line to clear any suspected choke. The flushing oil
connection may also be used as Utility connections.

As per P&ID 13 Clean Out Points (and hence 13 flushing oil connections) are
required to be provided but only 9 Clean Out Points (and hence 9 flushing oil
connections) have been provided.

All the 9 Clean Out Points are located inside pits.

Streams connected to OWS

• Drain from Vessels and Columns
• Drain from Pumps, Heat Exchangers, Coolers, Condensers

All CBD collections flow to CBD sump 207C-52 from where it can be pumped
(207G 37) to slop.

CBD sump details are given in Fig IVB.

9.2.5. AMIE SEWER: Ref Fig VA & V B

103

Amine Sewer underground Clean Out Points are provided with Utility connection
point which can be used on line to clear any suspected choke.

Originally 3 out of the 4 Clean Out points were provided with Utility
connections. Later on, utility connection point was provided to the 4th Clean Out
Point also (located in the LER area for draining Amine from 207E-10 and
207E-37.

Connections to Amine sewer: 207C-4, 207C-5, 207C-6, 207C-7, 207C-11,

207C-12, 207C-25, 207C-26, 207G-5A/B, 207G-6A/B, 207E-10, 207E-37.

All amine sewer drains collect in 207C-51 from where it can be pumped by
207G-36 to Rich amine return to ARU.

Amine sump details are given Fig V B

9.2.6 CAUSTIC SEWER: Ref Fig. VI

Caustic sewer constitutes surface level trench covered by checker plates.

Drains to Caustic sewer comprises drains from: 207C-31, 207C-43, 207C-45,

207G-23A/B, 207G-26.

Trench leads to a closed pit provided with a vent.

Caustic from the above pit collects in a neutralization pit where it is neutralized
before being let out to OWS.

Valve pit contains the isolation valve for the neutralized caustic solution. This pit
is provided with dewatering ejector.

Caustic sewer and the closed pit need to be kept clean by periodically water
washing. All safety measures need to be taken during cleaning.

9.2.7 BEARIG COOLIG WATER RETUR: Ref Fig: VII A & VII B

Underground Bearing Cooling Water (BCW) return piping network (WCR) is

provided with 6 flanged clean out points.

These clean out points facilitate online dechoking / flushing of piping from
different locations of the plant.

All condensate return from Steam supply / condensate recovery stations / points
was originally envisaged to be routed to pump coolant sump. This was, however,

104
 was not taken up subsequently. All condensate / steam trap outlets flow to CRWS
only.

Pump coolant sump.

9.2.8 STORM WATER SEWER: Ref Fig. VIII

Storm Water Sewer of OHCU has been provided with two isolation valves for the
purpose of routing Storm Water Sewer collections to CRWS & Storm water drain.

Normally Storm Water Sewer is lined up to OSBL Storm Water Drain only. The
two isolation valves are located inside two pits near the Neutralization tank.

Storm Water Sewer joins the offsite CRWS pit MHC-04.

9.2.9 DRIKIG WATER: Ref Fig IX

Drinking water system is solely for the purpose of Eye Washer & Safety Shower
(EW & SS) system.

Following deviation is noted in the drinking water system:

Out of the four (4) ISBL isolation valves as specified in OHCU U/G drawing
only two (2) have been provided. This means drinking water subheaders cannot
be isolated in two cases shown in the figure.

EW & SS totalling 5 nos. have been provided. Out of these 5 one EW &SS was
relocated to 207F-2 area from the originally proposed (as per drawing) 207G-32
caustic pump area. Hence, in future EW & SS is to be provided for this pump
before the first catalyst regeneration.

Four isolation valves are located in the four corners of OHCU (3 within the
OHCU plot and 1 at the north-west corner of future DHDS) which will help in
isolation of drinking water system.

9.2.10 FIRE WATER: Ref Fig X & Fig XI

Fig X shows firewater network of entire 3 MMTPA refinery.

105

Fig XI shows ISBL firewater network, which will help in quickly identifying
the hydrant locations and sprinkler systems.

106
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 CHAPTER – 10

LAB AALYSIS
10.1 ITRODUCTIO
Quality control plays a vital role in Petroleum Industries where Safety & Quality control are
utmost important. Laboratory monitors refining operations & exercises strict control on the
quality of product produced & dispatched. Laboratory results help the process plants to adjust
the operating parameters & produce spec products optionally.

CPCL laboratory is classified into various sub sections like, Shift control Lab, Development
Lab, Engine Lab, Water Lab, etc, which has its own unique functions. Few information related
to OHCU is furnished below.

10.1.1 Shift Control Lab:

As for as the unit is concern, the samples given regularly are tested by this lab & the results are
entered in PIN computer. Also any abnormal results are communicated orally to the respective
sections for fast correction.

10.1.2 Development Lab:

This section functions for carrying out precision tests (like gas analysis, crude Assay, etc.) &
investigation type of work (like purity verification for different chemicals (caustic, DEA, etc),
Suitability checking of indigenous chemicals (corrosion Inhibitors, antioxidants, etc).

10.1.3 Engine Lab:

This section deals with Engine related tests like finding Octane Number, Cetane Number, etc.

10.1.4 Pollution Control Lab:

This section deals with Pollution related tests in Atmospheric Air, Effluents, etc. Different
standards like MINAS recommended by PCB is verified and reported to the concern authorities.

10.1.5 Water Testing Lab:

This section deals exclusively for Water which is dealt in process units like BFW, Cooling
Water etc,.

10.2 REFIERY PRODUCTS QUALITIES & TEST METHOD

121
Different products from Crude through Off Gas to Asphalt, etc are having quality of their own
identity & similarity. But this section deals about the products handled in OHCU alone and the
testing methods.

Knowledge of the important tests carried on the respective unit product will help the operator to
understand better, the importance of controlling the operating variables on the process units.
Quality Requirements of different products & their methods are discussed below one by one.

10.2.1 GRAVITY:

Gravity is defined as the ratio of weights of equal volume of the oil to equal volume of water at
standard temperature (150C).This property is generally used to calculate or measure volume of
the respective product. It is also used extensively in blending operation. Hence this is not an
index of product quality.

Gravity is measured by means of a Hydrometer (which simply indicates a numerical value

graduated on it) & the observed reading is converted to 150C by using standard tables.

Note: Basic principle in gravity determination by Hydrometer is that floating object in a liquid
displaces a volume of liquid equal in weight to that of the floating mass.
Gravity can also be expressed in 0API = (141.5/ Sp. Gr. At 600F) – 131.5.

10.2.2 COLOUR:

Petroleum products are divided into two groups according to their colour, viz: White oil and
Black oil. This is an indication of contamination of the product and nothing to do with quality.

White Oil: Ranges from Colorless to Pale Straw. Saybolt Chromo meter is used to measure the
colour of white oil. The colour is determined in this method by measuring depth of oil necessary
to match a standard colour glass. The result is reported as “Saybolt Colour”. The colour scale
ranges from -16 to +30. The Larger the number, lighter the colour is.

Black Oil: Ranges from Pale Straw and darker products. ASTM colorimeter is used to measure
the colour of black oil. The colour is determined in this method by measuring a fixed thickness
of sample (mixture of oil to be measured 15% & +21 Saybolt colour oil 85%) & comparing that
with various glass discs. The result is reported as “ASTM Colour”. The colour scale ranges from
1 to 8. The Larger the number, darker the colour.

10.2.3 DOCTOR TEST:

122
Essential test for H2S and or RSH.
Equal volume of sample & Doctor solution (Sodium plumbite + caustic soda) are shake
vigorously. A pinch of sulphur is added and the mixture is shaken again.
Uncolored in sample – Report has Sweet or Negative.
Change in Colour – Report has sour or Positive.
1. An immediate black precipitate before addition of sulphur – report the presence of H2S
2. If the change is gradual going through orange, red, brown & black – report the presence
of RSH.

10.2.4 DISTILLATIO:

Distillation test is one of the test by which volatility is determined. It involves the general
procedure of vaporizing a known volume of a sample under prescribed conditions, Recording a
set of figure (Thermometer reading) & concluding with a distillation curve. The significance of
this test varies from product to product. For example, In crude oil it gives an idea of the volume
of fractions that can be obtained in ADU/VDU or give information for designing a refinery, etc.
but in case of Motor Gasoline 10 % distillation indicates the ease of starting an engine, etc,.

The distillation results are very important for control purpose. practically all distillation towers
are operated to obtain streams with a specified distillation.

10.2.5 FLASH POIT & FIRE POIT:

Flash Point is defined as the lowest temperature at which a sample can give off sufficient vapour
for momentary flame/ flash at test condition.
Flash Point is principally employed to indicate the fire hazards of the product i.e. safety in
storage point of view as well the quality of the product which is used mostly in combustion
purpose.
Different methods are available for testing the flash point like Open Cup method, Closed Cup
method, Abel method etc. Flash point varies with the apparatus and procedure.

Fire point is the lowest temperature at which the sample gets ignited and burns continuously for
5 seconds. The method is similar to Flashpoint.
This is also important in safety point of view.

10.2.6 POUR & CLOUD POIT:

Pour point is defined as the lowest temperature at which oil will flow on heating with out
disturbance under prescribed condition whereas cloud point is the lowest temperature at which
the sample begins to crystallize out on cooling. This is used mainly in heavy oils, & indicates the
pumping limits and waxy nature of the product.

10.2.7 SMOKE POIT:

123
Smoke Point is defined as maximum flame height in mm at which the fuel will burn with out
SMOKE. The sample oil is burnt in a standard lamp in which flame height can be varied against
a background of a graduated scale. The smoke point is measured by raising the wick until a
smoky flame is produced and then lowering to the point where the smoky tail just disappears.
The flame height, measured to the nearest mm is the smoke point of the sample. This is an
important test for kerosene. Higher smoke point is better for domestic lighting purpose. It also
indicates as a guide to assess the aromatic content of Kerosene.

10.2.8 VAPOUR PRESSURE:

This is defined as the pressure exerted by a vapour, which is in a state of equilibrium with
a solid, or solution at a specified temperature.
Vapour Pressure is an indication of light ends in a stock (which will reflect in losses in storage
or transportation). It is also important in safety point of view. Incase of gasoline it may cause
vapour lock in Auto Engine. The vapour pressure of non-viscous volatile petroleum products is
determined by Reid method. In this the sample is placed in a bomb connected to a sensitive
pressure gauge and heated in a water bath to 1000F. The vapour pressure is determined in the
presence of a volume of air four times the volume of sample. This standardizes the extent of
evaporation, lessens the effect of dissolved gases, and permits direct reading of the vapour
pressure in absolute units. Corrections to the pressure gauge reading are made for air expansion
and change in vapour pressure of water intentionally added to ensure constant humidity, for all
tests.

10.2.9 VISCOSITY:

This is defined as the measure of resistance to flow of oil. Viscosity is an important property for
many oils. This is used in all oil movement area, let it be through a wick in a kerosene lamp or
the pumping of oil through a circulating system or pipeline or ease of fuel oil atomization in
furnace. Lube oils are classified based on the viscosity (e.g.: Spindle, Light Neutral, etc.)
Many instruments are available for measuring viscosity, like Redwood viscometer, Say bolt
viscometer etc. In Redwood viscometer the time taken for a fixed volume of sample to flow
through a jet is measured and expressed as viscosity in seconds. Since the viscosity varies with
temperature (i.e. decreases for liquid and increases for gas), it is mandatory to inform the
temperature along with the viscosity result).

10.2.10 SULPHUR:

Sulphur is environmentally undesirable. It’s presence should also be limited in fuels to control
corrosion. Hence its tolerance is floated internationally. Lamp Test determines Sulphur presence
for light distillates & by Bomb method & Quartz tube method for heavy distillates. Sulphur in
the sample is oxidized to sulphur dioxide by combustion & further converted into sulphuric acid

in the presence of Hydrogen peroxide. With Sodium hydroxide, Sulphuric acid is determined
either volumetrically or gravimetrically & reported as “total sulphur”.

124
10.2.11 OCTAE UMBER:

This is a whole number which indicates antiknock character of gasoline in Petrol Engine. It is
the % by volume of Iso-octane in a mixture of Iso-octane & Normal Heptane that matches the
gasoline being tested. Test can be done either by Research method or Motor method. i.e. the
sample to be tested is used in a standard engine (which is calibrated with pure standards). The
test is carried in a CFR Engine with single cylinder. Octane Number in general represents
Research Octane number.

10.2.12 CETAE UMBER:

This is a whole number, which indicates knock character of Diesel fuel in Diesel Engine.
It is the % by volume of Normal Cetane in a mixture of Normal Cetane & Hepta Methyl Nonane
that matches the gasoline being tested. Testing method is similar to Octane Number. This is
determined in CFR Engine having single cylinder.

10.2.13 WEATHERIG TEST:

This test is intended to find out the presence of heavier hydrocarbons in LPG which may not
readily evaporate. A sample (conditioned – refrigerated) of 100ml in a weathering tube is
allowed to weather under specified conditions, and the temperature is observed when 95 % of
initial quantity has evaporated and reported as weathering.

10.2.14 GUM TEST:

Unsaturates present in fuel will oxidize resulting undesirable components called as GUM. In
general this test is carried for gasoline and it is common practice to refer to the yield of residue
obtained by an evaporation test as the gum content of the gasoline. This gum may cause in take
valves to stick or it can interfere with carburetor operation in Auto engine. Two types of Gum is
analyzed in lab, namely Existent Gum & Potential Gum.
Existent Gum – This is the amount of non-volatile residue, which is insoluble in Heptane after
evaporation of the sample in a jet of hot air at 1600C (for Jet fuels it is at 2320C). This reports the
tendency of gum formation.
Potential Gum – This is the amount of gum formed after the sample is aged in oxidation stability
bath and evaporated under specified condition.

10.2.15 COPPER CORROSIO:

This test serves as measure of corrosivity of the fuel with cooper, brass or bronze parts of fuel
system. In this method a copper strip is polished smoothly and immersed in the sample and put

into a bomb. This is placed into a water bath, which is maintained at the specified temperature
for specified time. The strip is removed from the sample, washed with Iso octane or Normal
Heptane, examined for evidence of etching or discoloration. The colour of the strip is compared
with ASTM copper strip corrosion standards colour code.

125
10.3 SAMPLIG AD QUALITY COTROL
Main objective of any process would be to produce on spec products. To produce on spec
products various controlling aspects are involved out of which lab results plays a vital role in it,
because spec products can’t be determined by seeing, tasting or smelling. Hence sending right
samples to lab comes into picture and the quality there of without misguidance, i.e. sample
which are not truly representative can cause bed customer relations and mislead the operator
with serious consequences. Hence sampling is foremost important like any other quality control
parameter.

Sampling are of two types in general viz: Grab Samples (spot sample) & Composite Sample.
Grab Sample: In this, entire sample is obtained at one time to represent the composition of the
total stream at that time, i.e. sample is collected at a certain common frequency from all units
running for analysis. This sample results is the one, which the operator uses & follows to make
routine adjustments in operating conditions of units if required.
Composite Sample: In this, equal portion of streams are put in a large sample container of
regular intervals over a period of time. The result of this sample is representative of the
composition of the stream of the running units over a period of time. Composite samples are
chiefly used mainly for 1) Determining losses of valuable products. 2) Evaluate effects of
changes in operating condition. 3) Make weight balance around the units.

10.3.1 SAMPLIG METHOD

Sampling method vary as determined by the

1) Nature - Gas or Liquid or Toxic etc.
2) Temperature - Hot or Low etc.
3) Pressure - HP or LP
4) Sample Container - Open type or Bomb type etc,
5) Sample Connections - SC1 or SC2 etc.

Gaseous sample – HP gas samples are generally collected in Bombs. LP gases are generally
collected in bladders.
Liquid sample – Light Insensitive samples are collected in Bottles. Light Sensitive samples are
collected in Aluminum container.
Different types of sample connections, their significance and their procedures are discussed in
the chapter “Work Instructions” of this manual.

10.3.2 SAMPLIG HAZARDS

Sampling Hazards can be of two types:

1) those which give bad samples and erroneous results, and
2) those that are unsafe.

126
Great care & extreme caution must be exercised when taking or handling samples. Every unit
will have special instructions on how to take samples accurately & safely and these should be
followed to the letter.

10.3.3 BAD SAMPLES & ERROEOUS RESULTS

As verbalized earlier improperly taken sample can cause serious, unnecessary & expensive
changes in operation, care is mandatory. A poor sample may be caused by any of the following:
1) Sample taken from a “Dead” line, which contains the product but has no flow
through it.
2) Sample taken during a “Period of Up Set” on the unit, during which operating
condition & product composition is changing.
3) Sample taken without “Bleeding off or Purging” through coolers or connection,
which case will reflect old sample & not the current one.
4) Sample of volatile nature taken “too Hot”, in which case lighter components will
vaporize.
5) Sample container not “sealed” properly, in which case lighter components will
vaporize.
6) Samples “contaminated with debris” from different sources.
7) Samples “improperly labelled” leading to false information.
8) Sample taken in “improper container” leading to side reaction while handling
(e.g. light sensitive sample should be taken in dark bottle instead of clear bottle)

10.3.4 USAFE SAMPLIG & SAFETY

Safety as in any other operation is foremost important in the process of sampling also. Few
notable incidents have occurred in the history of refineries, which has to be remembered. Hence
some of the safety precautions, which must be followed when taking samples, include the
following:

1) Use safety wears (Gloves, Face shields, Goggles, etc.) & locate the nearest fire
protection systems (Extinguisher, Blanket, Shower, etc,.)
2) Ensure surrounding area free from ignition source, any obstruction & sample in
direction of wind..
3) Ensure vapour space in the sampling container.
4) Keep complete control of the flow.
5) Ensure correctness & completeness in tagging to avoid accidents in lab.
6) Ensure sample coolers for its mechanical completion.

7) Ensure free flow of water for hot samplings.

8) Ensure grounding devices for static- electricity dissipation, where provided.
9) If necessary, to climb ladders or mount platforms for samples use both hands. If
necessary, special sampling equipment should be provided to allow both hands for
climbing.
10) Clean the surroundings for spillage if any after sampling.

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10.3.5 SAMPLIG RESULTS & ITS USAGE

Test results are frequently received which are not within the allowable limits of the
specifications. The integrity of the laboratory is not to be questioned but if the result seems
unreasonable, additional available operating information should be checked before changing the
unit operation. The single sample may truly indicate something is wrong, but it is possible that
the sample was taken during upset conditions, was improperly labeled, or improperly tested or
reported.

If the sample results indicate that corrective action should be taken, it is the duty of the operators
to de so. After corrective action has been taken and the unit has lined out, it is equally important
to resample and test the streams in question to see that the change in operation was proper &
effective.

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 CHAPTER – 11

START-UP, SHUT-DOW
AD
EMERGECY PROCEDURES

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11.1 IITIAL START-UP
The startup activities listed below are necessary to achieve a safe and orderly
initial unit startup. Pre commissioning and commissioning efforts for the feed and
fractionation sections can proceed concurrently with the first four steps of the
sequence if required.

11.1.1 Reactor Section Initial Tightness Testing

11.1.2 : Reactor Section Initial Dry out (without catalyst ) and Operating Pressure
Tightness Testing

11.1.3 : Catalyst Loading

11.1.4 : Reactor Section Heat up with fresh catalyst

11.1.5 : Catalyst Sulphiding

11.1.6 : Feed and Fractionation section flushing

11.1.7 : VGO Feed introduction

11.1.8 : Achieving on specification products

11.1.1 REACTOR SECTIO IITIAL TIGHTESS TESTIG

• Check all utilities for necessary blinds at appropriate locations.

• Ensure reactor section HP flare header is isolated and blinded.
• Ensure Hydrogen and Nitrogen lines are blinded at M/U Compressor suction.
• Check blinds for:
i) Oil section at Reactor feed pump discharge.
ii) Fractionation section at 207C9 and 207C10 liquid outlet line common flange.

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 iii) Water injection system spec blind 207FBV 3303 d/s (pump to be checked on
spill-back and kept ready).
iv) Sulfiding chemical injection system at removable spool flange (1 1/2" SS spectacle to
be provided).
v) Sour water R/d system at CHPS and CLPS boot water LCV d/s separately.
vi) Light Ends Recovery section (To be confirmed).

• MU H2 compressor available - Blind main H2 I/L line to 207C-32 / blind H2 at B/L.

• Availability of OSBL is ready.
• Isolation blind list for HP and LP section segregation.
• Refractory Dry out procedure for 207F1 during reactor dry out step, 207F2 during Hot oil
long circulation (Vendor procedure).
• Procedure and checklist for feed pump, RGC, and MU H2 compressor.

Pressure test with 6 kg/cm2 air:

• Blind H2 supply to make up compressor.

• Recycle compressor is lined up with suction 207 MOV-2705 and spill back
207MOV-2705 open, discharge 207MOV-2705 remain closed.
• Blind 207FV 1801 d/s spacer blind - 8”.
• Blind Water injection point 207FBV 3303 d/s to 207E-08 ( 2” ) & to 207E-09 ( 2”).
• Check the static mixer d/s elbow should be swung off u/s of E-09.
• Blind CHPS PSV bypass line to flare - 2”.
• Drop CHPS PSV’s d/s isovalve and end flange its flare side.
• Blind CHPS sour water 207LV 2404 A/B d/s isovalve’s u/s side – 3” – 2 nos.
• Blind CHPS hydrocarbon liquid side quench circulation suction point – 10” ( end flange).
• Blind HP Lean amine to 207C-04 line 207FV 3103 d/s spacer blind.
• Blind 207 HBV 2601/2602 d/s orifice flange - 6” – 2 nos.
• Blind 207FV 2601 (C-7 purge) to sour gas treating unit - 2”.
• 207FV 2601 d/s to atm side valve isolation is enough.
• Isolate and blind 207PV 2601 d/s to flare - 8”.
• 207C-7 outlet, RGC suction line tapping for regeneration dilution gas line ( 4” ) should be
end flanged and swung off.

• Blind N2 supply lines in RGC suction (3”) and discharge (3”).

• Isolate tappings for H2 analyzer .nothing should go through analyzer to flare.
• Regeneration air loops that are line through 207FV 2704 both elbows should be swung off.
Its tappings from the process lines should be end flanged – one flange near 207E-3 and one
flange in the down stream side of 207FT-2701.
• Blind 207FV-2804 d/s to CLPS inlet spacer blind – 6” (internal oil circulation line).
• Blind CLPS hydrocarbon outlet i.e. 207FV-2801 d/s line spacer blind – 10”.
• Blind CLPS sour water outlet line 207LV 2802 d/s isovalve u/s flange – 1 ½”.
• Blind startup H2 to CLPS outlet vapor line - 2”.
• Blind CLPS PSV bypass line to flare - 2”.

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• Drop CLPS PSV d/s isovalve and end flange its flare side.
• Blind steam out line for 207C-09 ,207C-10,207C-11 & 207C-12.(All blinds 2” ).
• Blind 207C-11 PSV bypass line - 2”.
• Drop 207C-11 PSV’s d/s isovalve and end flange it’s flare side - 4” – 2 nos.
• Blind 207C-12 PSV bypass line – 2”.
• Drop 207C-12 PSV’s d/s isovalve and end flange it’s flare side - 4” – 2 nos.
• Blind 207C-12 outlet gas to PSA unit ( 4” ) , to fuel gas ( 4” ) & to flare ( 4” ).
• Blind 207C-06 PSV bypass line – 2”.
• Drop 207C-06 PSV’s d/s isovalve and end flange it’s flare side.
• Blind startup fuel gas to sour gas ( 2” ) and to flare ( 2” ).
• Blind 207C-13 outlet gas ie PV 6606 d/s line - 1”.
• Blind N2 connection ( 4” ) in the make up compressor discharge line.
• Blind make up compressor common discharge line - 6”.
• Line up as follows:
a) Open 207E3A/B I/L minimum stop valve
b) Open 207E3A/B bypass 207TIC 1803
c) Open bed quench valves 207TV1911, 207TV1941, 207TV2003, 207TV2021
d) Open CHPS 207LCV2401
e) Open HP centrifugal separator 207LCV2401
f) Open HP H2S absorber bypass 207 HV2501
g) Open rich amine 207LV 2504
h) Open R/C compressor KOD 207LV 2601
i) Open CLPS vapor H2S absorber bypass 207 HV2901
j) Open CLPS vapor H2S absorber 207PV1901
k) Open CLPS vapor H2S absorber rich amine 207LV2901
l) Open CLPS vapor KOD 207LV 2908

• Keep open following valves:

a) CHPS interface 207LV2404
b) CLPS interface 207LV2802
c) CLPS hydrocarbon effluent flow 207FV 2801
d) CLPS vapor KOD 207PV 2903 A/B

e) RGC suction high set point PV2601

f) Rich flash drum 207PV 3201
g) Rich flash drum 207LV3201

• Make sufficient temporary air connections to reactor section. Follow normal path of flow.
• Introduce plant air reactor section and pressurize to 6 Kg/cm2.
• Soap test flanges, valve packing and instrument leads for leak.
• Blow down all low points drains and dead ends to eliminate water.
• Line up CLPS vapor KOD and RGC suction KOD high set points PVs.
To atmosphere 207PV2903/2601 and depressurize.
• Remove all air connections.

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Replace Air with itrogen:

• Ensure the high pressure hydrogen header from make-up hydrogen compressor section is
blinded, and Remove blind in startup N2 header.
• Admit N2 through HP H2 header and purge through the reactor section to atmosphere via
207PV2601 for 10 minutes
• Open each quench valves at a time in the beginning of sweep to expel air in the quench
lines
• Close 207PV2601 and allow the system pressure to N2 header pressure
• Open 207PV2903B to depressurize the reactor system to atmosphere for 10 minutes
• Once again open quench valves to expel air
• Close 207PV2903B and pressurize the system to N2 header pressure
• Repeat till O2 is less than 0.2% (v/v) at both vents
• Blow down all drains and dead ends till O2 is < 0.2%v/v
• Re pressurize the system to N2 header pr. And check for leaks

Tightness Test at ~25.0 kg/cm2(g) and ~30.0 kg/cm2(g) with itrogen:

• Isolate rich amine flash drum by blocking:

a) C-04 HP H2S absorber 207LV 2504 A/B d/s line.
b) C-04 HP H2S absorber oil skim lines ie 207HV-2501 d/s line.
c) C-07 RGC KOD drain line ie 207LV 2601 u/s line.
d) CLPS vapor H2S absorber rich amine line ie 207LV 2901 and oil skim lines.
e) C-12 CLPS vapor KOD 207LV 2902 d/s isovalve.
f) Fuel gas absorber rich amine line ie 207LV 6801 and oil skim line.
• Open S/U fuel gas to C6 and line 207PIC3201 to flare with set point of 7.3 Kg/cm2.
• Line up CLPS vapor KOD 207PIC2903 on auto with a set point of 30.5 Kg/hr off gas
routed to atmosphere.
• Keep 207PIC2601 on auto with a set point of 37.5 Kg/cm2.
• Ensure H2 to M/U compressor is blinded.
• Ensure M/U compressor spill back coolers are lined up.

• Keep M/U compressor high set point 207 PV6902 on auto with a set point of 22 Kg/cm2.
• Keep M/U compressor suction low set point 207PV6903 on auto with set point of
6 Kg/cm2.
• Keep M/U compressor disch pr Controller 207PIC6904 on local set point mode and
fully open.
• Introduce N2 to C32 and pressurize compressor to N2 header pressure.
• N2 purge M/U compressor and spill back system to expel air.
• Start a M/U compressor unloaded with 207PIC6904 fully open.
• Allow sufficient time for the compressor to warm up and prove reliability.
• Keep 207PIC6904 on auto with a set point of 6 Kg/cm2.
• Load the compressor to 25%.
• Slowly increase 207PIC6904 set point to 25 Kg/cm2.

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• Remove blind from HP H2 header and allow reactor section to equalize with compressor
discharge pressure gradually and then open the B/V wide.
• Check flanges, packing and instrument leads for leak.
• Increase 207PIC 6904 settings to 30 Ksc and when pr is achieved do a thorough leak test.
• Blow down all low point drain for any water.

Tightness Test at ~ 37.5 kg/cm2 g with itrogen:

• CLPS vapor KOD 207PIC2903 remain on auto with a set point of 30 Ksc
Venting to atmosphere.
• CLPS vapor H2S absorber is isolated from KOD and 207PIC2901 is kept on auto with a set
point of 37.5 Ksc venting to atmosphere.
• Slowly increase reactor system pr to 37.5 Kg/cm2.
• Perform a leak test before proceeding further.

Tightness Test at ~42.0kg/cm2(g) with itrogen and begin Heat up:

• Block CHPS hydrocarbon 207LIC2401A/B on jack and close D/s B/V. keep U/S B/U 30%.
• Block CHPS vapor centrifugal separator 207LIC2501 on jack and close D/S B/V keep u/s
B/V 30%.
• Switch M/U compressor disch pr control to remote set point mode allowing 207PIC2702
to reset 207PIC-6904.
• Keep 207PIC-2702 on auto mode and increase the set point to 42 Kg/cm2.
• Perform a leak test and correct leak if any.
• Ensure all quench valves are closed.
• Ensure RGC disch MOV HBV2705 is closed suction and all valves on spill back are open.
• Start RGC as per procedures and monitor disch temperatures.
• Once compressor is operating smoothly open disch MOV to establish recycle flow.
• Make sure MPT restrictions are adhered to (38 oC , 46.5 kg/cm2).
• Increase the turbine speed thru critical speed quickly.
• As speed is increased, reduce 207PIC2702 setting to stay within 46.3Ksc(at 207R-1 I/L).

• Increase speed to achieve max circulation with N2.

• Prepare for heat up:
a) Close E7 bypass
b) Fully open E3A/B minimum stop valve and close bypass valve
c) Keep quench valves closed
• Ensure appropriate flows are established in 207F1 convection coils.
• Ensure all reactor effluent air cooler fans are running.
• Purge 207F1 fire box and light pilots and main burners (as required by refractory dry out
procedures).
• Keep R1 I/L temp controller 207TIC1910 on auto and slowly increase the set point within
the heating rate limitations.
• Record furnace temperatures, R1 I/L temperatures, all reactor skin and nozzle TIs and
207R-1 O/L temp hourly.

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• As temp are increased N2 in the system will expand and has to bled to maintain 207PI-2601.
• Carefully blow all low point drains.
• As temp and pr are increased, leaks will become detectable do a thorough leak test.
• Once all reactor skin, internal and nozzle temp are above MPT (38 oC), increase
207PIC-2601 setting to max possible pr with N2.
• Slowly increase reactor system pr to max achievable with N2 by increasing 207P-2702 SP
• Check both M/U and R/C compressors performance.
• Continue to increase reactor temp to near normal working temp staying within rate
restrictions.
• As temp are being increased check water accumulations in CHPS.
• Maintain 378 oC for 4 hrs and check water collections in CHPS.
• As this is final leak test before H2 is admitted, do a thorough leak test.
• Blow all low point drains and instrument leads.

11.1.2. REACTOR SECTIO IITIAL DRYOUT (O CATALYST) AD

OPERATIG PRESSURE TIGHTESS TESTIG:
• HP system at 42 Kg/Cm2 with MU compressor on N2 service.
• Prepare RGC for start up as per vendor procedure:
a) N2 purge
b) Tightness test
c) Open suction and d/c gradually
d) Do tightness test 42 Kg/cm2
e) Start RGC on total spill back
f) Observe and take care of compressor d/c temperature
g) Establish recycle gas flow
• 207PIC-2702 set point (SV) to be kept below the limit of 46.3 Kg/Cm2 at reactor inlet
before achieving MPT.
• Furnace start up, dry out procedure as per vendor.
• 207E-7 bypass closed.
• 207G-3A/B minimum stopper wide open and bypass fully shut.

• Close all quench valves.

• 207F-1 outlet TIC on Auto with Set Point (SV) 8 oC / 15 oC minimum.
• Monitor the following temperatures:
a) Furnace temperature as per vendor procedure for refractory dry out
b) Reactor I/L and O/L temperatures
c) Reactor skin and nozzle temperatures
• Carefully monitor and control the HP loop pressure below 46.3 Kg/Cm2 at reactor I/L. If
necessary, bleed N2 through 207PIC-2601A/B to atm. during N2 circulation.
• Check intermittently all Low Point Drains, Sample points, Instrument lead lines and
dead end drains for stagnant water (when temperature is increased beyond MPT).
• As the system with recycle gas is established, check for leaks.
• When MPT is achieved, increase the system pressure by increasing 207PIC-2702 set point
to the limit of MU compressor and RGC on N2 service and reactor pressurization limit.
• As the reactor pressure is increased with N2 and increase the reactor temperature to normal

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 operating temperature of 370 oC.
• Monitor Water collection in CHPS in interface level indication.
• Maintain HP loop under maximum achievable N2 pressure at 378 oC for 4 hours for reactor
dry out.
• Dry out completion is indicated by no or little water collection in CHPS.
• Conduct leak test for all flanges, Valve packing, instrument fittings etc before introducing
Hydrogen; attend leaks if any.
• Drain all low points, instrument leak lines carefully for any water collection.
• Take 207PIC-6904 on local mode.
• Unload M/U compressor to 0% in step and stop the compressor.
• Depressurize and isolate / blind N2 line.
• Deblind H2 line to M/U compressor. Check if PSV is lined up to flare.
• Keep 207PIC-6903 & PIC-6902 on Auto mode. 207PIC 6903's set point should be
1 kg/cm2 less than 207PIC-6902 set point.
• Purge out K-2A/B/C loop thoroughly and ensure O2 content is 0.2 % maximum before
introducing H2.
• Open high pressure H2 valve gradually and establish the pressure.
• 207PV-2601A/B: 207PV-2601B to flare SV set at 1 Kg/Cm2 higher than normal operating
pressure of HP system.
• Replace N2 with H2 gradually Override 207PV-2601 to flare.
• Switch over M/U compressor d/c pressure controller 207PIC-6904 from local set point to
remote (207PIC-2702) resetting the RGC suction pressure.
• Increase reactor I/L pressure to 155.3 Kg/cm2 (90% of normal operating pressure) at the
rate of 10 Kg/cm2 taking care not to exceed CHPS normal operating pressure.
153.9 Kg/Cm2.
• Maintain 207R-1 I/L temperature at 378 oC.
• As pressure increases with H2, leaks that might not have been detectable while pressurizing
with N2 will become easier to locate. Make a thorough leak test with ultrasonic detectors.
• After the leak test and after fixing the major leaks, unload MU compressor to 25 %.

• Close valve on HP hydrogen to Reactor section.

• Ensure that MU compressor is running on Spill back mode. Switch over pressure control to
local mode.
• Block 207K-1 suction high set point pressure controller valve 207PIC-2601.
• Monitor system pressure loss for 1 Hour. It should be less than 3 Kg/Cm2.
• Check calibration, accuracy and response of all thermocouples, quench system, analyzers,
DP instruments connected to the reactor.
• After reaching equilibrium conditions, before cooling down, check reactor bed temperature
and skin temperature indications and correct for difference.
• Commission Sour Water Degasser; Keep CHPS sour water lined up:
a) Isolate Sour Water from CLPS 207C-9
b) Isolate Sour Water from Reflux drum 207C-17
c) Isolate Sour Water from Reflux drum 207C-15
d) Isolate Sour Water from De ethanizer Reflux drum 207C-21
e) Isolate Sour Water from 207C-23 Water draw off pot

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 f) Isolate Sour Water from 207C-28 Debutanizer reflux drum
g) Isolate Wash Water from 207C-40
h) Isolate Sour Water from 207C-41 Coalescer
• Commission 207C-13 pressure controller with Set Value 6 Kg/cm2 keeping off gas to flare
• Close 207FIC 6602 on 207C-13 effluent and line up to sour water system.
• Commission injection water drum 207C-8 N2 blanketing 207PIC-3302 with set point.
1.7 Kg/Cm2.
• Isolate sour water to 207C-8 and line-up boiler feed water. Bring up level to 50 % and take
207LIC-3301 on AUTO mode.
• Start 207G-4A/B on total spill back (207PIC-3302). Ensure that the pumps are running
without any electrical, mechanical or instrument problems.
• Remove water injection isolation blinds u/s of 207E-9 and 207E-8.
• Gradually introduce water to single injection point u/s of 207E-9. Stabilize make up water
flow and commission 207FIC-3304 on AUTO mode and increase injection water flow to
design.
• Observe for water collection in CHPS. When level appears, open one of the interface level
controllers 207LIC-2404 A/B to establish flow to 207C-13 and put it on AUTO mode.
• Open 207FIC-6602 when 207C-13 level reaches 50 % and establish flow to sour water
system. Take 207LIC 6602 on cascade when the system stabilizes.
• Check the spare water injection pump also for its performance.
• Switch over water injection to u/s of 207E8 and check for flow.
• Stop injection pumps and check chopper valve action. Maintain normal working pressure
and maximum recycle gas flow rate for the reactor cool down.
• Gradually reduce reactor 207R-1 I/L temperature within the rate of cooling restrictions
(MPT).
• Speed up cooling rate (within temperature restrictions) by -
a) Adjusting 3-way valve in 207E-7
b) Close min stop valve at 207E-3A/B inlet

c) Wide open 207E-3A/B bypass

• Safely attain MPT. Reduce 207K-1 suction pressure to 42 Kg/Cm2 at Reactor inlet (above
RGC minimum suction pressure).
• Allow reactor quench for uniform cool down of reactor when rate of cooling down reduces
substantially.
• Cut off 207F-1 burners when it is no longer required to control cooling down. Open peep
holes and air registers.
• Stop RGC and isolate when no more cooling is effective by recycle gas circulation
• Isolate the M/U compressors from reactor section at HP H2 header.
• Allow low pressure H2 to flow through the system to effect further cooling
• Depressurizing the HP system through the 207PIC 2601/2602 to 0.4 Kg/Cm2 and block the
depressurizing valves.
• Deblind start up N2 to HP H2 header and pressurize the system to 6 kg/cm2 (N2 to be
introduced at RGC discharge MOV d/s) and depressurize to flare. Repeat until H2 gets
purged out (0.2 % V maximum).
• Continue sweeping with N2 to HP system until reactor temperature comes down to

137
 allowable limit.
• Blind reactor section and reactors for entry.
• Test for combustibles and purge with air before issuing entry permit.
(Minimum 19.5% of oxygen is required for vessel entry for inspection and also ensure
flammable and combustible gases are not present).

11.1.3 CATALYST LOADIG

Catalyst loading details are provided in chapter-7.

11.1.4. REACTOR SECTIO HEAT UP WITH FRESH CATALYST

The reactor section is tightness-tested with nitrogen in the same manner as that used for tightness
testing the reactor section without catalyst, except that the initial test is with nitrogen rather than
air. The objective is to tightness test the reactor section at nitrogen header pressure, and then to
progressively higher nitrogen pressures with the make-up hydrogen compressors. This is done
before the recycle gas compressor is commissioned to circulate nitrogen through the reactor
section, and the reactor feed furnace is commissioned to dry out the catalysts and to achieve
MPT.

Fresh catalyst can absorb up to 10 wt % water in transportation, shipping, storage, and loading.
If not dried slowly, the catalyst may release water too quickly when heated, resulting in pore
damage and loss in catalyst surface area. In extreme cases, a sudden release of steam from the
catalyst may result in catalyst shattering (the popcorn effect).

The basic principle for drying catalyst is to circulate nitrogen through the reactors at the
maximum rate, fire the reactor feed furnace to heat the circulating gas stream to the minimum
temperature required to slowly release adsorbed water, and maximize effluent cooling to remove

as much water as possible from the circulating gas stream. Note that hydrogen is not introduced
until the catalyst is dry, and the reactor section has been heated above MPT.

Startup Summary

• At this point in the startup sequence, catalyst has been loaded, and the reactors are under a
dry air purge.

• Commissioning efforts required to bring the feed and fractionation sections to operation
readiness are either nearing completion or completed. The feed and fractionation sections
are on hot standby long-loop circulation.

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• All utility and support systems are assumed to have been commissioned earlier

• During this period the offplot hydrogen source and make-up hydrogen compressors should
have been prepared to deliver hydrogen to the Isocracker unit. Small quantities will be
required just prior to sulfiding, during sulfiding, and larger quantities will be required during
introduction of VGO feed. Discuss timing of hydrogen requirements with the hydrogen
production facility supervision. It should be confirmed that on-specification hydrogen will
be available at the required rate and times during startup.

• Whenever nitrogen or hydrogen is added to the system, it is important they be added at

appropriate locations to avoid upflow in the catalyst beds, which can cause catalyst
displacement.

• To prepare the reactor for catalyst sulfiding, and subsequent VGO feed introduction, the
commissioning sequences covered in this section are as follows:
– Clear the reactor section of oxygen and tightness test at ~6 kg/cm2 (g) with
nitrogen, up to and including the rich amine flash drum (207C6), after which
207C6 is isolated from the combined high and low pressure reactor section.

– Tightness test the combined high and low pressure section, up to and including the
CLPS vapor KO drum (207C12) at ~25 and then 30 kg/cm2 g with nitrogen
compressed by the make-up hydrogen compressors. Afterwards, 207C12 is
isolated from the combined high and low pressure reactor section.

– Tightness test the combined high and low pressure section, up to and including the
CLPS vapor H2S absorber (207C11) at ~42.0 kg/cm2 g with nitrogen compressed

by the make-up hydrogen compressors. Afterwards, the reactor high pressure

section is isolated from the low pressure section.

– Establish nitrogen recycle gas circulation, commission the reactor feed furnace, and
begin heating the reactor section to dryout the catalyst.

– Increase reactor inlet temperatures to ~135°C, the temperature required to begin

catalyst dryout. Temperatures are subsequently increased to 218 to 232°C to
complete catalyst dryout.

– Pressure the reactor section with hydrogen to establish a hydrogen partial pressure
between 14-28 kg/cm2 a.

– Adjust reactor temperatures for sulfiding, and start sulfiding operation.

– Sulfiding is completed.

ote:

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 • If the reactor low pressure section was not opened and exposed to air during catalyst
loading (remained under an inert gas blanket), it will only be necessary to clear oxygen
from the reactor high pressure section and tightness test at ~6.0 kg/cm2 g with nitrogen
before further tightness testing at ~42.0 kg/cm2 g.
• If the reactor low pressure section was opened during catalyst loading and exposed to
air, the reactor low pressure section should be subjected to the same tightness testing
steps as that specified during tightness testing without catalyst.

Clear Oxygen from the Reactor Section and Tightness Testing at ~6.0 kg/cm2 (g) With
itrogen:

The steps to clear oxygen from the reactor section are the same as that used when performing
this task with no reactor catalyst inventory. However, initial tightness testing is accomplished
with nitrogen rather than with air.

1. Ensure that all flanges opened or disturbed during catalyst loading are properly made up, all
temporary connections removed, and the unit area is clear of debris.

2. Remove blinds installed for vessel entry and/or other reasons according to the blind list.

3. Ensure the reactor section oil feed line is still blinded downstream of the oil feed control
valve (207FV-1801).

4. Ensure the blind is still installed in the combined effluent line from the CLPS and CLPS
vapor centrifugal separator level control valves to the fractionation section. This provides
positive isolation between the reactor and fractionation sections.

5. Ensure the lean amine line to and the rich amine line from the high pressure H2S absorber
(207C4) is isolated. Amine is not circulated through 207C-4 during sulfiding to allow
accurate measurement of hydrogen sulfide in the recycle gas stream.

6. Ensure the high pressure hydrogen header to the reactor section is isolated from the make-up
hydrogen compression section.

7. Align 207K-1 valves, as described for dryout without catalyst, to include the compressor in
the reactor tightness testing circuit.

8. Align 207K-1’s high set point pressure control valve (207PIC-2601) to vent to the
atmosphere, and open it in manual mode.

9. Align the CLPS vapor KO drum (207C-12) high set point pressure control valve
(207PV-2903B) to vent to the atmosphere, and close it in manual mode.

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10. Remove the startup nitrogen blind to the high pressure hydrogen header, downstream of the
isolation manifold between the make-up hydrogen compressor and reactor sections.

11. Admit nitrogen to the high pressure hydrogen header, and purge through the reactor section
to the atmosphere via 207PV-2601 for 5-10 minutes. Open each reactor quench control
valve for a time at the beginning of the sweep to clear oxygen from the quench lines. When
the sweep is completed, close PV-2601 in manual mode and allow the reactor section
pressure to stabilize at utility nitrogen header pressure [~6.0 kg/cm2 (g)].

12. In manual mode, slowly open 207PV-2903B to allow the reactor pressure to reduce, while
continuing to allow nitrogen to sweep through the reactor section to the atmosphere via
PV-2903B for 5-10 minutes. Once again, the reactor quench control valves are opened for a
time at the beginning of the sweep to clear oxygen from the quench lines. When the sweep
is completed, close PV-2903B in manual mode and allow the reactor section to stabilize at
utility nitrogen header pressure.

13. Repeat the above steps, until oxygen is less than 0.2 vol % at both atmospheric vent
locations.

14. Purge all dead-end piping runs to bleeder valves just upstream of isolation blinds for
subsystem, plot limit, etc., until oxygen content at each point is below 0.2 vol %.

15. Repressure the reactor section to the maximum pressure achievable from the nitrogen header.

16. During the time the reactor section is at maximum nitrogen header pressure, blow down all low
point drains and instrument leads to eliminate any freestanding water that may have
accumulated.

17. Soap test all flanges, valve packing, instrument fittings, etc., and carefully inspect for leaks.
Repair any leaks found before going to the next step.

Tightness Test at ~25.0 kg/cm2 g and ~30.0 kg/cm2g with nitrogen:

1. Isolate the rich amine flash drum (207C-6), from upstream vessels by double block valves.
Commission 207C-6’s startup fuel gas pressurization manifold to allow 207C6 to float on the
fuel gas header. Set C-6’s pressure controller’s (207PIC-3201) set point at ~7.3 kg/cm2 (g),
with the off gas routed to the flare, as a safety measure to prevent over pressuring this
system.

2. Alignments for tightness testing the combined high and low pressure reactor sections are the
same as that for performing these tightness tests without catalyst.

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3. Start a make-up hydrogen compressor, with the discharge pressure controller (207PIC-6904), in
local set point mode, controlling the discharge pressure. Slowly increase 207PIC-6904 set point
to ~25.0 kg/cm2 g, the first safe pressure to be achieved during this step. This also assures
there will be a forward-flow through the reactor section during the following steps.

4. While continually checking for leaks, introduce nitrogen to the reactor section to allow the
reactor section pressure to equalize with that being maintained on the make-up hydrogen
compressor discharge over a period of ~4 hours (providing no major leaks are discovered).
Soap test all flanges, fittings, etc. Any leaks found should be corrected before proceeding to
the next testing phase.

5. While continuing to check for leaks, slowly increase the reactor section pressure to
~30.0 kg/cm2 (g), by gradually increasing 207PIC-6904 set point.

6. Once the pressure has stabilized at ~30.0 kg/cm2 g, perform a thorough leak check and correct
leaks, if any, before proceeding to the next step.

7. During the time the reactor section is at this pressure, blow down all low point drains and
instrument leads to eliminate any freestanding water that may have accumulated.

Tightness Test at ~37.5 kg/cm2 g With itrogen:

1. Place the CLPS vapor KO drum’s (207C12) pressure controller (207PIC-2903) in automatic
mode with a set point of ~30.0 kg/cm2 (g), with the off gas routed to the atmosphere. This
pressure controller will vent any overpressure from 207C-11 to the atmosphere.

2. Place 207C-11 pressure controller (207PIC-2901) in automatic mode, with a set point of
~37.5 kg/cm2 (g). Any overpressure will be vented from the reactor low pressure section via
207PIC-2901 to 207C12, and then vented to the atmosphere via 207PIC-2903.

ote: Monitor 207C12’s pressure closely during this step, as the drum does not have an
external startup pressure source. It may be necessary to partially open the bypass valve
on 207C-11 pressure control valve (207PV-2901) to maintain pressure on 207C12.

3. Slowly increase the reactor section pressure to ~37.5 kg/cm2 (g) by adjusting 207PIC-6904
set point. Once the target pressure is achieved, soap test all flanges, fittings, etc. Any leaks
found should be corrected before proceeding to the next step.

Tightness Test at ~42.0 kg/cm2 g with nitrogen:

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1. Isolate the reactor high pressure section from the low pressure section by double block
valves at the CHPS hydrocarbon level control valves (207LV-2401A and 207LV-2401B)
and the high pressure centrifugal separator’s level control valve (207LV-2501).

2. Introduce hydrogen to the CLPS during this step to maintain pressure on the entire reactor
low pressure section.

• The CLPS vapor KO drum (207C12) pressure controller (207PIC-2903) remains in

automatic mode with a set point of ~30.0 kg/cm2 g. Switch the off gas routing from
the atmosphere to the flare.

• The CLPS vapor H2S absorber (207C11) pressure control valve (207PV-2901) is
opened in manual mode to create an open path to 207C12.

• Commission the startup hydrogen self-contained pressure regulator (207PCV-2812)

to maintain a positive pressure [~20 kg/cm2 g] on the reactor low pressure section.

3. Switch the make-up hydrogen compressor discharge pressure controller (207PIC-6904) from
local set point mode to remote set point mode. This allows 207K-1 suction pressure
controller (207PIC-2702) to reset 207PIC-6904 set point.

4. Place 207PIC-2702 in automatic mode to control the reactor section pressure.

5. Slowly increase the reactor section pressure to ~42.0 kg/cm2 g by slowly adjusting
207PIC-2702’s set point.

6. Once the target pressure is achieved, perform a thorough leak check at this pressure. Correct
leaks, if any, before proceeding to the next step. Don’t assume the initial tightness testing,
without catalyst, is sufficient, as system heating and cooling tends to cause flanges, etc., to
open up. In addition, reactors have been opened and isolated for entry, and then closed for
startup.

Establish Recycle itrogen Circulation:

Once the reactor section pressure is elevated above 207K-1 minimum operating suction pressure,
gas flow is established through the reactor section.

CAUTIO: Carefully monitor reactor section pressure profiles, as the reactor section behavior
will be somewhat different while operating with the increased differential pressure through the
reactor section, created by reactor catalyst inventory. With catalyst inventory in the reactors, it
is expected that the total differential pressure through the reactor section gas loop will not allow
the compressor to circulate the same volume as that circulated during catalyst dryout without

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 catalyst, without approaching surge conditions or exceeding the discharge temperature limits
specified by the vendor.

1. If 207K-1 was not included in the tightness testing circuit, purge with nitrogen and tightness
test it in preparation for startup.

2. Verify that all reactor quench controllers are closed in manual mode.

3. Verify that 207K-1 discharge MOV (207HBV-2705) is closed and the suction MOV
(207-HBV2701) and all valves on the antisurge line are open [including the automatic antisurge
control valve (UV-2701), UV-2701’s downstream manual block valve, and the spillback line
MOV (207 HBV-2704)].

4. Start 207K-1 on total spillback at minimum speed. As 207K-1 is being operated under
abnormal operating conditions (i.e., lower suction pressure and heavier molecular weight gas
than designed for), careful monitoring of the discharge temperature is required.

5. Once 207K-1 is operating smoothly, open the compressor discharge MOV (207HBV-2705) to
establish recycle nitrogen gas flow through the reactor section.

CAUTIO: At this point, all reactors are cold, and should not be allowed to exceed 25% of
design pressure until all skin points are above the MPT (38ºC) to prevent severe damage due to
“brittle fracture.”

Table 11.1 Reactor Pressurization limitations (MPT).

Equipment Design Pressure 25% of Design Pressure

207R-1, ICR First Reactor 185.3 kg/cm2 46.3 kg/cm2
207R-2, ICR Second Reactor 185.3 kg/cm2 46.3 kg/cm2

6. Increase the turbine (207K-1) speed through critical speeds without delay to avoid damaging
the rotating equipment. While operating on nitrogen at ~ 42.0/cm2 (g) suction pressure with
the catalyst inventory in the reactors, the total differential pressure through the reactor
section may prevent 207K1 from reaching minimum governor speed without approaching
surge conditions, or exceeding 207K1’s discharge temperature limits specified by the
vendor.

7. Increase turbine speed to achieve the maximum possible circulation rate while operating
207K-1 on 100% nitrogen, without subjecting the compressor to potential damage. Monitor
207R-1’s inlet pressure as the speed is being increased, and adjust 207K-1 suction pressure

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 controller (207PIC-2702), as needed, to stay below 25% [46.3 kg/cm2 (g)] of reactor design
pressure before achieving MPT.

Begin Heat up:

The recycle gas compressor continues to operate, circulating nitrogen through the reactors at the
maximum achievable rate. Reactor feed furnace pilots (and main burners as necessary) are
commissioned to begin heating the reactor section.

1. After completing the reactor section dryout (without catalyst), some valve positions were
changed to facilitate reactor cool down. Ensure that the valves in the reactor preheat system
are now set up to facilitate reactor heat up. Remember that as reactor temperatures increase,
adjustments to these valves will be required to maintain furnace duty.

2. Close all reactor quench control valves to prevent cooler gas from entering the reactors.

3. Ensure that preparations, required to protect the reactor feed furnace’s (207F-1) convection
coils, have been completed (boiler feed water and/or steam flows—depending on final
design details).

4. Before establishing fires in 207F-1, verify that the following conditions exist:
• Pressure at 207R-1 inlet (local 207PI-1901) is below 25% (46.3 kg/cm2) of the
reactor design pressure.
• 207K-1 is operating smoothly and circulating nitrogen at the maximum rate through the
reactor section.
• Reactor effluent air cooler (207E-9) fans are in operation.

5. Purge 207F-1 firebox and light pilot and main burners to begin drying the catalyst (assuming
no furnace refractory curing is required). When adding pilot and main burners, stagger the
locations so that temperatures throughout the fireboxes are as uniform as possible. Refinery
procedures governing the safe operation of furnaces should be followed.

6. Place 207R-1 inlet temperature controller (207TIC-1910) in automatic mode as soon as

possible, and slowly increase the temperature, subject to the heat up design limits , in order to
avoid the danger of thermal shock or stress to the furnace and reactors.

7. Record the following temperatures hourly:

• Reactor Inlet Temperatures
• All Reactor Skin and Nozzle TIs
• Reactor Outlet Temperatures

8. As 207F-1 burners are commissioned, nitrogen within the reactor section will expand. When
this occurs, make-up nitrogen should automatically reduce (207PIC-2702). Carefully

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 monitor reactor and make-up hydrogen compressor pressure control loops to ensure
appropriate control is maintained. In most cases, nitrogen has to be vented via 207K-1
suction high set point pressure controller (207PIC-2601) to prevent exceeding target
pressure.

9. Continue to monitor the reactor section for leaks, as piping expands when temperatures are
increased.

Catalyst Dryout:

During this phase of the startup, the reactor temperatures are increased to ~135°C in order to
begin slowly drying out the catalyst in a nitrogen atmosphere. The dryout process is conducted
to slowly release water that was absorbed on the catalyst during handling to prevent damage to
the catalyst pore structure and to avoid shattering the catalyst pellets due to rapid water release
(steam). Temperatures are increased to 218°C-232°C to complete the dryout process, and once
complete, reactor temperatures are reduced to 200°C and maintained at that temperature until
sulfiding steps are initiated.

Before implementing catalyst dryout steps, prepare the following to avoid potential headaches
and to avoid scrambling for information at the last minute.

• Summarize heat up and pressurization limitations of the reactors and other equipment.

During dryout, if the rate of water accumulation exceeds 0.1 wt %/hr of the catalyst weight, it is
important to hold R-1 inlet temperature until it drops below that level. This is to prevent
shattering the catalyst due to a high steam release rate.

For catalyst drying and sulfiding, final measures required to prepare the DMDS injection system
equipment for service should also be carried out.

1. If not already done so, establish a reference level in the CHPS by injecting water upstream of
the reactor effluent air cooler (207E-9), and then shut down and isolate the water injection
system. It will remain isolated until the catalyst dryout steps are completed.

2. During heat up and dryout, use extreme caution while blowing down all drains, sample
connections, instrument leads, and dead-end lines to remove any freestanding water from the
reactor section.

3. Slowly increase 207R-1’s inlet temperature to 135-175°C at a maximum rate of 10 °C/hr, or

within other limits.

4. Monitor water accumulation in the CHPS as catalyst dryout progresses. Significant water
accumulation is not expected until reactor temperatures are in the range of 135-175 °C.

146
5. If at any time the rate of water accumulation exceeds 0.1 wt % of the catalyst weight per
hour, stop increasing temperatures until the rate of accumulation drops below that level.
6. When all reactor bed temperatures are between 135 to 175°C, and the rate of water
accumulation has dropped to less than 0.1 wt % of the catalyst weight per hour, the reactor
inlet heat up rate can be increased to 24°C/hr.

7. Slowly increase 207R1’s inlet temperatures to 218 to 232°C.

8. The catalyst is considered dry when 207R1’s inlet is between 218 to 232°C, 207R1 outlet is
between 200 to 212°C, and 207R2’s inlet and outlet is between 200 to 212°C, and the rate of
water accumulation is less than 0.1% of the catalyst weight per hour. To bring reactor outlet
temperatures to 200 to 212°C more quickly, it is permissible to heat 207R1’s inlet to as high
as 232 to 288°C, but only if no hydrogen is present. Once the reactor outlets are at target
temperatures, 207R1’s inlet temperature should be reduced to 218 to 232°C.

9. Once the above steps are completed, soap test all flanges, fittings, etc. Any leaks found
should be corrected before proceeding to the next startup phase, as this is last chance to
check for leaks before hydrogen is introduced to the reactor section during the sulfiding
startup phase, so it is important to spend a little extra time while performing this tightness
test.

10. Reduce the reactor inlet temperature to 200°C to prepare catalyst beds for sulfiding.
Restricting the temperature to 200°C, until sulfiding steps are initiated, reduces the risk of
catalyst reduction.

11.1.5. CATALYST SULFIDIG

For catalyst Sulfiding procedure refer chapter-14 in this manual.

11.1.6. FEED AD FRACTIOATIO SECTIO FLUSHIG

• Ensure that isolation blinds are in place to segregate reactor section from feed and fraction
section.
• Ensure that the combined feed Fractionator & light ends recovery system has been purged
off air tightness tested and floating with hydrogen or nitrogen or fuel gas. Maintain pressure
as follows:
a) 207C-1 - 5.7 kg/cm2 (g) with N2
b) 207C-9 - 38.1 kg/cm2 (g) with low pressure H2
c) 207C-14 - 14.1 kg/cm2 (g) with low pressure H2
d) 207C-16 - 0.8 kg/cm2 (g) Fuel Gas
e) 207C-20 - 12 kg/cm2 (g) with low pressure H2
f) 207C-27 - 10.7 kg/cm2 (g) with low pressure H2
g) 207C-29 - 1.3 kg/cm2 (g) Fuel Gas
• Ensure VGO lines are blinded at B/L.
• Commission 207C1 N2 blanketing split range control 207PIC-1602 on auto with set point

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 5.7 kg/cm2.
• Line up 207C-14 as follows:
a) Block 207C-15 vapor line to 207E-22A/B
b) Line up 207PIC 4101 with a set point of 14.1 kg/cm2 to flare
c) Line up 207PCV 4107 to maintain 14 kg/cm2
• Line up Fractionator as follows:
a) Line up 207PIC 4502 with 0.7 kg/cm2.venting to flare
b) Line up 207PIC 4501on auto with a set point of 0.7 kg/cm2.
c) Line up start up fuel gas to maintain pressure.
• Bypass feed filters, Commission cooling water to 207E 17/E20, Commission steam side of
steam generation 207E-18 / 207E-36 venting to atm & Commission fans on 207E-12,
207E-13, 207E-16, 207E-19, 207E-14, 207E-21.
• Ensure al the steam tracing line are commissioned
• Ensure water is drained from all the low points of system.

System Filling and Once Through Flushing:

• Line up S/U diesel to hot VGO from Ref.3 207FV-1406

• Open 207FV-1406 to fill up preheat exchangers & build up 50% level in 207C-1.

• Line up pump out line from 207C-1 to 207G-12A.

• Commission 207G-12A minimum flow 207FIC-4401.
• Start 207G-12A as per procedure & increase speed until governor takes control.
• 207C-16 level is building up through 207G-12A minimum flow circulation.
• Line up 207G-12A discharge to 207FV-2801 & through 207C-9 common effluent
line via 207E-8, 207E-4 to 207C-14.
• Establish a flow of 124 m3/hr & place 207FIC-2804 on auto when 207C-14 level
reaches 50% open 207FV-4003 &through 207E-11A/B, 207E-6, 207F-2 & back to
207C-16.
• When 207C-14 level is stable keep 207LIC-4003 on auto resetting 207FIC-4003.
• When 207C-14 level is stable start 207G-12B on minimum flow circulation 207FIC-4402.
• Ensure that fans are running in 207E-21 & keep 207TIC-5203 on auto with set point 40oC.
• Make sure before routing bottoms to slop that all high point vents are opened & made gas
free; Open 207FV-5202 to allow fractionator bottoms to flow through
207E-11A/B, 207E-36, 207E-27, 207E-24 & 207E-21 to slop header.
• Once 207C-16 level & flows are stable place 207LIC-4301 on auto resetting 207FIC-5202.

Startup Diesel 207FV-1406 207C-1 207G-12A FV 2804

Outlet (124 m3/hr)

207E-11 207C-14 207C-4 207E-8 207C-9

207C-16 207G-12B 207E-11 207E-36 207E-27

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 Slop 207E-21 207E-24
(124 m3/hr )

• Ensure flows are established in 207F-2 convection coils.

• Commission 207F-2 pilots & main burners as required by refractory curing procedures.
• After 4hrs of once through circulation check Fractionator bottoms to slop for suspended
solids.

Flush Product Stripper and Product Fractionator Overhead Systems and Columns:

Slipstreams are taken from the Fractionator bottoms pump's discharge to flush rust and the scale
from the product stripper and the product Fractionator overhead systems and the column
internals, while continuing the once through flushing circuit.

Flushing Product Stripper Overhead Systems and Column:

• Line up startup diesel from 207G-12A/B common discharges to 207C-15. Bring up 75%
level.
• Start 207G07 A/B and pump out maximum rate to slop till level drops to 10%

207C-15 207G-7A/B 207FV-4101 Slop header

• 207C-15 can be varied between 75% to 10%. Limit import rate to ~13 m3/hr. However this
addition rate can be determined by observing 207C-16's bottom export rate to the slop oil
header.
• Refill 207C-15 to 75% start the second pump at maximum export rate and repeat the
process till rundown to the slop oil header is free of suspended solids
• Once 207G-7A/B discharge is free of debris route 207G-7 A/B discharge through
207FV- 4001 to top of 207C-14 at the rate of ~13 m3/hr. Maintain a slip stream through
207FV-4101 to slop oil header.

Flushing Product Fractionator Overhead Systems and Column:

• Line up flushing oil to 207C17 and buildup 75% level.
• Line up flushing oil to slop header through 207FV-4601; Start reflux pump 207G-11A/B
and pump at maximum rate till level drops to 10%.
• Refill and repeat the process with the spare pump.
• Continue the process till rundown to the slop oil header is free of suspended solids.
• Refill 207C-17 to 50%, start a reflux pump, establish ~20.5 m3/hr through 207FV-4601 to
slop. Keep 207LIC-4501/FIC-4601 in automatic mode with a set point of 50% level.

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• Line up as:

207G-11A/B 207FV 4301 (20.5 m3/hr) 207C-16 top

• Place 207FV-4301 in auto mode with a set point of 20.5 m3/hr. Maintain a slip stream to
slop through 207FV-4601.
• Continue once through flushing at ~124 m3/hr until a visual rundown sample from 207C-16
bottoms to slop oil header appears clear from suspended solids.
• At this point, the following startup oil flow conditions should exit:

~124 m3/hr of startup diesel from storage to the feed section.

~124 m3/hr through 207FV-2804.

~13 m3/hr of flush oil to 207C-14 top through 207FV-4001.

0.5 m3/hr of flushing oil to slop oil header through 207FV-4101 from 207C-15.

20 m3/hr flushing oil to 207C-16 top through 207FV-4301.

0.5 m3/hr of flushing oil to slop header from 207C-17 through 207FV-4601.

124 m3/hr of flushing oil from 207C-16 bottom to slop oil header.

11.1.7 LOG LOOP CIRCULATIO

• When 207C-16 bottoms sample appears free of suspended solids and/or water hot long loop
flush oil circulation is started.
• Ensure Fractionator steam generator 207E-36 has been commissioned and venting to
atmosphere.
• Lineup feed filter and backwash system.
• Lineup hot source (upstream of 207E-21) long loop circulation by opening 207FV-1408 to
transfer 110 m3/hr of Fractionator bottom back to feed system (upstream of 207E-1).
• If continuous back wash occurs after long loop circulation reverts back to once through
flush circuit.
• Increase internal circulation rate to ~173.5 m3/hr or until a mechanical limit is reached, to
improve flushing efficiency.
• Increase long loop circulation rate (207FIC-1408 ) to ~158m3/hr.
• Maintain startup diesel import and export rates at~15 m3/hr.
• After 2-3 hrs of long loop circulation, stop all flows and allow water to settle for ~2 hrs,
and then drain the water.
• If the dry out is carried out firing to be adjusted during above steps.
• Re-establish circulation as previously.
• Increase firing in 207F-2 and temp to 85-90 oC if dry out permits.
• As temperatures are increased more scales will be loosened and trapped in feed filters
• Maintain this condition for 24 hrs.
• During this period run spare pumps and check suction strainers.
• As oil temps are being increased reflux pump are to be stopped to protect seals.
• Introduce flushing oil to upstream of 207FV 4001 and block reflux line isolation valve.
block startup diesel to 207C-15.
• Empty out 207C15 to slop, stop the pump and drain the remaining diesel to CBD.

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• Introduce flushing oil to upstream of 207FV 4301 and block reflux line isolation valve;
Block startup diesel.
• Empty out 207C-17 to slop stop 207 G-11A/B and drain remaining diesel to CBD.
Once 207C-16 bottoms become free of solids and feed filter bach wash frequency is less,
discontinue the flushing oil flow to the product stripper and fractionator reflux drums. Reroute
the flushing oil direct to each column's reflux line up stream of their respective reflux flow
control valves. These control valves will maintain previously established flush oil rates.
The flush oil routing s are changed before increasing the flush oil temp above 950 C, to avoid
damaging reflux pump seals. It also prevents getting high pour point VGO into the uninsulated
naptha systems.

Product Stripper:

• Gradualy introduce flush oil to the up stream of 207FV-4001, and block flush oil to
207C-15.
• Close the block valve in 207G-7A/B discharge to 207FV-4001.

• Empty out remaining startup diesel in 207C-15 as follows:

207C-15 207G-7A/B 207FV-4101 Slop oil header

• Once 207C-15 is emptied out close 207FV-4101 and isolate the slop oil header line.
• Ensure 207FIC-4001 is maintaining ~13 m3/hr flush oil to 207C-14.
• Place 207TIC-4101(207C-14 overhead temperature controller) in automatic mode.

Product Fractionator:

• Gradualy introduce flush oil to the up stream of 207FV-4301, and block flush oil to
207C-17.
• Close the block valve in 207G-11 A/B discharge to 207FV-4301.
• Empty out remaining startup diesel in 207C-17 as,

207C-17 207G-11A/B 207FV-4601 Slop oil header

• Once 207C-17 is emptied out close 207FV-4601 and isolate the slop oil header line.
• Ensure 207FIC-4301 is maintaining ~20 m3/hr flush oil to 207C-14.
• Place 207TIC-4502 (207C-16 overhead temperature controller) in automatic mode.

Product Fractionator Pump Around and Side Cut Streams Flushing:

• Fill up 207G-8A/B suction line from CT-3.

• Keep 207FV 4801 closed and start a pump.
• Open FV-4801 and fill up Kero pump around circuit 207E-38A/B, 207E-14 and back to
tray-42 of 207C-16.
• Establish pump around flow; Bleed the gas from high point vents of piping and exchangers.

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• Once pump around circuit is stable increase rate to ~ 132m3/hr place 207FIC 4801 on auto
• After 3 hrs change to spare pump and clean suction strainers.
• Flush the pump around circuit for 6hrs and then stop, allow to settle for minimum 30
minutes, then drain water in all low point drains.
• Reestablish pump around as before.
• Open 207C-18 LV 4701 and build up 75% level
• Line up kerosene 207FV 4702 to slop header start 207G 13 A/B pump and pump out to
slop at maximum rate till level drops to 10%
• Refill level to 75% and start the spare pump. Pump out at maximum rate. Clean suction
strainers.
• Repeat the above steps until run- down samples are solids free
• Block kero to slop block valve and build up 75% in 207C-18, stop the pump allow to settle
for 30 minutes and drain off water at low points
• Liquid fill 207G-9A/B suction line from CT-1 keep FV-5003 closed.

• Start a pump open 207FV-5003 slowly fill up diesel pump around circuit 207E-15,
207E-26 and E-18 and back to 207C-16 tray-28.
• Establish diesel pump around flow. Bleed the gas from piping and exchanger high point
vents.
• Once stabilized increase circulation rate to 188 m3/hr.
• After 3 hrs change pumps and check suction strainers.
• After 6 hrs stop circulation allow to settle for 30 minutes and drain for water from low
points.
• Open 207C-19 LV-4901, fill up 207C-19 to 75 % level.
• Bypass coalescer filter, coalescer and salt drier.
• Line up 207FV-5101 to slop.
• Start 207G-14A/B pump & pump out at maximum rate via 207E-2, 207E-19 and
207E-20A/B. to slop. Bleed gas from high point vents.
• Commission fans to 207E 19 & check 207TI 4906.
• Refill 207C 19. Start the spare pump. Pump out at max rate to slop. Check the suction
strainers.
• Repeat the above steps until run- down samples are solids free.
• Close 207FV 5101. Close block valve on diesel to slop. Stop pump. Build up level to 75 %.
Allow 30 min settling and drain water at low points.
• Check pump suction strainers.

11.1.8 THERMAL CYCLIG:

• Switch cold source to hot source long loop circulation.

• Temp change ~400C.
• After 2 hours switch back to hot source. Bypass 207E -6 if needed to increase temperature.
• Repeat thermal cycling 5 hours or as long as indication of scale loosening is present
(shown by back wash frequency).
• Once thermal cycling is complete return to hot source long loop circulation

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• Remove blinds from 207C-9 / 207C-10 common effluent line and internal circulation to
207C-9 inlet.
• Line up 207FV-2801.
• Slowly introduce flushing oil to inlet of 207C-9 & build up 50 % level.
• Open 207FV-2801 while closing B/V on effluent line.
• Once stable keep 207LIC-2801 / 207FIC-2801 on auto.

11.1.9 HOT FLUSHIG OF FEED AD FRACTIOATIO SECTIO

• Water must be eliminated before increasing temp

• Gradually increase firing in 207F2at a rate of 8 oC per hr to 125 oC
• Monitor pr profiles
• After attaining 125oC maintain for 8 hrs; If feed filter backwash frequency is normal,
thermal cycling is to be repeated.

Start up aptha to 207C-15 / 207C-17:

Ensure startup flushing oil is completely emptied out from 207C-15 & 207C-17. If the flushing
oil is remaining in the drums, pump out as mush as possible to slop header and then remaining to
OWS to prevent sending flushing to the light end section.

• Introduce start up naphtha to 207C-15, build up 50% level and start a pump 207G-7A/B.
• Open 207FV4101 and establish ~6.5 m3/hr flow to 207E-22A/B.
• Keep 207LIC/207/ FIC 4101 on auto. Adjust startup naphtha rate to 207C-15 to maintain a
stable drum level and the export rate to 207E-22 A/B.
• Introduce start up naphtha to 207C-17 and build up50% level start pump 207G-11A/B.
• Open 207FV 4601and establish ~10.4 m3/hr flow to 207E-22A/B.
• Keep 207LIC-4501 / 207FIC-4601 on automatic mode.
• Keep the rate from 207C-27 to 207C-29 and from 207C-29 to slop oil header at
~16.55 m3/hr, or about 88% of design.
• Adjust startup naphtha rate to 207C-17 to maintain a stable drum level and the desired
export rate to 207C-27, then to 207C-29 , then to slop header.
Discontinue flushing oil previously routed to up stream of 207FV-4001 and 207FV-4301
that is reflux lines to 207C-14 and 207C-16 respectively. This step is accomplished before
displacing startup diesel from the combined feed and fractionation sections with VGO, to
prevent getting high pour point VGO into the column overhead systems.
• Increase startup naphtha to 207C-15.
• Ensure the line to the slop oil header is blocked.
• Close the valve on the startup diesel line, upstream of 207FV-4001, and open the valve
from the discharge of 207G-7A/B.
• Ensure 207C-14 reflux flow control valve 207FV-4001 maintains ~13 m3/hr.
• Maintain a minimum export rate to light end section for stable reflux drum level control.
• Increase start up naphtha to 207C-17 and build up 50% level start pump 207G-11A/B.
• Close the valve on the startup diesel line, upstream of 207FV-4301, and open the valve
from the discharge of 207G-11A/B.

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• Ensure 207C-16 reflux flow control valve 207FV4301 maintains ~13 m3/hr.
• Maintain minimum export to light end section for stable reflux drum level control.

Displace diesel with VGO:

• 207C-16 bottom temp is ~1250C.
• Hot long loop circulation at temp of ~ 1250 C.
• Adjust internal circulation to 124 m3/hr & long loop circulation to 109 m3/hr.
• Line up VGO from CDU-3.
• Keep 207LIC 1601 on auto resetting 207FIC-1406 to maintain level in 207C-1.
• Slowly reduce start up diesel rate to 207C-1. Automatically VGO will be drawn to maintain
level in 207C-1 to desired level.
• Slowly reduce & cut off long loop circulation.
• At this point following conditions will exist:

~124 m3/hr of VGO from Ref- 3 CDU/VDU at 1700C ( ~ 50 % of design feed rate )

~124 m3/hr internal circulation from 207G-12A to 207C-9 inlet.

~124 m3/hr of VGO from 207C-16 to slop header.

• Continue on once through circulation till entire diesel is displaced with VGO.
• Once VGO is flushed out completely, reestablish hot long loop circulation at ~ 109m3/hr
through 207FIC 1408.

• Now the condition will be as:

VGO 207C-1 207G-12A 207FV-2801 207C-9 O/L

15 m3/hr 124 m3/hr

Long loop circulation 207G-12B 207C-16

109 m3/hr

Slop header 207E-21A/B

15 m3/hr

• Adjust firing adjustment to increase207C-1 oil temp. to ~1700 C.

• Hold at this condition till final preparation in the reactor section is completed to introduce
oil feed.

11.1.10 APHTHA FLUSHIG OF LIGHT EDS RECOVERY SECTIO

Once startup diesel flushing oil from reflux drums to columns is rerouted directly to the reflux
lines, flushing activities in the light end section can be started.

Once through aphtha flush:

154
• Drain all water from low drains, pumps, exchangers, instruments, etc.,
• Ensure cooling water is commissioned to 207E-22A/B, 207E-23A/B, 207E-25A/B,
207E-30A/B & 207E-31A/B.
• Ensure fans are running in 207E-39, 207E-29 & 207E-28.
• Ensure LPG treatment section is isolated, made air free , tightness tested & floating fuel gas
or N2 blanketing.
• Isolate amine to & from 207C-25.
• Line up 207C-20, 207C-22, 207C-25 pressure control 207PIC-6806 to flare.
• Commission 207PCV-5504 to maintain pressure at ~12 ksc. Place 207PIC-6806 in auto
with set point slightly above that being maintained by 207PCV-5504.
• Line up 207C-27 overhead high set point pressure control valve 207PV-6003 to flare.

• Commission 207C-27 207PCV-5903 to maintain pressure at ~10.7 ksc. 207PIC-6003 in

auto with set point slightly above that being maintained by 207PCV-5903.
• Line up 207C29 OVERHEAD high set point 207PV-6202 to flare
• Commission 207C-29 overhead startup fuel gas 207PCV 6205 to maintain pressure at
1.3 kg/cm2.
• Line up 207C-29 bottoms to by pass 207C-44. Ensure 207FV-6301 is blocked. Line up
207FV-6302 to slop. Make sure Naphtha to NHT / CRU block valve is closed.
• Ensure Naphtha from 207C-15 is lined up to 207E-22 A/B through 207FIC-4101 at the rate
of ~6.5 m3/hr
• When 207C-21 level is approximately 50 %, start 207G-17 A/B pump & open
207FV- 5601 & establish flow to 207C-20.
• When flow is stable keep 207LIC-5601 / 207FIC-5601 on auto.
• When 207C-20 level is approximately 50%; Start a bottom pump (207G-16A/B) open
207FV-5502 to establish a flow to 207C-27. Commission 207E-24 to add heat.
• When flows are stable keep 207LIC / 207FIC-5502 on auto.
• When 207C-27 level is approximately 50% line up 207FV-5902 to establish a flow to
207C-29. Commission 207E-26 to add heat. When flows are stable keep 207LIC-5701 /
207FIC-5902 on auto.
• When 207C-29 level is ~ 50% start a bottom pump (207G-20A/B) & pump out Naphtha to
slop via 207E 28 & 207E-31A/B. Keep 207LIC-6101 / 207FIC-6302 on auto. Commission
207E-27 to add heat.
• Line up startup Naphtha from 207C 17 to 207C 27 inlet. Keep 207C-17 level/flow control
loop (207LIC-4501 / 207FIC-4601) in auto and a transfer rate of ~10.4 m3/hr.
• Maintain the export rate from 207C-29 to slop at ~16.55 m3/hr.
• Continue once through circulation till naphtha splitter bottom is free of solids.

Establish Startup aptha to the Debutanizer and aphtha Splitter Reflux Drums:

• Commission startup naphtha to 207C-28 and build up 50% level. Ensure LPG export line to
the LPG caustic treating section is isolated.
• Start 207G-21A/B open 207FV-5901 to establish a reflux flow of ~3 m3/hr.
• Switch-off reflux pump and check suction strainers.

155
• Check 207C-27 bottom for suspended solids, if found free of solids, block naphtha to
207C-28 and stop reflux pumps.
• Commission startup naphtha to 207C-30 & build up 75% level.
• Line up 207FV-6201 to slop header. Start reflux pump (207G-24A/B) & pump out to slop
at maximum rate until level drops to 10%.
• Refill to75% run the spare pump and pump out at maximum rate to slop. Check suction
strainers.
• Repeat the above steps until naphtha to slop is solid free.
• Refill 207C-30 to 50% start a reflux pump & place 207LIC-6201 / 207FIC-6201 on auto.
• Through 207FIC-6101 establish a reflux flow of around 12.5 m3/hr. Place 207FIC-6101 on
auto. Keep minimum export rate.

Establish Internal aphtha Circulation:

• Once 207C-29 bottoms rundown sample is free of suspended solids, naphtha from
207C-29 is transferred to sponge oil reflux drum to establish internal naphtha circulation in
the light end section.
• Slowly establish naphtha flow of ~8.6 m3/hr through 207FV 5801 to 207E-23 A/B &
naphtha starts collecting in 207C-24. Once flow is stable keep 207FIC 5801 on auto with
SP of around ~8.6 m3/hr.
• When 207C-24 level is ~50%, start pump 207G-19A/B & route naphtha to 207C-22 via
207FV-5802. Once flow is stable keep 207LIC-5802 / 207FIC-5802 on auto.
• As 207C-22 level build up ~50% start pump 207G-18A /B & transfer naphtha to
207E-22A/B via 207LIC-5701 / 207FIC-5701.
• As 207C-20 bottom level increases reduce startup naphtha being imported from 207C-15
and 207C-17.
• Once naphtha internal circulation is stable at ~8.6 m3/hr, increase the rate to 17.2 m3/hr via
207FIC-5801.
• Maintain a slip stream from 27 C-29 bottom to slop oil header.
• Monitor 207C-29 bottom to slop for suspended solids. Once it is free of suspended solids,
the rundown can be to heavy naphtha storage.
• Change over pumps periodically & check suction strainers
• Line up 207C-14 overhead 207PIC 4101 to export vapor to 207E-22A/B and isolate line to
flare header.

11.1.11 VGO - FEED ITRODUCTIO

• Reduce the internal circulation rate from ~124 m3/hr to ~100 m3/hr ( 40% of Design )
• Reduce long loop circulation rate from ~109 m3/hr to ~50 m3/hr, via 207FIC-1408
• Keep hot straight run VGO at ~1750C to 207C-1 at the rate of ~59 m3/hr
• Keep 207C-16 to slop header at the rate of ~59 m3/hr
• Ensure following conditions

VGO import ~59 m3/hr

Surge drum inlet temp ~170 0C

207F-1 COT is 2050C

156

Internal circulation rate is ~100 m3/hr

Hot long loop circulation rate is ~50 m3/hr

207C-16 bottoms temp. is ~1750C

VGO export rate from 207C-16 bottom ~59 m3/hr

207R-1 and 207 R-2 inlet temp. is ~ 2050C

207R- inlet pressure is ~155 kg/cm2 (90% of normal pressure)

Reactor quench control valves are in auto Set point 2050C

Start 207G 3A/B reactor feed pumps.

Start 207G 5A/B amine circulation pumps as per procedure.

• Watch filter backwash frequency as flow rates are changed

• Reroute internal circulation to CLPS outlet line.
• Carefully liquid fill and gas fill the HP feed line up to 207FBV-1802. By opening
207FIC-1801 on MANUAL mode. Close the d/c valves of feed pumps once liquid filled.
Start a reactor pump on minimum circulation.
• Introduce VGO to 207R-1 by carefully opening feed pump discharge valve & the bypass
on 207FBV-1802 quickly increase feed rate to 124 m3/hr within 3-5 min .
• After establishing ~124 m3/hr quickly, place 207FIC-1801 in auto for the SP of 124 m3/hr.
• Reset 207FBV-1802 SOV (207FY-1802A) which opens 207FBV-1802 and then close its
bypass. Before closing the by pass valve of 207FBV-1802 test its function by giving a false
low-low oil feed flow signal which will trip the chopper valve. Reset 207FY-1802A after
removing the false signal. Bypass valve must be closed and locked.
• Adjust 207F 1 firing to maintain 207R 1 I/L temperature at 205 0C.
• Monitor the bed temp carefully for any bed temp escalation. Maintain 205 0C in the entire
beds inlet using quench flows. When the temperature at the inlet to bed below has returned
to below 205 0C, quench can be stopped to the bed above.
• Initial feed-in may evolve a high heat leading to a delta temperature of 55 0C across bed.
• If any catalyst temperature exceeds 315 0C and continues to increase,

Increase oil feed

Increase quench to the beds above & below the hot spot

Cut back furnace fires and bypass preheat exchangers to reduce the reactor
I/L temperature.

Reduce system pressure by ~14 Kg/cm2.
• Immediately after feed-in, switch the internal circulation from 207G 12A pump discharge
to the short-loop source to maintain flow to Fractionator section via the reactor effluent
system.
• Open short-loop block valve to route hot Fractionator bottoms from u/s of the 207E-21 to
the internal circulation line.
• Slowly close the internal circulation block valve on 207G-12A discharge, making sure
internal circulation controller 207FIC-2804 maintains ~ 100 m3/hr to CLPS outlet
• Discontinue Long loop circulation to prevent catalyst fines, washed from the catalyst, from
being returned to the reactor. Close long loop flow controller 207FIC-1408.
• Pressure will rise as feed fills the reactor section. Monitor 207K-1 suction pressure.
Keep 207PIC-2601 in auto of S.P. ~153 kg/cm2, to automatically bleed gas to the flare.

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• When temperature wave reaches 207R-2 2nd bed, reduce feed rate to ~40% (~100 m3/hr)
to avoid filling the CHPS too quickly.
• After feed introduction to 207R-1, level should begin to build up in CHPS in 45 – 60 min.
When oil level builds up in CHPS, commission CHPS level control valves to transfer liquid
to CLPS.
• Blind start up hydrogen header to the reactor low pressure section, and ensure the CLPS
and CLPS vapor H2S absorber are holding ~37.55 kg/cm2 by adjusting 207PIC-2901.
Ensure 207C-12 and 207C- 6 are holding at ~30 kg/cm2 g and 7.3 kg/cm2 by adjusting
207PIC-2903 and 207PIC-3201 respectively.

• When CHPS to CLPS and CLPS to Fractionator section flows are steady, gradually reduce
and then stop the short loop circulation via 207FIC-2804. Hold 170 – 175 0C at 207F-1
outlet.
• Gradually increase 207PIC-2702 set point to ~153 kg/cm2g, RGC design operating
pressure. Set 207PIC-2601 at higher SV than 207PIC-2702 S.P, which results in no bleed
to flare. In this case, 207PIC-2702 controls reactor pressure by resetting make-up hydrogen
compressor d/c 207PIC-6904 S.P, which regulates compressor spill back.
• Begin water injection u/s of 207E-9. When water accumulates in CHPS and CLPS,
commission the interface level controls and the sour water degasser system.
• When the system is fully under control, oil feed rate should be increased to 60 – 75 % of
design. Higher feed rates assure better distribution in the reactors prior to increasing
temperature to achieve conversion.
• Start increasing reactor temperatures according to the following table:

Table 11.2: EXPECTED CAT Vs MAXIMUM HEATIG RATE

0
C < Expected CAT Maximum heating rate, 0C / hr
56 28
28-56 11
11-28 6
<11 3

• Adjust the top bed temperature first and then each succeeding lower bed next. Continue
increasing temperatures until desired conversion is achieved. When increasing
temperatures, subtract ~15 Deg C from estimated temperatures to allow for super activity
shown by fresh HYDROCRACKER catalysts. Hydrogen consumption may be used as a
rough guide for conversion levels until conversion can be verified with reactor effluent or
product samples.
• As the reactor temperatures are increased H2 consumption will increase accordingly.
So adjust 207K-2 loading as required.
• As the reactor temperatures are increased, put 207E6 on temperature control with
207TIC-2002, to adjust 207R-2 temperature profile.

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11.1.12 ACHIEVIG O SPECIFICATIO PRODUCTS

• Maintain the reactor feed rate at ~60-75% of design (150 to 200m3/hr), while making final
CAT adjustments to reach required conversion levels. Allow suitable time for reactor
section to reach equilibrium before making changes in feed & fractionation section.
• As CAT increases lighter products will appear in fractionation section.

• Ensure 207C-14 overhead condenser 207E-12 fans are commissioned to cool the
temperature of I/L stream to 207C-15 to ~ 60 Deg C after stripping steam is introduction
and heat load on the column increases.
• Commission 207E-4 temperature controller 207TIC-2102 and gradually increase inlet
temperature of 20 C-14 to design conditions i.e. 1410C
• Ensure 207C-16 overhead condenser 207E-13 fans are commissioned to condense
Fractionator overhead vapors going to 207C17, after stripping steam introduced and heat
load increase on 207C16. Keep 207TIC-4502' S.P. at ~55 0C.
• Prior to introducing steam to 207C 14 and 207C 16, ensure that the superheated steam lines
are warmed up and cleared of water up to the inlet valve on each column nozzle.
• As 207C-14 heats up, introduce stripping steam carefully via 207FIC-4002 at ~25% of
design rate (3.6 ton/hr) initially and then gradually increase to 3.6 ton/hr. As condensate
collects in 207C-15, commission interface level control loop 207LIC-4104 and export
water to the water degasser drum 207C-13.
• Gradually increase inlet temperature of 207C-16 to design level.
• As 207C-16 heats up, introduce stripping steam carefully via 207FIC-4305 at ~25 % of
design rate initially and then increase to ~3.425 ton/hr as the start up progresses.
• When condensate begins to collect in 207 C-17, commission one of the sour water pumps
207G-10 A/B and commission automatic interface level control loop 207LIC-4503
exporting water to injection water drum.
• When sufficient naphtha carryover to 207C-15 and 207C-17 occurs, adjust reflux rates as
required to maintain design column overhead temperatures of ~141 Deg C and ~113 Deg C
respectively.
• Place 20 TIC-4003 of 207C14 on AUTO mode resetting 207FIC-4001.
• Place 207TIC-4302 of 207C16 on AUTO mode resetting 207FIC-4301.
• If enough vapors starts venting through 207PIC 6806 from 207C-25 to flare, as the
conversion is increases, close startup hydrogen to C-20 vapor outlet line. Maintain 207C-20
top temperature at ~52 0C. Commission lean amine flow to 207C-25 i.e. FV6801 and
commission 207LIC6801 rich amine from 207C-25 to 207C-06. Commission lean amine to
207C-25, preheating system. Keep 207TDIC6801 on auto mode at required set point, to
control the temperature difference between 207C-25 inlet lean amine and Inlet vapors.
Once enough lean amine flow is established, check 207C-25 outlet gas samples. If it on
specification, line 207PIC-6806 to off plot fuel gas header and isolate the line to flare.
• When over flash liquid rate 207FI-4304 is sufficient, gradually increase kerosene and diesel
pump around rates to design.
• Begin to draw side products and match draw rates to design draw temperatures (278 0C).

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• Draw diesel to 207C-19 by putting 207LIC-4901 on AUTO mode and pumping to slop via
207FIC-5701. Target draw off temperature of ~278 Deg C. As 207C19 heats up, introduce
stripping steam (superheated MP steam) via 207FFIC-4901 at 25 % of design rate and
increase to design rate.
• Draw kerosene to C-18 by putting 207LIC-4701 on AUTO mode and pumping to slop via
207FIC-4702. Target draw off temperature is ~175 Deg C. Commission reboiler to meet
flash point specifications.

• When Naphtha carryover to 207C-15 and 207C-17 are sufficient to provide target reflux
rates and naphtha export for stable reflux drum level control, start up naphtha to reflux
drums should be discontinued.
• When 207PIC-6003 and 207PIC-6202 starts venting to flare, close makeup H2 to 207C-27
and close fuel gas to 207C-29 top vapor line.
• Establish 207C-27 and 207C-29 overhead temperature and pressures to design values.
When level builds up in 207C-28 establish reflux and start exporting LPG to treatment
section. When 207C 30 level builds up introduce reflux & export excess to Lt. naphtha slop
• Adjust light end section to achieve on-specification products.
• Once the reactor and fractionation sections are lined out with all products on-specification,
increase feed rate to the target level. While feed rates are increased, the reactor CATs
should be increased as required.

ote: Cracked feed stocks should not be introduced to the ISOCRACKING unit for at least
3 days after the unit is running steadily at full conversion. When cracked stocks are
finally introduced, they should be brought in gradually.

The following Chopper valves/ control valves need to be checked periodically

to ensure their reliability as per the process designer’s recommendations and
OHCU HAZOP study:

Table 11.3

SL
o. Tag numer Service Remarks

1. 207FBV -1802 Feed chopper Valve Check the valve trip function after taking the
bypass on line (Force- off from PLC).
2. 207FBV -3104 Amine chopper valve Check the valve trip function after taking the
bypass on line ( Force-off from PLC)
3. 207FBV -3303 Injection water chopper Bypass is not provided;
valve Check the valve trip function by stopping the
water injection pump.
4. 207TV -1803 207E-3 tube (feed) Check the spare valve for stroke response
bypass TV
5. 207LV -2404B 207C-2 LV (spare) Check the spare valve for stroke response.

160
 6. 207LV -2504B 207C-4 amine LV (spare) Check the spare valve for stroke response.
7. All the stop check valves in the Hand wheel should be partially turned
HP circuit. periodically to assure proper operation of the
stop check valve.

11.2 SHUT-DOW PROCEDURE

The unit will be shut down for maintenance, and the reactor loop will be brought to any of the
following conditions:

• Reactors remain under hot gas circulation at full pressure when the shutdown will be of short
duration.

• Reactors are cooled and depressurized but remain under nitrogen purge for reactor loop
maintenance.

• Reactors are cooled and depressurized for catalyst skimming, regeneration, or dumping.

11.2.1 SPECIAL FEATURES OF THE SHUTDOWN SYSTEM

• The reactor section can be blinded from the feed and fractionation section, with the feed and
fractionation sections remaining under pressure and on long-loop circulation if turnaround
efforts are not required in the feed and fractionation sections.

• A pump out line the reactor feed surge drum to the fractionator bottoms “A” pump’s suction
is provided to clear hydrocarbon liquid from the drum, if turnaround efforts require.

During shutdowns, precautions must be taken to avoid the following, whether planned or
unplanned:

• Exposing personnel to toxic or noxious conditions when catalyst is drained or when

equipment is entered.

• Fire possibilities when the reactors are opened, due to explosive hydrogen-oxygen mixtures,
or exposure of pyrophoric material to air.

• Furnace or catalyst coking, by keeping temperatures under control.

• Cooling reactors at rates that exceed cooling guidelines as described in Section 5.1.4.

• Potential formation of highly toxic nickel carbonyl compound when the reactors are cooled
below 205°C.

161
• During OHCU shutdown (for maintenance activity involving vessel opening), CO level in
the recycle gas is to be monitored carefully – reactor temperature should not be lowered
below 205ºC unless CO concentration in the recycle gas is < 10ppm.

11.2.2 PREPARATIONS FOR A PLANNED SHUTDOWN

For a planned shutdown (e.g., catalyst regeneration or replacement), some work can be done in
advance, such as:

• Prepare blind lists and blind list accounting procedures for required isolations.

• Have test equipment onsite for:

– CO Test for Nickel Carbonyl
– pH Tester for Acid or Caustic Waters
– Explosive Gas and Hydrogen Analyzers
– Oxygen Analyzer (If Vessel Entry is Planned)

• If inert atmosphere entry into the reactors is planned, have the necessary personnel protective
equipment on hand.

• Have the necessary materials onsite to complete the shutdown.

• Inform all interested parties of shutdown plans.

• Have temporary piping spools, blinds, gaskets, etc., onsite.

• Erect staging (scaffolding).

• Ensure adequate storage space is available in the offplot slop oil storage system.

• Plan for any unbalanced utilities.

11.2.3 SHUTDOWN PROCEDURE

Feed to the reactor section is gradually reduced to 50% of design, while concurrently reducing
the CATs to maintain on specification products, and then oil feed is stopped. Once oil feed has
been stopped, a catalyst hot stripping period commences with reactor temperatures at the value
they were at before they were first reduced at the outset of the shutdown, and with the recycle
gas rate at design. After hydrocarbons are stripped from the catalyst beds, reactor may be cooled
and depressured, should follow the below given limits.
Final nitrogen purging and other appropriate activities are carried out to prepare the reactor
section for standby status, catalyst skimming, catalyst unloading, catalyst regeneration, or
general maintenance.

162
Reduce Feed Rate and Begin Reactor Cool down:

1. Reduce catalyst temperatures first, and then gradually reduce oil feed in increments of ~5%
every 20 minutes, such that feed conversion remains at the desired level to continue
producing on-specification products. Bed quench controllers are adjusted simultaneously
with reactor inlet temperatures to lower all catalyst temperatures evenly.

2. As the oil feed rate is reduced, the reactor feed and effluent flow rates will not be in balance
for short periods. This is why feed reductions should be gradual, as recommended above.
Monitor the reactor feed/effluent heat exchanger feed-side outlet temperatures closely, and
make gradual adjustments to maintain controllable furnace duty in the reactor feed furnace
(i.e., ~20-30°C temperature increase).

3. The product draw rates from the product fractionator (207C-16) sidecut systems should be
reduced proportionately as the oil feed rate is reduced. Keep draw temperatures constant to
maintain on-specification products. Sample product streams on short intervals, and route
products to the slop oil header, once they fail to meet specification.

4. When oil flow from the CLPS to the product stripper (207C-14), and subsequently to the
fractionator feed furnace (207F-2), falls below 50% of 207F-2 design flow rate (or minimum
flow rate recommended by the furnace vendor). Ensure the emergency circulation low set
point flow controller (207FIC-4201) has opened to route 207C-16 bottoms from the
discharge of the fractionator bottoms pumps to 207F-2 inlet to maintain a minimum oil
flow to the furnace. Flow must be maintained to minimize potential furnace tube coking
as oil feed to the reactor section is reduced and ultimately terminated.

5. If oil feed is reduced below the reactor feed pump minimum flow requirement, ensure the
minimum flow controller performs correctly to protect the pump.

6. As the reactor temperatures and oil feed rate is being reduced, the working pressure and
recycle gas rate to the reactor section should be maintained at design values; however, the
hydrogen make-up consumption will fall. Closely monitor the make-up hydrogen
compressor loading and pressure controller performance as the hydrogen make-up
requirements reduce.

7. To prevent bleeding RGC suction gas to flare, unload or shut down make-up hydrogen
compressors as required.

8. If the shutdown is of short duration and it is desired to keep the feed and fractionation
sections hot, hot long-loop circulation can be established before stopping feed to the reactor
section. After the oil feed rate is at 50% (~124 m3/hr), do the following:

• Ensure the fractionator bottoms 207G12B pump is in service.

163
 • Align the fractionator bottoms 207G-12A pump to draw oil from the reactor feed
surge drum and discharge through the internal circulation line to the downstream side
of the CLPS, to establish an internal circulation rate of ~100 m3/hr (~40 % of design
feed rate), via 207FIC-2804. This will draw VGO feed into the feed section at 90%
of the design rate (~124 m3/hr feed to the reactor section and ~100 m3/hr of internal
circulation). There will still be sufficient capacity in the feed section to continue
supplying the reactor feed pump at 50% of design.

• Establish hot long-loop circulation at ~85 m3/hr, via 207FIC-1408. The VGO import
rate to the feed section will reduce proportionately. This assures that ~15 m3/hr of
VGO feed will continue to be imported and the same amount exported from
207C-16 bottoms to the slop oil header.

9. Reduce the reactor feed furnace firing (maybe to pilots only), stop the feed pump, and block
in the pump discharge. This is a convenient time to check that the feed pump discharge
emergency block valve (chopper valve) closed automatically on low flow.

• As soon as the reactor feed pump is shut down, simultaneously increase the:

• Internal circulation to ~124 m3/hr (via 207FIC-2804), or ~50% of design feed rate.

• Long-loop circulation to ~109 m3/hr (via 207FIC-1408). This should establish a feed
import rate and 207C16’s bottoms export rate of ~15 m3/hr.

11. Once oil is displaced from the reactor high and low pressure sections, isolate the high
pressure section from the low pressure section, and commission the startup hydrogen line to
the low pressure section to maintain pressure on that section. Additionally, commission the
startup hydrogen line to 207C-14 and the startup fuel gas line to 207C-16 to allow oil
circulation through the combined feed and fractionation sections.

12. Start reducing 207C-16 inlet temperature. While still above ~125°C, align startup diesel to
the feed section, and isolate the VGO feed line to displace the heavier feedstock from the
feed and fractionation section before cooling down below 125°C.

13. Revert back to the once-through flush circuit to expedite this task, and then reestablish
the previous long-loop circulation conditions.

14. Once naphtha production stops, isolate 207C-14 and 207C-16’s export systems and shut
down the light end section.

15. Once VGO is displaced from the feed and fractionation sections, diesel flush oil can be
routed to the top of 207C-14 and 207C-16 to aid in cool down, and to flush heavier oils from
column trays.

164
16. Slowly switch the long-loop circuit to the cold source. Monitor the unconverted oil air
cooler outlet temperatures to ensure the maximum rundown temperature to storage is not
exceeded.

17. Cool 207C-16 inlet temperature to either standby conditions or cooler for complete
shutdown.

Catalyst Hot Gas Stripping:

When oil feed has been discontinued, catalyst hot gas stripping is initiated to remove as much
hydrocarbon from the catalyst as possible.

1. Once oil feed has been discontinued, maintain normal reactor section working pressure and
continue the design recycle gas rate.

2. Increase 207R-1 and 207R-2 inlet temperatures to ~315°C (or end–of-run temperature
conditions) to begin a catalyst “hot gas” stripping period. Adjust the reactor feed/effluent
exchanger temperature controller, as required, for accomplishing the most effective heatup.

3. When hydrocarbon liquid stops collecting in the CHPS (usually ~4 hours), stop water
injection.

4. If the unit is being shut down for brief maintenance, which does not require stopping the
recycle gas compressor, continue circulation at normal working pressure. If the feed outage
will be 3 days or less, reduce the reactor temperatures to 265°C. If the feed outage will be
more than 3 days, cool the reactors evenly to ~205°C. Stop the amine circulation to avoid
catalyst leaching.

5. If the shutdown is for catalyst regeneration, catalyst replacement, or maintenance that requires
stopping the recycle gas compressor or depressuring the reactor section, continue circulation at
normal pressure for 4 hours after hydrocarbon liquid stops collecting in the CHPS. Then
reduce reactor temperatures evenly to ~205°C as discussed in the next section.

Reactor Cool down:

Cool and depressure the reactor section after hot gas stripping is completed. The reactor section
is then cleared of hydrogen with nitrogen, cleared of nitrogen with air, and then isolated.

1. Maintain normal working pressure and the maximum recycle rate to cool the reactors in the
shortest time, within the cooldown limits as specified

165
2. Slowly reduce the reactor feed furnace (207F-1) outlet temperature, taking care to stay safely
above 38°C (MPT). During this step, monitor all reactor skin, nozzle, and internal temperatures
hourly to assure even reactor cooling and that cooldown rates are not exceeded (i.e., catalyst
beds, nozzles, skin points, etc.).

ote: 207R-1 inlet pressure should be reduced below 46.3 kg/cm2 (25% of reactor design
pressure) before any reactor internal, reactor skin, or reactor nozzle temperature drops below
MPT 38oC.

3. Displace hydrocarbon liquids from the CHPS to the CLPS, and from the CLPS to the product
stripper (207C14), and block the level control valves.

4. Displace water from the CHPS and CLPS to the water degasser drum (207C-13), and block
the interface level control valves.

5. When permitted by cooling rate restrictions, speed cooling as follows:

• Minimize preheat to 207F-1, by opening the reactor feed/effluent exchangers

(207E3A/B) bypass and closing the minimum-stop valve (to mechanical stop).

• Minimize preheat to 207F1 by adjusting the three-way valve on the reactor

effluent/recycle gas exchanger (207E-7) to close the exchanger inlet port, thus fully
bypassing the exchanger.

• Ensure all reactor effluent air cooler (207E-9) fans are running and the cooler is set up
for maximum cooling.

6. If the shutdown does not involve opening the reactors, but it is necessary to cool below
205°C, continue cooling with Step.16.

7. If the shutdown is for catalyst regeneration or change out, or for maintenance that requires
opening the reactors, begin to monitor recycle gas samples for CO content.

8. Ensure that the recycle gas stream CO content is below 10 ppm before reducing any reactor
temperature below 205°C to prevent the possible formation of highly toxic metal carbonyl
compounds. If CO is less than 10 ppm, continue cooling with Step 16.

CO Content in the Recycle Gas is Greater Than 10 ppm and the Reactors
Will Be Opened:

9. If more than 10 ppm CO has been detected in the recycle gas, and the reactors will be
opened, the CO must be purged before cooling can continue to eliminate possible formation
of metal carbonyls. Isolate the high pressure H2S absorber (207C-4) and void amine from the

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vessel. Stop recycle gas circulation while catalyst temperatures are still safely above 205°C to
avoid cooling any portion of any catalyst bed below 205°C. Before depressuring the reactor
section, check that all valves listed below are closed.

• Discharge block valves on the reactor feed pumps.

• Block valves on the oil feed line.

• Block valves on the CHPS, high pressure centrifugal separator and CLPS
hydrocarbon lines, and the CHPS and CLPS water lines.

• Recycle gas compressor motor-operated discharge valve (207 HBV-2705).

• High pressure hydrogen header from the make-up hydrogen compression section.

• Water injection lines, blocked and blinded.

• Low pressure hydrogen supply header to the make-up hydrogen compression

section.

10. Depressure the reactor section to ~0.4 kg/cm2 (g), and purge nitrogen through the reactor
section. When purging, nitrogen should be admitted to allow it to follow the normal
downward flow path through the catalyst beds.

• Remove the startup nitrogen blind to the downstream side of the high pressure
hydrogen header isolation manifold to the reactor section.

• Admit nitrogen and purge through the reactor section to the flare, via the recycle gas
compressor (207K-1) suction high set point pressure control valve (207PV-2601),
for 5-10 minutes, and then close the valve.

• Admit nitrogen and purge through the reactor section to the flare, via the CLPS
vapor KO drum (207C-12) high set point pressure control valve (207PV-2903B),
for 5-10 minutes, and then close the valve.

11. Allow the reactor section’s pressure to increase to nitrogen header pressure,
~6.0 kg/cm2 (g).

12. Once again, depressure the reactor section to ~0.4 kg/cm2 (g) and purge nitrogen through
the reactor section and out to the flare as before.

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13. Repressure the reactor section to nitrogen header pressure. Separately purge nitrogen to
the flare through 207PV-2601 and 207PV-2903B.

14. Switch the make-up hydrogen compressors to nitrogen service, following approved
refinery isolation and purging procedures.

15. With the make-up hydrogen compressors operating on nitrogen, repressure the reactor
section to ~40.0 kg/cm2 (g). Start 207K-1 and circulate through the reactors. Reestablish
207F-1 main burners (if the furnace was reduced to pilots only before stopping oil feed)
to maintain reactor temperatures above 205°C for at least 2 hours. Then analyze the
recycle gas stream for CO. If the CO content still exceeds 10 ppm, go back to Step 7 and
repeat the depressuring, purging, and repressuring steps (Steps 10 through 15).

CO Content in the Recycle Gas is below 10 ppm:

16. At this point the CO content in the recycle gas stream must be below 10 ppm, unless the
reactors are not to be opened. The reactors can now be cooled below 205°C, following
the cooling rate restrictions. Continue to circulate nitrogen through the reactors, with
207K-1 suction pressure being maintained at ~40.0 kg/cm2 (g).

17. If the reactors are not cooling down evenly (time-wise), equalize cooldown time by
adjusting quench flows to assist in evenly cooling the reactors.

18. Continue to reduce 207F-1’s fires. As the reactor section temperatures decrease to near
MPT, carefully monitor all reactor temperatures.

CAUTIO:
The reactors should be depressured below ~46.3 kg/cm2 (g) (25% of reactor design pressure)
before any reactor internal, nozzle, or skin temperature drops below MPT.

19. When 270 F-1 is no longer needed to control the cooling rate, pull the fires and purge the
firebox. Convert 207F-1 to an air cooler by opening dampers, air registers, available
inspection ports, etc.

20. Continue circulating nitrogen until the reactors (including the shells) have cooled to
within 10°C of 207F-1 outlet temperature or until the hottest reactor temperature
(including the outer wall skin thermocouples) are below 45°C (or other refinery
temperature requirements for vessel entry).

21. When the reactors can no longer be cooled with recycle gas, shutdown and isolate RGC.

22. Block in the reactor section as described in Step 9.

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23. Depressure the reactor section to ~0.4 kg/cm2 (g) by testing the emergency depressuring
valves to the flare, close the valves, and then purge the reactor section as in Steps 10
through 13.

24. Continue sweeping utility nitrogen through the high pressure loop and out to the flare,
via 207K-1 suction high set point pressure controller (207PIC-2601), to cool the
reactors to the maximum temperature allowed for vessel entry, as specified in refinery-
approved vessel entry procedures. Use reactor shell temperatures as a guide.

25. Test to ensure that combustibles have been purged from the reactor section. If necessary,
repressure the reactor section with nitrogen, depressure again to the flare, and repeat as
necessary to lower hydrogen concentrations to acceptable limits.

26. The reactor section is now ready for installation of isolation blinds (following accurate
blinding list) and/or opening. Maintain the reactors under a slight nitrogen pressure to
ensure that no oxygen is admitted.

CAUTIO:

When air, water, and sulfidic scale are all present, polythionic acids may form. Polythionic
acids will crack austenitic stainless steel. Cracking occurs very quickly, even at ambient
temperatures. Precautions should be taken to avoid situations that may be conducive to stress
cracking.

During turnaround, it is prudent to assume that when austenitic stainless equipment is to be

exposed to air and moisture, all other conditions necessary for stress corrosion cracking
(stresses, sulfides scale, and sensitization) will be present. The best protection for austenitic
stainless steel is to keep it dry, free of air, and warm to prevent condensation of moisture. If this
is not possible and the austenitic steel will be subject to contact with air or moisture, it should be
neutralized by washing with a soda ash solution to this exposure. The austenitic equipment that
will not be opened during the turnaround should be sealed in a nitrogen atmosphere.

11.3 EMERGECY PROCEDURES

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The most important aspect of handling emergency situation is to put the OHCU Unit into a safe
position. The actions may be reducing the pressure by dumping or controlling the temperature,
increase or decrease the feed flow or gas flow depend on emergency situation.
The worst emergencies are temperature excursion & runaway, and leak in high pressure area. So
care should be taken to control before reach this point.

When an emergency occurs, measures must be taken to avoid:

• Personnel hazards
• Equipment damage
• Furnace coking
• Excessive catalyst coking and/ or fouling

Steps frequently taken to move from an emergency situation to a safe situation are:
Furnace firing reduced to only pilot fires. Completely extinguish if there is an open fire or a gas
release.
• Reactor temperatures under control.
• Make-up hydrogen flow is at the desired rate or has been stopped, depending on the
situation.
• Feed pump is shutdown, unless left running to provide catalyst cooling.
• Recycle compressor is running normally (or safely shutdown in some cases).
• Reactor loop emergency depressurizing system us available, or the reactor loop has been
depressured to a safe level if required.
• Reactor effluent air cooler fans are running.
• Separator liquid levels are under control..
• Water injection has been stopped.
• Amine system has been shut down.

CATALYST

HEA
T
HYDROGE
OIL

In this “heat triangle” for a hydrogenation reactor, the elements are oil, hydrogen, and catalyst.
Eliminating any one of the three factors would stop the reaction and thereby prevent the
uncontrolled heat release. Hydrogen is the only factor that can be removed quickly enough to
prevent an uncontrolled heat release.

If VGO feed to the reactor is stopped, an extended period will be required before the oil can be
swept and then stripped, from the catalyst beds- in other wards the oil will be more or less

170
stagnant on the hot catalyst. If hydrogenation reactions are not suppressed and ultimately
stopped, oil decompositions, resulting in catalyst fouling by coke laydown, will be experienced.
When possible to prevent coking, a flow of liquid feed must be maintained through the reactors.
Catalyst tends to hold its temperature for considerably long periods. Changes in the reactor oil
feed temperature will not show in the reactor outlet temperature for many minutes. The only fast
response available to the operator is to reduce the reactor section pressure and limit hydrogen
availability. By limiting make-up hydrogen, the available hydrogen in the reactor section will
begin to be significantly reduced immediately. This will limit the hydrogen available for
hydrogenation reactions and the heat release from these reactions will decrease. The overall
reactor section pressure will also fall as hydrogen is consumed. If the pressure is not decreasing
fast enough, the emergency depressuring valve is opened to accelerate the depressuring rate.

EMERGECY PROCEDURES ARE PRESETED I 3 FORMATS AS FOLLOWS:

11.3.1 - DESCRIPTIVE FORMAT,

11.3.2 - TABULAR FORMAT,

11.3.3. - LOGIC CHARTS.

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11.3.1 EMERGECY PROCEDURES - DESCRIPTIVE FORMAT

This section presents recommended procedures to be followed during most serious emergencies.
When an emergency occurs, measures must be taken to avoid personnel hazards, equipment
damage, and furnace coking and excessive catalyst fouling.

The following initial steps should protect the catalyst and equipment from
damage during almost any upset:

1. Reduce heat input to the reactors to keep reactor temperatures under control:
- Reduce 207F-1 firing to pilots, or cut fires completely,
- Bypass the feed / effluent exchangers in order to lower the reactor inlet temperature.
- Due to the lower temperature, the reaction rate and the heat releases in the catalyst
are reduced.
- Cooler oil flowing through the reactors will also provide a better heat sink.
- Lower furnace temperatures will substantially reduce the risk of coking in the furnace
tubes.
- Take care, while open the 207E-3 bypass to avoid overheating the effluent
downstream.

2. Maintain recycle gas flow through the equipment:

- Maintaining recycle gas flow helps maintain oil flow through the piping, Feed/effluent heat
exchangers, feed furnaces, and reactors.
- If oil resides an extended time in the reactors at high temperatures, the extent of catalyst
coking and fouling increases substantially.
- Recycle gas also serves as a heat sink to remove sensible heat from the reactors.

3. Limit hydrogen availability to minimise heat release.

- Reducing make-up hydrogen removes one corner of the “heat triangle,” there by
minimizing one of the major sources of heat release.
- Opening the emergency depressurizing valve will reduce the pressure more rapidly.

Switch Feed Stocks:

Instead of fresh feed, UCO will release less heat because of its lower levels sulfur, and heavy
molecules, due to low viscosity the UCO maintaining good flow distribution at lower
temperature. Keeping oil through the reactor provide additional heat sink.
The start up long loop circulation line is used for this purpose.

At the time of unit is shutdown in response to an emergency, hydrocarbon should be hot stripped
from the catalyst before the unit is to be restarted. Hot gas stripping with recycle gas at 3150C
(or reactor temperature conditions at the time of emergency) is the optimum way of hot stripping
catalyst. For serious upsets that require a complete with drawl of VGO feed, CLG recommends
hot gas stripping for 8-12 hours.

DESIG FEATURES RELATED TO EMERGECY SITUATIOS

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There following are some the major design features regarding potential emergency situations
that could be experienced:

1. Automatic- Reactor feed furnace main burners trip

- on loss of oil feed FT/FALL-1802 fall below 90 m3/hr
or
- on loss of recycle gas FT/FALL-2202 fall below 84189 Nm3/hr

2. High pressure loop emergency depressuring device, with backup Instrument air supply:
207HBV-2601/2602.

3. Emergency electrical power or steam turbine backup to critical equipment. Like RGC lube oil
CEP, and fractionator bottom pump

4. Emergency quick-closing ‘chopper’ valves for equipment isolation in cases of

• low oil feed flow (207FBV-1802), 90 m3/hr, feed pump run indication failure
• low high pressure amine flow (207FBV-3104) 70 m3/hr amine pump run
indication failure
or
• low injection water flow (207FBV-3303). 3 m3/hr

5. Automatic- emergency oil flow to the fractionator feed furnace 207F-2 on loss of feed flow to
prevent pass stalling (207FIC-4201).

6. Loss of total oil flow to the 207F-2, automatic-ally trips the furnace to minimum firing
(207FALL-4202 / I -4201). 75 m3/hr

7. Ability to recycle cold fractionator bottoms to the reactor feed section to provide cold feed to
the first reactor in the event of an extreme catalyst temperature event (207FIC-1408)

A panel-mounted pump stop is provided for the reactor feed pump

to aid in quickly stopping liquid feed when appropriate:
HS-1702A for 207G-3A and HS-1707A for 207G-3B

Emergency depressuring valves HS-2601 and HS-2602 are operable

from the ‘Control panel’ (with ADS proposed), to facilitate
depressuring the system as per the emergency handling requirement.

Any time the unit is shut down, as much hydrocarbon as possible should be stripped from the
catalyst. If it is necessary to open the reactor the normal shutdown procedure should be

173
followed. To start up after an emergency shut down, follow the procedures given at the end of
this section.

The recommended handling of several types of upsets is outlined in the following sections. The
procedures should be memorized and reviewed frequently to ensure familiarity. Table at the end
of this section summarizes the emergency procedures.

11.3.1.1 COMPRESSOR FAILURE

There are two compressor services associated with the CPCL OHCU: ‘Make-up hydrogen’
207K-2 and ‘Recycle gas 207K-1

11.3.1.1.1 LOSS OF MAKE-UP HYDROGE

The Hydrocracker unit cannot continue to run without a steady supply of make-up hydrogen
because without make-up hydrogen most of the remaining hydrogen in the high-pressure loop
would soon be consumed. As a result, the reactor section pressure, recycle gas purity, and
hydrogen partial pressure will decrease. These conditions increase carbon deposition on the
catalyst.

If partial loss of make-up hydrogen occurs, operation can be continued if the feed rate to the
reactor section is immediately reduced. The feed rate must be reduced without delay to prevent
the reactor section from depressuring due to consumption of available hydrogen. To prevent
excessive reaction when the feed rate is reduced, reactor temperatures must be decreased at the
same time that the feed rate is decreased in order to maintain the same product conversion.

If all makeup hydrogen compressors fail, or if a total loss of make up hydrogen occurs, the
reactor sections must be shutdown.

The main objective is to reduce total loss of make-up hydrogen occurs, the reaction section must
be shut down. The main objective in this situation is to reduce catalyst temperatures as quickly
as possible to prevent coking. When makeup hydrogen is stopped the high-pressure loop will
depressure as the oil consumes the hydrogen in the recycle gas. As hydrogen is consumed, the
pressure of the recycle loop as well as the hydrogen partial pressure will drop. Oil on the catalyst
at high temperature with low hydrogen partial pressure will result in coking. It is therefore
necessary to cool down the catalyst quickly.

The shut down procedure is as follows:

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IMMEDIATE ACTIOS:

1. Cut off 207F-1 main burners: 207PIC-1809 (pilot burners to remain lit for fast recovery if
hydrogen is quickly restored).

2. Carefully bypass the reactor feed/effluent exchangers (207E-3A/B) and the reactor
effluent/ recycle gas exchanger (207E-7) to reduce heat input to the reactor feed furnace
(207F1), as needed, to control catalyst temperatures. For maximum cooling, fully open 207E-
3A/B bypass (207TIC--1803) and close the feed inlet minimum stop valve to the mechanical
stop. Adjust the 207E-7 three-way inlet valve to fully open the bypass port.

3. Maximize recycle gas flow (207FI - 2201) to improve cooling (Maximize RGC speed).

4. Stop reactor bleed gas flow (if any): 207FIC--2601

Maximize quench flow to the catalyst beds:

(Rx.1: 207FI-1901 and 207FI-1902,

Rx.2: 207FI-2001 and 207FI-2002)

SECODARY ACTIOS

While the above actions are being carried out, an attempt should be made to restore make-up
hydrogen to the reactor section.

Make-Up Hydrogen ot Restored

1. When the low-pressure hydrogen supply to the make-up hydrogen compressor suction
(indicated by 207PI-6903) is lost, the low set point suction pressure controller will fully open the
compressor spillback valve. As soon as it is recognized that hydrogen is lost, unload the
make-up hydrogen compressors as necessary.

2. If reactor temperatures are under control (stable or decreasing), discontinue oil feed
to the reactor section (207G-3A/B trip: HS-1702A / HS-1707A); Experience has shown
that pressure loss is substantially reduced by quickly discontinuing feed.

3. Stop water injection to the reactor effluent air cooler (FC-3304).

4. Cut reactor feed furnace pilot fires; (Pilot UV-1802, 207F-1 ESD at panel HS-1801A);
if not already done, and have the outside operator block-in the fuel gas.

When the CAT is lowered and feed is removed, Rx. system pressure 207PIC-2702 should
remain high enough to circulate hydrogen with the recycle gas compressor. Maintain the reactor

175
section at the maximum possible pressure. Alternatively, if it is not possible to continue to run
the recycle gas compressor, or the make up hydrogen compressors are out of service, depressure
the reactor section and continue cooling the catalyst with once-through nitrogen.

6. Continue cooling until catalyst temperatures are at about 260°C.

7. If make-up hydrogen is not available within 8 hours, cool the reactor to about 205°C and
continue recycle gas circulation.

If Make-Up Hydrogen is restored:

1. After make-up hydrogen is restored, purge nitrogen from the reactor section (if it was
introduced). Increase the reactor section pressure PC-2702, at a rate of 15-20 kg/cm2/hr, to 90%
of design (155 KSC) to allow for the oil feed-in pressure surge.

2. If the recycle gas compressor was stopped, restart the RGC and establish flow to the reactors.

3. If fires in the reactor feed furnace was totally extinguished, purge with steam and fire the
furnace to heat the reactor inlet, at a rate of 15-20°C/hr, to ~38°C below the reactor inlet
temperature at the time the emergency began.

4. Reintroduce feed to the reactor section at 50% of design rate. When the reactor temperatures
and downstream separator systems are stable, return to pre upset conditions, following the
normal startup steps previously discussed.

11.3.1.1.2 RGC FAILURE

RGC failure is a serious emergency. About ¾ of the heat of reaction is absorbed by the recycle
and quench gas entering the reactors (the rest is absorbed by the oil and oil vaporization).
Without the ability to control reaction temperatures in the reactors, a temperature excursion
could occur if proper corrective action is not taken. To slow down the reactions and limit the
heat release in the reactors significantly, the reactors must be cooled and the hydrogen pressure
reduced quickly.

IMMEDIATE ACTIOS

The following immediate actions, although listed sequentially, should be performed

simultaneously:
1. Ensure 207F-1 main gas trip due to low recycle gas flow (207FT/FALL-2202: I-1702)
- pilot fires to remain in service.

2. Reduce the make-up hydrogen intake flow (207FI-2701) to about 25% (~17,092 Nm3/hr)
of the total design make-up flow (~68,370 Nm3/hr) by shutting down/unloading the make-up
hydrogen compressors and manually adjusting the compressor spillback control valve (207PV-

176
6904). Although make-up hydrogen is a fuel for the reactors, some gas is needed to aid in
moving the oil through the reactor section; 17,092 Nm3/hr will limit the temperature rise to
about 30°C.

3. Continue oil feed 207FIC--1801 to the reactor section at design rate i.e. 249.2 m3/hr.
Oil feed is the main source of heat removal from the feed furnace and the reactors.

4. Close 207K-1 discharge MOV (HBV-2705) to ensure depressuring flow follows the normal
flow path through the reactors, and start depressuring the reactor loop by operating one of the
emergency depressuring valves: HBV-2601/2602 (panel-mounted switches HS-2601/2602);
While depressuring the system,
- Do not exceed a depressuring rate of 21.0 kg/cm2/min.
(limited by the flare header pressure),
and
- Do not exceed a pressure drop of 14 kg/cm2 across the reactors in order to avoid
mechanical damage to the internals.

5. Maximize the bypass rate around the reactor feed/effluent exchangers (207E-3A/B) and
the reactor effluent/recycle gas exchanger (207E-7) to reduce heat input to the reactor feed
furnace (207F1). For maximum cooling, fully open 207E-3A/B bypass (TIC--1803) and close
the feed inlet minimum stop-valve to the mechanical stop. Adjust the 207E-7 3-way inlet valve
to fully open the bypass port.

SECODARY ACTIOS

1. Stop water injection to the reactor effluent air cooler 207E-9 (FC-3304)
To eliminate the possibility of water back flowing into the upstream exchangers. Monitor the
interface level in the CHPS after water injection is stopped and block in the interface control
valve if required.

2. Monitor and maintain levels in the separators and columns as the reactor section
pressure drops. Open both level control valves on the CHPS if necessary to remove oil.

While the above actions are being carried out, an attempt should be made to restart the
recycle gas compressor.

Recycle Gas Compressor ot Restarted Within 5 Minutes

Unless there is evidence of a temperature excursion during the following steps, continue
attempting to restart 207K1 with an open spillback, and restore flow carefully to the reactors.

When flow is restored, stop cooling and depressuring and return to normal conditions after
reactor temperatures are under control.

177
1. Continue depressuring the reactor loop, via the emergency depressuring valves,
stopping at 40 kg/cm2 g.

This pressure should be sufficient to displace oil from the CHPS, low enough to minimize
reactions, and still high enough to satisfy the recycle gas compressor’s minimum operating
suction pressure.
2. If catalyst temperatures are not under control at 40 kg/cm2 (g), (appear to be
increasing), continue to depressure the reactor section, stopping at 20 kg/cm2 (g).

(Note: At about 25% of design it becomes difficult to move liquid through the separator).
This pressure should be low enough to stop all reactions; however, feed may have to be
discontinued at the lower pressure due to the inability to displace liquid from the CHPS. If
temperatures still appear to be increasing, depressure to ~0.4 kg/cm2 (g) and prepare to introduce
utility nitrogen to sweep the catalyst.
3. If at any time during depressuring the hydrocarbon liquid from the CHPS becomes
difficult to transfer to the CLPS:

- Open the CHPS second 207LCV--2404A/(B).

- Reduce the CLPS system pressure, by reducing the high set point pressure controller
(207PIC-2903) set point on the CLPS vapor KO drum (207C-12), to increase liquid
transfer. It may also be necessary to adjust the product stripper’s (207C-14) pressure
controller set point (207PIC-4104) to a lower setting to improve liquid transfer from
the CLPS to 207C-14.

- Reduce (or stop) the oil feed flow to the first reactor.
4 .Begin to recycle “cold source” fractionator bottoms to the reactor feed section via the
long-loop flow controller (207FIC--1408). Gradually change feed over to maximum cold
source fractionator bottoms and minimum fresh feed from off plot.
5. Continue purging with once-through make-up hydrogen 207FI-2701 to cool the reactors
to ~260°C. As soon as it is safe to do so, gradually increase the make-up hydrogen rate to
improve oil displacement and reactor cooling. Be prepared to reduce hydrogen again if any
reactor temperature begins to trend upward.
6. If make-up hydrogen was also lost, feed will have to be discontinued sooner than stated
above. In this case, continue depressuring to allow utility nitrogen to be introduced to the
downstream side of the closed recycle gas compressor discharge MOV (207HBV-2705), via the
emergency/startup nitrogen connection, to once-through sweep the reactors to continue cooling
the catalyst to ~260°C.
7. If conditions dictate, continue to shut down in an orderly manner.

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If RGC is restarted within 5 Minutes

1. Start 207K-1 on total spillback.

2. Carefully reestablish recycle gas flow 207FI-2201 to the reactor section (taking care not to
overfill the CHPS).

3. Confirm reactor temperatures are under control.

4. Introduce additional make-up hydrogen (as indicated by 207FI-2701) to stabilize the

reactor section pressure.

5. Continue with unit restart following startup procedure.

If RGC is restarted after 5 Minutes

1. If 207K-1 has been down for more than 5 minutes and is now capable of being returned to
normal operation, repressure the reactor section with make-up hydrogen to ~40 kg/cm2 (g).

2. When the reactor section pressure is increased to 207K-1 minimum operating suction
pressure i.e. 40 kg/cm2 (g)., restart the compressor with the spillback valve 207 UV-2702 100%
open.

3. Once 207K-1 is operating satisfactorily, open the discharge MOV (HBV-2705) and slowly
reestablish recycle gas flow through the reactor section, while watching catalyst temperatures
closely. Since the reactor section may be “oil packed,” proceed cautiously as recycle gas is
reintroduced to the reactors. Closely monitor CHPS and CLPS levels to prevent any liquid
carryover. The reactor bed temperatures should start to cool as heat is removed, but hidden hot
spots could result in excessive reaction rates when recycle gas is restored.

4. If any catalyst temperature increases unexpectedly, use quench gas to bring temperatures
under control and stop increasing reactor pressure 207PC-2702: If temperatures cannot be
controlled, depressure to remove hydrogen, and then repressure and circulate with nitrogen, if
possible, to cool the reactors to ~260°C, after which the nitrogen can be displaced by
depressuring and repressuring with hydrogen.

5. Once the reactor temperatures are under control, slowly restore the reactor section pressure
207PC-2702 to feed-in conditions. Once the pressure is stabilized, the reactor inlet temperatures
should be lined out at ~38°C below the inlet temperatures at the time the emergency began.

6. Inspect the unit for leaks and equipment damage.

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7. Reintroduce feed to the reactor (if removed) at 50% of design rate, i.e. 50% of 249.2 m3/hr. =
124.6 m3/hr. When reactor temperatures and downstream separator systems are stable, return to
preupset conditions, following the normal startup steps previously discussed.

11.3.1.1.3 LOSS OF RGC AD MUGC

If both recycle gas and make-up hydrogen compressors are lost, proceed as in the case of loss of
the recycle gas compressor.

11.3.1.2 LOSS OF OIL FEED

When oil feed is lost, the objective is to control the reactor temperature, which may otherwise try
to surge upward. Though the oil feed failure is normally not as hazardous as loss of recycle gas,
Catalyst damage may result if correct emergency actions are not followed. Continued reaction of
oil soaked on the catalyst (low LHSV and high temperature) can result in reactor temperatures
exceeding the design values. This is compounded by the fact that the Rx. inlet temperature
controller is often slow to react to the significantly lower furnace feed rate.
Temperatures can be kept under control by cooling and by removing the other reactant, make up
hydrogen.

There are two types of feed loss:

- Loss of fresh feed to the feed surge drum,
- Loss of feed pump.
The response to each is a little different.

11.3.1.2.1 LOSS OF VGO FEED TO THE REACTOR FEED SURGE DRUM

As already known there are four different sources of VGO feed to the OHCU, viz.
1. 207FIC--1406 Hot VGO from refinery-3,
2. 207FIC--1407 Hot VGO from refinery-2,
3. 207FIC--1404 Cold VGO from tankage, and
4. 207FIC--1402 Hot visbreaker VGO

One or more of these feed sources may fail any time. When there is a total feed failure from all
the offplot sources (the chance for which is very remote), liquid- holdup in the reactor feed surge
drum (207C-1) will provide a surge time of 20 minutes high level to low level) and 10 minutes
(50% level to low level). If VGO feed is not restored beyond this time, reactor feed pump 207G-
3A/(B) needs to be shutdown, following feed surge drum low level.

IMMEDIATE ACTIOS

1. Quickly decrease the reactor temperatures

180
- by increasing the recycle gas flow 207FI-2201,
- by increasing the quench flows:
Rx.1 207FIC--1901/1902
Rx.2 207FIC--2001/2002
- by closing off 207F-1 main gas 207PICV-1809 (pilots to remain open)
and.,
- by bypassing 207E-3A/B tube-side .

2. Reduce the feed rate 207FIC-1801 to 50% of design

i.e. 50% of 249.2 m3/hr = 124.6 m3/hr, to extend the time available to correct the problem.
Adjust the fractionation and light end section operating parameters to maintain on-spec products.

3. Maintain reactor loop pressure 207PC-2702.

SECODARY ACTIOS

While the above actions are being carried out, an attempt should be made to restore VGO feed to
the reactor feed surge drum.

1. otify off plot personnel about the loss of feed.

2. If VGO feed to reactor feed surge drum cannot be reestablished, shutdown the reactor
feed pump and proceed with the guidelines described below (immediate step-4 onwards), for
loss of reactor feed pump.

11.3.1.2.2 LOSS OF REACTOR FEED PUMP

Loss of 207G-3A/(B) reactor feed pump is very serious and requires quick response by the
control room personnel to prevent potential catalyst damage. Without the recycle oil as a
heat sink, there is a possibility of reactor temperature rise. If an operating pump suddenly fails,
the spare pump must be quickly put into operation. This means that the spare pump must always
be maintained in a ready state (warmed up and ready to start). If the spare pump is started when
not properly warmed up, the sudden change in suction fluid temperature can damage the pump,
possibly resulting in a seal leak to the atmosphere or wear ring seizure.

IMMEDIATE ACTIOS

1. Ensure 207F-1 main gas 207 UV-1803 has automatic-ally “tripped” due to low oil feed
flow (I-1801), and that the main burners are extinguished (pilots to remain in service). Use
quench to cool the reactors to at least 38°C below the temperature they were at before the event
began.

181
2. Bypass 207E-3A/B (207TIC--1803) and close the feed inlet minimum stop valve to the
mechanical stop;
Adjust the 207E-7’s three-way inlet valve to fully open the bypass port.

3. Maximize recycle gas flow 207FI-2201 to cool and displace oil from the catalyst.

4. Ensure that the oil feed chopper valve 207FBV-1802 is closed, following low low flow
signal from 207FT/FALL-1802 (I-1806)

SECODARY ACTIOS

While the above actions are being carried out, an attempt should be made to restore feed to the
reactor section.

1. Manually close the feed flow control valve 207FV--1801 to better prevent any backflow
from the high-pressure system.

2. Attempt to restart the reactor feed pump, or spare, on total spillback (FV-1704 / FV-1710).

3. Monitor and maintain levels in the CHPS, CLPS and other columns. As the liquid flow from
the CLPS to the fractionator feed furnace begins to diminish, assure that emergency circulation
flow 207FV-4201 from the fractionator bottoms pumps to the fractionator feed furnace has
automatic-ally started to maintain the total flow through the furnace above the minimum
requirement.

4. As feed is lost and temperatures drop, hydrogen consumption will decline. Unload the
make-up compressors as necessary to stay within the spillback system capacity.

4. Use quench to control reactor temperature, if necessary. If temperatures begin to rise out of
control, stop make-up hydrogen and emergency depressure (207 HS-2601/2602) as
necessary. Do not exceed a depressuring rate of 21.0 kg/cm2/min.

5. Verify that all unconverted oil air cooler fans are in service and the fractionator bottoms (to
offplot) temperature 207TIC--5203 does not exceed design (normally ~90°C). Cut back on the
fractionator feed furnace outlet temperature 207TIC--4209, and manually reduce flow through
the cooler if necessary. It is acceptable to let the fractionator bottoms level 207LI-4301 increase
(within level transmitter range) because flow to the fractionator from the reactors will eventually
stop.

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Feed Pump is ot Running on Spillback Within 10 Minutes

1. Hold unit condition until the reactor feed pump is ready to run or it is determined to further
shutdown the unit.

2. Wait until reactor temperatures are at least 38°C below where they were at before the feed
pump failure and are stable before attempting to restart the feed pump and reintroducing feed to
the reactor section. After feed is introduced at 50% (124.6 m3/hr) of design, return to pre upset
conditions at a feed rate within the limit of the UCO air coolers. Increase feed rate and
conversion to where they were at before the event began.

Feed Pump is Running on Spillback Within 10 Minutes

1. If all reactor temperatures are dropping, and it has been less than 10 minutes since the reactor
feed pump failure, reintroduce VGO feed at 50% (124.6 m3/hr) of design.

2. Return to pre upset conditions at a feed rate within the limit of the unconverted air coolers.
Increase feed rate and conversion to where they were at before the event began.

11.3.1.2.3 REACTOR TEMPERATURE EXCURSIO

A temperature excursion is not likely to occur if proper emergency actions are taken in a
timely manner. However, if unchecked, it can cause serious damage to the catalyst and
reactors. The hydrogenation reactions are exothermic. In addition, the reaction rates increase
with increasing temperature. If reactor temperatures are not controlled properly (furnace
temperature, quench gas control, reactor feed/effluent exchanger interaction, etc.), temperature
increases will increase the reaction rate, which results in more heat being generated. The net
effect is an accelerating temperature rise.

A gradual temperature increase is usually called an excursion. A faster, rapidly accelerating

temperature increase would be called a runaway. In either case, the emergency actions are the
same since an excursion can become a runaway with little warning.

If reaction temperatures get high enough (~480°C), thermal (not catalytic-) hydrocracking can
result, greatly increasing the heat release. If thermal hydrocracking occurs to an appreciable
degree, reactor bed temperatures can increase to over 800°C within minutes.

o temperature point in the reactors, bed or skin, should ever be allowed to exceed 440°C.
This provides a 14°C safety margin below the mechanical design limit of 454°C to account
for possibly higher temperatures where TIs are not located. Therefore, it is important to
respond before a temperature reaches 440°C.

183
If any temperature increases 8°C above its normal level unexpectedly, use quench as required.
Quench provides cooling for the hot catalyst and should bring temperatures back down.
Whenever any temperature point approaches 420°°C, or continues to increase after
attempting to control with quench, it may be an indication of a serious temperature
excursion that has the potential of becoming a temperature runaway if proper actions are
not taken.

IMMEDIATE ACTIOS

1. Raise the quench flow to maximum to the offending reactor bed:

Rx.1 2nd bed I/L 207FIC--1901, 3rd bed I/L 207FIC--1902,
Rx.2 1st bed I/L 207FIC--2001, 2nd bed I/L 207FIC--2002
Check that the reactor bed inlet quench valves are not sticking and that quench gas is going
into the reactor.

2. When quench gas is increased, gas feed to the reactor inlet may decrease. Maximize recycle
gas compressor speed to achieve maximum recycle gas to cool and displace oil from the catalyst.

2. Extinguish the reactor feed furnace main burners: 207PV-1809. The pilot burners remain in
service, but can be extinguished if required.

4. Maximize the bypass rate around the reactor feed/effluent exchangers (207E-3A/B) and the
reactor effluent/recycle gas exchanger (207E-7) to reduce heat input to the reactor feed furnace
(207F1). For maximum cooling, fully open 207E-3A/B bypass (207TIC--1803) and close the
feed inlet minimum stop valve to the mechanical stop. Adjust the 207E-7 three-way inlet valve
to fully open the bypass port.

5. At this point, if the temperature excursion condition is not under control (i.e.,
temperatures are increasing), depressure the reactor loop by opening the emergency
depressuring valve. Do not exceed a reactor section depressuring rate of 21.0 kg/cm2/min., or
the design pressure differential of 14.0 kg/cm2 across any reactor.

6. Stop all make-up hydrogen to the reactor loop:

Unload the running MUGC as required and stop the compressor if required.

7. Continue oil feed to the reactor section at design rate (249.2 m3/hr) to carry heat out of the
reactors.

SECODARY ACTIOS

1. If at any time during depressuring the hydrocarbon liquid from the CHPS becomes
difficult to transfer to the CLPS:
- Open the CHPS second level control valve 207LCV--2401A/(B)

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- Reduce the low-pressure separator system pressure, by reducing the high set point pressure
controller 207PIC-2903 set point on the CLPS vapor KO drum 207C-12, to increase liquid
transfer. It may also be necessary to adjust the product stripper 207C-14 pressure controller
207PIC-4104 set point to a lower setting to improve liquid transfer from the CLPS to
207C-14.

2. Reduce (or stop) the oil feed flow to the reactor.

3. Verify that all reactor effluent air cooler fans are operating.

All Reactor Temperatures Are ot Under Control

1. Stop water injection to 207E-9: 207FIC-3304.

2. Notify emergency response team of potential equipment failure.

3. Continue depressuring the reactor loop, via the emergency depressuring valves HBV-
2601/2602, stopping at ~40 kg/cm2 (g). This pressure should be sufficient to displace oil from
the CHPS, low enough to minimize reactions, and still high enough to satisfy the recycle gas
compressor minimum operating suction pressure. Maximize gas circulation.

ote: If catalyst temperatures are not under control at this point, continue with the steps below:

4. Continue to depressure the reactor loop to the minimum pressure required to operate the
recycle gas compressor, and continue to circulate gas through the reactors to cool the catalyst.

5. Stop the recycle gas compressor and close the discharge MOV HBV-2705.

6. Continue to depressure the reactor loop, the system pr. being indicated by PC-2702.

7. When the reactor loop pressure (207PV-2702) is low enough, introduce nitrogen to the
downstream side of the recycle gas compressor discharge MOV, via the emergency/startup
nitrogen connection. Sweep nitrogen through the reactors for final cooling.

All Reactor Temperatures Are Under Control

1. When catalyst temperatures in the reactors have cooled to 260°C, and the reactor section is
stable, stop depressuring and maintain the then reactor loop pressure with make-up hydrogen.
Closely monitor catalyst temperatures when hydrogen is reintroduced.

2. Maintain the current feed rate to the reactor section.

3. Evaluate reactor bed temperatures to determine if the unit should be returned to preupset
conditions.

185

ote: If reactor design temperatures (454°C) were exceeded, irreversible damage may have
occurred to: - Reactor Metal
- Reactor Outlet Piping
- Feed/Effluent Exchangers
In such an event, a thorough metallurgical investigation should be made.

4. Inspect the unit for leaks.

5. If there is no equipment damage or unit leaks, and the reactor temperatures are stable, the
unit can be repressured and reheated. If feed was stopped, it should be reintroduced at
temperatures at least 38°C below the temperature the reactors were at before the emergency
began, and the unit slowly returned to preupset conditions.

11.3.1.4 GAS LEAK OR FIRE I THE HIGH PRESSURE REACTIO SECTIO

A leak in the high-pressure reactor section can be a serious emergency that requires immediate
action to prevent harm to personnel and equipment. The first moves made will determine the
extent of damage done. Be decisive and act promptly.

When a leak occurs in the high-pressure reactor section, the entire high-pressure section will
start to depressure through the leak. These escaping gases can provide fuel for a serious fire.

The high-pressure leak may result in noise levels, which prevent good communication. It is
important to know what to do during such an emergency.

186
IMMEDIATE ACTIOS

Make the following moves simultaneously, with the target being to depressure the high pressure
loop and put inert nitrogen into the reactor section as soon as possible.

1. Main and pilot burner fires in the reactor and fractionator feed furnaces should be
immediately extinguished:
- Emergency trip switches at control panel 207 HS-1809A and 207 HS-4201A
for the respective furnaces.

2. Cool reactor beds quickly with quench:

Rx.1 2nd bed I/L 207FIC--1901, 3rd bed I/L 207FIC--1902,
Rx.2 1st bed I/L 207FIC--2001, 2nd bed I/L 207FIC--2002;
maximize reactor feed/effluent exchanger 207E-3A/B bypass rate, and continue recycle gas
207FI-2201 as long as possible to assist cooling.

3. Make-up hydrogen to the reactor section must be stopped by unloading and shutting down
the make-up hydrogen compressors and closing the isolation valve in the high-pressure hydrogen
header (i.e. compressor d/c valve). If possible, depending on the location of the emergency,
preparations should be made to operate one of the make-up hydrogen compressors on nitrogen.

4. The reactor feed pump 207G-3A/B must be shut down. Ensure that the oil feed chopper
valve 207FBV-1802 has tripped shut, and close the reactor feed pump discharge valve as soon as
possible.

5. Begin to depressure the reactor loop to the flare, via the emergency depressuring valve
207HBV-2601/(HBV-2602).

6. otify refinery fire service, even if there is no fire. In case of fire, cool surrounding
equipment with water.

SECODARY ACTIOS

7. Block in the main and pilot burner fuel gas supply to all furnaces, and admit snuffing steam
into the fireboxes, if safe to do so.

8. Monitor CHPS and CLPS hydrocarbon levels carefully to prevent blowing high-pressure gas
into the low pressure vessels.

9. Stop water-injection pump and ensure the injection water chopper valve has closed.

10. shut down the RGC when the reactor section pressure is at 40 kg/cm2 (g).

187
11. Start nitrogen to the reactor section when the pressure drops below the utility nitrogen header
pressure. Maintain nitrogen flow until all hydrocarbon vapors are displaced from the reactor
section.

12. If the leak has not been contained, maintain a nitrogen flow from the leak location to prevent
pulling air into the reactor section.

13. Assuming there is no fire, at this point, it is safe to determine what caused the leak, and to
assess damage that may have been incurred.

11.3.1.5 UTILITY FAILURES

11.3.1.5.1 LOSS OF ISTRUMETATIO

Instrument failure can be from two causes:

Instrument power failure

or
Instrument air failure,
both of which are unlikely to occur, because:

- Instrument power is backed up with batteries (ups) and an emergency generator,

and.,

- The instrument air is supplied from three compressors - two on electricity and the third on
steam ( common for plant air service also); apart from these, an HP receiver provides I/A
backup for about 20 minutes to all the units in refinery-3, in case of failure of all the
compressors.

In the event of instrument air failure the following will result:

- Heater fuel (FG /FO) will be cut-off,

- All CVs. will go to their respective fail-safe position, and
- Quench valves and feed/effluent exchanger bypass will remain in their present position,
- Fail-safe position of all control valves in the high-pressure section essentially blocks-in the
section in the event of an instrument air failure.
- One item demands immediate action:
The CHPS level control valve 207LV-2404A/B will fail closed, causing the liquid level in
the separator to rise rapidly. The control valve should be opened manually (via hand-jacks)
to avoid liquid carryover into the high pressure H2S absorber 20C-4, and possibly recycle gas
compressor shutdown due to a high level in the recycle compressor KO drum.

The following is a summary of control-valves fail-safe positions:

188
 1. The reactor quenche valves -
Rx.1 2nd bed I/L 207FIC--1901, 3rd bed I/L 207FIC--1902,
Rx.2 1st bed I/L 207FIC--2001, 2nd bed I/L 207FIC--2002;
and
Feed/effluent exchanger bypass 207TV-1803 fail in their present position, and then
slowly drift open (FLO).

2. All raw oil feed valves fail-close:

207 FIC--1406 Hot VGO from refinery-3,
207FIC--1407 Hot VGO from refinery-2,
207FIC--1404 Cold VGO from tankage, and
207FIC--1402 Hot visbreaker VGO

3. The reactor feed surge drum nitrogen blanketing valve PV-1602A fails-open and the vent
valve to the flare PV-1602B fails closed. The drum will stabilize at refinery utility nitrogen
header pressure.

4. The high-pressure oil feed control valve FIC--1801 and oil feed chopper valve FBV-1802
fail-close;
Field Operator action is required to bypass the emergency chopper valve’s trip device in
order to reintroduce feed – to be confirmed.

5. The reactor feed pump minimum flow spillback valve FV--1704 fails-open.
If the emergency chopper valve FBV-1802 and the feed pump discharge Stop-check valve fail,
full reactor pressure could be diverted directly to the reactor feed surge drum 2071.

6. The reactor feed furnace and fractionator feed furnace main and pilot burner
fuel supply trip shut and cannot be reintroduced without a field operator resetting the trip
device:

207F-1 main FG UV-1803 & PV-1809, pilot FG UV-1802

207F-2 main FG UV-4205 & PV-4223, pilot FG UV-4202
FO supply 207 UV-4203 & PV-4227,
FO return 207 UV-4204.

7.The reactor loop emergency depressuring valves HBV-2601/2602 are fail-open valves
with spring-return actuators that are held closed by instrument air. An instrument air volume
bottle, on each emergency depressuring valve, has double check valves on the instrument air
supply line to prevent the emergency depressuring valve from (nuisance) opening on loss of
plant instrument air. The air volume bottle air capacity allows at least three valve strokes. The
electrical controls to each emergency depressuring valve include redundant solenoids, both of

189
which must deenergise to open the depressuring valve. This prevents ‘nuisance’ depressuring if
one of the solenoid valve’s electrical coils fail, thereby still providing fail-safe operation. If a
fire or other mishap damages the wiring to both solenoids, the unit will be depressured.

8.The make-up hydrogen compressor spillback valve 207PV-6904 fails-open and the
compressor capacity loaders will unload, stopping hydrogen make-up flow to the reactor
section.

9.The recycle gas compressor spillback valve 207 UV-2702 fails in place, and then slowly
drifts open (FLO).

ote: Recycle gas flow 207FI-1801 must be maintained at high rates through the reactor feed
furnace and reactor quench lines, to ensure proper furnace tubes and reactor cooling. Therefore,
final details of design must provide the ability for the recycle gas compressor to continue to
operate and circulate gas when instrument air supply is lost
-to be clarified / confirmed with BHEL.

10.The product stripper overhead pressure control valve 207PV-4101 fails-close.

11.The-fractionator overhead pressure control system fails, with the fractionator overhead
condenser 207E-13 bypass valve 207PV-4501B closed and the condenser outlet valve 207PV-
4501A open. The fractionator reflux drum high set point pressure control valve 207PV-4502 to
the flare fails-close.

12.Steam generator BFW FCV-s. fail in place and then slowly drifts closed (FLC):
207E-5 FV-2102, 207E-18 FV--5001, 207E-36 FV-5201
13.CHPS, CLPS and all columns LCV-s. Fail-closed, including water draw LCVs.

14. The water-injection control-valve 207FV--3304 and chopper-valve 207FBV-3305

fail-close; the chopper valve requires a field operator to reset the trip device to reopen the valve
after the emergency. The injection water pump minimum flow pressure control valve
207PV-3503 fails-open.

15. All product flow control valves fail closed.

16. All reflux and pumparound flow control valves in the fractionation section
Fail-open.

17. Stripping steam control valves of the product stripper, fractionator, and
diesel stripper fail-close.

IMMEDIATE ACTIOS

190
Once an instrument air failure has caused the unit control valves to go to a fail-safe position,
these steps are to be followed:

1. Manually block fuel to the Rx. and fractionator feed furnaces. Verify that the main burners
are extinguished.

2. Loss of instrument air to the make-up hydrogen compressor capacity loading-device will
unload the compressor. Adjust the capacity loading-device to 0% loading to prevent a sudden
surge of make-up hydrogen to the reactor loop when instrument air pressure is restored.

3. Begin depressuring the reactor section to ~40 kg/cm2 (g). The emergency depressurization
valve 207 HBV-2601/2602 backup air supply allows the valves to be opened from the control
room or from a safe, easily accessible location in the field. Should the backup instrument air
supply be lost, the emergency depressuring valves will go to fail-open position.

4. Maximize recycle gas compressor speed to achieve maximum recycle gas to cool and
displace oil from the catalyst.

5. Verify that the oil feed chopper 207FBV-1802 valve is closed.

6. Closely monitor catalyst temperatures. If any temperature begins to increase out of control,
proceed as if it is a temperature excursion.

SECODARY ACTIOS

7. Set the controllers (in the control room) to reflect their positions in the field. If the valve
fail-closed, take the controller in manual mode and open. Opening of valves (such as fuel gas)
on a sudden resumption of instrument air pressure could cause an explosion in the furnaces (if
the trip solenoid valve functions incorrectly, etc.).

8. Shut down the reactor feed pump 207G-3A/B and close the discharge valve.

9. Shut down the injection water pump 207G-4A/B and close the discharge valve.

10. Manually control the levels in the steam generators with the boiler feed water level control
valve bypasses. To prevent overfilling, blow down valves may be opened as required.

11. Shut down the make-up hydrogen compressors 207K-2A/B/C.

12. Manually control the levels in separators and columns with the hand-jacks or bypasses. If all
level indications are lost it will be difficult to control these levels. Monitor the local pressure
gauges in the low-pressure systems for indications of gas blowing through.

191
13. Manually control the reactor low-pressure section pressure by using
(CLPS vapor KO drum to the flare) 207PV-2903B bypass valve.

14. Isolate the CHPS and CLPS sour water interface level control valves. Manually block one
valve on each letdown manifold.

Instrument Air ot Restored

15. Continue with an orderly unit shutdown.

Recycle Gas Compressor Lost

16. If the recycle gas compressor shuts down during this emergency, do not maintain the reactor
loop pressure. Continue to depressure at a rapid rate to reach ~50 kg/cm2 (g) in order to stop all
exothermic reactions. If the make-up compressor cannot be restarted and/or loaded to sweep the
unit at 50 kg/cm2 with hydrogen or nitrogen, continue to depressure to ~0.4 kg/cm2 (g).

17. When the reactor section pressure reaches ~0.4 kg/cm2 (g), purge the reactor loop with low-
pressure hydrogen or nitrogen flowing through the unloaded hydrogen make-up compressor.

18. Continue the unit shutdown.

Instrumentation Restored

19. When instrumentation is restored, the control room operator should take control of valves
and make control moves as necessary.

20. Reestablish the reactor loop temperatures and pressure, observing the reactor temperature
and pressure restrictions, and then reestablish normal operating conditions.

11.3.1.5.2 POWER FAILURE

When a general refinery power failure occurs, the reaction section must be shut down
immediately due to loss of electric pump and compressor drivers and one-half of the fans on the
reactor effluent air cooler and unconverted oil air cooler. The steam-driven recycle gas
compressor is available for cooling down the reactor.

Major equipment which will shut down:

- Reactor Feed Pumps 207G-3A/(B)

- Most Air Cooler Fans

192
 - Injection Water Pump 207G-4A/(B)
- Make-Up Hydrogen Compressors207K-2A/B/C
- Most Low Pressure Process Pumps

Equipments, which will continue to run on emergency power:

- Half of the Fans on the Reactor Effluent Air Cooler

- Half of the Fans on the Unconverted Oil Air Cooler

Equipments, which will continue to run with steam turbine drive:

- Recycle Gas Compressor 207K-1

- RGC Lube Oil Pump 207G-90A
- RGC condensate pump 207G-92A
- Fractionator Bottoms 207G-12A

IMMEDIATE ACTIOS

In the reaction section, the emergency is virtually the same as loss of feed.

1. Ensure furnace main burners UVs. have automaTIC-ally “tripped” due to low oil feed
flow, and that the main burners are extinguished (pilot fires to remain in service). Use quench to
cool the reactors to at least 38°C below the temperature they were at before the event began.

2. Monitor and maintain levels in the separators and columns. As the liquid flow from the
CLPS to the fractionator section begins to diminish, assure that emergency circulation flow
(207FV--4301) from the fractionator bottom pump 207G-12B to the fractionator feed furnace
207F-2 has automaTIC-ally started to maintain the total flow through the furnace above the
minimum requirement.

3. Control reactor temperatures by bypassing the reactor feed/effluent exchangers

207E-3A/B and the reactor effluent/recycle gas exchanger (207E-7).

4. Maximize recycle gas to cool and displace oil from the catalyst. The loss of half of the fin
coolers 207E-9 may cause the compressor suction temperature to rise. The compressor must be
shut down when the suction temperature exceeds the maximum temperature allowed by the
manufacturer.

5. Verify the oil feed chopper valve FBV-1802 is closed due to 207FALL-1802 low oil flow
trip: (interlock I-1806).

6. Closely monitor catalyst temperatures. If any temperature begins to increase out of control,
proceed as if it is a temperature excursion.

193
SECODARY ACTIOS

7. Switch all the controllers (affected by the loss of electric motors or pumps and compressors)
to the manual mode, and set control valves to reflect their fail-safe position in the field.

8. Failure of 207K-2A/B/C will cause a rapid loss of pressure due to H2 depletion and loss of
pressure control. If the reactor has not been cooled below 260°C before the compressor has to be
shut down, it will be necessary to depressure and continue cooling the reactor with make-up
hydrogen or nitrogen.

Power Is ot Restored

9. If power cannot be restored, shutdown the unit as per procedure.

Power Is Restored

10. Hold system pressure at 40 kg/cm2 (g).

11. Verify that electrical power is restored and reliable.

12. Return unit to preupset conditions using refinery-approved procedures.

11.3.1.5.3 LOSS OF COOLIG WATER

Cooling water failure will cause:

- RGC failure due to loss of the surface condenser, ejector condenser and lube oil cooler.

- Loss of MUGC due to loss of cylinder jacket cooling.

- Eventual loss of oil feed due to loss of lube oil cooling for the reactor feed pump.

- Product R/D temperatures will increase.

Proceed as in the case of loss of make-up hydrogen. If the reactor feed pump is lost before oil
feed has cooled the reactors, continue depressuring to the pressure level of the nitrogen header,
then cool with nitrogen.

194
11.3.1.5.4 LOSS OF VHP STEAM

VHP steam failure will result RGC failure. Proceed with steps described for loss of RGC.

Startup following an emergency shutdown:

With make-up hydrogen, increase the reactor section pressure to ~ 90% of normal operating
pressure, and establish pressure control consistent with the pressuring restriction outlined in the
reactor pressurization section. While pressuring the system, watch temperatures closely. If any
catalyst temperature increases unexpectedly, use quench gas to bring temperatures under control
and continue pressuring at a slower rate. If temperatures cannot be controlled, reduce pressure
and continue maximum recycle gas circulation.

When the reactor temperatures and pressure are lined out, oil feed can be introduced.

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11.3.1.6 OTHER EMERGECIES

LOSS OF FUEL OIL FOR FRCTIOATOR FURACE 207F-2

The following steps to be taken to handle the fuel oil loss to sustain the unit with lower feed rate.
• Check the fuel oil supply U/V and Control valve, if its okay,
• Check the fuel oil strainer dp.
• Inform to SRU to restore the fuel oil pressure if oil pressure is not restored
• Close the individual oil burner block valve and flush it.
• Increase the fuel gas pressure up to 1.7 kg /cm2
• Feed rate can be reduced up to turndown rate of 110 m3/hr as per requirement.
• Reduce the conversion
• Close maximum possible the 207E 6 by pass to pick up more heat from reactor effluent.

LOSS OF PUMPAROUD PUMPS

Diesel Pump-around 207G-9A/B: Try to take spare pump immediately. If the spare pump is
not available the unit can not sustain for long time because diesel pumparound is removing more
heat from fractionator and using the heat for kerosene stripper and debutanizer reboiler.
Kerosene Pump-around 207G-8A/B: Try to take spare pump immediately. If spare pump is
not available reduce the feed rate, increase the diesel pumparound and reflux rate to manage the
plant for some time. Route Kerosene to slop or Diesel.

LOSS OF FRACTIOATOR REFLUX PUMPS 207G-11 A/B:

Try to take spare pump, if it’s not coming up, increase the Diesel and Kerosene pumparounds,
reduce the feed rate and reduce the conversion, monitor the fractionator pressure to manage the
situation until receiver 207C-17 level is under control. Liquid has to be drained to CBD to
manage level.

LOSS OF PRODUCT STRIPPER REFLUX PUMP 207G-7A/B:

Try to take spare pump immediately. If it’s not come on line manage some time by
• Reduce the feed rate
• Reduce the conversion
• Reduce the stripping steam quantity
• Monitor the fractionator pressure
• Open the receiver 207LC4101, and route the product stripper overhead liquid to slop
• Shut down the LER, route the Naptha to slop and LPG to off spec
• Route 207C 15 off gas to flare.

LOSS OF PRODUCT PUMPS:

DIESEL PRODUCT PUMPS 207G-14A/B:
Try to take spare pump immediately, unit can manage some time by reduce the feed rate, reduce
the conversion and put UCO to slop. Since feed preheat is not available watch the feed filter DP.
Other wise go for shut down because diesel can not be admit in to UCO for long time.

196
KEROSEE PRODUCT PUMPS 207G-13A/B:

Try to take spare pump, if it’s not come online slip the kerosene in to diesel and increase the
diesel draw rate. Since feed preheat is not available watch the feed filter DP.

LOSS OF FRACTIOATOR BOTTOM PUMPS 207G-12A/B:

Try to take spare pump, Due to the uncontrollable 207C-16 bottom level, reduce the feed rate,
cut off stripping steam, increase the level in 207C-2, 207C-9 and 207C-14 up to allowable limit.
If flow is not restored, go for shutdown.

LOSS OF WATER IJECTIO PUMPS 207G-4A/B:

Try to establish water injection, if its not restored with in 8 hrs go for shut down.

LOSS OF BOILER WATER:

Due to the BFW flow low low interlock 207F-1 will trip.
Go for shut down procedure.

QUECH GAS VALVE FAILURE:

Try to take in hand jack mode immediately to control the bed temperature.

LOSS OF AMIE PUMPS 207G-5A/B:

Try to take spare pump after getting clearance from panel, if both pumps are not restored:
1) Inform SRU block about the failure of Amine.
2) Close the Amine flow control valve 207FIC-3103.
3) Ensure that the chopper valve 207FBV-3104 is closed.
4) Ensure 207C-4 level is at about 45 % (close LC and Block valve if required).
5) If 207C-4 Amine level is very low, ensure that 207LIC 2404 goes to Manual mode and is
in unlatched condition.
6) Keep 207C-4 bypass HIC-2502 open.
7) Ensure that 207C-5 and 207C-6 pressures are normal.
8) Send a sample of Recycle gas to lab for H2S and HC.
9) CAUTION: As H2S content in Recycle gas is high, air mask must be worn before taking
Recycle gas sample.
10) As H2S accumulation is anticipated, start Recycle gas bleeding from 207C-7 PIC- 2601
such that system pressure is maintained at 153.8 Ksc g taking additional Hydrogen
from HGU.
11) After 4 hours again send a sample of Recycle gas for H2S content.
12) Observe conversion levels and product qualities for Sulfur content.

197
DUMP VALVES MALFUCTIO AD MAUAL OPERATIO:
It’s an air fail to open control valve. It’s having instrument air volume bottle with NRV
provision. If it is necessary to close the valve for process requirement, it can be closed by using
hydraulic jack facilty.
• Close the instrument air to the LCV regulator
• Depressurize the air hold up by drain the both air regulator (one to I/P and another at valve
positioner)
• Close the hydraulic port balancing knob and needle valve near by handle,
• Pump the handle
• First two to three stokes are idle then pressure will be felt
• After the idle stroke, close the valves
• Don’t give the over torque it will damage the port
• For opening the valve just open the balancing knob.

207C-2 and 207C-4 LCV MALFUCTIO AD MAUAL OPERATIO:

It’s an air fail to close valve, in case of malfunction of the valve on line, try to take the spare
valve into line; if required the valve can also be opened by using the hand-jack provision.
Hydraulic mode operation:
• Confirm the u/s and d/s valves positions as required
• Close the instrument air to the LCV regulator
• Depressurize the air hold up by drain the both air regulator (one to I/P and another at valve
positioner)
• Close the hydraulic port balancing knob and needle vlave near by handle,
• Pump the handle
• First two to three stokes are idle then pressure will be felt
• After the idle stroke, open the valve as per requirements.
• Don’t give the over torque it will damage the port
• For closing the valve just open the balancing knob as per requirements.

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11.3.4 EMERGECY LOGIC

CHARTS

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LOSS OF RECYCLE GAS COMPRESSOR

IMMEDIATE STEPS TO TAKE

REACTOR FEED REDUCE MAINTAIN START CAREFULY

FURNACE FIRES MAKE-UP H2 OIL FEED DEPRESSURING MAXIMIZE
TO PILOTS. FLOW TO RATE AT DESIGN USING THE BYPASS AROUND
REMOVE PILOTS 25% DESIGN EMERGENCY REACTOR
AS NEEDED DUMP VALVE FEED/EFFLUENT
TO COOL EXCHANGERS

WARNING

Note

Verify this
For maximum cooling,
with outside
fully open the bypass,
operator.
and close the pinch
Stop water injection Monitor separator and valve to the minimum
to the reactor column levels closely. stop.
effluent air cooler.

HYDROGEN RECYCLE IS RESTORED WITHIN 5 MINUTES OF LOSS

Yes No

Restart the recycle gas

Continue depressuring the When all reactor temps
compressor with spillback fully
reactor system until are below normal and
open (if compressor is down).
~40 kg/cm2 (g) is reached, falling, stop oil-feed to
CAUTION the reactor section.
and hold at this pressure.

Carefully reestablish recycle If any reactor

gas flow to the reactors. temperature
increases unexpectedly,
CAUTION continue to depressure,
CAUTION and admit utility nitrogen. HYDROGEN RECYCLE IS RESTORED
Do not overfill Monitor catalyst temps for
evidence of temperature Yes No
the CHPS.
excursion.
Pressure the system Continue purging with
After it is confirmed that to 40 kg/cm2 (g) with once-through H2 and cool
reactor temperatures are make-up H2 (if needed). reactors to at least 260°C.
under control, increase
make-up H2 to stabilize
reactor section pressure. Restart the recycle gas
CAUTION compressor on total spillback.

The reactors will be oil CAUTION

CONTINUE WITH UNIT packed - proceed slowly.
RESTART FOLLOWING REFINERY
ESTABLISHED PROCEDURES Carefully reestablish Monitor catalyst temps for
recycle gas flow to the evidence of a temperature
reactors. excursion.

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LOSS OF MAKE-UP HYDROGEN

IMMEDIATE STEPS TO TAKE

CUT REACTOR CAREFULLY BYPASS STOP REACTOR MAXIMUM MAXIMIZE

FEED FURNACE THE REACTOR SYSTEM QUENCH TO RECYCLE
FIRES TO PILOTS. FEED/EFFLUENT BLEED GAS REACTOR GAS RATE
REMOVE PILOTS EXCHANGERS, AS FLOW, IF ANY BEDS (SPEED UP
AS NEEDED TO NEEDED, TO CONTROL RGC)
COOL CAT TEMPERATURES

Note CAUTION
WARNING
For maximum cooling
the bypass should be Watch gas-feed to the
furnace while doing
Verify this opened, and the MAKE-UP HYDROGEN IS RESTORED this to ensure
with outside pinch valve closed to
minimum stop. adequate flow.
operator.
No

Yes

Unload make-up H2 Stop oil feed to unit if

compressors when reactor temperatures
low pressure are stable or falling.
hydrogen is lost.

Increase catalyst Increase system

temps to 38ºC pressure with hydrogen
below previous to 90% of design at
15-20 kg/cm2 (g)/hour. Stop water injection to the Cut pilot fires and
conditions.
reactor effluent air cooler. have outside operator
block the fuel gas.

CAUTION
Yes
HYDROGEN MAKE-UP IS RESTORED
Rate of
temperature No
increase
15-20ºC/hour. Continue to circulate recycle
hydrogen as long as system
pressure allows RGC to run.

REESTABLISH UNIT CONDITIONS

PRIOR TO THE LOSS OF Yes
MAKE-UP HYDROGEN HYDROGEN MAKE-UP RESTORED
WITHIN AN 8-HOUR PERIOD

Inspect the unit for leaks. No

Reduce temperatures to 205ºC, and

continue recycle gas circulation.

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LOSS OF VGO FEED TO THE REACTOR

FEED SURGE DRUM

IMMEDIATE STEPS TO TAKE

QUICKLY INCREASE
QUICKLY RECYCLE MAINTAIN
REDUCE
REDUCE HYDROGEN REACTOR
REACTOR FEED
REACTOR TO LOOP
TO 50% OF
TEMPERATURES MAXIMUM PRESSURE
DESIGN
(SPEED UP RGC)

ATTEMPT TO REESTABLISH VGO FEED TO THE

REACTOR FEED SURGE DRUM
These actions
extend time FEED IS RESTORED WITHIN 10 MINUTES
to correct
problem.
Yes No

REESTABLISH UNIT Shutdown the reactor

CONDITIONS PRIOR TO feed pump.
THE LOSS OF VGO FEED

If catalyst temperatures Refer to loss

begin to increase out of of reactor
Inspect the unit for leaks. control, stop make-up feed pump.
hydrogen and
depressure the reactor
section.

Continue to cool
reactors to
~260°C.

Hold unit conditions until

offplot feed is restored, or
it is determined to further
shutdown the unit.

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LOSS OF REACTOR FEED PUMP

IMMEDIATE STEPS TO TAKE

REACTOR CAREFULLY BYPASS INCREASE

FURNACE FIRES THE REACTOR RECYCLE VERIFY THAT THE
TO PILOTS. FEED/EFFLUENT HYDROGEN TO EMERGENCY OIL
REMOVE PILOTS EXCHANGERS, AS MAXIMUM FEED ISOLATION
AS NEEDED TO NEEDED, TO DESIGN VALVE HAS TRIPPED
COOL CONTROL CAT TEMP

WARNIN
WARNIN
GG

Attempt to restart Manually Establish emergency

Verify this circulation through
the feed pump or close
with outside
spare on total the oil feed the
operator. product fractionator
spillback. control valve.
feed furnace.

As system pressure Use quench to cool the Verify that all

increases, reactor as needed. If unconverted
unload make-up compressors temperatures are out of air coolers are in service
as needed to stay within control, emergency and that the flow to
spillback capacity. depressure. storage is less than 90ºC.

FEED PUMP IS RUNNING ON SPILLBACK WITHIN 10 MINUTES OF LOSS

N
Yes o

If all reactor temperatures are Hold unit conditions until the

dropping reactor feed pump is ready
and less than 10 minutes have passed to run, or it is determined to
since the feed pump failure, further shutdown the unit.
reintroduce
feed at 50% of design.
REESTABLISH UNIT Wait until reactor
CONDITIONS PRIOR TO temperatures are 100ºC
THE LOSS OF FEED PUMP below preupset conditions
before reintroducing feed.

Inspect the unit for leaks.

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REACTOR TEMPERATURE
IMMEDIATE STEPS TO
TAKE
REACTOR BLOCK INCREAS START INCREASE CAREFULLY MAXIMIZE INCREASE
FURNACE FIRES MAKE-UP E DEPRES- OIL FEED BYPASS AROUND THE QUENCH TO
TO PILOTS. HYDROGEN RECYCLE SURING RATE TO REACTOR AFFECTED
REMOVE PILOTS TO REACTOR GAS TO USING THE MAXIMUM FEED/EFFLUENT BEDS TO
AS NEEDED LOOP MAXIMUM EMERGENCY DESIGN EXCHANGERS MAXIMUM
TO COOL (SPEED DUMP VALVE
UP RGC)

WARNIN
WARNING CAUTIO
G Start or verify that all reactor effluent
N
air cooler fans are running.
Watch gas feed to
Verify this
furnace while doing
with this to ensure
outside Monitor separator and column
levels as unit is depressured. adequate flow.
operator.

ALL REACTOR TEMPERATURES ARE UNDER

CONTROL

Yes N
o

When all catalyst bed

temperatures are below
260°°C, stop depressuring. Hold system pressure at Notify Emergency
Stop and block
Maintain current reactor 40 kg/cm2 (g) with Response Team
water injection.
section pressure with recycle gas compressor of potential
make-up hydrogen. at maximum rate. equipment failure.
CAUTION

Closely Maintain reactor feed.

monitor Yes
catalyst
temperatures. ALL REACTOR TEMPERATURES ARE UNDER CONTROL

Evaluate reactor bed

N
temperatures to determine if
o
unit should be returned to
preupset conditions.
Depressure to above When catalyst
Stop
recycle gas compressor’s temperatures
hydrogen
Inspect the unit for leaks. minimum suction reach 260°°C, bleed, if
pressure, and continue stop fresh feed any.
maximum circulation. to unit.
If there are no leaks, and
no mechanical damage,
return unit to preupset
conditions.

Continue with unit shutdown.

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GAS LEAK OR FIRE I THE HIGH PRESSURE

SECTIO

IMMEDIATE STEPS TO TAKE

BLOCK STOP FEED DEPRESSURE NOTIFY

ALL FURNACE MAKE-UP PUMPS SYSTEM USING FIRE
FIRES TO PILOTS HYDROGEN AND THE EMERGENCY DEPT.
FROM DCS / BLOCK DEPRESSURING OF
OUTSIDE OPERATOR FEED TO VALVE LEAK
BLOCK FUEL GAS REACTORS

WARNIN
WARNING
G

Verify this
with
outside Block the fuel gas to all furnaces, and start snuffing steam
operator. to to the fireboxes, if safe to do so.

AS SOON AS POSSIBLE DO THE FOLLOWING

Monitor separator Stop water Shutdown recycle Start nitrogen to

System pressure must
levels to prevent injection compressor when the system when
be below nitrogen
blowing high pressure to the react effluent system pressure is pressure permits.
header pressure.
gas into low pressure air cooler. at 40 kg/cm2 (g).
vessels.

Maintain nitrogen
flow until all
hydrogen
vapors are displaced
with nitrogen.
At this point the unit is at a safe
condition
so further determination of cause of
leak and damage incurred may be
made.

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LOSS OF INSTRUMENTATION

IMMEDIATE STEPS TO
TAKE
MANUALLY EMERGENCY INCREASE VERIFY CLOSELY MONITOR
BLOCK SET HP DEPRESSUR RECYCLE THE CAT TEMPS. IF ANY
FUEL GAS HYDROGEN E HYDROGEN TO OIL FEED BEGINS TO INCREASE
VALVES MAKE-UP REACTOR MAXIMUM CHOPPER OUT OF CONTROL,
TO ALL COMPRESSOR SECTION TO DESIGN VALVE DEPRESSURE
FURNACES LOADERS TO 2
40 kg/cm (g) (SPEEDUP RGC) CLOSED SYSTEM
0%

WARNING
WARNING Refer to reactor
CAUTION temperature
If the RGC trips, open excursion
emergency depressuring emergency
Verify this valve and depressure unit. procedure.
with
outside
operator. AS SOON AS POSSIBLE DO THE
FOLLOWING

CAUTIO In manual mode on the DCS, place all

N control valves in their failed position. Closely monitor the
CHPS level. Control level CAUTION
with hand jacks or spare
Have level control valve.
outside Isolate the CHPS and CLPS While on handjack
operator interface sour water level an operator must be
verify valve control valves. stantioned at the
positions. Use the bypass on the CLPS level controller and
vapor KO drum high set point DCS operator must
pressure controller to control closely monitor
Shutdown the reactor feed
the reactor low pressure pressure and level.
pump and close discharge
section. Route to the flare.
valve.

Shutdown make-up H2 compressors. Manually control steam

generator levels, level control
valve bypasses.

Shutdown
water
injection pump.

Follow refinery procedures to

further safely secure the unit.

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LOSS OF ELECTRICAL POWER

IMMEDIATE STEPS TO TAKE

REACTOR ESTABLISH CAREFULLY INCREASE VERIFY START

FURNACE FIRES EMERGENCY BYPASS REACTOR RECYCLE REACTO DEPRESSURING
TO PILOTS. CIRCULATION FEED/EFFLUENT HYDROGEN R TO 40 kg/cm2 (g)
REMOVE PILOTS FLOW EXCHANGERS, TO FEED USING THE
AS NEEDED THROUGH THE AS NEEDED, TO MAXIMUM VALVE EMERGENCY
FOR COOLING. FRACTIONATOR CONTROL CAT DESIGN CLOSED DEPRESSURING
FEED FURNACE TEMP VALVE

WARNING
WARNING Closely monitor
The following major equipment will be catalyst temps. If
lost: any begin to
increase out of
Verify this • Reactor feed pump control, depressure
with outside • Half of the air coolers system.
operator. • Injection water pump
• Make-up hydrogen compressors
Refer to reactor
In manual mode on the DCS, temperature
place all control valves in the excursion emergency
fail safe position. procedure.

ELECTRICAL POWER IS RESTORED

N
o Yes

Start securing the unit by blocking: Hold system pressure

• Feed pumps at 40 kg/cm2 (g).
• Oil feed control valve
• Make-up hydrogen
Verify that electrical
power is restored and
reliable.
Further secure unit if
power outage will be
extended.
Return unit to
preupset
Conditions.

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TOTAL LOSS OF COOLING WATER

IMMEDIATE STEPS TO TAKE

REACTOR CAREFULLY BYPASS MAXIMIZE MAXIMIZE

FURNACE FIRES THE REACTOR RECYCLE QUENCH TO
TO PILOTS. FEED/EFFLUENT GAS RATE REACTOR
REMOVE PILOTS EXCHANGERS, (SPEED UP BEDS
AS NEEDED FOR AS NEEDED, TO RGC)
COOLING CONTROL CAT TEMP

Without cooling water, the following critical

WARNIN
WARNIN Not equipment will be lost in ~15-20 minutes
GG e due
For maximum cooling, to high mechanical temp:
Verify this the bypass should be fully 1. Recycle gas compressor
with open and the pinch valve 2. Feed pump
outside closed to minimum stop. 3. Make-up H2 compressors
operator. 4. Others

COOLING WATER IS RESTORED WITHIN 10 MINUTES

Yes No

Maintain current system Start depressuring the unit Ensure emergency circulation
pressure with make-up using the emergency was established through the
hydrogen. depressuring valve. fractionator feed furnace.

CAUTION

Closely monitor Shutdown reactor Shutdown recycle Shutdown make-up Close oil
catalyst temps. feed pump. gas compressor. hydrogen feed valves.
compressors.

Evaluate unit conditions

to deterine if unit
should be restarted.
Close depressuring Shutdown water Secure unit by
valve when the unit’s injection system. blocking recycle
pressure reaches gas compressor -
Inspect the unit for 2
40 kg/cm (g) -- this is to feed pumps - feed
leaks.
allow oil to flow from the control valve –
CAUTIO CHPS. make-up hydrogen.
N
If any reactor temp increases
unexpectedly, continue to
depressure and admit utility Follow normal procedures
nitrogen. to further safely secure
unit.

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LOSS OF VERY HIGH PRESSURE STEAM

IMMEDIATE STEPS TO TAKE

WHEN RECYCLE GAS COMPRESSOR IS LOST DUE TO
LOSS OF HIGH PRESSURE STEAM

REACTOR START MAINTAIN CAREFULY BYPASS REDUCE

FURNACE FIRES DEPRESSURING OIL FEED THE REACTOR MAKE-UP H2
TO PILOTS. USING THE RATE AT FEED/EFFLUENT FLOW TO
REMOVE PILOTS EMERGENCY DESIGN EXCHANGERS, AS 25% OF
AS NEEDED DUMP VALVE NEEDED, TO CONTROL DESIGN
FOR COOLING. CAT TEMP CAUTION

If quench is used,
WARNING
WARNING monitor cat beds
carefully since using
quench will reduce
Verify this reactor inlet feed gas
with outside rate.
operator. Stop water injection Monitor separator and Start RGC lube and
to the reactor effluent column levels closely. seal oil electric pumps
air cooler. and stop steam turbines.

HIGH PRESSURE STEAM IS RESTORED WITHIN 5 MINUTES

Yes No

Restart the recycle gas When all reactor temps

CAUTION Continue depressuring the
compressor with spillback fully are below normal and
reactor system until
open (if compressor is down). falling, stop oil-feed to
~40 kg/cm2 (g) is reached,
Monitor catalyst temps for and hold at this pressure. the reactor section.
evidence of a temperature
excursion.
Carefully reestablish recycle
gas flow to the reactors.
CAUTION

Do not overfill the CHPS. HP STEAM IS RESTORED

Yes No
After it is confirmed that
reactor temperatures are Pressure the system Continue purging with
under control, increase to 40 kg/cm2 (g) (if once-through H2 and cool
make-up H2 to stabilize below) with make-up H2. reactors to at least 260°°C.
reactor section pressure.
Evaluate steam
Restart the recycle gas situation and
CAUTION compressor with the determine if
spillback fully open. further unit
CONTINUE WITH UNIT The reactors will be oil shutdown is
CAUTION
RESTART FOLLOWING packed - proceed slowly. necessary.
ESTABLISHED REFINERY
Monitor catalyst temps
PROCEEDURES for evidence of a
Carefully reestablish
recycle gas flow to the temperature excursion.
reactors.

10

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CHAPTER-12

CATALYST REGEERATIO
12.1 Introduction:
During normal operation some reaction by products accumulate as coke on the catalyst and
reduce its activity, which requires compensating catalyst temperature increase to maintain
desired conversion. Eventually temperature gets so high that the reactor design temperature is
reached, the product yields degrade, or the desired product qualities can't be achieved at full feed
rate. The lost activity can be substantially regained by regenerating the catalyst, unless it was
poisoned by metals in the feed, or sustained substantial other damages.

12.1.1 Regeneration Overview:

Catalyst regeneration consists of two distinct phase: an Oxidation phase followed by the
Reduction phase.

The oxidation process is a controlled burn of the accumulated coke in an atmosphere of dilute
oxygen in circulating nitrogen, followed by reduction of metal sulfates, unavoidably formed on
the catalyst in the oxidation phase, to sulfides, in an atmosphere of dilute hydrogen in nitrogen.
The regeneration is completed by sulphiding the catalyst.

The combustion products from the reactors are cooled in the reactor feed/ effluent exchangers
(207E-3A/B), bypassing effluent exchanger (207E-4, 207E-5, 207E-6, 207E-7 and 207E-8)
before being further cooled in reactor effluent air cooler (207E-9). The combustion products
must be maintained above 2880C to prevent condensation of sulfurous acids in these exchangers.
During both phases of regeneration, reactor effluent gases from 207E-3A/B are quenched with a
dilute caustic solution before further cooling in 207E-9. Sulfur oxides and carbon oxides
produced during the burn are neutralized and cooled by the dilute caustic quench. The quench
recirculation pump (207G-32) circulates caustic quench solution from the CHPS (207C-2)
through a static mixer (207M-4), before being injected into the reactor effluent between 207E-
3A/B and 207E-9.

The gas is separated from the caustic solution in the CHPS and is recycled. The caustic solution
is recirculated as quench to the inlet of 207E-9 by 207G-32. Spent caustic is bled from the
CHPS to maintain a low level of dissolved solids (maximum of 10%). Make-up caustic
(15 wt %) is injected at the suction of the water injection pump (207G-4A/B). The caustic
solution is combined with water from the injection water drum (207C-8). This dilute caustic
solution is pumped to combine with the circulating quench solution at the suction of the quench
pump 207G-32 to maintain the pH between 7.5 and 8.5. The make-up hydrogen compressors are

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used to provide make-up air for the oxidation phase. The make-up air is diluted with inert
recycle gas at the suction of the make-up

compressors. This dilution gas from the suction header of the recycle gas compressor flows
through 207PIC-6906 to control the suction pressure of the make-up compressor. Make-up air is
added to the suction and is continuously monitored for the rate of oxygen concentration at the
compressor suction and at the reactor inlet. The oxygen concentration and compressor discharge
temperature are continuously monitored. The maximum oxygen concentration varies from
4 mole % at the start of the oxidation phase, when residual hydrogen or hydrocarbon may be
present, to 7% after the first 24 hours of burning. The dilute make-up air is combined with the
preheated inert recycle gas from the recycle gas compressor (207K-1), and the mixture is heated
in the feed/effluent exchangers (207E-3A/B) and the reactor feed heater (207F-1) to reactor inlet
conditions before the gas mixture enters the reactor.

The regeneration process should be carried out at the maximum discharge pressure allowed by
the make-up hydrogen compressor vendor. This will maximize the recycle gas flow rate within
the limits set for oxygen concentration and discharge temperature of the make-up hydrogen
compressors. The objective is to regenerate the catalyst with the make-up hydrogen compressor
fully loaded and the spillback fully shut. A fully closed spillback will prevent oxygen
recirculating in the system. Also this assures maximum delivery of gas from the make-up
hydrogen compressor to the reactors, which will speed the regeneration process. The pressure
controller alignments suggested in these guidelines for both regeneration phases achieves this
objective.

System pressure is not controlled during regeneration; pressure will be maintained by adding
fresh make-up nitrogen at the suction of the make-up compressor and impurities as CO / CO2
will be vented out to atmosphere.

Oxygen content at the reactor inlet is closely monitored, and analyzer readings should be
verified by checking samples to laboratory at least once per shift.

Inter bed quenches will remain shut during regeneration.

The process flow and control diagram for catalyst regeneration is shown in drawing 207-0014.
Facilities and process control features unique to regeneration are shown. The pressures and flow
rates shown are estimates.

12.2 Oxidation Phase:

The oxidation phase is a controlled burn of coke on the catalyst with 0.5 vol % oxygen in
nitrogen. Initially, the temperature is 345°C at the reactor inlet. The maximum temperature rise
across any bed or across the reactor must be controlled to <55°C. After this burn wave is
completed, the reactor inlet temperature is raised to 400°C for a second burn and finally to

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440°C for the third burn wave. Between Step 1 and 2 & Step 2 and 3 the oxygen content at
the reactor inlet is maintained at 0.5 vol %. During the third burn wave, the oxygen
concentration at

the reactor inlet can be increased to 1.5 vol % as the temperature rise across each bed approaches
zero.

The procedure given below can be used to perform full or partial catalyst regeneration. A partial
regeneration (pacification burn) should be used only if the catalyst is to be discarded or removed
for metals recovery. Partial catalyst regeneration removes the combustible and pyrophoric
material from the catalyst so that it may be more safely unloaded and shipped in an air
atmosphere. The process flow and the equipment used for a partial regeneration are the same as
for the full regeneration. The essential differences, as compared to a full regeneration, are that
instead of the two or three successive burns at increasing temperatures, a partial regeneration
consists of a single burn and the reduction phase is eliminated. After regeneration is completed,
the reactors may be cooled and prepared for catalyst unloading.

12.2.1 First Burn (345 oC)

1. Proceed for a planned shutdown. Keep the system under a slight nitrogen pressure at a
reactor temperature of about 205°C. All oil should have been removed from the high pressure
system. In addition to the nitrogen purges carried out during a normal shutdown, ensure that the
following are well purged:

• The Make-Up Hydrogen Compressors (207K-2A/B/C)

• The Recycle Gas Compressor (207K-1)
• The Regeneration Caustic Quench Solution Circulation System

2. While maintaining a small nitrogen flow through the reactor section to prevent air from
entering the reactors, install the regeneration quench piping, vent piping for the atmospheric
bleed, necessary isolation blinds, etc.

3. Install oxygen analyzers at the make-up hydrogen compression suction [upstream of the
first-stage suction drum (207C-32)] and 207R-1 inlet gas stream to continuously monitor oxygen
concentration.

• Make-up hydrogen compressor suction (207AT-6901). This analyzer is wired to the DCS
for continuous monitoring and to enable the alarm system.

• 207R-1 inlet. This analyzer can be a portable battery operated Teledyne, multiple range,
or equal.

• Recalibrate 207LIC-2401 for circulating quench solution.

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• Recalibrate flow instruments in the recycle gas system to circulating nitrogen gas.

• 207E-6 exchanger shellside will be out of service while the tubeside will be live during the
regeneration. The shell is protected by design to withstand this condition. To protect the
connected piping, have the shellside in / out blinded.

• Test all shutdown interlocks, including the make-up air injection (207FV-6904) valve trip
action.

4. Disconnect vents and safety valve discharges where oxygen will be present from normal
blow down and flare systems.

5. Ensure the make-up hydrogen compressors are blinded to isolate the make-up hydrogen
compressor section from the off plot hydrogen unit, and the reactor section from the oil feed and
fractionation sections.

6. If non-compounded lubricants are to be replaced in the make-up hydrogen compressors, use

a lubricant specially compounded for oxidation resistance.

7. Install portable instruments and change or recalibrate permanent instruments as required for
regeneration service. Provide new meter factors, as required, for measuring inert gas and
oxygen rather than hydrogen and hydrocarbons.

8. Pressurize the reactor section to nitrogen header pressure [~6 kg/cm2 (g)], via the startup
nitrogen connection on the downstream side of the isolation manifold between the make-up
hydrogen compression and reaction sections.

9. Open the startup nitrogen connection to the make-up hydrogen compressor suction header
and pressurize the make-up hydrogen compression section to nitrogen header pressure
[~6 kg/cm2 (g)].

10. Start a make-up hydrogen compressor unloaded with the spillback manually open.

11. If the reactors are cold, at no time the pressure in the reactor be allowed to exceed
46.3 kg/cm2 (g) until all skin points are above MPT (Minimum pressurisation temperature)
Severe damage to the reactors can occur from “temperature embrittlement” at pressures greater
than 46.3 kg/cm2 (g) and temperatures below MPT.

12. Set the controllers, as described below, in preparation for pressuring the reactor section with
nitrogen to the maximum pressure permitted by MPT limits at 207R-1 inlet [below 46.3 kg/cm2 g,
25% of the design pressure of 185.3 kg/cm2 (g)].

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• Place the recycle gas compressor suction high set point pressure controller
(207PIC-2601) in automatic mode with a set point of ~40 kg/cm2 (g), a value safely below the
MPT restriction.

• Switch the make-up hydrogen compressor discharge pressure controller (207PIC-6904)

from remote set point mode to local set point mode. This prevents the recycle gas compressor
suction pressure controller (207PIC-2702) from resetting 207PIC-6904 set point. 207PIC-2702
does not play a part in the regeneration pressure control scheme. Place 207PIC-6904 in manual
mode and open the spillback valve.

• Place the make-up hydrogen compressor suction pressure controller (207PIC-6903) in

automatic mode with a set point of ~5.0 kg/cm2 (g), or ~1.0 kg/cm2 (g) below the nitrogen
header pressure [~6.0 kg/cm2 (g)]. While pressuring (and subsequent oxidation), 207PIC-6903
prevents the make-up hydrogen compressor suction pressure from going too low. Should the
pressure fall below set point (due to compressor capacity exceeding the nitrogen header supply
limits), 207PIC-6903 will send an override signal to the compressor spillback control valve
through the low signal selector (PY-6904) to open the spillback valve to satisfy set point.

• Place the make-up hydrogen compressor regeneration suction pressure controller

(207PIC-6906) in automatic mode with a set point of ~5.5 kg/cm2 (g), or 0.5 kg/cm2 (g) higher
than the low set point pressure controller (207PIC-6903), to prevent the controllers from
interfering with one another. In normal regeneration operation, with 207PIC-6906 controlling
the make-up hydrogen compressor suction at ~5.5 kg/cm2 (g), 207PIC-6903’s set point is
satisfied and its output signal will not open the spillback control valve. 207PIC-6906 routes
inert dilution gas from the recycle gas compressor suction to the make-up hydrogen compressor
suction (~14,930 Nm3/hr during the first burn and ~12,050 Nm3/hr during the third burn) in
order to avoid high oxygen concentrations in the make-up hydrogen compressors.

13. Start the make-up hydrogen compressor on total spillback. Load the compressor, as
limited by nitrogen availability, and begin increasing the reactor section pressure. Should it be
necessary to limit the pressurization rate, due to nitrogen availability, the startup nitrogen supply
to the make-up hydrogen compressor suction header can be pinched. This will cause the suction
pressure to drop. At 5.5 kg/cm2 (g), 207PIC-6906 will begin drawing in dilution gas from the
recycle gas compressor suction (even though the recycle gas compressor is not running). Should
this be insufficient to maintain the make-up hydrogen compressor suction pressure above
5.0 kg/cm2 (g), 207PIC-6903 will have a low output signal, which will open the make-up
hydrogen compressor spillback control valve.

14. When the recycle gas compressor suction pressure allows, start the compressor and the fans
on the reactor effluent air cooler (207E-9). Circulate gas at a maximum rate and begin heating
207R-1 inlet to 345°C. Follow heat up restrictions.

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15. Once MPT is achieved, and as the reactors are continued to be heated, increase the recycle
gas compressor high set point pressure controller (207PIC-6903) set point to ~50 kg/cm2 (g), or
slightly above the recycle gas compressor target suction pressure of ~48 kg/cm2 (g).

16. When 207R-1 inlet target pressure is reached, startup nitrogen is added to the suction just
enough to maintain the system pressure. The suction pressure will be maintained at
~5.5 kg/cm2 (g) by 207PIC-6906, with flow through the dilution gas line from the recycle gas
compressor suction. 207PIC-6906 receives its pressure output signal from the low set point
pressure controller on the make-up hydrogen compressor suction (207PIC-6903). It should be
necessary to bleed nitrogen to maintain reactor section pressure, due to gas expansion, the high
set point pressure controller (207PIC-2601) at the recycle compressor suction will automatically
open.

17. During the regeneration process, make-up spillback is manually shut and flow to the reactor
is not controlled.

18. Prepare a dilute caustic solution of between 7.0 and 8.0 pH in the water injection system and
establish a 60% level in the CHPS (207C-2), using the injection water pumps (207G-4A/B).
When the level is established and stable, start the quench recirculation pump (207G-32).
Monitor the CHPS level closely, as the caustic quench solution can foam and carry over into
downstream equipment and cause corrosion and catalyst poisoning.

19. As the reactor temperatures approach 345°C, adjust the feed/effluent exchanger (207E-3A/B)
bypass to maintain the temperature of the effluent leaving 207E-3A/B above 288°C to prevent
condensing sulfur and carbon oxides. Set 207E-3A/B’s outlet temperature indicator (207TI-1812)
low alarm at 290°C, and test the alarm to make sure it works. This will provide a safe margin
away from the expected acid dew point of the effluent gases during regeneration. If the
temperature goes lower, the exchangers could corrode very rapidly.

20. Test the recycle gas sample for hydrogen content. It should be not more than 2.0 vol %. Bleed
out system and add fresh nitrogen to make the system ready for air injection.

21. Adjust the quench solution circulation rate to design (210 m3/hr) or higher to obtain a stream
temperature of ~93°C (207TI-2301), or lower, entering the 207E-9. Control the stream
temperature leaving 207E-9 (207TIC-2306) to maintain the CHPS temperature as low as possible.

22. Install a temporary pH analyzer on the suction of the quench recirculation pump (207G-32)
suction to continuously monitor the recirculating stream pH. When the pH drops below 7.5, add
dilute caustic from the water injection system at a low rate to control the pH in the range of
7.5 - 8.5 (measured at atmospheric pressure). Check the accuracy of the temporary pH analyzer
once each shift with a portable pH meter. The pH should not be allowed to go below 7.0, nor
above 9.0. Control may be difficult until carbon dioxide (CO2) is being formed in the reactor.

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Once the burn wave is definitely established and CO2 is present in the effluent gases, it should only
be necessary to add caustic at a low steady rate or batchwise at intervals of 1-2 hours to maintain
the pH above 7.5.

ote: Once CO2 is being formed in the reactor, the caustic quench solution will be, in part,
converted to carbonates and bicarbonates, both of which are buffers which maintain a constant
pH while reacting away incoming acids. Since the solution pH will go to the buffer’s value, and
controlling pH in a specific range (7.5 and 8.5) is next to impossible, the objective becomes
keeping the pH above 7.5. When sulfur is oxidized, SO2 and SO3 will come over as acids and
react with the carbonate. This reaction can cause foaming when the CO2 is liberated.

23. Analyze the circulating quench solution for total dissolved solids at 1-hour intervals. Drain
spent caustic to offplot disposal facilities to maintain less than 10 wt % dissolved solids in the
circulating quench solution. Add make-up water from the water injection system to maintain a
steady level in the CHPS. It will be necessary to increase the make-up caustic rate to maintain
pH control after spent caustic draining has started. Spent caustic at regeneration pressure
contains a significant amount of dissolved CO2 and nitrogen. These gases should be vented
before measuring the sample for pH. The pH of high pressure caustic is about 0.5 pH unit less
than the pH measured at atmospheric pressure.

24. Set the interbed quench controllers manually shut. Quench gas will not be used during the
regeneration; burning severity is controlled by rate of air addition.

25. Start adding make-up air from the plant air system by gradually increasing the ratio of
make-up air to inert recycle (dilution) gas at the suction of the make-up hydrogen compressors
from zero, by adjusting the ratio controller (207FFIC-6904) set point. Carefully watch the
concentration of oxygen to not exceed 4.0% at the make-up hydrogen compressor suction and
0.5% at 207R-1 inlet.

26. Observe 207R-1 burn wave by closely monitoring catalyst bed temperatures. The
temperature increase across any catalyst bed, or across the total reactor, should not exceed 55°C.
Be on guard for a possible localized hot spot that indicates the presence of a “coke ball,” which
can take several hours to burn through. There may be such areas away from the temperature
indicators and completion of burning activity will be well indicated by lack of exotherm in the
bed followed by oxygen breakthrough at the reactor outlet.

27. Load the make-up hydrogen compressor as necessary to maintain the discharge pressure at
the maximum achievable.

28. When the burn wave breaks through 207R-1, the burn will begin in the 207R-2.

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29. Sample the recycle gas for hydrogen. When no hydrogen is present, the air rate may be
increased. The oxygen content should not exceed 0.5% and reactor temperatures should not
exceed 400°C at any point.

30. Maintain the regeneration make-up gas oxygen content at or below 4.0% until analysis
shows the recycle gas to be free of hydrogen for at least 24 hours. The oxygen content may then
be increased, providing it does not exceed 7.0 vol %, by adjusting the ratio controller
(207FFIC-6904).

31. Follow the progress of the burn waves by observing catalyst bed temperatures. Some
oxygen may break through before a burn wave gets to the bottom of the reactors. When this
happens, cut back on the air rate and maintain the oxygen content at the reactor inlet no more
than 0.5%.

32. Continue to follow the progress of the burn wave through 207R-2. Watch for oxygen
breakthrough before the burn wave reaches the bottom of the reactor and adjust the regeneration
gas flow controller (207FIC-2704) accordingly. When the burn wave has passed through the
bottom bed and no temperature rise is evident anywhere, the first burn is nearly complete.
Reduce the make-up air rate (207FFIC-6904) to keep the oxygen content of 207R-1 inlet gases
below 0.5%.

33. The first or primary (pacification) burn is complete when:

a. The regeneration air rate has been reduced to 15% of design.
b. The oxygen consumption is verified by analyses to be less than 15% of that achieved in
Step-29 (by oxygen analyses).
c. The recycle gas oxygen content is steady below 0.5% for at least 1 hour.

12.2.2 Second Burn

34. Raise the reactor inlet temperatures gradually to 400°C to start the second burn. Adjust the
ratio controller (207FFIC-6904) on the make-up compressor suction to hold 0.5% oxygen in the
regeneration gas to 207R-1. Do not allow any of the temperature to exceed 455°C. The second
burn wave should move down the reactors faster than the first. Sometimes it’s not seen at all.
Occasionally, the second burn is diffused with some local burning with oxygen breakthrough at
the same time. Do not exceed 0.5% oxygen in the regeneration gas to 207R-1. Hold 400°C
reactor inlet temperatures and 0.5% oxygen until the wave passes through 207R-2 bottom bed.
The second burn is complete when:

a. The regeneration air rate has been reduced to 15% of the air rate used during the burn wave.
b. The oxygen consumption is verified by analyses to be less than 15% of that achieved during
the burn wave.
c. The recycle gas oxygen content is steady below 0.5% for at least 1 hour.

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12.2.3 Third Burn

35. Raise reactor inlet temperatures gradually to ~440°C for the third burn. Uses quench gas to
maintain 207R-2’s inlet temperature at 440°C. Increase the ratio controller (207FFIC-6904) set
point to increase the make-up air rate to the make-up compressor suction and to increase the
reactor inlet oxygen concentration to between 1.0% and 1.5%, but do not allow any temperature in
any reactor to exceed 482°C for more than 1 hour. If a burn wave is seen, hold these conditions
until it passes through the bottom beds.

36. Once the third burn wave breaks through 207R-2, increase the oxygen concentration to 3.0% at
440°C reactor inlet temperatures. Hold for 6 hours or until the oxygen consumption is reduced to
a low rate, as indicated by a drop in reactor inlet oxygen content of less than 1.0% for 2 hours with
make-up air stopped. This completes the third and final burn.

12.2.4 Cool Reactors for Entry:

37. Start cooling the reactors gradually according to the cooling rate restrictions. When the
temperatures reach ~205°C, transfer as much of the caustic quench solution as possible to
available storage, and hold it there for use during the reduction phase. To prevent nickel
carbonyl formation, CO must be lowered to <30 ppm before continuing cooldown. This will
require a purge step. Drain the CHPS and flush the caustic quench solution piping with boiler
feedwater. Carefully drain all traces of water from the high pressure system. When the system
is free of water, continue cooling the reactors until the reactors are cool enough to enter. Stop
the recycle gas compressor and depressure to the atmosphere.
The catalyst now contains active metals in the oxide and sulfate forms; all precautions taken for
fresh catalyst loading should apply here.

38. Open 207R-1 top manway and, after appropriate safety protocols are in place, clean out the
top set of internals. Inspect the top layer of catalyst and replace it if there is any evidence of a
crust. Then close up the reactor to prepare for the reduction phase.

39. If used, replace the special oxidation-resistant lubricant to the make-up hydrogen
compressors with the normal noncompounded lubricant to prevent catalyst poisoning. Be sure
to flush out all of the old lubricant.

12.3 Reduction Phase:

After the oxidation phase is complete, metal sulfates (by-products of the oxidation) are reduced
to sulfides in a controlled reaction with a reactor inlet temperature of 345°C and a 1.0-2.0 vol %
ydrogen-in-nitrogen mixture. Since the reduction phase reaction is highly exothermic, make-up
hydrogen flow should be metered accurately to maintain this dilute hydrogen-nitrogen mixture.
This is accomplished by bringing hydrogen into the make-up hydrogen compression section
through a small flow control valve that bypasses the main valve on the low pressure hydrogen

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line to the make-up compressor section. During reduction, hydrogen concentration in the export
gas from the make-up hydrogen compressors should be limited to ~16.0 vol %.

1. Remove the portable oxygen analyzers and blind plant air to the make-up hydrogen
compressors, but leave other regeneration instruments and piping in place. Reconnect all flare
tie-ins to normal, for reduction phase.

2. The make-up hydrogen compressors, reactor section, and recycle gas compressor must now be
purged with nitrogen to remove oxygen. When purging, the purge nitrogen gas should be
introduced at a point to allow the nitrogen to follow the normal downward flow path through the
catalyst beds. Nitrogen is introduced to the reactor section, downstream of the isolation
manifold between the reactor and make-up hydrogen compressor sections. Table 12-1 lists the
estimated nitrogen requirement for this step.

• Block in the recycle gas and make-up hydrogen compressors and purge with nitrogen
to remove oxygen.

• Depressure the reactor section to ~0.4 kg/cm2 g and purge nitrogen through the
reactors to the atmosphere from the recycle gas compressor suction, until air is
removed.

• Pressure the reactor section to nitrogen header pressure and then depressure to the
flare system, via the recycle gas compressor suction high set point pressure controller
(207PIC-2601). Repeat this step twice more.

3. Set the regeneration pressure controllers, as described for the oxidation phase, in preparation
for repressuring the reactor section with nitrogen to the maximum pressure permitted by MPT
limits at 207R-1 inlet. In this case, the make-up hydrogen compressor regeneration suction
pressure controller (207PIC-6906) routes inert dilution gas from the recycle gas compressor
suction to the make-up hydrogen compressor suction (~15,430 Nm3/hr) in order to avoid high
hydrogen concentrations in the make-up hydrogen compressors.

4. Spillback control valve shall remain shut reduction process.

5. Pressure the reactor section to nitrogen header pressure [~6 kg/cm2 g], via the startup
nitrogen connection on the downstream side of the isolation manifold between the make-up
hydrogen compressor and reactor sections.

6. Open the startup nitrogen connection to the make-up hydrogen compressor suction header
and pressure the make-up hydrogen compression section to nitrogen header pressure.

CAUTIO: At this point the reactors are cold. At no time is the pressure in the reactors to be
allowed to exceed 46.3 kg/cm2 g until all skin points are above MPT. Severe damage to the

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reactors can occur from “temperature embrittlement” at pressures greater than 46.3 kg/cm2 g and
temperatures below MPT.

7. Start a make-up hydrogen compressor on total spillback. Load the compressor, as limited by
nitrogen availability, and begin increasing the reactor section pressure. Should it be necessary to
limit the pressurization rate, due to nitrogen availability, the startup nitrogen supply to the
make-up hydrogen compressor suction header can be pinched. This will cause the suction
pressure to drop. At 5.5 kg/cm2 g, 207PIC-6906 will begin drawing in dilution gas from the
recycle gas compressor suction (even though the recycle gas compressor is not running). Should
this be insufficient to maintain the make-up hydrogen compressor suction pressure above
5.0 kg/cm2 g, 207PIC-6903 will have a low output signal, which will open the make-up
hydrogen compressor spillback control valve.

ote: To minimize the reduction phase time, the compressor loading should always be the
minimum required to satisfy 207PIC-6904 set point with minimum spillback, while providing
the maximum delivery of gas from the make-up hydrogen compressor to the reactors.

8. When the recycle gas compressor suction pressure allows, ensure the fans on the reactor
effluent air cooler (207E-9) are still on, start the compressor, and establish maximum circulation
through the reactor section.

9. Purge and reestablish fires in the reactor feed furnace. Begin heating up the reactor section
according to the design restrictions. Verify that all reactor quench control valves operate
properly, and adequate quench flow can be achieved to each quench point.

10. Once MPT is achieved, and as the reactors are continued to be heated up, increase the
recycle gas compressor high set point pressure controller (207PIC-6903) set point to
~50 kg/cm2 g, or slightly above the recycle gas compressor target suction pressure,
~48 kg/cm2 g.

11. Recharge the caustic quench solution (that was stored after the oxidation phase) and establish
circulation to the static mixer (207 M4). Set the circulation rate at design (210 m3/hr), or higher,
to obtain a temperature of 93°C (207TI-2301), or lower, entering 207E-9. Control the stream
temperature leaving 207E-9 (207TIC-2306) to maintain the CHPS temperature as low as possible.

12. When 207R-1’s inlet target pressure is reached, block in the startup nitrogen to the make-up
hydrogen compressor suction, while continuing to run the make-up hydrogen compressor. The
suction pressure will be maintained at ~5.5 kg/cm2 g by 207PIC-6906 with flow through the
dilution gas line from the recycle gas compressor suction. 207PIC-6906 receives its pressure
output signal from the low set point pressure controller on the make-up hydrogen compressor
suction (207PIC-6903). Should it be necessary to bleed nitrogen to maintain reactor section

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pressure, due to gas expansion, the high set point pressure controller (207PIC-2601) at the
recycle compressor suction will automatically open.

13. Increase 207R-1 inlet temperature to 345°C, and hold until temperatures are at least 315°C
throughout 207R-1 and 207R-2.

14. As 207R-2 outlet temperatures approach 315°C, adjust the feed/effluent exchanger
(207E 3A/B) bypass to maintain the temperature of the effluent leaving 207E3A above 288°C to
prevent condensing sulfur and carbon oxides. Set 207E-3A/B outlet TI (207TI-1812) low alarm
at 290°C, and test the alarm to make sure it works. This will provide a safe margin away from the
expected acid dew point of the effluent gases during regeneration. If the temperature goes lower,
the exchangers could corrode very rapidly.

15. Hydrogen will be introduced to the make-up hydrogen compression section during the next
step. Precautions should be taken to prevent hydrogen from entering the refinery utility nitrogen
system.

ote: The hydrogen used for reduction must be manufactured hydrogen. There should be
essentially no hydrocarbons larger than methane.

16. Isolate the startup nitrogen connection to the make-up hydrogen compressor suction header.

17. Slowly introduce hydrogen to the make-up hydrogen compressor suction header, via the
regeneration hydrogen flow controller (207FIC-6903), to obtain 1.0-2.0 vol % hydrogen in
207R-1 inlet gas. After each incremental increase in hydrogen addition, analyze the inlet gas to
ensure the hydrogen concentration does not exceed 1.0-2.0 vol %. Once the concentration level
is achieved, analyze the reactor inlet gas every 2 hours thereafter.

ote: The hydrogen rate required for reduction is so small that the reactor section will probably
slowly lose pressure during reduction due to leakage. If the regeneration pressure control loops,
previously discussed, cannot maintain pressure and still provide required recycle gas and quench
gas rates, nitrogen will have to be added. This should be done at the suction of the make-up
hydrogen compressor to increase the reactor section pressure to the desired value. If this
becomes necessary, the hydrogen source should be isolated before introducing nitrogen to the
make-up compressor suction header, and afterward the nitrogen should be isolated before
reintroducing hydrogen.

18. The addition of hydrogen should cause a temperature rise of ~14 to 22 °C for each volume
percent hydrogen in the reactor inlet gas. This temperature rise should move down through
207R-1 in a definite wave. When the reduction wave breaks through 207R1, the wave will begin
in 207R-2. No hydrogen should appear in 207R-2 effluent gases until the reduction wave has
passed through 207R-2. Immediately after hydrogen addition is begun, start checking the

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recycle gas stream for hydrogen (either by laboratory analysis or the hydrogen analyzer) to
ensure that no hydrogen is leaking through. Do not exceed 2.0% hydrogen at 207R-1 inlet, even
if the temperature rise is less than expected. If no temperature rise occurs, or if hydrogen is
present in 207R-2 effluent, stop hydrogen addition. Then increase the reactor temperature 14°C
and start again.

19. Start monitoring the recirculating quench solution pH via the temporary pH analyzer
installed on the quench recirculation pump (207G-32) suction. When the pH drops below 7.5,
add dilute caustic from the water injection system at a low rate to control the pH in the range of
7.5-8.5. Check the accuracy of the temporary pH analyzer once each shift with a portable pH
meter. The pH should not be allowed to go below 7.0, nor above 9.0.

20. Test for solids in the recirculating quench stream at 2-hour intervals. Bleed caustic quench
solution to the drain and make-up with dilute caustic solution from the water injection system, as
required, to remain below 10 wt % solids.

21. If after 1-2 hours the reduction is proceeding smoothly, slowly increase the hydrogen
concentration to 2.0-3.0% at 207R-1 inlet, and then follow the progress of the reduction wave by
observing catalyst bed temperatures. If the temperature rise exceeds 55°C, or if reactor
temperatures at a reduction wave reach 385°C, stop increasing hydrogen content. Do not exceed
3.0 % hydrogen at 207R-1 inlet under any circumstances, and do not allow the temperature to
exceed 400°C at any point in the reactors during this step.

22. When hydrogen breaks through 207R-2 bottom bed, reduce or stop hydrogen addition as
required to maintain 2.0-3.0% hydrogen at 207R1 inlet. Check the recycle gas hydrogen content
at 1-hour intervals and batch in hydrogen as required to hold 2.0-3.0% hydrogen at 207R-1 inlet.
Hold reactor temperatures at 345°C and 2.0-3.0% hydrogen at 207R-1 inlet for at least 8 hours
and until hydrogen consumption has dropped to a low rate (indicated by a drop in hydrogen
content in the recycle gas of less than 1.0%/hr with hydrogen addition stopped for at least
2 hours).

23. Discontinue hydrogen addition and cool the reactors slowly to about 205°C. Test recycle gas
for CO content. The maximum allowable in the system is 10 ppm to prevent formation of
carbonyls. Hold reactor temperature >205°C in case the CO level is higher and until is purged
out to allowable limit. Stop quench solution circulation and drain all quench solution from the
system. Carefully drain all sample taps, instrument leads, etc., to ensure that the caustic is
drained thoroughly. Then flush the system downstream of the reactor with chloride-free water
from the water injection system to remove the last traces of caustic.

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24. Extinguish furnace fires and stop the recycle gas and make-up hydrogen compressors.
Depressure to about 0.4 kg/cm2 g.

25. While maintaining a slight positive nitrogen pressure on the reactor section, disconnect the
regeneration piping and reconnect the normal process piping. Change instrument ranges and
settings as required for normal operation.

26. The catalyst is now ready for sulphiding and feed introduction. The startup procedure is
same as that for fresh catalyst except for the following:

• The initial purging operations may be deleted.

• No dry out step is required.

• Catalytic reformer hydrogen cannot be used for sulphiding regenerated catalyst.

(Catalytic reformer hydrogen can be used, after hydrogen sulfide breakthrough, for
lower activity hydrocracker catalysts.)

• The sulfur uptake will be somewhat less (approximately two-thirds of that for fresh
catalyst).

• Less by-product water will be formed during sulphiding.

• The catalyst may require a somewhat higher temperature to achieve the required degree
of feed conversion; however, the same feed introduction temperature should be used as
for fresh catalyst.

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12.4 Safety Precautions:

12.4.1 Oxygen Content of Oxidation Gas:

Oxygen content of the regeneration gas used during the oxidation phase must be carefully
controlled at all times, even if a smaller-than-expected temperature rise occurs. If the oxygen
concentration goes above 1.0% while significant quantities of coke remain on the catalyst, it is
possible to get a large enough temperature rise to damage the catalyst or the equipment,
especially during the high temperature third burn. If a temperature rise over 55°C is observed
across any reactor bed, or total reactor, cut back oxygen injection immediately to suppress the
liberation of heat.

Before raising the reactor inlet temperature, be sure that the oxygen content of the gas into the
reactor is at or below 0.5%. If it is higher than 0.5%, turn off the air supply and inject inert gas
into the system until the excess oxygen is bled off.

The oxygen concentration in the make-up gas compression system is limited normally to
6.0-7.0%. This limitation is necessary to keep the oxygen-hydrocarbon content in the
compression system below the explosive limit during the latter parts of the regeneration. Early
in the regeneration, hydrogen may be present in the recycle gas. The oxygen concentration at
the compressor suction must be limited to 4.0% until the hydrogen is removed, usually in the
first 24 hours.

12.4.2 Localized Coke Pockets:

After the burn wave has passed through the reactor, additional burning may still occur because
of localized coke pockets within the system. This type of burning will show no immediate
temperature rise unless it is located near a thermocouple. In time, such a temperature rise will be
detected by the thermocouples. Therefore, reactor bed temperatures should be carefully
observed, even after the temperature wave has apparently passed through the reactor. It may be
necessary to reduce the oxygen content of the gas to avoid excessive local temperatures in the
catalyst beds.

12.4.3 Hydrogen Content of Reduction Gas:

Hydrogen content of the reduction gas must be carefully controlled, even if a smaller-than-
expected temperature rise occurs. If the hydrogen concentration goes too high, excessive
temperatures may result, causing a loss of catalyst activity. If a temperature rise over 55°C is
observed across the reactor, cut back hydrogen injection immediately.

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12.4.4 Flare System:

During the oxidation phase, relief valves should be vented to the atmosphere to avoid explosive
mixtures in the hydrocarbon flare system and loading the flare system with inert gases
(nitrogen).

12.4.5 CO

Inert gas containing CO should not be used to purge the catalyst.

12.5 Emergency Procedure - Regeneration:

The purpose of this emergency procedure is to safe guard the equipments or catalyst damage by
caustic or sulfur oxides in the event of the loss of quench circulation or recycle gas flow.

12.5.1 Loss of Quench Recirculation:

Loss of quench solution circulation will have extremely serious consequences unless prompt
action is taken. The two main hazards are the accumulation of acids in the equipment
downstream of the quench solution injection point (if operation is continued) and the possibility
of quench solution backflow into the reactor (if gas circulation is halted too soon). The former
will damage vessels, heat exchangers, and piping. The latter can affect both the reactor and the
catalyst.

If quench solution circulation is lost, immediately extinguish furnace fires and stop the injection
of make-up oxygen or hydrogen to the reactor section. Continue gas circulation. Thoroughly
drain the quench solution to ensure no quench solution remains in the piping and heat
exchangers, which may latter flow back into the reactor. Then stop gas circulation. Block in the
recycle gas compressor and reduce system pressure at ~0.7 kg/cm²/min., via the high set point
pressure controller on the recycle compressor suction (207PIC-2601). Depressure to the
atmosphere if the recycle gas contains oxygen (oxidation phase) or depressure to the flare header
if the gas contains hydrogen (reduction phase). When the system has depressure sufficiently,
nitrogen may be introduced to maintain a continuous purge through the reactor section.

12.5.2 Loss of Recycle Gas Compressor:

If the recycle gas compressor stops, the make-up air or hydrogen must be stopped immediately;
ensure 207FV-6904 has tripped off. Immediate action must be taken to guard against backflow
of quench solution into the reactor. Stop the quench solution circulation. Then block in the
recycle gas compressor and reduce the reactor section pressure at ~0.7 kg/cm²/min., via
207PIC-2601. Depressure to the atmosphere if the recycle gas contains oxygen (oxidation
phase) or depressure to the flare header if the gas contains hydrogen (reduction phase). Drain
the quench solution system piping and reactor effluent air cooler as thoroughly as possible.

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When the system has depressure sufficiently, nitrogen may be introduced to maintain
a continuous purge through the reactor section.

12.5.3 Loss of Make-Up Process water when using a Recirculating Quench:

If process water is stopped, solids build up in the circulating quench solution and can no longer
be controlled. Regeneration may be continued on a short-term basis until a solids concentration
of 10 wt % is reached. At this point, make-up air or hydrogen injection must be stopped. Gas
and quench solution circulation is continued until process water is again available.

12.5.4 Loss of Make-Up Caustic:

If make-up caustic flow is stopped, make-up air or hydrogen injection should be cut off
immediately. Continue operating the recycle gas compressor. Also, continue quench solution
circulation until sulfur oxides are removed from the system. If the recirculating quench solution
pH becomes too low, continuing the above operation will result in a rapid buildup of acids in the
equipment. Should the pH drop below 7, cut the furnace fires and cool the reactor section, but
do not cool the catalyst below 205°C. Then stop quench solution circulation and drain the
quench solution from the system piping and reactor effluent air cooler. Then stop the recycle
gas circulation. Partially open 207PIC-2601 and introduce nitrogen at a low rate to maintain a
continuous purge through the reactor section.

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TABLE 12-1
SUMMARY OF GAS REQUIREMETS
Table 12.1 Gas Requirements For Regeneration
Reactor Gas Requirements (1)
Operation Status Nm3 Gas
Dryout and Pressure Test
Pressure at 0 kg/cm2 (g) Empty 1,470 (2) N2
Pressure to 6 kg/cm2 (g) Empty 5,270 (2) Plant Air
Pressure to 30 kg/cm2 (g) Empty 22,800 (2) N2
2
Pressure to 37.5 kg/cm (g) Empty 10,700 (3,4) N2
Pressure to 42 kg/cm2 (g) Empty 2,280 (3,4,5) N2 or H2
Pressure to 155.3 kg/cm2 (g) Empty 15,100 (3,4,5) H2
Reactor System Heatup With Fresh Catalyst
Pressure at 0 kg/cm2 (g) Full 1,200 (6) N2
Pressure to 6 kg/cm2 (g) Full 3,430 N2
Pressure to 30 kg/cm2 (g) Full 15,231 (4) N2
Pressure to 37.5 kg/cm2 (g) Full 3,810 (4) N2
Pressure to 42 kg/cm2 (g) Full 2,290 (4) N2
Shutdown
System Purge for CO/H2 Elimination Full 8,000 (7) N2

Notes:
1. Quantities shown do not assume any contingency. Volume based on estimated system
volume and should be checked by CPCL based on as-built drawings and layout.
2. Based on empty reaction section volume (includes low pressure separators).
3. Based on empty reaction section volume (does not include low pressure separators).
4. The gas requirement shown for this pressure test is the gas required in addition to the gas
already in the system from the previous test.
5. The requirement assumes simultaneous heating and pressuring of gas in the system. An
additional nitrogen purge will be required before opening reactors to lower H2 level to a safe
limit.
6. Based on loaded reaction section volume (does not include low pressure separators).
7. This quantity is required for each repeat of steps for CO purging in the Normal Shutdown
Procedures.

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CHAPTER – 13

SPECIAL PROCEDURES
13.1 CHEMICAL CLEAIG
Important pipes such as oil pipe line for lubrication, Suction line of compressor, etc., are
chemically cleaned by acid & soda solution for removing rust scales, grease, etc.,(formed during
casting & other process of pipe manufacturing) which other wise will scour packing rings,
piston rods, cylinder bore, damage the valves, damage the bearings, erode the impeller, etc.
The following sequence of operation is generally followed:
a) Flushing with potable water thoroughly to remove dirt, dust, loose rust & foreign matter
b) Degreasing
c) Inhibited acid circulation
d) Rinsing
e) Passivation

Chemical Cleaning for CS line (MUG suction line)

1) Ensure all safety precautions are adequate.

2) Ensure adequate quantity of potable water is available for cleaning operation, utilities such
has air, nitrogen, etc are available adequately

3) Ensure the testing apparatus & reagents are ready for test during process & proper
arrangement for sampling.

4) Positively isolate the system intended for chemical cleaning ( preferably with blinds).

5) Drop all instruments, filters, venturies, etc. in the loop.

6) Provide temporary loop connection for circulation purpose (as per the loop drawing).

7) Rig up a temporary tank & circulation pump with auxiliary facilities such as heating
arrangement, hoses, temperature gauges, etc.

8) Circulate potable water through the loop to remove all extraneous matter.

9) Check the loop for any leak & attend to it if any.

10) Degreasing is carried out by filling & circulation of sodium hydroxide ( caustic potash)
solution of concentration 50 gms / lit on 100% purity basis for 2 hours, maintaining
a temperature of 65 to 750C ( Checking parameter – Alkalinity).

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ote: for SS piping, non-ionic surfactant of concentration 0.2% at 500C for 2 hour is used for
VHP steam line Potassium hydroxide (causTIC- potash) of concentration 2% at 70 – 750C for
1 ½ hours is used.

11) Drain the solution & circulate potable water till Inlet & Outlet pH are same ( Checking
parameter – pH).

12) Pickling is carried out by filling & circulation of HCL solution of 5 –10% by weight on
100% basis with pH adjusted to 3.5 to 4.0 with ammonia for 6 hours, maintaining a temperature
of 50-600C. Add corrosion inhibitor at the rate of 1 litre/100 liters of water (Rodine 92 – 33%
strength).
Caution: Total iron content of the circulating solution should not exceed 5000 mg/lit)

ote: for SS piping, Nitric acid of concentration 10-15% by volume on 67% purity basis at
room temperature for 30 – 60 min (for 15-50mm size) with stopping time of 10 minute for VHP
steam line citric acid of concentration 3% (100% purity basis) at 800C for 6 hours is used).

13) Drain the solution & circulate potable water till Inlet & Outlet pH are same (Checking
parameter –pH.

ote: for SS piping drying can be followed after this without Passivation.

14) Neutralization is carried out by filling the system with 2% causTIC- soda & circulates for 1
hour at 40 – 500C. (
o neutralization for SS & VHP line).

15) Passivation is carried out by filling & circulation of passivation solution (SHMP – 2-3% by
Wt. On 67% purity basis, for 2 – 4 hours at 70 – 750C with pH 5.5 to 6.5.

ote: for VHP line Tri sodium phosphate – 1%, sodium nitrite – 0.5% by wt on 100% purity
basis for 2 hours at 70 – 750C is used.

16) Hold the solution for a duration of 12 hours.

17) Drain the passivating solution (no potable water circulation).

18) Dry the loop with clean dry air.

19) Protect the loop if it is not used immediately.

20) Record all the readings taken from Field & Lab in the prescribed file.

ote:
• Chemical cleaning depends on proper operation, monitoring & chemical controls during
operation
• Full bore flow should be ensured while circulating various chemicals

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• Vents should be provided in all high points to remove air & acid fumes
• Pickling of suction drum & equipment should be done separately if required
• Flushing should be done with high velocity in reverse direction
• Dead ends if any should be cleaned by filling or immersion method
• For CS lines Corrosion inhibitor should be added prior to the addition of acid. Also
carbon steel test coupon is used to find the effectiveness of scale removal.
• Neutralisation arrangement should be made for complete neutralisation of acid pickling
& alkali before disposing
• Circulation must be completed without interruption

Calculation:

MUGC suction:
Volume of the pipe - 5.51 m3
Citric acid - 175 kg (3%)
Corrosion Inhibitor - 12 liters (Rodine or 11 litres of coronil of 0.1 – 0.2%)
Liquid Ammonia - 20 liters or till pH is maintained
HCL - 700 liters
Potassium hydroxide - 275 kg (50 gpl)
SHMP - 175 kg (2- 3%)
Caustic- soda - 55 kg (2%)

VHP Steam line:

Volume of the pipe - 7.5 m3
Citric acid - 225 kg (3%)
Corrosion Inhibitor - 7.5 liters (Rodine 0.1% wt)
Liquid Ammonia - 50 liters or till pH is maintained
Tri sodium phosphate - 75 kg (1%)
Sodium Nitrate - 37.5 kg (0.5%)

13.2 ALKALI BOIL OUT

13.2.1 General:

Alkali Boil out is a pre-commissioning activity required in steam generation system for the
following reasons
• To eliminate deposits which may affect the heat transfer rate thus the operational efficiency
• To achieve the goal in the shortest possible time after commissioning
• Oil, Grease & other debris like welding slags etc., are removed easily by alkali boil out with
out disturbing the iron oxide protective layer.

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Chemicals generally used for alkali boil out operation are

1) Tri sodium phosphate (on 90% purity basis)
2) Sodium Carbonate (on 80% purity basis)
3) Caustic- soda (on 48% purity basis)

13.2.2 Procedure:

Chemical soaked water is circulated through the system, which will boil out the waterside. Wet
steam is generated using the flue gas in the furnace, during furnace drying operation & steam
vented out to atm, which will boil out the steam side.

13.2.3 Steps to be followed:

• Take all safety aspects into consideration like PPEs. etc.

• Ensure all instruments connected to the Steam generation system is in operating condition
• Blind at export steam to main header B/V
• Open steam drum vent in 207C-50
• Fill DM water steam drum (207C-50) up to 50% & activate the LC in auto mode (ensure
level through local gauge glass. Always level must be visible in gauge glass).
• Open & close all drains to remove sludge if any.
• Open the vessel manway, add required amount of chemicals inside the vessel & close the
vessel manway (chemicals are added per 1000 kg of the total system water)

ote: Commercial trisodium phosphate has a max P2O5 content of 20% so that per 1000 kg
water content 0.5 kg Na3PO4 have to be added to the water in order to obtain a P2O5 content
of 100 ppm
• Start the circulation pump (207G-38) & establish BFW circulation.
• Ensure all PSV's are lined up (in 207C-50, 207E-5, 207E-36, 207E-18).
• Light up the furnace as per the standard procedure.

Taken granted that process coil circulation is established,

• Raise the steam drum pressure to 5 ksc app. & maintain that pressure till boil out completes.

• Once steam plume appears in the steam vent, close it & back up the steam
a) 207F-2 up to B/L main B/V
b) 207E-5 vent & drain
c) 207E-18 vent & drain
d) 207E-36 vent & drain

• First blow down commences after 6 hrs ( ensure drum level before starting blow down)
at 4 kg/cm2 (blow down should be down blow down drum 207C-53 & exchanger
207E-40A/B.

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• Further blow down is carried after every 4 hrs app. Till boil out completes.

• Collect the blow down sample & check the oil content, Alkalinity content, SiO2 content.
(Oil content in the blow down is < 15 ppm, Alkalinity should not be allowed to fall below
5 mval/l).

• Boil out is said to be completed if the SiO2 content in the consecutive blow down sample
remains constant. (If the value is above the permitted value then repeat the boil out
procedure with fresh chemical).

• Cool down the furnace, add DM water & rinse the system until the sample exhales oil
content < 5 ppm.

ote: Continue Chemical cleaning process.

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13.3.1 General otes on Turbine

• Maximum O/P 4275 KW

• Steam pressure 48.5 ata (55.2 max) (instantaneously it can raise upto 66.2 ata for 12 hours
per annum)
• Condenser pressure – 0.14 ata
• Steam temperature – 4250C , deviation upto 4350C is allowed (maximum temperature of
4630C is allowed for 80 hours per annum)
• No load steam consumption is 0.3 TPH
• Vibration amplitude of 40 micron is good & the ratio of shaft to bearing vibration should be
in the ratio of 3:1
• Over speed cam lift – 7.54 mm

Table 13.2 RGC over Speed Cam Lift, Governor Lift

Oil pressure Governor Feed back Servo
in kg/cm2 Lift in mm lever in motor lift
mm in mm
1.5 0 0 0
2.23 7 1.847 21
3.26 11.4 4.4 34.2
4.18 17 6.74 51
4.5 20 7.54 60

• Surface condenser capacity – 20000 kg/hr

• CEP capacity – 22.5 TPH each
• ESV dia – 125, Pilot valve dia size - 16, filter mesh size – 1.6 mm.
• Operate turbine on full speed to avoid steam loss (at low speed, loss will be more)

Table 13.3: RGC Speed Vs Steam Consumption

Turbine output Steam Turbi Increase in steam

MW Flow ne consumption %
TPH speed
%
1 5 100 0
2 9 90 4
3 13 80 9
4 15 70 12

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Table 13.4: Correction aspects

Steam Steam I/L Temp. Steam Condenser Steam

0
Pressure ata flow % C flow pressure ata flow
% %
58.5 1.25 455 1.0 0.157 - 1.5
52.5 0.50 445 2.0 0.151 - 1.0
50.5 0.25 435 3.0 0.146 - 0.5
48.5 0.00 425 3.0 0.140 0.0
46.5 - 0.50 410 - 2.0 0.134 0.5
44.5 - 1.00 405 - 3.0 0.126 1.0
41.0 - 2.00 385 - 6.0 0.112 2.0

• Compressor Trips on:

a) 207C-7 very high level (207LSHH-2603/04/05) & Process trip if any.
b) Primary seal gas to vent pressure high (207PSHH-3762 / 3)
c) Compressor or Turbine vibration (207XSHH-3701)
d) Axial displacement (207ZSHH-3701)
e) JB temperature (207TSHH-3715)
f) TB temperature (207TSHH-3721)
g) Turbine Speed (207SSHH-3701 2/3 logic & 207SSHH-2726 of WWG)
h) Condenser pressure (207PSHH-2747)
i) Control oil pressure low ( 207PSLL-2726)
j) Trip oil pressure low (207PSLL-2730) (bypass switch is provided fur S/U KS-2704)
k) LO HDR pressure low (207PSLL-3723)
l) Manual governor trip switch (207HS-2702A/C) (Emergency trip PB)
m) Hot well level high (207LAHH-2742)
n) Compressor start PB (207HS-2702B)

• Compressor start permissive logic light glows 207 XL2716 when it meets the
following:
a) LO HDR pressure is normal (207PSL-3722)
b) LO over head tank level normal (207LAH-3704)
c) Compressor S/C & D/C opened (207ZSH-2701)
d) Compressor anti surge valve opened (207ZSH-2704 & 207ZSH-2702)
e) Barring gear disengaged
f) Pressing the machine reset button either in field or panel (207HS-2702B is in field)
g) Trip reset push button if any (207PB-2703A/B) (ESV opened)

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• MOP S/U condition

a) LOP D/C pressure low (207PSL-3710)
b) LO HDR pressure low (207PSL-3722)
c) N2 to Barrier & Secondary seal pressure normal (207PSL3754)
Note: Interlock I-2701 to energize or de-energize SOV 2741 for starting / stopping TD LOP.

• Primary oil pressure varies with the square of the speed.

• Stand by LOP auto cut in actuates for the following condition:

a) LOP D/C pressure low (207PSL 3710)
b) LO HDR pressure low (207PSL 3722)

• Emergency LOP auto cut in actuates in the for the following condition
a) LOP D/C pressure low (207PSL 3710)
b) LO HDR pressure low (207PSL 3722)

• CEP S/U condition

a) Pump D/C pressure low (207PSL 2764)
b) Hot well level high & trips on low level (207LT 2742/43)
c) Main CEP steam I/L valve open (207 ZSH 2740)

• Stand by CEP pump auto cut in actuates for the following condition
a) Pump D/C pressure low (207PSL 2764)
b) Hot well level high & trips on low level

• Barring gear S/U condition

a) Turbine is stand still (207 SSL 3702)
b) LO HDR pressure is normal (207PSL 3732)
c) Barring motor engage/disengage (207 HS 3704)

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RGC SET VALUES

Table 13.5:

Description Value Remarks

LO to barring Motor (207PAL-3732) 1.5 kg/cm2
MOP D/C pressure (207PAH-3711/12) 9.5 kg/cm2
LO D/C HDR pressure (207PAL-3710) 6.5 kg/cm2 Auto cut in set pressure
LO HDR pressure (207PAL-3722) 1.5 kg/cm2 Auto cut in set pressure
LO HDR pressure (207PAL-3723A/B/C) 1.0 kg/cm2 2/3 logic for compressor trip
CEP D/C pressure (207PAH-2762/63) 6.0 kg/cm2
CEP D/C pressure (207PAL-2764) 6.5 kg/cm2 Set pressure for auto cut in
Condenser pressure (207PAH-2746) -0.6 kg/cm2
Condenser pressure (207PAHH-2747) -0.4 k kg/cm2 Set pressure for turbine trip
Chamber pressure (207PAH-2742) 26.4 kg/cm2
VHP steam I/L pressure (207PAH-2740) 53.3 kg/cm2
VHP steam I/L pressure (207PAL-2740) 43.6 kg/cm2
Gl. steam HDR pressure (207PAH-2748) 0.1 kg/cm2
DP across LO filter (207PDAH-3716) 1.6 kg/cm2
DP across compressor (207PDAH-2704) 32.1 kg/cm2
Seal gas DP with reference gas 0.5 kg/cm2
Turbine Over speed 15374 rpm 2 / 3 logic for turbine trip
(207SAHH-3701A/B/C)
Axial Displacement of turbine TB side 0.7 mm
(ZAHH3702A/B)
Compressor Axial Displacement 0.7 mm
(207ZAHH-3701A/B)
Vibration of turbine FJB side 58 microns
(207XAHH-3703A/B)
Vibration of turbine RJB side 58 microns
(207XAHH-3704A/B)
Compressor vibration OTB side 100 micros
(207XAHH-3701A/B)
Compressor vibration TB side 100 micros
(207XAHH-3702A/B)
Compressor JB metal temperature 1000C
(207TAHH-3715 / 16 / 17) OTB side
Compressor JB metal temperature 1000C
(207TAHH-3718/19/20) TB side

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Description Value Remarks

0
Compressor TB metal temperature 120 C
(207TAHH 3721/22/23/24/25)
Temperature turbine TB 1000C
(207TAHH 3726/27/28/29/30)
Temperature turbine JB TB side 1280C
(207TAHH 3731/32/33)
Temperature turbine JB OTB side 1280C
(207TAHH 3734/35/36)
Temperature compressor JB TB side 1100C
(207TAHH 3731/32/33)
Temperature compressor JB OTB side 1100C
(207TAHH 3734/35/36)
Compressor D/C temperature 93.50C
(207TAH 2703/13)
LO temperature after cooler 49.50C
(207TAH 3705)
Compressor TB side drain oil 770C
temperature (207TAH 3711)
LO tank level (207LAL 3702) 1350 mm
LO over head tank level 2175 mm For start permissive
(207LAL 3704)

• Antisurge controller 207UV-2702 gets signal from compressor suction flow 207FT-2703B,
suction pressure 207PT-2721 & discharge pressure 207PT-2722.

• Barring motor (207G-93) capacity is 2 lpm at a head of 10 m.

• Turbine type – NK 25/28-3, compressor type BCL –306A

13.4 COOLIG WATER PASSIVATIO

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13.4.1 General

Passivation is a pretreatment process for cleaning & non-reactive (non-corrosive) film formation
on metal surfaces of cooling water system. The pretreatment involves two steps:
1) Thorough cleaning of metal surface, by low pH water circulation, and
2) Development of protective film on the metal surface, by circulating passivated chemical
water.
This applies to all metal surfaces, which are exposed to cooling water contact, but directed
primarily to carbon steel. This is done to make the effective film formation/maintenance by
corrosion inhibitors, which is online line treatment for cooling water system.

13.4.2 Procedure

Preparatory work in OHCU

1) Remove all instruments
2) Provide temporary loop connection for the C/W supply & return header for
a) Make up Gas compressor
b) LER section
c) RGC
d) Reverse the B/L 'U' loop blind to out position
e) 207E-22 & E-25 (it is SS tube exchanger)
3) Disconnect all pump C/W flanges & place a dummy plate on pump side
4) Keep open end flanges/cap in all vents & drains in the circuit
5) Provide dummy flanges in all Thermowell points.
6) Insert a coupon in suitable place.(generally in B/L)

13.4.3 Low pH water circulation

1) Start low pH water circulation by opening the unit B/L B/V.

2) Check the water sample for pH (6 – 6.2), Iron (5 ppm max) & Turbidity (30 NTU) content
in different locations & report the condition to the concern so as to maintain the prescribed
value. Maintain the condition for 8 hours with out any flushing.
3) Backs flush all the exchangers & for every 4 hours till the completion of passivation.
Sample coolers is also flushed the same way
4) Open Pump coolant B/V at B/L once the main header completes one cycle (this is to avoid
instability in maintaining pH & other chemical addition).
5) Flush each pump individually till water is clear visually for every 4 hours to avoid dead
end condition till passivation is complete.

6) For 207E 22 & E25 open I/L & O/L B/V separately & flush the line to avoid dead end for
every 4 hours, till passivation is complete.
7) Generally the recommended duration for low pH water circulation is 48 – 72 hours
8) Ensure clear water during every flush.

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ote:
Low pH water is maintained at 6 – 6.2 by acid addition (H2SO4) in cooling tower cell at slow
rate. Iron & Turbidity content is maintained by blow down / make up in cooling tower & by
increasing pH. (caustic- is used to increase the pH value inform to utility about flushing action
time to time.

13.4.4 Passivated chemical water circulation

• Following chemical levels are maintained in cooling water & the circulation is made for
5 days with out any loss of water

Table 13.6

Sl. no. CHEMICAL LEVEL

1 Organo-Phosphate as PO4 (HEDP 50 –60% active acid content) 80 – 100 mg/lit
2 Sodium Hexa Meta Phosphate as PO4 (SHMP) 40 – 50 mg/lit
3 pH 7.0 – 7.5
4 Surfactant 20 – 30 mg/lit

• Check the coupon for the effectiveness of passivation

• Start the regular cooling water treatment immediately
ote: In cooling tower the following sequences of actions are taken
• Turbidity is adjusted around 30 ppm & pH to 7.0 – 7.5
• Add 5% HEDP by gravity & bring up the phosphate level to 80 – 100 mg/lit (NaOH
can be added to maintain the pH range)
• Add clean solution of 5% SHMP & bring up the phosphate level to 40 – 50 mg/lit
• When the phosphate & pH level is stabilized, surfactant @30 ppm is added at slow
rate (surfactant produces foam, hence pump to be taken care of).

13.5 SULPHIDIG

13.5.1 Aim: To convert Metal Oxides in the catalyst to metal sulphides which in turn promotes
a smooth start up, better selectivity & lower catalyst fouling.

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13.5.2 Chemical used: DMDS (Dimethyl Disulphide)

13.5.3 Type: Liquid Phase Sulphiding (for better distribution over the catalyst).

13.5.4 Carrier oil: Diesel (injected at 207G-3A/B suction)

13.5.5 Reactions:
Two Exothermic reactions occur during sulphiding process, namely Decomposition &
Conversion.
Decomposition: DMDS undergo decomposition/cracking to form H2S & Methane at
the temperature range of 218 to 2320C. Reaction is chemically represented by
CH3-S-S-CH3 + 3H2 → 2CH4 + 2H2S
Conversion: Metal oxides are converted into metal suphides
2H2S + 3iO + H2 → i3S2 + 3H2O

13.5.6 Properties:
Unit Number: 2381, Auto Ignition Temperature: 3000C, Flash Point: 160C, UEL: 16, LEL: 1.1,
Boiling Point: 107 – 1100C (for more details refer chemical handled topic in this manual)

13.5.7 First Aid: On contact with --

Eyes: Flush with water
Skin: Flush with water
Swallow: Induce vomiting
Inhalation: Remove the victim to fresh air
(for more details browse chemical handled topic in this manual)

13.5.8 Preparatory work:

Ensure all PPEs available.
Ensure DMDS is available adequately.
Ensure dragger Tubes are available for sampling.
Ensure Log sheets are available.
Ensure chart/graph prevailing sulphiding rate addition Vs. carrier oil is made available.
Ensure DMDS system is complete in all aspects.
All instruments are calibrated & checked (particularly Recycle gas Flow meter,
Analyzer, RGC suction PT, CHPS LT).
Inform H2 plant about the sulphiding process & the requirement of the quality (more c3
content in H2 will induce cracking reaction & uncontrolled exothermic reaction).

13.5.9 Plant Condition before Sulphiding

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• Feed & Fractionation section under start up diesel circulation at 1700C (Viz:
124 m3/hr of internal circulation to CLPS via 207FC2804 by 207G 12B, 109m3/hr
of Hot long loop circulation at 1700C via 207FC1408 & 15m3/hr to slop via
207LC-4301 / FC-5202 with the help of 207G-12A).
• Reactor section is under N2 gas circulation at 2000C for catalyst dry out at
42 kg/cm2.
• Make up compressor is running with H2 at a set pressure of 48 kg/cm2.
• Water injection system is commissioned and running on recirculation.
• MUG to reactor section B/V is closed.

Table 13.7

Sl. no. STEPS TO BE FOLLOWED Date Initial

1 Check the quench control valves (207R-1 – TV1911 & TV1941,
207R-2 – TV 2003 & TV2021) & the response of the bed
temperature (207R-1 – TE-1911/21 & TE-1940/51).
2 Ensure all skin temperature are above MPT 380C
(207TXI-1902/07/10/15/18/24/2002/2007/2010/2016).
3 Increase the RGC Suction set pressure
(207PT2601/2702/PT6904) equal to MUG D/C pressure.
4 Increase the Reactor I/L temperature to 2000C
(207TE-19100 & TE-1809).
5 Increase the MUG D/C pressure to 50 ksc (207PT-6904)
6 Equalize MUG & reactor section by slowly opening the B/V & wide
after equalizing
7 Depressure RGC by 10 ksc app, increase RGC S/C set pressure &
achieve hydrogen partial pressure to the range of 14 to 28 ksc
(confirm by sampling & with analyzer
207AI-2702) (ensure MPT). Take 207PC-6904 on MUG in auto.

8 If temperature raise is envisaged suspend further addition of

hydrogen & normalize after temperature under control.

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Sl. no. STEPS TO BE FOLLOWED Date Initial

9 Reduce the Internal circulation to 100m3/hr (207FV-2804 & Long

loop circulation to 50m3/hr(FV-1408).
10 Reduce reactor I/L temperature to 1500C
(207TE19100 & TE1809).
11 Maintain long loop circulation temperature at 1500C (207TE-5204).
12 Start the feed Pump 207G-3A or B as per standard start up procedure.
13 Open the feed chopper valve (207FBV1802) in bypass.
14 Introduce feed to the reactor (207FT1801) slowly & to the required
level of 50 % with in a duration of 3-5 minutes by 207FV-1801 (Take
Chopper valve on line after feed rate is achieved).

15 Maintain the F1 temperature at the range of 150 – 1700C (207TE-

1809) (adjust E3 bypass if required to have the ∆T)
16 Adjust quench flow to maintain the bed temperature (150 –1700C).
(207R-1 – TV-1911 & TV-1941, 207R-2 – TV-2003 & TV-2021)
17 Stop long loop circulation (close 207FC 1408) after 30 minutes of
feed introduction
18 Control CHPS level through 207LV 2402A/B & CLPS level through
FV-2801 and put CHPS 207LC2402 & CLPS 207LC 2801 in auto
after level stabilizing
19 Stop internal circulation (207FV-2804)once CHPS & CLPS stabilizes
20 Stop S/U H2 make up to CLPS & take 207PC-2901 on CLPS on auto
at 37.5 ksc, 207PC2903 on C12 on auto at
30 ksc & 207PC3201 on C6 on auto at 7.3 ksc
21 Increase feed rate (207FT1801) to reactor if the condition is under
control to 60 to 100 % of design at an increment of
10 – 20%
22 Establish long loop circulation after ensuring that the bottom is free
from fines (207FV-1408)
Low Temperature Sulphiding Commences
23 Increase the rector Inlet temperature to 200 – 205 0C at an increment
of 100C/hr (207TE1910/71)
24 Maintain H2 partial pressure. These increases the hydrogen partial
pressure to the range of 14 - 28 ksc (ensure MPT). (i.e. by increasing
the RGC suction PC set point & by bleeding)

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Sl. no. STEPS TO BE FOLLOWED Date Initial

25 Reset the injection water chopper valve & Start water injection to
207E-9 at design rate of 6 m3/hr (207FT3304, FV-3304) & take
207LC 2404 on CHPS water side on auto (note down the LC
opening after stabilizing)
26 Ensure the hydrogen concentration in analyzer on RGC is 60%
(207AI- / T2702).
27 Start DMDS injection at the rate of 1.0 –2.0 wt% sulphur of carrier
oil (note down the consumption to estimate total sulphur
consumption. Take reading every hour)
28 Watch the temperature raise in the 207R-1 first bed as the DMDS
breaks through due to reaction (50C raise approx.)
29 Adjust forward quench rate (207FT1901) to maintain 207R-1
second bed I/L temperature at 2050C (207TE1911).
30 Watch the temperature raise in the 207R1 second bed as the DMDS
breaks through due to reaction (50C raise approx.)
31 Adjust forward quench rate (207FT1902) to maintain 207R-1 third
bed I/L temperature at 2050C (207TE1941).
ote: If there is no evidence of the DMDS decomposition, counter check the DMDS pump
& if sure of the flow stop DMDS, increase reactor inlet temperature by 50C & restart DMDS
injection after stabilizing
32 Watch the temperature raise in the R1 third bed as the DMDS breaks
through due to reaction (50C raise approx).
Note: Adjust 207E3 bypass to maintain207 F1 ∆T
33 Adjust forward quench rate (207FT2001) to maintain R2 I/L
temperature at 2050C (207TE2003).
34 Watch the temperature raise in the 207R2 first bed as the DMDS
breaks through due to reaction (5 0C raise approx).
35 Adjust forward quench rate (207FT2002) to maintain R2 second bed
I/L temperature at 2050C (207TE2021).
36 Watch the temperature raise in the 207R2 second bed as the DMDS
breaks through due to reaction (50C raise approx).
ote: DMDS rate to maintain a total of 10 wt % of H2S equivalent in the carrier oil as long as
the bed ∆T & overall ∆T can be maintained at less than 100C & all catalyst temperature can be
maintained at less than 260 0C.
37 Check the CHPS water LC opening, which indicates reaction is
taking place as the water is the byproduct of the reaction ( total
amount of water is 10.0 wt% max).

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Sl. no. STEPS TO BE FOLLOWED Date Initial

ote: Another check is to isolate the LC before DMDS injection & do the same after DMDS
injection & compare the raising rate. Prominent odour of DMDS in the sour water is one of the
indications for non reaction of DMDS. Maintain the hydrogen partial pressure by bleed off to
flare & the bed temperature as the wave proceeds from one bed to another bed in both reactor.
38 Maintain the total H2S level of 1-2 vol% by sampling every ½ hour
& adjust the DMDS rate. Maintain this condition till the DMDS rate
is injected to 50% of the theoretical rate
ote: This is to check for channeling of bed. i.e break through happens at 30 – 50% of the
theoretical DMDS rate & if it happens before that means channeling is evident. If so then make
sure RG is maximum & check for radial temperature for maldistribution
39 Discontinue DMDS, if RGC sample reveals H2S rate is constantly
maintaining (allowable loss of H2S equals to leakage quantity)
Restart if H2S level drops more than leakage rate.
HIGH TEMPERATURE SULPHIDIG COMMECES
40 Increase the reactor temperature to 300 – 315 0C ( at 14 0C/hr)
41 Achieve H2 partial pressure to the upper limit of 28 ksc by
increasing the RGC S/C set point (207PT2702)& through bleeding
(207PT2601)
42 Start DMDS injection again to maintain the total H2S level of 1.0 -
2.0 vol. % at this elevated temperature.
43 Concurrently increase Catalyst bed inlet temperature by adjusting
quench & maintain at a level of 300-3150C
44 Reduce reactor inlet & bed temperature if H2S level reduces to 1.0
vol. % because of appreciable reaction ( ∆T raise of 100C across any
bed or overall is an indication of severe reaction)
45 Maintain the condition till 100% of the theoretical requirement of
DMDS is injected.
HOT SOAKIG COMMECES
46 Once 100% of the theoretical DMDS is added, catalyst should be
hot soaked for 4 hours at 300 – 3300C. (DMDS can be injected to
maintain total H2S content of 1.0-2.0 % vol, if required)
47 Sulphiding is said to be completed if the reactor out let temperature
is maintaining at 300 – 3300C for 4 hours, after Sulphiding
exotherms have passed through the bed (with little or no ∆T) & all
quench valve are closed
ote: Temperature at any time should not increase to more than 3300C ( this stage will occur
after 60-100% of the theoretical sulphur has been aborbed)
48 Reactor pressure & temperature can be increased to, start of run
condition ( 172.5 ksc at the rate of 15 ksc/hr & 2000C )

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DMDS Volume calculation:

Table 13.8

Reactor Catalyst Theoretical Requirement

kg sulphur / 100 kg catalyst
R1 ICR 122ZSB 00.7
ICR 134LAQ 11.8
ICR 126 09.5
ICR 126L 09.5
ICR 114ZF 09.6
R2 ICR 126 09.5
ICR 126N 09.6
ICR 114ZF 09.6

13.6 STEAM HEADER WARMIG UP PROCEDURE

1 Check for Mechanical completion.

2 Ensure Unit B/L B/V is closed & Blind is in Out position.
3 Ensure all vents & drip legs drains are open.
4 Ensure all traps are bypassed/dropped.
5 Open the Dead end flange in main & sub-headers.
6 Ensure all Instrument tappings in the header is isolated & Orifice plate removed.
7 Inform Power plant regarding steam consumption. Crack Open the Unit B/L B/V.
8 Close the vent B/Vs one by one when the steam started venting on the flow stream
direction.
9 Keep minimum opening in the drip leg drains & allow to drain the condensate.
10 Open the unit B/L B/V little more is insufficiency is felt.
11 Pertain the condition for 12 hours which is the warming period.
12 Check the pipe rack for any expansion & dislocation of the header & prepare the check
list and attend to it.
13 Close the unit B/L B/V fully.
14 Open all the vents & Drains ( to avoid pulling of vacuum).
15 Allow the header to cool down for 12 hours.
(This will make the header to contract which in turn will remove the scales in the header).

13.6.1 Flushing
16 Inform Power plant regarding steam consumption.
17 Crack Open the Unit B/L B/V.
18 Line up the pressure tapping at unit B/L.

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19 Close the vent B/V's one by one when the steam started venting on the flow stream
Direction.
20 Keep minimum opening in the drip leg drains & allow to drain the condensate.
21 Blow the header for 2 hours with the steam at pressure of 5 KSC.
22 Repeat the steps from 6 to 22 if the header needs further removal of rust.
23 Close the unit B/L B/V after completing the flushing operation.
24 Open all vents & drains to avoid pulling of vacuum.
25 Box up the end flanges with new spiral gasket in main & sub headers.
26 Open drip leg flanges, clean the mug collected if any & box up with new spiral gasket.
27 Inform Power plant regarding steam consumption.
28 Crack Open the Unit B/L B/V.
29 Close the vent B/V s one by one when the steam started venting on the flow stream.
direction once dry steam is visible through it.
30 Line up the steam trap once dry steam is visible through drip leg drains, close the bypass &
check the functioning of the trap (for immediate check pour some cold water on the trap).
31 Increase the unit B/L B/V to wide slowly with the coordination of Power Plant
32 Final check the whole system for any leaks, trap functioning, header pressure,
temperature, etc.

13.7 FURACE DRYOUT

1. Follow all safety aspects, like PPE's etc.

2. Burners – Pilot, Fuel Gas, to be ready for lighting in all aspects.
3. DCS system should be ready for the heater and associated interlocks and controllers
should be checked in all aspects.
4. The following utilities system should be commissioned:
Fuel Gas System. Confirm FG takes off to 207F1 and 207F2 from pipe rack is blinded.
All main fuel gas and pilot gas cock valves to keep closed.
Flare Gas System
Instrument Air System
LP Steam System
MP steam System
Record for entering the progress of dry out procedure.
5. All Heater Control valves & solenoid valves to be checked. Ensure all thermocouples,
pressure & flow indications are working. Bypass all Interlocks related to furnace.
6. Ensure stack damper is opened else open it.
7. Thoroughly purge firebox with steam/air for 30 minutes & ensure draft is developed.
8. Carry out a gas free test to confirm that the firebox is free of gas (in case of burner failure).
9. Deblind the fuel gas lines and light the pilot burners (if there is any delay in lighting the
burners, blind the fuel gas lines).
10. Remove moisture from inside the refractory with only pilots on for 2 days.
11. Light main burners and raise arch temperature to 120 oC @ 25 C/hr. hold the temp.

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for 12 hrs. (CPCL practice 24 hrs.)

12. Raise arch temperature to 200 oC @ 25 C/hr.
(Rotate the burners for uniformity of heat distribution).
13. Introduce steam when arch temp is 200 oC (1.8T/hr/pass).
(Introduction of steam at lower temp will result in condensation & hammering).
14. Hold the temp. at 200 oC for 24 hrs.
15. Check all burners, observe conditions inside the firebox & inspect areas of expansion
Tube metal temp. Should not exceed 500 oC.
16. Raise arch temperature to 400 oC @ 25 oC/hr. Hold the temp. for 24 hrs.
17. Check all burners, observe conditions inside the firebox & inspect areas of expansion.
Maintain uniformity of heat distribution. Tube metal temp. should not exceed 500oC.
Increase supply of steam to the coils to maintain tube skin temperature.
Check damper movements.
18. When FG ring pressure reaches 1.8kg/cm2 take FG PIC on AUTO.
19. If FG pressure is above min set pressure take FG low pressure interlock on line.
20. Check the operation of stack dampers.
21. Raise arch temperature to 500 oC @ 25 oC/hr. Hold the temp. for 24 hrs.
22. Check the functioning of instruments, controllers & alarms.
23. Reduce the arch temperature @50 oC/hr.
24. Cut off steam to coils when arch temp reaches 200 oC.
25. When the arch temp reaches 150 oC cut off firing and blind fuel gas line.
26. Continue to cool the fire box.
27. At 50 oC firebox entry is possible (based on gas free test).
28. Enter the firebox and inspect the refractory for any cracks or defects.

13.8 RETRACTIG SOOT BLOWER MAUALLY

Long Retractable soot blower (LRS) is used to remove deposits from the surface of the furnace
tubes by directing jets of steam through a nozzle located in the retractable lance, operated
automatically for the rotation along with to & fro motion simultaneously for the lance. At the
time of any failure of power or control supply during operation of soot blower, the blower
should be immediately brought to its starting position to avoid any possible damage to.

1) Heating surface
2) Soot blower lance

For this purpose the following procedure is followed:

a) Switch off power & control supply if it is on
b) Close the main & individual soot blower steam isolation B/V
c) Declutch the coupling by pulling it outward
d) Insert the hand crank & rotate until the blower reaches home position
e) Remove hand crank & engage the coupling by pushing it inward

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ote:
• No soot blower should be operated for second time within one hour interval to avoid
damage to motor winding
• No soot blower should be operated without steam when furnace is on
• No lance should be left inside the furnace without any steam or subjected to temperature
more than 550 0C
• Standard traverse speed is 2.45 m/min & rotation speed is 10.4 rpm
• No soot blower should be operated with wet steam

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13.9 FURACE OPERATIO CHECK LIST

START

CHECK DRAFT

HIGH LOW

CHECK O2 CHECK O2
O TARGET

HIGH LOW HIGH LOW

CLOSE OPE CLOSE OPE

STACK BURER STACK BURER
DAMPER REGISTER DAMPER REGISTER

RETUR TO START RETUR TO START

CHECK O2

HIGH LOW
O TARGET

CLOSE BURER OPE BURER

REGISTERS REGISTER

RETUR TO START GOOD OPERATIO

RETUR TO START

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CHAPTER-14

SPECIAL EQUIPMET AD THE OPERATIO

14.1 STATIC MIXER
The main function of the mixer is to provide precise blending & dispersion of all flowable
material, with minimum pressure drop by redirecting the flow pattern present in the pipe. This
has absolutely no moving parts in its construction.

In the static mixer, there is a helical mixing element which directs the flow materials radically
towards the pipe wall & redirects back to the center. Additional velocity reversal & flow division
result from combining alternating right & left hand elements, increasing mixing efficiency. By
this way all material is continuously & completely mixed eliminating radial gradients in
temperature, velocity & material composition.
Material of construction of our Static mixer is Monel – 400 for M-4 & 316L SS for M-5
(200BHN).
Rated efficiency of both the mixer is 99%.
Rated pressure drop across M4 – 2.5 ksc
Rated pressure drop across M5 – 1.0 ksc

14.2 STEAM TRAP

Steam widely used in process units is moved through steam lines. Steam loses some heat even
after best insulating the lines. Droplets of water (condensate) so formed develops water hammer
(blow of slugs of water in the pipe line with loud bang while moving with steam whose pressure
will be in the range of √ of density leading to pipe blow off at severe cases) & finally blocks the
steam flow.

Steam trap acts as an automatic condensate removing device.

14.2.1 Function of the steam trap

a) Discharges condensate without removing live steam

b) Eliminates air/co2 from the system
c) Automatically removes condensate as quickly as it collects

Note: Non condensable reduce the efficiency in the way as it acts as insulating layer & mix with
the steam to reduce the temperature & finally it is more susceptible to corrosion.

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14.2.2 Method of operation:

All steam traps have the mechanism that senses the presence of steam & stops steam
flow, while allowing condensate & air to pass through. This mechanism may operate in one of
the three basic ways

1) Mechanical Type: This works on the response to the difference in density between the
steam & condensate

2) Thermo Dynamic Type: This works on the response to the heat energy available with
steam.

3) Thermostatic Type: This works on the response to the temperature difference between
steam & condensate.

1. Mechanical Type:

Float traps are one of the mechanical traps that are widely used in our refinery. A typical float
trap consists of the following parts: 1. float, 2. connecting rod, 3. trap valve, 4. trap casing,
5. inlet and 6. outlet. In the float trap, condensate enters the trap through inlet & the level rises
inside the trap. As the level rises it lifts the float to rise higher, thereby opening the outlet valve
& permitting the condensate to flow out. Float responds directly to the amount of condensate
flowing.
Disadvantage of this type is it is inefficient in removing air. This is overcome by incorporating
thermostatic type along with it & another type called inverted bucket is also used which works
on the same principle like Mechanical trap.

2. Thermo Dynamic Trap:

Tilting disc-type impulse trap is one of the Thermodynamic type trap that is widely used in our
refinery. A typical tilting disc consist basically a disc contained in a casing & connected to an
inlet & outlet. When the trap is in operation, pressure in the inlet raises the disc off of the seating
surfaces that contact the inlet & outlet. This allows condensate to flow out through the discharge
port. The flow of condensate at the underside of the disc tends to reduce the pressure under the
disc. When hot condensate reaches the low pressure area on the underside of the disc, some of
the condensate flashes to steam. At the same time, flashing condensate flows outward into the
side wall of the casing. This cause a pressure builds up in the area above the disc that shuts the
disc. The disc stays closed until the pressure above the disc is reduced from the steam
condensing. When the pressure above the disc becomes low enough, the disc rises, condensate
flows out & the cycle repeats.

Piston type impulse thermodynamic trap is also one type of trap which works on the same
principle like thermodynamic trap.

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3. Thermostatic Type:

Bellow Type trap is one of the Thermostatic type trap that is widely used in our refinery. A
typical bellow type trap consist of the following parts 1) casing 2) trap inlet 3) trap outlet 4)
bellow 5) trap valve 6) valve seat. The bellow is filled with a mixture of alcohol & water that
boils at a lower temperature than plain water. When the steam approaches the inlet, the mixture,
which is inside the bellow boils, the bellow expands & the trap valve is closed. If the condensate
enters the trap inlet, the bellow will compress & the valve is opened allowing the condensate to
flow out. The cycle repeats.

Distinct advantage of bellow trap is they will not freeze & hence can be used in out door use &
secondly it get rids of air so easily. Disadvantage of this type is limitation of pressure & bellows
are sensitive to water hammer.

Shrouded Bellow type, Bimetallic type, Liquid expansion type are a few developed traps
working on the principle like thermostatic trap.

14.3 RGC
The main purpose of the RGC isto compress the unreacted H2 rich gas and recycle back through
the high pressure reactor loop, to aid for hydrocracking & hydrotreating reactions in reactor.

This is a Turbine driven compressor, for uninterrupted functioning & for immediate response to
the process changes. All technical information regarding the turbine is given in the RGC start up
procedure in this manual. Operation of the various important devices are discussed here.

14.3.1 RGC – DESCRIPTIO OF VARIOUS PARTS

14.3.1.1 Turbine:

It is a mechanical device (aerodynamically shaped), which converts the momentum in the steam
into rotary motion with the help of turbine blades (X 22 CrMoV121- 0.21%C, 12.0% Cr, 0.8%
Mo, 0.3% V, 0.40% Ni, < 3% Si). This is impulse type turbine with pressure – velocity
compounding. The main parts of the turbine are Rotor, Casing, Bearings, Seals, ESV, Control

Oil skid, Actuator, Wood Ward governor. Each part is explained within the scope of this manual.
Blades are mounted on the rotor.

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14.3.1.2 Bearings:

Bearings are used to reduce the friction between the rotor & rotor support. It also takes the shock
loads / forces. Two types of bearings are used in our turbine namely Thrust bearing & Journal
bearing.

Thrust Bearing: It takes up the residual axial thrust forces of the turbine & also serves the
purpose of fixing the rotor in its axial position with respect to the turbine housing.

Journal bearing: It is of tilting pad type due to required stability characteristics & the loading of
the turbine. It supports the center portion of the turbine rotor

14.3.1.3 Labyrinth Gland:

It is one of the seal which forms without mechanical contact between the moving rotor &
stationary turbine casing.. This acts on the principle of transforming potential energy into kinetic
energy & subsequently dissipating the kinetic energy by formation of eddies.

14.3.1.4 Seal Rings:

The seal rings seals the bearing housing from the turbine casing where the turbine rotor
penetrates the casing. Seal Ring is a spilt axial type fixed in the grooves of the bearing there by
fixed in axial position. Together with the turbine rotor sealing lip, which is matched to the seal
ring, the seal ring prevents any leakage.

Sealing gas is passed (at approx 1 bar) between the sealing ring to prevent the oil from any
aggressive atmosphere

14.3.1.5 Electronic Governor

The electro- hydraulic speed control circuit comprises of speed transmitter controller, electro-
hydraulic convertor, control valve actuator and control valves. The speed controller in the
woodward electronic governor feeds a signal based on the actual speed/ load to electro
hydraulic-convertor. The electro hydraulic convertor converts the electrical signal in to
proportional hydraulic signal called as secondary oil pressure.

14.3.1.6 Elctro hydraulic convertor

The elecro hydraulic convertor is connecting link between electronic and hydraulic parts of
electro hydraulic governing system. The output signal of electronic governor is fed to the torque
motor of electro hydraulic convertor (I/H). The torque motor positions the control slide, which in
turn builds up the secondary oil pressure proportional to the signal. This secondary oil pressure
is transmitte to the control valve actuator.

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14.3.1.7 Control Valve Actuator servo motor

The actuator transmits the secondary oil positioning pulses for the control valves to the valve
operating levers. The lever system raises or lowers the control valve so that the steam flow
always corresponds to the preset or required turbine output.
Actuator pilot valve receives the control pulses from the secondary oil circuit, which is
transmitted to the control valve positioner, which alters the power oil to actuate the control lever.

Mode of operation:
Any change in the secondary oil pressure brings about a corresponding displacement of the pilot
piston. With increasing secondary oil pressure, the pilot piston is moved upward thus enabling
pressure oil to flow into the space above the actuator piston which in turn moves the lever down
there by allowing the steam to flow through turbine. If the secondary oil pressure drops, the
movement is reversed. Feed back system is provided to bring back the pilot piston to its neutral
position (i.e. set position).

14.3.1.8 Damping device:

Damping device damps out the quick oscillations in secondary oil pressure generated by electro
hydraulic convertor. This helps in improving this stability of the governing system.

14.3.1.9 Emergency Stop Valve ESV:

ESV is a device which shuts off the steam to turbine in minimum time duration if any
disturbances occur in any means, which will damage the equipment.

ESV is operated hydraulically. The valve opening is initiated by starting device. Operating the
pilot piston in the starting device in appropriate direction, the pressure oil from trip oil circuit
will flow behind the ESV piston. By overcoming the spring tension the piston in the starting
device is pressed against the piston disc. On further operating the piston in the starting device the
pressure oil from the trip oil circuit will be admitted in the front portion of the piston in ESV. On
further operating the starting device the oil pressure in front will increase & oil pressure behind
the piston in PSV will decrease as this port will now be connected to drain in the starting device.
This will open the ESV.

At any time if there is any disturbance to the pressure in the trip oil, then the spring pressure will
be more & will push the piston in ESV to close position. The starting device is again reset for
fresh start up. If unfortunately it has not been reset, then the pressure oil form trip oil circuit will
drain through the ESV with out any action on ESV valve movement.

ESV testing device is provided which enables to check the proper functioning of the ESV during
normal operation. By opening the ESV testing lever, pressure oil will be admitted to the space
behind the test piston, which will then be pushed into its ultimate closing position. Noting point

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is that, pressure required to push the piston to closing position is to be noted. If the
pressure required is more than the standard, then it calls for attention.

14.3.1.10 Tester for Emergency Stop Valve

Testing device is provided to check the proper functiong of emergency stop valve during normal
operation of turbine if the testing device is operated, it will admit the pressure oil to the space
behind the test piston of emergency stop valve, which will then be pushed against the piston and
move the piston and valve spindle towards the closed postion (Partial closing).

14.3.1.11 Over Speed Testing Device

Over speed testing device is used to test the shafts over speed tripping device function without
actually tripping the system & increasing the speed of the machine. The cross section of the
device is shown below:

Mode of operation:
The hand lever is pressed down slowly to the stop from control position e via d, c to position b
and held in this position. The middle groove of the pilot valve is now lined up with the oil
pocket adjacent to connection e2 i.e. pressure oil now flows directly via the starting device to the
emergency stop valve, bypassing the main trip valve and thus the emergency stop valve remains
open.

If the pilot valve is moved further downwards by slow clockwise direction of the hand wheel –
to control position a (refer figure) pressure oil will enter the oil pocket adjacent to connection H.
four semicircular notches in the lower face of groove allow the oil pressure in the line to the over
speed trip to be metered accurately. While watching the pressure gauge the pressure is increased
until at the prescribed pressure the pin of the over speed trip suddenly flies out – indicated by the
operation of the main trip valve. After the test the hand wheel is turned back to its original
position. First the oil flow to the over speed trip is interrupted an it resumes its normal position.
When the hand lever is also released, but not before 10 seconds have elapsed, the pilot valve is
moved upwards by the pressure oil. Connection E1 and E2 are joined together again. Shortly
before this – control position c and d switching oil flows via connection M to the underside to
the underside of the auxiliary piston of the main trip valve causing it to latch in hydraulically.

As mentioned before the pilot valve moves upwards automatically as soon as the hand lever is
released. A cushion of oil between the cover and valve prevents it rising too rapidly. The reset
time is adjusted with the aid of the throttle screw, which determines the oil flow. The reset time
(recommended value 10 to 20 seconds) should be so adjusted that the emergency trip is not
operated when the pilot valve moves up automatically.

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14.3.1.12 Tripping device

Whenever the turbine is to be tripped, the governing oil pressure trip oil line after tripping device
drained by tripping device. Thus pressure in front of stop valve piston disc and secondary oil
pressure falls, resulting in closure of stop valve and control valves. The tripping device is
operated on the occurance of any one of the following:
- Manual operation
- Actuation of over speed governor
- Rotor axial movement

14.3.1.13 Over speed Governor

Over speed Governor protects the turbine against speeds higher than safe value for turbine
operation. Over speed governor consists of and eccentric pin located inside the turbing shaft and
held in position with a spring. At a reset (speed trip) cetrifuagal force of eccentric pin overcomes
the sprin force and the pin moves out of shaft. The out ward movement of the pin actuates a
lever of tripping device and thereby tripping the turbine.

14.3.1.14 Axial shift protection

When ever the turbine rotor movement in axial direction is excessive, then a protection on the
rotor comes underneath the lever of tripping device and actuates the lever and thereby tripping
the turbine.

14.3.1.15 Trip solenoid valve

Trip solenoid valve facilitate the tripping of turbine from the remote place such us control room
thro push botton whenever the solenoid valve is de-energised, interrupts oil supply to trip oil
circuit and simultaneously depressurizes the trip oil circuit. Solenoid valve is also de-energised
by any one of the signals initiated by limit value monitoring devices.

14.3.1.16 Emergency Trip Gear

The purpose of the emergency trip gear is to cut of the trip oil circuit on an emergency.

Mode of operation:
Pressure oil serving as trip oil is admitted to the emergency trip gear from over speed testing
device. This pushes the piston against the spring force, which simultaneously closes the drain
port & sends back the trip oil to over speed testing device. At the same time it latches the trip
lever. On any case if the trip oil is interrupted the spring forces piston to open the drain port
which in turn cuts the trip oil flow to starting device & I/H converter. Trip oil flow can also be
disturbed, by actuating the lever wither manually or by axial movement of the shaft or by over
speed pin.

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14.3.1.17 Seal gas system

RGC seal assembly consists of three seals namely 1) Primary seal 2) Secondary seal &
3) Barrier seal

Primary Seal:
One on the compressor impeller side or the inboard seal is called the primary seal. Primary seal
unit seals against full operating pressure through exposure of the seal by clean gas (tapped from
RGC D/C & filtered) at slightly higher pressure than the system. The residual leakage of the
primary seal is collected in the port in front of the interstage labyrinth, which in turn connected
to the flare.

Secondary Seal:
One on the bearing side or the out board seal is called the secondary seal. Secondary seal unit is
fully unloaded and its function starts only when the primary seal breaks out. In normal operation,
N2 is injected to secondary seal maintaining a positive DP over the flare pressure. Part of this N2
passes through the interstage labyrinth which in turn connects to flare.

Barrier Seal:
Barrier seal is provided between secondary seal & compressor bearings, to prevent entry of lube
oil into seal zone.

Sealing System Description:

Gas from the discharge is tapped & passed through a duplex filter to provide clean gas at the
inlet of primary mechanical gas seal. The filtered clean gas is injected in front of the primary gas
seal with a DP achieved by 207PDCV-3761 controlled by 207PDIC-3761 in DCS.

Differential pressure gauges 207PDI-3757 & differential pressure switch high 207PDSH-3758 is
provided across filter to indicate DP & 207PDAH-758 in DCS annunciates in case of filter
chokage.Gas leaking through the flare is through a orifice & pressure switch 207PSH-767 is
provided. In case it senses high pressure it indicates to DCS through Alarm.
207PSHH-3763A/B/C sends signal to machine interlock that trips on 2 out of 3 voting logic on
sensing high pressure.

N2 for secondary & Barrier seal is taken from N2 plant. For secondary seal, 207PCV 3751
reduces the pressure & the DP is achieved by the needle valve provided in the line (207PDI3768
indicates). 207FI 3751 annunciates in case of high flow required to maintain the requisite DP
Pressure for barrier seal is regulated by means of needle valve provided in the line.

During Start up separate N2 hook up to be given till the compressor reaches a speed of
1000 – 1500 rpm & can provide sufficient DP of 0.5 ksc across the dry seal. Also a N2 line

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provided to the upstream of the filter to facilitate purging of the compressor to expel air
during start-up.

During RGC start-up,

1) Fill the loop with N2 through the clean gas filter, to obtain start up suction pressure in the
loop (suction and discharge valves are closed). At this point DP is ‘0’.
2) Open the N2 to the seal to maintain a minimum DP (bottle nitrogen is used).
3) Start the RGC as per standard procedure.
4) Close the N2 line up the clean gas from the RGC discharge.

For RGC start-up procedure, please refer chapter-13 (Special procedures).

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14.4 FEED FILTER 207T-1

Feed filter 207T-1 is used to filter the oil feed and remove solids and particulates which would
otherwise laydown on the first Rx. top bed catalyst, leading to premature plugging of the top bed.
The filter consists of 4 banks, each bank having 10 stations. Each station consists of 12 filter
elements of mesh size 20µm. The filter is capable of removing solids particles of size 20µm and
above. The design solid loading to the filter is 20-40 ppm under normal operation (200 ppm under
upset situation).

A differential pressure indicator 207PDI-1505 is used to measure the degree of plugging of the
feed filters. When a differential pressure of 1.4 Kg/cm2 is reached, filter backflushing is actuated.

Design backwash flow is 30 m3/hr. Each bank is backflushed in sequence with a slipstream of
filtered feed taken from the outlet of the feed filter until all banks have been backflushed and the
pressure drop has returned to normal.

Maximum allowable ∆P across filter is 2.7 Kg/cm2 (normal flow direction)

14.4.1 BACKWASH OIL COSUMPTIO:

Table 14.1

Flowrate 30 m3/hr
Time 30 sec./ one station backwash
5.5 min./ one bank (10 stations)
22 min./ total (4 banks)
Backwash oil volume 00.25 m3/station
02.50 m3/ bank
10.00 m3/ total

14.4.2 FILTER OPERATION:

1. Mode selection at control panel:
Select one of the following modes:
- Auto back wash mode (by preset timer or preset ∆P)
- Manual mode ( 1 particular bank can be selected from any of the four banks)
- Off ('maintenance mode')

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2. Set up the timers:

Table 14.2.

TIMER ADJUSTABLE DESIG SET TIME

AME RAGE
Back wash auto start delay 1-12 hour(s) 6 hours
T0
T1 Delay (backwash start0.5-10 seconds 1 second
signal)
T2 Backwash timer 10-180 seconds 30 seconds

3. Backwash steps (as per instrument control):

3.1 Getting input signal:
Backwash sequence will start (on getting the input signal) under the following conditions:
a. Signal from 'adjustable electronic timer', when time is up.
b. Signal from PDAH of PDI-1505 (∆P across the filter), 1.4 Kg/cm2
c. Signal upon manual order (at manual mode in control panel).

3.2 Backwashing each station:

a. Close inlet line
b. Open drain line
(Solenoid operated)

3.3 T2 time up (refer timer set up table above)

3.4 Backwash finish

a. Close drain line
b. Open inlet line
(Solenoid operated)

3.5 Next station backwash starts (return to the step 3.2 above).

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14.5 REACTOR FEED PUMP:

14.5.1 Reactor Feed Pump-207G-3 A/B - Operating Procedure:

14.5.1.1 Priming:
In preparation for starting the pump it is important that the pump be completely filled with
liquid. Under no circumstance must the pump be run dry as certain parts within the pump depend
on the liquid pumped for their lubrication. Without this lubrication wear rings which have close
running clearances will tend to seize causing serious damage and expense.

 Verify that discharge valve and drain valves are closed.

 Open suction valve slowly, so the pump gets filled with liquid, with a rate which
should not exceed 25 m3/hr.
 Open discharge valve and allow to fill gradually with liquid.
 Open pump vent valves.
 When a full stream flows from the vent, close the valve.
 Close discharge valves.
 After 5-10 minutes open vent valves.
 When a full stream flows from the vent, the pump is primed, close the vent valve and pump
is ready for operating.
The pressure and the temperature in the seal chamber or the barrier fluid must not exceed 21.0
kg/cm2 G and 205 0C respectively

I. Recirculation control valve:

Check the stem travel on the recirculation control valve (207FV-1704 and 207FV-1710) to make
sure that it will properly pass the minimum flow (130 m3/hr) at start-up. Make sure all valves in
the recirculation line are open. A closed valve in this line can cause rapid overheating if the
pump is operated with main discharge valve closed.

14.5.1.2 Start the pump:

Start the pump with recirculation control valve open, allow flow through the recirculation line
until the pressure is steady. After pump capacity has been built up beyond the recirculation
control capacity, the control should be checked to insure that it is operating properly.

14.5.1.3 Pump running:

As soon as pump is running make the following routine checks:

 Check suction and discharge pressures indicating normal operation of the pump.
 Compare differential pressure with pump curve to locate operating condition
 Check if seal system is operating properly.
 Check seal leakage.
 Check for excessive vibration of pump and motor.
 Check the motor current reading, which indicates load on the motor.

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14.5.1.4 Continuous operation:

Make the following checks at frequent intervals during the first 2 hours or operation.

 Check suction pressure gauge. Any unusual drop in pressure would indicate that the suction
strainer is getting clogged and should be cleaned.
 Check discharge pressure.
 Check seal leakage to atmosphere to see if seals are operating properly.
 Check bearing temperatures. Within the 2 hours time frame the temperature rise per minute
must become zero, so bearing temperature at constant level.
 Check for excessive bearing vibration of pump and motor.
 Check the motor current reading.

14.5.1.5 Stopping:

Before stopping the pump establish a minimum flow required, through the recirculation line and
then close the discharge valve. This will prevent water hammer on the check valve. Then stop
the pump. If stopped pump is to be kept as hot standby, establish a warm-up flow through the
pump.

Attention:

Starting the pump when the suction valve is closed must be avoided. Running a pump dry
(resulting from a closed suction valve, or loss of suction pressure) can result in serious damage
to the pump. In similar fashion, damage may result if the recirculation line is closed and the
pump allowed operating at little or no flow for any length of time. The liquid will heat up above
the flash point and the effect will be similar to loss of the suction pressure.

14.5.2 Warming up procedure:

1. Make initial fill with a clean, low viscosity liquid with a temperature not exceeding ambient
+100 0C.
2. For warm up a pump or maintaining a stand by in a warm condition, inject the hot warm-up
liquid into the bottom of the barrel via the drain connection, and to have this liquid leave the
pump through the suction nozzle. Keep suction valve wide open, to allow the liquid flowing
through the complete pump uninterruptedly and to prevent the pump with its shaft sealing device
from getting under maximum injection pressure.
3. Warm-up time depends on the size of the pump, the number of stages, the wall thickness of
barrel and covers and the ambient temperature, and could, therefore be different for each

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application. Flowserve recommends continuation of the warm-up until the temperature

difference between the barrel outside and the liquid to be pumped is not more than 100 0C.

14.5.3 Pump lubrication:

Type of lubrication - Lube oil system

Oil specification - SHELL TURBO OIL T 46 (ISO VG 46)

Quantity for initial fill - 520 liters

Recommended time between oil changes - Depending on environment it is recommended to

Check for water and dirt contamination periodically (Every 2-6 months). Oil may not contain
more than 1 mg KOH/g. unless oil becomes contaminated it is recommended to change or filter
the oil at periods of general overhaul.

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14.6 HP LEAN AMINE PUMP 207G-5A/B

14.6.1 hp lean amine pump 207g-5 a/b - operating procedure:

14.6.1.1 Priming:

In preparation for starting the pump it is important that the pump be completely filled with
liquid. Under no circumstance must the pump be run dry as certain parts within the pump depend
on the liquid pumped for their lubrication. Without this lubrication wear rings which have close
running clearances will tend to seize causing serious damage and expense.

 Verify that discharge valve and drain valves are closed.

 Open suction valve slowly, so the pump gets filled with liquid, with a rate which
should not exceed 25 m3/hr.
 Open discharge valve and allow filling gradually with liquid.
 Open pump vent valves.
 When a full stream flows from the vent, close the valve.
 Close discharge valves.
 After 5-10 minutes open vent valves.
 When a full stream flows from the vent, the pump is primed, close the vent valve and pump
is ready for operating.

Maximum allowable Seal Chamber pressure:

Dynamic: 52.7 kg/cm2
Static : 71.4 kg/cm2

14.6.1.2 Recirculation control valve:

Check the stem travel on the recirculation control valve (207FV-3101 or 207FV-3102 )to make
sure that it will properly pass the minimum flow ( 115 m3/hr ) at start-up. Make sure all valves in
the recirculation line are open. A closed valve in this line can cause rapid overheating if the
pump is operated with main discharge valve closed.

14.6.1.3 Start the pump:

Start the pump with recirculation control valve open; allow flow through the recirculation line
until the pressure is steady. After pump capacity has been built up beyond the recirculation
control capacity, the control should be checked to insure that it is operating properly.

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14.6.1.4 Pump running:

As soon as pump is running make the following routine checks:

 Check suction and discharge pressures indicating normal operation of the pump.
 Compare differential pressure with pump curve to locate operating condition
 Check if seal system is operating properly.
 Check seal leakage.
 Check for excessive vibration of pump and motor.
 Check the motor current reading, which indicates load on the motor.

14.6.1.5 Continuous operation:

Make the following checks at frequent intervals during the first 2 hours or operation.

 Check suction pressure gauge. Any unusual drop in pressure would indicate that the suction
strainer is getting clogged and should be cleaned.
 Check discharge pressure.
 Check seal leakage to atmosphere to see if seals are operating properly.
 Check bearing temperatures. Within the 2 hours time frame the temperature rise per minute
must become zero, so bearing temperature at constant level.
 Check for excessive bearing vibration of pump and motor.
 Check the motor current reading.

14.6.1.6 Stopping:

Before stopping the pump establish a minimum flow required, through the recirculation line and
then close the discharge valve. This will prevent water hammer on the check valve. Then stop
the pump. If stopped pump to be kept as hot standby, establish a warm-up flow through the
pump.

Attention:

Starting the pump when the suction valve is closed must be avoided. Running a pump dry
(resulting from a closed suction valve, or loss of suction pressure ) can result in serious damage
to the pump. In similar fashion, damage may result if the recirculation line is closed and the
pump allowed to operate at little or no flow for any length of time. The liquid will heat up above
the flash point and the effect will be similar to loss of the suction pressure.

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14.6.2 Pump lubrication:

Type of lubrication - Lube oil system

Oil specification - SHELL TURBO OIL T 46 ( ISO VG 46 )

Quantity for initial fill - 365 liters

Recommended time between oil changes - Depending on environment it is recommended to

check for water and dirt contamination periodically (every 2-6 months). Oil may not contain
more than 1 mg KOH/g. Unless oil becomes contaminated it is recommended to change or filter
the oil at periods of general overhaul.

14.7 MUGC 207K-A/B/C

START SEQUECE:

1. Check Utilities available.

a) Power supply
b) Plant cooling water
c) Jacket cooling Water
d) Instrument air
e) Plant air
f) Nitrogen
2. Check compresser comforms to instruction manual
3. Check controls active
a) Local control panels
b) DCS
c) PLC
4. Check all the instruments in the system be lined up.
5. Open driver purge valves and start purge system
6. Check reservoir levels
a) Lube oil reservoir
b) Lubricator reservoir
c) Cooling water reservoir (Expansion Reservoir)
7. Switch heaters in auto position
a) Lube oil heater
b) Lubricator heater
c) Cooling water heater
8. Set auxiliary driver switches in auto position.

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9. Line up cooling water supply and return lines to 207K-2A/B/C cylinder jackets and
all packings / stuffing boxes. Put cooling water system in operation if not running. Keep
standby pump in auto mode. Confirm temperature and pressure of cooling water supply to
207K-2A/B/C cylinder jackets are normal.
10. If the compressor is opened for maintenance purpose, purge the compressor throughly with
nitrogen and then with hydrogen. Make sure no air is present in inside the compressor
cylinders.
11. Set capacity control to 0%.
12. Line up nitrogen to I.C. of all cylinders. Keep the individual flows to all I.C. as required.
13. Confirm positive ∆P is maintained between all cylinders’ I.C and O.C.
14. Keep all cylinders I.C., O.C. and stuffing box drain tank's drains in closed condition.
15. Keep stuffing box drain tank's vent line to flare lined up.
16. Line up nitrogen to all rod drop measurement sensing elements.
17. Do compressor barring if it is not barred over the last 24 hours
a) Start auxiliary Lube oil pump in manual mode
b) Unlock barring device
c) Start compressor barring for minimum one revolution, maximum two revolutions.
d) Relock barring device
e) Stop auxiliary Lube oil pump and set selector switch to auto mode.
18. Clear all alarms and set overrides (reset button) i.e. override on low lube oil and lubricator
pressure and low process pressure alarms for 60 sec.
19. Check for compressor start healthy condition. If it is not healthy correct the faults and go
back to step no:11.
20. If the compressor start conditions are healthy, start the compressor by pushing
207HS-7001A.
21. Now automatically prelube timer will be started. In this step Lube oil and lubricator pumps,
which are in auto position, will get started.
22. If all alarms and trip values are healthy within 30 seconds of prelube start, prelube will be
continued automatically.
23. If all alarms and trip values are not healthy lubricator will get stopped, prelube timer will be
resetted and post lube timer (15 minutes) will be started automatically. Then the start up
sequence will go back to step no: 11.
24. After 45 seconds of prelube start, compressor motor power will get switched on
automatically.
25. After 20 seconds of motor start, prelube will end.
26. "Start sequence completed" indication will glow to indicate that compressor is ready to load
and safe guarded.
27. Load the compressor in step wise – 0% - 50% - 75% - 90% - 100% as required.
28. After loading the compressor check up the suction loaders stem position to counter check
the compressor load.

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14.8 FRACTIOATOR BOTTOM PUMP-TURBIE-207ST-12A

14.8.1 PUMP DETAILS

Turbine rating - 215 KW

- 3000 rpm
- 2 hand valves open
- 46 kg of steam consumed /kw-hr
Turbine manufacturer - ELLIOT
No. of stage - One
Allowable speed, Maximum - 3150 rpm
Minimum - 2550 rpm
Maximum continuous speed - 3150 rpm
Trip speed - 3465 rpm
First critical speed - 3500 rpm
Potential maximum power - 290 kw
DOR, viewed from governor end - CW
Exhaust line PSV set value - 7.0 kg/cm2

Casing Design:
Table 14.4

Inlet Outlet
2
Maxi. Allowable pressure (kg/cm ) 49.2 7.0
Maxi. Allowable temperature 0C 399 399

Turbine Data:
Steam Minimum ormal Maximum Design
Inlet pressure ( kg/cm2 ) 9 10.5 12.5 15
Inlet temperature 0C 200 200 240 280
Exhaust pressure ( kg/cm2 ) 2.7 3.5 4.5 7.0

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14.8.2 207ST-12A (G-12A) TURBINE STARTUP PROCEDURE:

1. Prime the pump and keep the pump warmed up. Line up heating steam to stuffing box
jackets. Check the oil level in the seal flush reservoir. Confirm there is enough cooling
water flow through pump pedestal, bearing houses, seal flush coolers and cooling coils in
the seal flush oil reservoirs.
2. Keep open all the drains in the turbine and keep open all traps’ bypass valve i.e. from two
steam chest and from turbine casing.
3. Line up cooling water lines to and from turbine steam end bearing housing
4. Confirm that MP Steam inlet line and LP Steam outlet lines are in warm up condition upto
the turbine isolation valve.
5. Slowly open MP Steam 1" bypass valve across 207PBV-4403 to warm up the turbine.
6. Once dry steam starts coming, close all the drains and steam trap's bypass valve.
7. For proper warm up, check 207TI-4401 in local panel, should show a temperature close to
the MP Steam header value.
8. Keep the auto manual switch in LCP, in Manual mode.
9. First press Emergency stops mushroom type push button.
10. Push the start push button once, this will provide signal to the governor (EDG) for
initialization. The trip lever shall be manually latched-on to the knife edge.
11. Release Emergency stop push button.
12. Second push of the same start push button will provide signal for the EDG to actuate the
governor valve actuator to take the turbine to ramp speed and finally to set speed.
13. Simultaneously, inlet solenoid valve 207PY-4403 will get a signal through PLC to open the
steam control valve 207PBV-4403.
14. Now turbine will pick up speed to set value. Once set speed is reached check the turbine
and pump for any abnormalities.
15. For turbine to start in auto mode in standby condition, it is necessary that the Turbine is
initialized in the EDG and the governor is kept ready to ramp condition by

Press the Emergency stop push button

Push the Start push button once in LCP

Keep the trip lever latched-on to the knife edge

Check the display on the EDG to read "Press start to RUN"

Release Emergency push button
Now the turbine is ready for auto start on closure of pressure switch contact through PLC.

16. For stopping the turbine, once the stop push button is pressed in the LCP, the PLC relay
(207R-1) gets de-energized and its contact opens the relay C1 in LCP. Thereby the power
supply to start contact in EDG is cut off and EDG will give output command to close the
governor valve. Simultaneously PLC will cut off the power to solenoid 207PY-4403,
thereby closing the inlet steam control valve 207PBV-4403.

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CHAPTER-15

CHEMICALS HADLED
15.1 MATERIAL SAFETY DATA SHEET
15.1.1 CAUSTIC (SODIUM HYDROXIDE) aOH
Strength: 15%

Properties

- pH: : >10 Varies with temperature.

vapor density (air=1) : NA
boiling point : 102º C - 140º C (5-50%)
freezing point : -4º C - 12º C (5-50%)
solubility : soluble in water and alcohol;
insoluble in hydrocarbon solvents.
specific gravity : 1.11 - 1.53 (10 - 50%)

- Caustic is toxic (may be fatal if swallowed) and highly corrosive (causes irreversible eye
and skin damage).

- Caustic is a colorless aqueous solution, may react with strong acids or strong oxidizing
agents, such as chlorates, nitrates, peroxides, etc.

- May liberate hydrogen gas on contact with zinc, aluminum, magnesium or cadmium.

Health Hazards

Eye: Contact with the eyes causes permanent damage, including blindness.

Skin: Contact with the skin causes permanent damage, including burns and scars.

Ingestion:
May be severely irritating and cause permanent damage to the mouth, throat, and stomach.

Inhalation: Mists of this material may cause respiratory irritation.

Signs and Symptoms Of Exposure: Eye damage or irritation: may include pain, tearing,
reddening, swelling, and impaired vision. Skin injury: may include pain, discoloration, swelling,
and blistering. Symptoms of severe irritation or ulceration of the digestive tract may include
nausea, vomiting, diarrhea, and, in severe cases, collapse, shock, and death. Respiratory
irritation: may include coughing and difficulty breathing.

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First aid measures

Eye: Flush eyes with water immediately while holding the eyelids open. Remove contact
lenses, if worn, after initial flushing, and continue flushing for at least 15 minutes. Get
immediate medical attention.

Skin: Wash skin immediately with plenty of water and remove contaminated clothing and shoes.
Get medical attention. Discard contaminated clothing and shoes or thoroughly clean before
reuse.

Ingestion: If swallowed, do not induce vomiting. Give the person a glass of water or milk to
drink and get immediate medical attention. Never give anything by mouth to an unconscious
person.

Inhalation: Move the exposed person to fresh air. If not breathing, give artificial respiration. If
breathing is difficult, give oxygen. Get medical attention if breathing difficulties continue.

ote To Physicians: Probable mucosal damage may contraindicate the use of gastric lavage.

Fire Fighting Measures: This material will not burn. For fires involving this material, do not
enter any enclosed or confined fire space without proper protective equipment, including
self-contained breathing apparatus.

Accidental Release Measures: Stop the source of the leak or release. Clean up releases as soon
as possible, observing precautions in Exposure Controls/Personal Protection. Contain liquid to
prevent further contamination of soil, surface water or Groundwater. Neutralize spill with a
weak acid such as vinegar or acetic acid and absorb with absorbent clay or diatomaceous earth.
After removal, flush contaminated area thoroughly with water.

Personal Protective Equipment

Eye/Face Protection: Wear chemical goggles and a face shield.

Skin Protection: Wear protective clothing to prevent skin contact. Selection of protective
clothing may include gloves, apron, boots, and complete facial protection and will depend on
operations conducted. Suggested materials for protective gloves include:

<Neoprene> <Polyethylene (or PE)> <Polyvinyl Chloride (Also referred to as "Vinyl" or

"PVC")> <4H (Polyethylene-Ethylene Vinyl Alcohol Laminate)> The thin laminates
(Silver Shield, 4H) should be worn as an under-glove.

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Respiratory Protection: Determine if airborne concentrations are below the recommended

exposure limits. If not, wear a NIOSH approved respirator that provides adequate protection
from measured concentrations of this material. Use the following respirators: Dust and Mist.
Use a positive pressure, air-supplying respirator if there is potential for uncontrolled release,
exposure levels are not known or other circumstances where air-purifying respirators may not
provide adequate protection.

Handling And Storage: Do not get in eyes, on skin, or on clothing. Do not breathe mist.
Do not taste or swallow. Wash thoroughly after handling. Store away from strong oxidizing
materials or strong acids.

15.1.2 DIETHAOLAMIE (DEA)

Strength: 20%

Properties:

- Flash point : 138º C

Boiling point : 217º C
Melting point : 27 - 31º C
Explosion limits in air : upper 10.6 %, Lower 1.6 %
Solubility : water -z26130
Specific gravity : 1.097
Vapor density : 3.6 g/l
pH : 11.0 - 12.0

- DEA is harmful if swallowed (target organs: liver and kidneys), poses risk of serious damage
to eyes and is irritating to respiratory system and skin.
- Absorbs CO2 from air.
- Gets oxidised by the oxidising agents like copper, copper alloys, Zinc and galvanized iron
- Hazardous combustion or decomposition products are carbon monoxide, carbon dioxide

Health Hazards
- Causes skin irritation.
- Harmful if absorbed through the skin.
- Harmful if inhaled material is irritating to mucous membranes and upper respiratory
tract.
- Harmful if swallowed (target organs: liver, kidneys and blood)

First Aid Measures

- Wear suitable protective clothing.
- In case of contact, immediately flush eyes or skin with copious amounts of water for at least
15 minutes while removing contaminated clothing and shoes.

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- If inhaled, remove to fresh air. if not breathing give artificial respiration. If breathing is
difficult, give oxygen. Assure adequate flushing of the eyes by separating the eyelids with
fingers.

Extinguishing Medium:
Carbon dioxide, dry chemical powder or appropriate foam.

Special Firefighting Procedures:

Wear self-contained breathing apparatus and protective clothing to prevent contact with skin and
eyes.

Unusual Fire And Explosions Hazards:

Emits toxic fumes under fire conditions.

Accidental Release Measures

Wear self-contained breathing apparatus, rubber boots and heavy rubber gloves. Absorb on sand
or vermiculite and place in closed containers for disposal.

Personal Protective Equipments

Wear approved respirator, chemical-resistant gloves, safety goggles, protective clothing.

Handling
- Do not breathe vapor.
- Do not get in eyes, on skin, on clothing.
- Avoid prolonged or repeated exposure.
- Wash thoroughly after handling.
- Wash contaminated clothing before reuse.
- Keep tightly closed.
- Store in a cool dry place.

15.1.3 DIMETHYL DISULFIDE

CH3-S=S-CH3

Properties:

- Flash point : 16º C

Autoignition temperature : 300º C
Flammable limits: upper : 16 lower: 1.1
Vapor pressure : 0.42 psia
Vapor density : 3.25
Boiling point : 107-110ºC (225-232º F)
Melting point : NA

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Freezing point : -84.7 º C (-120.5ºF)

Solubility in water : insoluble
Solubility in other materials : alcohols, hydrocarbons
Specific gravity : 1.063 @ 20º C
Viscosity : 0.62 cp @ 20º C
Molecular weight : 94.20
Decomposition temperature : 390º C

- DMDS is a pale yellow liquid with a strong garlic-like odour, its liquid/vapor is flammable
and if swallowed/inhaled harmful.

- Incompatibility: contact with combustible materials may enhance the risk of fire; solid bleach
(or strong oxidizers) may cause violent reaction and fire.

Health hazards:

- Inhalation and skin contact are expected to be the primary routes of occupational exposure to
DMDS.

- DMDS has a strong objectionable odour that may cause headache, nausea and irritation to the
eyes and respiratory tract, especially when prolonged exposure occurs in a confined area or leak
situation without adequate ventilation or breathing protection. The odor threshold is
approximately 8 parts per billion (ppb).

- Inhalation of the vapors may cause upper respiratory tract irritation, with nausea, dizziness
and headache and, at higher exposures, temporary nervous system depression with possible
effects such as weakness, confusion, loss of coordination and loss of consciousness. Although
rare, exposure to DMDS has been reported to produce skin-irritation on prolonged contact.

- DMDS is considered, on the basis of single exposure animal tests, to be moderately toxic
orally, slightly irritating to eyes and skin and, although no more than slightly toxic after skin
contact, rapid and reversible depressant effects on the central nervous system may be produced.
studies with laboratory animals also indicate that repeated exposure may cause effects on the
blood (anemia).

First Aid Measures:

Eye Contact: Immediately flush with plenty of water. get medical attention if irritation persists.

Skin Contact: Flush the area with plenty of water. Remove contaminated clothing and shoes.
wash clothing before reuse. Get medical attention if irritation develops and persists. Thoroughly
clean shoes before reuse.

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If Swallowed: Induce vomiting immediately as directed by medical personnel. Get medical

attention. Hospitalize if required. Never give anything by mouth to an unconscious person.

If Inhaled: Remove to fresh air. If not breathing, give artificial respiration. If breathing is
difficult, give oxygen, get medical attention and hospitalize if required.

Fire Fighting Measures

- When burned, the following hazardous products of combustion can occur:

carbon dioxide, carbon monoxide, sulfur oxides and hydrogen sulfide.

- Extinguishing media: use water spray, carbon dioxide, foam or dry chemical

- Water may be ineffective. Use water spray or water fog to cool surrounding surfaces and
prevent fire damage or rupture of containers. Fire fighters and others who may be exposed to
products of combustion should wear full fire fighting gear (full bunker gear) and self-contained
breathing apparatus. Fire fighting equipment should be thoroughly decontaminated after use.

Accidental Release Measures

In Case Of Spill Or Leak: Ventilate the area. Contain the spill by building a dike using
absorbent material. Neutralise spill with household bleach solution. Do not use solid bleach as
fire or violent reaction can occur. Collect the liquid and solid absorbent into a drum approved for
waste disposal. Flush area with water. Consult a doctor

Handling & storage

Handling: Keep away from heat, sparks and flame. Keep container closed. Use only with
adequate ventilation. Do not taste or swallow. Avoid contact with eyes, skin and clothing. Wash
thoroughly after handling. Container is hazardous when empty. Emptied container retains vapor
and product residue. Follow labeled warnings even after container is emptied. Residual vapors
may explode on ignition. Do not cut, drill grind or weld on or near this container. Improper
disposal or reuse of this container may be dangerous and/or illegal.

Storage: Store away from excessive heat, from sources of ignition and from reactive materials.
Ground all metal containers during storage. Limit indoor storage to areas equipped with
appropriate automatic sprinkler system.

Personal Protective Equipment:

Eye/Face Protection: Where there is potential for eye contact, wear chemical goggles and have
Eyewash system available.

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Skin Protection: Wear appropriate chemical resistant protective clothing such as rubber apron,
chemical resistant gloves to prevent skin contact. Wear face shield and chemical resistant
clothing when splashing may occur. Rinse contaminated skin promptly. Wash contaminated
clothing and clean protective equipment before reuse. Wash skin thoroughly after handling.

Respiratory Protection:

Avoid breathing vapor or mist. Use approved respiratory protection equipment like
self-contained breathing apparatus (SCBA) or positive-pressure airline with auxiliary self-
contained air supply.

15.1.4 HYDROGE SULPHIDE H2S

Properties:
Flash point : Gas
Autoignition temperature : 2600 C
Flammability limits : Lower: 4.3, Upper: 45.5 (% v/v in air)
Vapor pressure : 18.5 KSC @ 200C
Vapor density (air=1) : 1.18
Boiling point : -600C
Melting point : -860C
Solubility : Soluble in water, alcohol, and petroleum fractions.
Specific gravity : 1.54 liquified
Molecular weight : 34

- H2S is a colourless, poisonous and extremely flammable gas with rotten egg odour; odour
of rotten eggs is not a dependable indicator of the presence of H2S at concentrations over
100 ppm. Since the sense of smell can not be relied upon to detect the presence of H2S the
concentration should be measured by the use of portable devices.

- Heavier than air; may accumulate in low places such as pits, trenches and sumps.

- When burned, hydrogen sulphide forms sulphur forms sulphur dioxide (SO2), a poisonous,
colourless gas with a pungent odour.

Health Hazards

Eye: This substance is a moderate eye irritant and could cause prolonged (weeks) impatient of
your vision. The degree of the injury will depend on the amount of material that gets into the eye
and the speed and thoroughness of the first aid treatment.

Skin: This substance is not expected to cause prolonged or significant skin irritation.

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Ingestion: Material is a gas and cannot usually be swallowed.

Inhalation: This substance is highly toxic to internal organs if inhaled. The degree of injury
will depend on the airborne concentration and duration of exposure. Hydrogen sulphide has a
strong rotten-egg odor. However, with continued exposure and at high levels, H2S may deaden a
person's sense of smell. If the rotten egg odor is no longer noticeable, it may not necessarily
mean that exposure has stopped. At low levels, hydrogen sulphide causes irritation of the eyes,
nose and throat. Moderate levels can cause headache, dizziness, nausea and vomiting, as well as
coughing and difficulty breathing. Higher levels can cause shock, convulsions, coma and death.
After a serious exposure, symptoms usually begin immediately.

First aid measures

Eye: Flush eyes immediately with fresh water for at least 15 minutes while holding the eyelids
open. Remove contact lenses if worn. If irritation persists, see a doctor.

Skin: No first aid procedures are required. As a precaution, wash skin thoroughly with soap and
water. See a doctor if any discomfort is experienced.

Ingestion: Not expected to be an ingestion problem. See a doctor if any discomfort is

experienced.

Inhalation: Do Not Attempt To Rescue Without Wearing Self-Contained Breathing Apparatus

Or Supplied Air Respirator With Escape Air Bottle. If a person is overcome by hydrogen
sulphide, you should move the person to fresh air. If breathing has ceased or is labored, you
should begin artificial respiration immediately. The affected person should be kept at rest and
warm, and placed under a physician's care as soon as possible. Because H2S is oxidized quite
rapidly in the body, no permanent after-effects should normally occur from acute exposures
unless oxygen deprivation of the nervous system is prolonged.

ote to physicians: Administration of 100% oxygen and supportive care are the preferred
treatment for poisoning by hydrogen sulphide gas.

Fire Fighting Measures

This material presents an extreme fire hazard. Gas forms mixtures with air which can catch fire
and burn with explosive violence. Invisible mixture spreads easily and can be set on fire by
many sources such as pilot lights, welding equipment, and electrical motors and switches.
Determine if airborne concentrations are below recommended exposure limits for H2S. If not,
wear a NIOSH/MSHA approved air-supplying respirator.

Extinguishing media: Stop gas flow. Use water for cooling.

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Accidental Release Measures

If this material is released into a work area, evacuate the area immediately. Spills and Leak: Any
spill or leak, no matter how small, may be a potential hazard. When H2S is detected, prompt
notification should be given to appropriate personnel. No one shall enter the area until it has
been tested by someone wearing proper respiratory protective equipment. Only workers wearing
breathing apparatus shall enter the area until the H2S concentration is below 10 ppm.

Personal Protective Equipment

Eye/Face protection: Do not get this material in your eyes. Eye contact can be avoided by
wearing chemical goggles.

Skin Protection: No special skin protection is necessary.

Respiratory Protection: Respiratory protective equipment should be available to all employees

who could be exposed above the permitted exposure limits for H2S. Only positive-pressure
breathing air respiratory protective equipment is acceptable. Air purifying devices are not
permitted. Fixed or portable manifolds for supplied air may serve one or more workers and
should be located to minimize the length of breathing air hose required. Supplied air respirators
or SCBAs shall be of the positive pressure type and have an alarm system for low air supply.
All breathing apparatus should be located at clearly identified stations within the work area. The
location of respirators should be planned to assure at least one extra available breathing
apparatus. Posted maps indicating the location of SCBAs can be a useful emergency aid in a
facility.

15.1.5 ICKEL CARBOYL [i (CO)4]+

Nickel carbonyl, an extremely toxic and volatile substance, is formed when nickel (nickel
sulphide as well as elemental nickel) is in the presence of carbon mono oxides. During OHCU
shutdown (for maintenance activity involving vessel entry), CO level in the recycle gas is to be
monitored carefully – reactor temperature should not be lowered below 205ºC unless CO
concentration in the recycle gas is < 10ppm.

205 ºC
Ni3S2 + CO [ Ni(CO)4 ]+ + SO2 ( to be balanced )
Catalyst Nickel carbonyl

The permissible exposure limit of ickel carbonyl is 0.001 ppm or 0.007 mg/m3.

Properties
Nickel carbonyl is an extremely toxic, flammable liquid and vapor; vapor may cause flash fire
colorless to brownish volatile liquid with sooty or musty odor.

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Flashpoint : - 20º C
Autoignition : + 60º C
Flammability (Explosive) Limits : Lower: 2, Upper: NDA
(% by volume in air)
Vapor Pressure : 400 mmHg @ 79 ºF
Vapor Density (Air = 1) : 5.89
Boiling Point : 109 ºF
Solubility : Soluble in hydrocarbon solvents;
Insoluble in water.
Melting Point : -13 ºF
Specific Gravity : 1.32 @ 17 ºC (H20 = 1)
TLV : 0.05 ppm

Health Hazards
Immediate Health Effects

Eye: Contact with the eyes causes severe irritation. Symptoms may include pain, tearing,
reddening, swelling and impaired vision.

Skin: Not expected to be harmful to internal organs if absorbed through the skin. Contact with
the skin causes irritation. Contact with the skin may cause an allergic skin reaction. Symptoms
may include pain, itching, discoloration, swelling, and blistering.

Ingestion: Highly toxic; may be fatal if swallowed. May be irritating to mouth, throat, and
stomach. Symptoms may include nausea, vomiting, and diarrhea.

Inhalation: Highly toxic; may be fatal if inhaled. The vapor or fumes from this material may
cause severe respiratory irritation. Symptoms of respiratory irritation may include coughing and
difficulty breathing.

Delayed health effects: Reproduction and Birth Defects: Breathing this material may cause
birth defects based on animal data.

Cancer: Prolonged or repeated exposure to this material can cause cancer.

This material contains Nickel Carbonyl. Vapor concentrations above the exposure standard may
cause initial headache, giddiness, weakness of limbs, cold and clammy skin, increased rspiration,
nausea, vomiting, tightness of chest, coughing and breathing difficulties. Removal to fresh air
usually brings relief from symptoms. However, within 12 to 36 hours later, sharp chest pains
accompanied by rapid breathing and rising temperature may occur. In addition, dizziness,
nausea, vomiting, metallic taste, insomnia and anxiety may be present. In severe cases, rapid

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pulse, delirium, convulsions and other signs and symptoms of central nervous system
disturbances may appear. Death may occur from delayed chemical pneumonitis and pulmonary
edema.

First aid measures

Eye: Flush eyes with water immediately while holding the eyelids open. Remove contact lenses,
if worn, after initial flushing, and continue flushing for at least 15 minutes. Get immediate
medical attention.

Skin: Wash skin with water immediately and remove contaminated clothing and shoes. Get
medical attention if any symptoms develope. To remove the material from skin, use soaps and
water. Discard contaminated clothing and shoes or thoroughly clean before reuse.

Ingestion: If swallowed, do not induce vomiting. Give the person a glass of water or milk to
drink and get immediate medical attention. Never give anything by mouth to an unconscious
person.

Inhalation: For emergencies, wear a NIOSH approved air-supplying respirator. Move the
exposed person to fresh air. If not breathing, give artificial respiration. If breathing is difficult,
give oxygen. Get immediate medical attention.

Personal Protective Equipment

Use process enclosures, local exhaust ventilation, or other engineering controls to control
airborne levels below the recommended exposure limits. . If engineering controls or work
practices are not adequate to prevent exposure to harmful levels of this material, the personal
protective equipment listed below is recommended.

Eye / Face Protection: Wear eye protection such as safety glasses, chemical goggles, or face
shields if engineering controls or work practices are not adequate to prevent eye contact.

Skin Protection : Wear protective clothing to prevent skin contact. Selection of protective
clothing may include gloves, apron, boots, and complete facial protection depending on
operations conducted. Suggested materials for protective gloves include: Chlorinated
Polyethylene (or Chlorosulfonated Polyethylene), or Nitrile Rubber, or Polyvinyl Chloride (PVC
or Vinyl), or Viton.

Respiratory Protection: Determine if airborne concentrations are below the recommended

exposure limits. If not, wear a NIOSH approved respirator that provides adequate protection

from measured concentrations of this material, such as: Full-Face Supplied-Air Respirator Use a
positive pressure, air-supplying respirator if there is potential for uncontrolled release, exposure

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levels are not known, or other circumstances where air-purifying respirators may not provide
adequate protection.

Fire fighting measures

For fires involving this material, do not enter any enclosed or confined fire space without proper
protective equipment, including self-contained breathing apparatus.

Spill Management: Stop the source of the release if you can do it without risk. Contain release
to prevent further contamination of soil, surface water or groundwater. Clean up spill as soon as
possible, observing precautions in Exposure Controls/Personal Protection. Use appropriate
techniques such as applying non-combustible absorbent materials or pumping. All equipment
used when handling the product must be grounded. A vapor suppressing foam may be used to
reduce vapors. Use clean non-sparking tools to collect absorbed material. Where feasible and
appropriate, remove contaminated soil. Place contaminated materials in disposable containers
Protective Measures: Eliminate all sources of ignition in the vicinity of the spill or released
vapor. If this material is released into the work area, evacuate the area immediately. Monitor
area with combustible gas indicator and dispose of in a manner consistent with applicable
regulations.

Extinguishing media: CO2, DCP, Foam and Water fog.

15.2 Chemicals consumption rate

Table: 15.1

DMDS for Catalyst Sulfinding 45 m3

15 wt% Caustic for LPG Washing (1st Batch /

2.2 m3/ 1.1 m3
Following Batches – Once per 27 days

120,000 Nm3
Nitrogen for Start up
40,000 Nm3/ hr. (Max)

15 wt% Caustic for Regeneration (Every 2 Years) 1,555m3

Lean Amine 287.7 m3/hr

Soda Ash For Neutralization (BY DDC)

Salt for Diesel Salt dryer 30 m3

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15.3 LUBRICATIO SCHEDULE

Table 15.2

EQUIPMET SERVICE LUBE OIL

UMBER
207G-3A/B Reactor Feed Pumps Servo prime 46
Servo mesh SP 320 for pump gear box and
207G-4A/B Injection Water Pumps cranck case,
Serroneum 100 for Lubricator
207G-5A/B Hp Lean Amine Pumps Servo prime 46
Moly Grease No 2 for Spline Shaft
207G-6A/B Clps Vapor Lean Amine Pumps
Appol oil Dexron for Gear Box
207G-7A/B Product Stripper Reflux Pumps Servo prime 46
207G-8A/B Kerosene Pumparound Pumps Servo prime 46
207G-9A/B Diesel Pumparound Pumps Servo prime 46
207G-10A/B Fractionator Sour Water Pumps Servo prime 46
207G-11A/B Fractionator Reflux Pumps Servo prime 46
207G-12A/B Fractionator Bottoms Pumps Servo prime 46
207G-13A/B Kerosene Product Pumps Servo prime 46
207G-14A/B Diesel Product Pumps Servo prime 46
207G-16A/B Deethanizer Bottoms Pumps Servo prime 46
207G-17A/B Deethanizer Reflux Pumps Servo prime 46
207G-18A/B Sponge Oil Absorber Bottoms Pumps Servo prime 46
207G-19A/B Sponge Oil Absorber Reflux Pumps Servo prime 46
207G-20A/B Naphtha Splitter Bottoms Pumps Servo prime 46
207G-21A/B Debutanizer Reflux Pumps Servo prime 46
207G-23A/B Caustic Washer Circulation Pumps Servo prime 46
207G-24A/B Naphtha Splitter Reflux Pumps Servo prime 46
207G-26 Spent Caustic Pump Servo prime 46
207G-27A/B Water Washer Feed Pumps Servo 320
Moly Grease no.2 for Spline Shaft
207G-28 Make-Up Caustic Pump
Appol oil Dexron for Gear Box
Servo mesh SP 320 for pump gear box and
207G-30 Sulfiding Chemical Pump cranck case,
Serroneum-100 for Lubricator
Moly grease No 2 for Spline Shaft
207G-31A/B Back Wash Oil Pumps
Appol oil Dexron for Gear Box
207G-32 Quench Recirculation Pump Servo prime 46
207G-33A/B Condensate Pumps Servo prime 46

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EQUIPMET SERVICE LUBE OIL

UMBER
207G-36A/S Amine Sump Pump Servo gem 2
207G-37A/S CBD Servo gem 2
207G-38A/B BFW Circulation Pumps Servo prime 46
207G-39A/B Pump Coolent sump Pumps Servo gem 2
207G-42A/B Neutralisation solution Pump Servo prime 46
207G-50A/B Antistatic additive dosing Pump Servo 320
207K-1 Recycle gas compressor Servo System – HIHLP 46
207K-2A/B/C Make up gas compressor Bearings:
Motor – Shell Rotella MX-30
Compressor – ISOVG 68 ESSO Unirex N2

Cylinder and Stuffing boxes

- Shell Corona H- 150

Barring device gear Box

- Shell Tivela SC-320
Barring device Air motor
– Shell Tellus 37

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CHAPTER-16

HADIG OVER OF EQUIPMET

16.1 ITRODUCTIO
Failure of equipment's in continuous process industries like refinery is inevitable, in spite of
various precautionary measures like inspection, routine maintenance etc,. Hence the procedure
for handing over of these equipment's for carrying out various maintenance (normal, shutdown,
etc) work comes into picture. Improper procedures followed in handing over of equipment's will
cause extraneous expenditure. Hence it is as important as any other procedure. Here are some
procedures for equipment's commonly used in refinery.

Main aim in handing over of process equipment's like tower, vessel, etc should be of expelling
the hydrocarbon atmosphere so that we have a safe, non explosive & breathable internal
atmosphere for maintenance activity to take place.

Dos on Plant Start Ups

• Check for cleanliness
• Check for completion of jobs as per work list
• Check for Blind removal, proper Gaskets & Undated in the blind list
• Commission of utilities systems such as Steam, Water, Plant air, Instrument air etc,.
• Expel air to avoid formation of explosive mixture
• Pressure/Vacuum test the system for Pulling Out the Leaks
• Back in Inert material to avoid air entry
• Drain water from all low points positively to avoid explosion
• Activate all Instrument Loops
• Hot Oil circulation to be made slowly to avoid sudden expansion of entrained water
• Temperature raise should be gradual & steady to avoid thermal shocks
• Ensure lineup of PSV/TSV of individual equipments/ lines

Dos on Shut Down

• Prepare the work list
• Decommission the unit as per proved procedure
• Depressurise the system to flare
• Drain the system to CBD/OWS
• Purge the system to expel HC
• Positively isolate the system with blinds
• Prepare the equipment's as per procedure for entry of personnel

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Dos on Emergency
• Prevent Over heating or Cooling the system
• Avoid sudden Pressurizing or depressurizing the system

Donts on Plant Start Ups

• Do not be panic or hasty
• Do not ignore established systems & procedures
• Do not follow any short cut methods
• Do not run unnecessarily
• Do not distract others
• Do not ignore symptoms of problems
• DO not forget PPEs.

16.2 HADIG OVER OF PROCESS EQUIPMET

16.2.1 TOWERS & VESSELS

Steps to be followed for handing over of Vessels, Towers, etc:

1) Isolate the incoming & outgoing lines with the nearest valve
2) Depressurize & Drain the equipment ( depressurizing – through vent or through flare
depending on the case, draining – through equipment drain valve & also don’t forget to
break vacuum during draining operation)
3) Wash the vessel with water if possible
4) Isolate all the instruments connected to the equipment at root valve
5) Replace hydrocarbon vapors by inert material like Steam, N2 etc,. through equipment
vents.
6) Positively isolate with blind, all the inlet & outlet line at the nearest to the equipment
7) Open the top most man way first and consecutively one below the other if inside
atmosphere is satisfactory after testing with explosive meter
8) Ventilate the vessel with eductor
9) Analyze the inside atmosphere for O2 content (allowable 19.5% minimum for man entry)
10) Precautions to be taken before handing over equipment:
a) Update the master blind list with duly signed and dated.
b) Check the surrounding area clean up
c) Check for pyrophoric iron & if existing, keep that wet with water.
d) Get explosive meter test done in vessel & surrounding areas, if hot work is to be
done. Also keep fire-fighting devices near by, close the drains with wet gunny
bags, running water hoses & steam lancer as stand by.
e) Generate the safety work permit
f) Ensure one stand by person for vessel entry exclusively
g) Ensure one stand by person till the first torch is lit in case of hot work.

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Steps to be followed for taking back of Vessels, Towers, etc.:

a) Check the Vessel/Tower for Maintenance completion (in all respect – Mechanical,
Instrument, Cleanliness, etc,)
b) Generate a safety permit to box up the Vessel/Tower (Man Way & Tray)
c) Deblind the Vessel/Tower & Update it in Mater Blind list
d) Keep open the Vessel Vent & Drain B/V
e) Steam out the Vessel/Tower Vigorously ( Minimum 8 hours)
f) Pressure test the Vessel/Tower ( pressure limit unique to each vessel)
g) Attend to the leaks if any & repeat steps e & f
h) Close the Vessel/Tower Vent & Drain B/V
i) Back up FG/N2 to the system immediately
j) Drain the condensate completely( with a frequency of an hour )
k) Cap or End flange the Vessel/Tower Vent & Drain points.
l) Vessel/ Tower is ready for service.

16.2.2 HEAT EXCHAGER

Steps to be followed for handing over of Heat Exchanger

a) Bypass the exchanger if permissible
b) Isolate PSV's if any
c) Isolate the Hot Medium I/L
d) Isolate the Hot Medium O/L after the hot stream has cool down enough
e) Isolate the Cold Medium I/L
f) Isolate the Cold Medium O/L
g) Drain the Shell /Tube side streams to OWS/CBD ( Case basis)
h) Provide breathing provision to avoid vacuum pulling or for complete draining
i) Depressurize the system either to Atmosphere/Flare/Blow Down (Case basis)
j) Replace hydrocarbon vapors by inert material like Steam, N2 etc,. through exchanger
drain/vent.
k) Positively isolate with blind, all the inlet & outlet line at the nearest to the equipment
j) Precautions to be taken before handing over equipment
1) Update the master blind list with duly signed and dated.
2) Check the surrounding area clean up
3) Check for pyrophoric iron & if existing, keep that wet with water.
4) Get explosive meter test done near the exchanger areas, if hot work is to be done. Also
keep fire fighting devices near by, close the drains with wet gunny bags, running water
hoses & steam lancer as stand by.
5) Generate the safety work permit.

ote: In case of Stainless Steel tube exchanger, chemical soaking to be done before handing
over the exchanger to any maintenance work. Please note that isolation of this tube to be done

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while purging operation is carried out, otherwise atmosphere air will enter into the exchanger
and cause stress corrosion cracking.

To avoid stress corrosion cracking, Exchanger bundles will be subjected to chemical soaking
operation. The chemicals generally used for SS tubes are Sodium Carbonate – 2% strength &
Sodium Nitrate – 0.5% for duration of 8 hours.

Steps to be followed for taking back Heat Exchanger:

a) Check the Exchanger for Maintenance completion (in all respect – Mechanical, Instrument,
Cleanliness, etc,)
b) Generate a safety permit to box up the Exchanger
c) Deblind the Exchanger & Update it in Mater Blind list
d) Keep open the Exchanger Vent & Drain B/V
e) Steam out the Exchanger Vigorously ( Minimum 8 hours)
f) Pressure test the Exchanger ( pressure limit unique to each vessel)
g) Attend to the leaks if any & repeat steps e & f and drain all the condensate.
(Note: Steps e to f are particularly after turnaround)
Line up PSV's if any.
h) Open Cooling Medium I/L minimum to expel non condensable from the system ( this
activity is not required for gas service
i) Close the vent B/V once the liquid comes out through the vent
j) Close the drain B/V after draining for water if any, after giving sufficient settling time
k) Open the cold medium O/L
l) Open Wide the cooling Medium I/L, drain all the condensate.
m) Open Hot Medium I/L minimum to expel non condensable from the system (this activity is
not required for gas service
n) Close the vent B/V once the liquid comes out through the vent
o) Close the drain B/V after draining for water if any, after giving sufficient settling time
p) Open the Hot medium O/L
q) Open Wide the Hot Medium I/L.
r) Close the exchanger bypass B/V on Cold Medium slowly & the Hot Medium

ote:
1) Opening & Closing of B/V should be slow & steady
2) Cooling water O/L temperature should not exceed 40 0 C
3) Velocity of cooling water flow should be 8 ft/sec/in to avoid fouling

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16.2.3 PUMPS

16.2.3.1 COLD PUMP

Steps to be followed for handing over of cold pump:

Following steps are to be followed for pump de-pressurizing of the pump:

• Close discharge valve first & then suction valve,

• Pump casing liquid to be drained by opening the casing drain and vent into CBD or OWS.
• For LPG & high RVP product service pump casing liquid to be vent in to flare and de-
pressurize the pump.
• After completion of draining, close the drain and vent.
• If pump service is for heavy product, take FLO and drain in to CBD or OWS.
• If pump service for Caustic, Amine, Anti-oxidant or other chemical drain pump to
respective connection like caustic pit or ABD. Then flush with water two or three times.
• If mechanical seal flush line is there, close seal flush line valve.
note: Ensure pump casing is liquid free by checking drain line and seeing pump
pressure gauge.
• If mechanical seal and pump bearing cooling water line is there, close cooling water line
valve.
• Pump motor & its auxiliary motors power supply isolate from sub-station.

Now the pump is ready for handing over to maintenance.

16.2.3.2 HOT PUMP

Steps to be followed for handing over of hot pump:

De-pressurising the pump:
• Following steps are to be followed for pump de-pressurising.
• Close first discharge and warm-up valve then suction valve.
• Cool pump below 200 deg. C.
• Pump casing liquid to be drained into CBD or OWS
• If mechanical seal flush line is there, close seal flush line valve.
• If quench steam line is there, close quench steam valve.
• If pump service is for heavy product, take FLO and drain into CBD or OWS (for flushing
the pump casing).
• After completion of the draining close the drain and vent

OTE: Ensure pump casing is liquid free by checking drain line and seeing pump pressure
gauge.

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• If mechanical seal and pump bearing cooling water line is there, close cooling water line
valve.
• Pump motor & it's auxiliary motors power supply isolate from sub-station.
• Now pump is ready for handing over to maintenance.

Steps to be followed for taking back pump:

• Get clearance from maintenance department to ensure that job is completed

• Check the freeness of shaft rotation by rotating the shaft manually
• Ensure the couplings, coupling guard etc.,
• Line up bearing cooling water, Seal flushing lines, and fill the lube oil
• Gradually open the NRV bypass or open the suction valve.
• Open the vent valve gradually and ensure that air is completely vented out by seeing
sufficient quantity of liquid is coming out. Gradually open the drain valve to ensure the
casing is free of water.
• If its hot pump or heavy product pump take FLO to casing vent it and then open the suction
valve gradually displace the FLO by open the drain and vent.
• Close the drain valve and vent valve.
• Open the suction valve fully.
• Check the pressure gauge for minimum suction pressure.
• Inform to control room to energies the pump.
• After getting electrical clearance start the pump.
• Watch the pressure gauge for shut off pressure and no load amps.
• Gradually open the discharge valve fully.
• Check the pressure, amps, vibration and seal.
• Inform to control room about normality.

16.2.4. RECYCLE GAS COMPRESSOR 207K-1:

Stop the turbine as per procedure and ensure that steam valve is closed.

De-pressurising the compressor:

Following steps are to be followed for compressor de-pressurising..
• Close discharge valve, spillback valve and suction valve or its MOV.
• Close the primary seal gas and secondary seal gas valves.
• De-pressurise the compressor gas into flare.
• Take N2 in suction line & fill compressor & its line with N2 then de-pressurise into flare.
Repeat this operation two or three times.
• Stop lube oil circulation.
• Ensure all drain and vent valves connect to flare should be kept close.

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Now compressor is ready for handing over to maintenance.

note: If the casing/lines of pump/compressor connected with the system are to be opened during
the maintenance job, the connected lines to be blinded.

16.2.5. MAKE UP GAS COMPRESSOR 207K-2A/B/C:

Stop the Compressor as per procedure and inform to deenergise the power.

De-pressurising the compressor:

Following steps are to be followed for compressor de-pressurising..
• Close discharge double block valves , and suction valve.
• De-pressurise the compressor gas into flare thro individual discharge to flare (safety by
pass), and 2nd and 3rd stage suctionr drain KOD
• Take N2 in suction line, fill compressor & its line with N2 then de-pressurise into flare.
Repeat this operation two or three times.
• Close the nitrogen to SB and chambers.
• Close the individual water circulation valve SB and cylinder jacket.
• Ensure that all drain and vent valves connected to flare are closed.

Now compressor is ready for handing over to maintenance.

note: If the casing/lines of pump/compressor connected with the system are to be opened during
the maintenance job, the connected lines to be blinded.

16.3 CATALYST REMOVAL:

Depressurize the reactor and cool it as per procedure given in chapter 11.
Ensure the reactor is blinded as per blind list.
The catalyst can be removed by opening the catalyst dump nozzle located in the bottom head of
the reactor. The catalyst beds are connected by a catalyst drainpipe through the inter bed
internals. Most of the catalyst will then drain out of the reactor when the drain plug is removed.
The remainder is removed by sweeping or shoveling it into the drainpipes or by vacuuming.

If the catalyst has not been regenerated, covered the drums in which spent catalyst can be stored
safely should be ready for use before catalyst is drained. Alternatively, the catalyst can be
drained into an open hopper if it is soaked down with water as it leaves the reactor and is kept
wet until it has been disposed of. This should be done only if catalyst is to be disposed of water
washing destroys the catalyst and it cannot be reused. If the catalyst is to be discharged after
dumping, a simplified catalyst regeneration procedure may be used. When the catalyst has
stopped draining out of the bottom of the reactor, workmen may enter to remove residual
catalyst. This work may be done in either inert atmosphere or in an air atmosphere. If the
catalyst has been regenerated, the residual catalyst may be removed in an air atmosphere without

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special precautions. Regenerated catalyst is not pyrophoric, and regeneration effectively

eliminates the possibility of fires, evolution of noxious vapors etc. However, the reactor should
be well ventilated and tested safe for entry; respirators and emergency air supply should also be
provided. If the catalyst has not been regenerated, special precautions are required as outlined in
the following sections.

REMOVAL OF RESIDUAL CATALYST I IERT GAS ATMOSPHERE

Plant experience indicates that spent unregenerate ISOCRACKING catalysts generally

pyrophoric under normal conditions. Further, there may be significant quantities of pyrophoric
iron sulfide in the reactor inlet. Therefore, it is recommended that unregenerated catalyst
dumping operations be carried out in an inert atmosphere. When the catalyst has stopped
draining out of the bottom of the reactor, continue to purge with nitrogen to prevent air from
entering the reactor.
Remove the internal manway and catalyst. Remove the remaining catalyst by sweeping or
shoveling it into the drain pipes or by vacuuming. A safe breathing apparatus must be provided
for workmen entering the inert atmosphere within the reactor. Because a long time is required to
get in and out of the reactor (the space available for movement inside the reactor is limited),
breathing apparatus should include a backup air supply sufficient to allow workmen to escape
from the reactor in case the primary air supply fails.

REMOVAL OF RESIDUAL CATALYST I A AIR ATMOSPHERE

Unregenerated residual catalyst can be removed with the reactor filled with air if the necessary
precautions are taken. The reactor working space must be ventilated and tested for safe entry
before workers enter the reactor to remove residual catalyst. To prevent the catalyst from drying
out, heating up, and evolving hazardous or noxious vapors, the reactor is first flooded with
water. After flooding, the water level is dropped to immediately below working level, but not
lower; and the working space is tested to determine if safe for entry. If unsafe, flood the reactor
again and repeat the test. Water should be available in and out of the reactor to wet the catalyst
in case it begins to heat up. The water level is progressively lowered but kept immediately below
the working level as the workmen proceed downward in the reactor. Breathing apparatus must
be used by workmen in the reactor or when handling catalyst if any noxious vapors are evolved
from the catalyst or if there is any possibility that CO was in contact with the catalyst during the
Shutdown., following. Workmen entering the reactor must have an emergency air supply piped
to the working area by hoses whether or not breathing apparatus is used. Ensure that all traces of
catalyst and residual matter are removed from the reactor. The carbonate solution may deposit a
sludge on the reactor internals as it is drained, therefore, it will be necessary to thoroughly clean
and water flush the reactor after the residual catalyst is removed. Particular attention should be
paid to the cleaning of the catalyst support screens or excessive reactor pressure drop may
develop after the unit is started up. It will be necessary to ensure that the reactor is dry before
replacement catalyst is loaded. Ensure that all traces of flushing water have been removed and
purge the reactor with dry air or nitrogen.

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TOP BED CATALYST REPLACEMET

Reactor plugging at the top catalyst layer could result from excessive deposits of iron contained
in the feed. If much plugging develops as indicated by an increase in top bed pressure drop, it
will be necessary to shut down and replace the top layer of catalyst when the top bed pressure
drop approaches the design limit. The following procedure should be used for top bed catalyst
replacement. If the catalyst has been regenerated, no special precautions are necessary. However,
the precautions described should be followed when replacing top bed catalyst in an
unregenerated reactor. The reactor is entered through the top manway. A nitrogen purge in the
top section of the reactor must be continued while the top bed catalyst is removed by shoveling
or vacuuming into buckets. The buckets are removed to fill drums. Facilities for soaking down
the filled drums are advisable. Before removing catalyst, the top bed should be carefully
inspected and only the catalyst that is causing the plug should be removed. Before replacing the
Catalyst for the loading procedure and for the amounts and types of catalyst required in the top
bed. Sulphiding is not required if 0.6 m or less of the top bed is replaced with fresh catalyst. If
more than 0.6 m of catalyst is replaced with fresh catalyst, the catalyst must be sulphide before it
is contacted with hydrocarbon. The Sulphiding procedure is the same as for fresh catalyst,

SAFETY PRECAUTIOS HAZARDOUS VAPORS

Highly toxic nickel carbonyl may be formed at reactor temperatures below 205 Deg C if the
recirculating gas contains an appreciable concentration of CO. Therefore, the reactor should not
be cooled in hydrogen below 205 Deg.C unless the recirculating gas is free CO. For purposes of
this discussion, the system should be considered free of CO only if the make-up hydrogen has
contained less than 10 ppm total carbon oxides (CO + CO2) and there is no possibility of carbon
oxides entering the system via extraneous sources. If carbon oxides are present at concentrations
above 30 ppm in the circulating gas (which in normal operating would correspond to a
concentration of about 10 ppm in the make-up hydrogen), the recycle gas must be replaced with
nitrogen before cooling the reactor. After nitrogen is added, the recirculating gas should be
analyzed before cooling is resumed to ensure that carbon oxides have been effectively displaced.
Further purging should be employed if necessary to bring to CO content of the cooling gas to
less than about 30 ppm. Nickel carbonyl is formed by the reaction of nickel with CO. Although
liquid at ambient temperature, the vapor pressure of nickel carbonyl is high enough that it can
exist in the vapor phase in hazardous concentrations. If there is any possibility that CO was
present in the gas used to cool the reactor below 205 Deg C or for purging, highly toxic nickel
carbonyl should be assumed to be present in the atmosphere surrounding the catalyst when the
reactor is opened. In such case, fresh air breathing apparatus must be used by workmen in the
reactor and when handling catalyst removed from the reactor. Respirators would not provide
adequate protection. Some carbonyl compounds can be adsorbed through the skin; therefore skin
protection should be provided. Other hazardous or noxious vapors may be evolved from the
unregenerated catalyst when the reactor is opened; for example:

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1. Hydrocarbons may be desorbed from the catalyst, especially if the reactor was not sufficiently
cooled.

2. Combustion products (SO2, CO2 and CO) may be evolved if the catalyst is exposed to air. If
the catalyst is unloaded in air fresh air breathing apparatus should be available in case hazardous
or noxious vapors are evolved.

EXPLOSIVE MIXTURE AD PYROPHORIC MATERIAL

The repeated nitrogen purge of the reactor system will decrease the possibility of an explosive
hydrogen-oxygen mixture forming in the reactor when it is opened. Purging also removes
recycle and make-up gases remaining in the system after operation is stopped. However, the
unregenerated catalyst continues to evolve hydrocarbons; it is essential that the reactor be cooled
as low as possible before it is opened. Although reactor internals and the hot piping are stainless
steel, it is possible that some iron sulfide may accumulate in the reactor system from trace
quantities of iron in the feed and scaling of low alloy steel lines and equipment. For this reason,
also it is important that the catalyst be sufficiently cool before the reactor is opened to minimize
the possibility of iron sulfide ignition and resultant fires.

PURGIG
If it is necessary to purge a reactor containing "live" catalyst, follow the procedure outlined
below. Note also that all stagnant lines which may contain hydrogen should be purged
separately.
1. Strip hydrocarbon from catalyst (as required).
2. Cool reactor, observing CO precautions.
3. Relieve system pressure to relief header until pressure is 0.4 kg/cm2.
4. Pressure system to 10kg/cm2.
5. Relieve pressure again to 0.4kg/cm2 to relief header.
6. Again pressure system to 0.4kg/cm2 with N2.
7. Relieve pressure to 0.4 kg/cm2. Purge through system including compressors with N2 for five
minutes. Keep system pressure at 0.4 kg/cm2 of N2.
8. System is now ready for
a. Regeneration
b. Catalyst dumping (inert atmosphere or water flood.)
c. Catalyst "scalping" (inert atmosphere).
d. Blinding reactor for external maintenance.
9. Do not open reactor containing used sulphide catalyst to the air until Step 8 (a) or 8 (b) is
done.

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CHAPTER-17
DCS FACILITIES AVAILABLE

Refinery-3 DCS engineering and commissioning is done by Yokogawa Bluestar Ltd. (YBL),
Bangalore. Refinery-3 DCS package is called CS-3000, which has a 'windows' based operating
system.
The following is brief write-up about the salient features of CS-3000 package and the facilities
available in the DCS:

I REFIERY-3 COTROL ROOM

• the V-net bus (domain) can connect upto 64-stations, as follows:

V-NET CAPACITY UTILIZED CAPACITY

HIS
FCS HIS Total FCS Total
EXA OPC
OHCU HGU CDU SRU Engineering Sub Total
Server
48 16 64 35 3 3 3 3 1 1 14 48

ote: 1.FCS - Field Control Station, HIS - Human Interface Station.

2.HIS is otherwise called EOPS in centum excel package.
3.EXA OPC server is OLE for Process Control, where OLE stands for object linking
embedded; With this server, DCS process information can be transmitted through Ethernet
to an outside client elsewhere, like technical services dept., Company high official residences, etc.
For accessing the transmitted data, the client should have the OPC client software in his PC.

FOR OHCU

• 5 FCS (Field Control Stations) are provided:

- 3 FCS numbered 28,29 and 30 for field-to-DCS signaling,
- 2 FCS numbered 31 and 35 for PLC-to-DCS communication.

• 3 HIS (Human Interface Stations) are provided, numbering 52, 53 and 54.

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• 2 ANN and 3 AUX consoles are provided, two for HP and one for LP sections of the unit,
with the HP and LP ANN panels corresponding to their HP and LP AUX panels
respectively.

• 12 PLCs. are provided as follows:

- 4 for MUGC
- 1 for RGC
- 2 for Flowserve pumps (207G-3A/B and 207G-5A/B)
- 2 for feed filter
- 2 for HP and LP sections
- 1 for ADS
The CPU of the PLC is called CCM (Critical Control Modules).

• CCTV system (PELCO - make) with cameras 3 nos. positioned towards the plant, is
provided, to have effective vigilance of the plant area.

• Printers 2 nos. are provided, one for logging and the other for alarm print purposes.

• Neumann communication is provided with facility to communicate:

Refinery-1, Shift managers room (at Refinery-1 control room), OPH, Ref.3 SS (MCS),
New CPP control room, DHDS and FCCU.

• As the operating system is windows-based, improved graphics quality is available;

Out of around 800 pages available for graphics programming in ref.3, OHCU graphics are
provisionally programmed in about 110 pages.

• Trending facility:
REAL TREND LONG TERM TRENDING
Sampling Trending No. of tags Sampling time Trending No. of tags
time period period
1 second 48 minutes 256 tags 1 second, 5 to 60 days 2560 tags
or (2 blocks 1 minute, (20 blocks
10 seconds of 128 tags 2 minutes, of 128 pens each,
(optional) each, 5 minutes totalling 320 pages
totaling or - 2 blocks for
32 pages) 10 minutes high speed
1sec. sampling
and
18 blocks for
1min. to 10 min.
sampling).

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Note: 1 .Though trend grouping for each HIS can be done independently, grouping is
normally kept same for the 3 HIS, to keep similarity.
2. Through "Real trend" sampling time option of 1 second or 10 seconds is
available, normally 1-second sampling time is opted, for obvious reasons; this option
can be made from the "Engineering station"
3. "Long term trending" trending time can be 5 to 60 days, as opted from the
"Engineering station".

• Number of tags in OHCU is around 2800, as against around 13,000 of all blocks in ref.3;
The DCS system capacity is 32,000 tags.
• Alarm capability:
60,000 alarms or 6 months (whichever is earlier), as against <10,000 in Centum excel.
• All the operation messages like changing the MV, AUTO/MANUAL mode changing, etc
are recorded in the historical alarm summary, giving very good tracking of the plant
operation.
• OGMs: 20 operator guide messages (max. 80 characters each), can be programmed.
• Number of “Function keys" is 64, as against 32 in Centum Excel package.
• Security level: 3 security levels are availalable
- OFF-USER: for regular panel personnel
- ON-USER: for shift-in-charges, etc.
- ENGN.USER: for group assignment and other programming.
Unlike in earlier versions (like Centum excel), the user can log-in from the system without
using any engineering keys.

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8.3 COMPRESSORS:
MAKE UP GAS COMPRESSOR - 207K-2A/B/C:

General details:

Compressor make - THOMASSEN COMPRESSION SYSTEMS BV - Netherlands

Rated capacity - 42,000 Nm3/hr
Speed - 333 rpm
Total shaft power - 3892 kW
Required driver power - 4300 kW
DOR facing driven end - C.W
Stroke length - 360mm
Avearge piston speed - 3.99 m/s
No. of stages - Three stages – four cylinders

Motor:
Motor make - ABB OY - Finland
Motor type - Synchronous
Supply voltage - 6600 KV
Speed - 333 RPM
Driver power - 4300 kW
Full load current - 408 Amps
Power Facator - 0.95

Table 18.4: Operating condition / performance of 207K-2A/B/C

Hydrogen case itrogen case

Units Stage-I Stage-II Stage-III Stage-I Stage-II Stage-III

Rated capcity Nm3/hr 42,000 41920 41880 10823 10823 10823

2
Suction pressure Kg/cm 20.50 42.01 91.00 6.90 16.26 39.94
0
Suction temp. C 40.00 40.00 40.00 40.00 40.00 40.00
2
Disch. Pressure Kg/cm 42.80 92.50 188.70 16.59 40.74 100.00
0
Disch. temp C 119.00 126.00 119.00 144.00 150.00 145.00
Comp. ratio 2.11 2.22 2.09 2.43 2.53 2.53
Volume ratio 1.69 1.73 1.63 1.88 1.92 1.88
Average mol.wt Kg / 2.10 2.10 2.10 28.01 28.01 28.01
kgmol
Gas purity 99.50% pure H2 100.00% pure N2

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Hydrogen case
Units Stage-I Stage-II Stage-III

No. of cylinders 2 1 1
Vol. Efficiency % 85.44 81.56 82.37
2
Working pre. Kg/cm 43.22 96.01 186.73
2
Design pre. Kg/cm 50.00 111.00 214.00
2
Relief valve set Kg/cm 47.65 105.72 204.30
2
Hyd. Test pre. Kg/cm 75.00 167.00 325.00
2
Pneumatic test Kg/cm 50.11 111.00 214.00
pressure(helium)
CW jacket pre. Kg/cm2 11.90 11.90 11.90
Piston type Cast type hollow ( self vented )
No. of piston 4 6 6
rings/cylinder
No. of rider rings/ 2 2 2
cylinder
Jacket cooling Forced feed cooling with
water/EG

Cylinders / stuffing boxes lubrication system:

Lubricator type - Plunger type multi point lubricator with

integral reservoir
Lubricating oil - SHELL – CORONA H-150
Crankcase oil - SHELL – ROTELLA MX-30
Lubricating oil consumption - 7.6 liters / day (normal )
Reservoir contents - for 30 hours

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Control sequence diagram:

Type of capacity control - Stepwise control

- Manual selector switch

Control steps - 0-50%-75%-90%-100%

On air/power failure - compressor shall unload

Maximum no load running time - 10 minutes

CLEARACE POCKETS
n= Unloaded CYLIDER SIDES
1 2 3 4 CYLIDERS
O = Loaded HE CE HE CE HE CE HE CE 3 2 4

100% O O O O O O O O O O O

90% O O O O O O O O n O O

75% n O O O O O O O n n n

50% n O n O n O n O n n n

0% n n n n n n n n n n n

N2 case O O O O O O O O n n n

HE: Head End

CE: Crank End

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18.5 FURACES
Table 18.6: 207F-1 FEED FURACE

No. of cells Two Fuel type: Fuel Gas

No. of passes Two Fuel gas pressure max: 1.8 kg/cm2
RADIATION
SECTION CONVECTION SECTION
Service HC tubes SG I Tubes SG II Tubes BFW Tubes
Design pressure 190.6 17 17 29
elastic (kg/cm2 g)
Operating pressure In/out
(kg/cm2 g) 177.8/172.8
Design Tube Metal 551 343 343 343
temp. o c
Operating Temp. o c In/Out
356/378
Corrosion 1.5 3.0 3.0 3.0
Allowance- mm
Hydro test Pressure 350 40 40 65
( kg/cm2 g)
Material of A312TP 316 A335 Gr P 4 A106 Gr-B A106 Gr-B
construction L
No of tubes (both 24 24 56 16
pass)
No. of rows / pass 12 3 7 2
Type Bare tube Bare Tube Finned tube Finned tube
Inlet Top Bottom Bottom Bottom
Outlet Bottom Top Top Top

Heat Duty : 8.13 MMKcal/hr.

Design Flow : 2,69,690 kg/hr.
Furnace Type : Twin cell cabin heater/ Horizontal tubes, Two passes Flow down
Burner make : HAMWORTHY / Unimax Flat Flame
No of Burners : 56 (four rows each rows having 14 burners)

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Table 18.7: 207F-2 FEED FURACE

No. of cells: Two Fuel type: Fuel Gas & Fuel Oil Maximum fuel gas pr: 1.8 kg/cm2
Maximum fuel oil pr: 6.3 kg/cm2
No of passes Four (two passes / cell)
Service HC tubes SSH SG
Design pressure elastic (kg/cm2 g) 11.1 17 17
Operating pressure (kg/cm2 g) In / Out 9.1 / 1.8
Design Tube Metal temp. o c 535 427 427
Operating Temp. o c In / Out 319 / 360
Corrosion Allowance- mm 1.5 3.0 3.0
Hydro test Pressure (kg/cm2 g) 35 40 40
Material of construction A 312 JP 347 A 335 GR P11 A 335 GR P11
No of tubes Radiation 72 (16+2/pass) --------- --------------
Convection 48 + 16 spare 32 40
No. of rows Radiation 9 --------- --------------
Convection 6 + 2 spare 4 4
Type 3 Studded Studded Studded
3 Bare
Inlet Top Top Bottom
Outlet Bottom Bottom Top

Heat Duty : 12.65 MMKcal/hr

Design Flow : 2, 19,172 kg/hr
Furnace Type : Twin cell cabin heater/ Horizontal tubes, Four passes Flow down
Burner make : HAMWORTHY/ Unimax
No of Burners : 14 (Two rows each rows having 7 burners)

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18.6 FEED FILTERS:

The feed filter is supplied by Fuji filter mfg. co. Ltd., Japan. The filter consists of 4 banks, each
bank having 10 stations. Each station consists of 12 filter elements of mesh size 20µm. The filter is
capable of removing solids particles of size 20µm and above. The design solid loading to the filter
is 20-40 ppm under normal operation (200 ppm under upset situation).

When a differential pressure of 1.4 Kg/cm2 is reached, filter backflushing is actuated. Design
backwash flow is 30 m3/hr. Each bank is backflushed in sequence with a slipstream of filtered feed
taken from the outlet of the feed filter until all banks have been backflushed and the pressure drop
has returned to normal.

Maximum allowable ∆P across filter is 2.7 Kg/cm2 (normal flow direction)

BACKWASH OIL COSUMPTIO:

Flow rate 30 m3/hr

Time 30 sec./ one station backwash
5.5 min./ one bank (10 stations)
22 min./ total (4 banks)
Backwash oil volume 00.25 m3/station
02.50 m3/ bank
10.00 m3/ total

FILTER OPERATIO:

1. Mode selection at control panel:

Select one of the following modes:
- Auto back wash mode (by preset timer or preset ∆P)
- Manual mode (1 particular bank can be selected from any of the four banks)
- Off ('maintenance mode')

2.Set up the timers:

TIMER AME ADJUSTABLE DESIG SET TIME

RAGE
Back wash auto start 1-2 hour(s) 6 hours
T0 delay
T1 Delay (backwash start 0.5-10 seconds 1 second
signal)
T2 Backwash timer 10-180 seconds 30 seconds

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3.Backwash steps (as per instrument control):

3.1 Getting input signal:

Backwash sequence will start (on getting the input signal) under the following conditions:
a. Signal from 'adjustable electronic timer', when time is up.
b. Signal from PDAH of PDI-1505 (∆P across the filter), 1.4 Kg/cm2
c. Signal upon manual order (at manual mode in control panel).

3.2 Backwashing each station:

a. Close inlet line
b. Open drain line
(Solenoid operated)

3.3 T2 time up (refer timer set up table above)

3.4 Backwash finish

a. Close drain line
b. Open inlet line
(Solenoid operated)

3.5 ext station backwash start (return to the step 3.2 above).

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CHAPTER-21

BLID LIST

Please refer OHCU master blind list

available in the control room

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CHAPTER-23

SAFETY EQUIPMET

Safety is a science which deals with aspects which keep away the working atmosphere out
of hazard. Hence safety is the prime consideration in the design of process plants.
Disregard of safety is comparable to criminal negligence. The general safety code applies
to all the employees

23.1 Hazards in Refineries

Introduction:
Indian Oil industry is about 100 years old. In 1985, a safety council composed of senior
officials of the Ministry of Petroleum & Natural Gas was constituted with chief executives
of the Oil Companies & other concerned heads of statutory bodies as an Apex body. The
council is assisted by a safety Directorate. All activities of refineries are under the
Jurisdiction of the safety Directorate.
Hydrocarbons handled in Petroleum industry are highly toxic & corrosive which are
present in the crude oil & its finished products. The people working in the petroleum
industry are always exposed to danger of fire, explosion, pollution & health hazards.
Hazards in refineries are overcome by various means in various stages, which are
discussed below:
23.1.1 Design Safety:
Potentially hazardous situation in refinery is generally get created during start up,
shutdown & emergency, because of various causes like utility failure, instrument failure,
etc. To handle all such situation, facilities like Relief or Disposal system, Shutdown
system, Instrument with Manual / Auto system, etc., are provided & necessary procedures
are followed. All these aspects are looked into right at the stage of design.
Area of concern in petroleum industry is the disposal systems including routing of safety
valves, discharge to atmosphere, vent stacks, condensable & non condensable blow downs
to flare, flare height, location & size, remote depressurizing, insulation & fire proofing
instrumentation and fail safe trips for critical equipment. Static electricity has been cause
of many fires in the oil industry. Refineries also deal with toxic chemicals. Health
monitoring is necessary for the operating personnel who work in the areas where these
toxic chemicals are handled.

23.1.2 Layout
Layout consideration has to be given for the inter spacing between 1) Equipment within the
process block 2) Utilities 3) Tankage & Loading gantries to minimize the involvement of
adjacent equipment in the event of fire. The effects of radiant heat from storage tanks &
the BLEVE effects from LPG storage vessels are to be given serious consideration.

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23.1.4 Operating Procedures:

In many of the worst disasters which took place all over the world, it was not the
technology that was lacking rather the discipline required to follow procedures & good
operating practices. Adhering to written procedures, keeping the instruments healthy &
online are some of the essential items of a good operating discipline.

23.1.5 Static Equipment:

Crude containing napthenic acid, which affects transfer lines. vessels & piping in MEA
services are susceptible to cracking. All equipment, pressure vessels, pipe lines, are
tankage are to be periodically checked for corrosion aspects for different operating
conditions.

23.1.6 Fire:
Fire in petroleum industry can breakout due to any of the following reasons; spark by
electrical circuit, hot work, storage vessel not earthed, etc,. Hence a good fire protection
systems like detectors, monitors, sprinklers, etc, should be considered inside the plant to
kill the fire if triggered.

23.1.7 Health Hazard:

Health hazard for men can be caused by to air/water/thermal/noise pollution due to
1) H2S, SO2, etc. higher than acceptable limits
2) Flying of solid catalyst dust, solid sulphur particles
3) Acid & Alkali burns due to handling
4) Leakage/Spillage of toxic chemical such as phenol, formaldehyde, chlorine, etc.
Hence periodic health check up programs, training, etc. can be considered to control the
health hazard.
Hence epitome of the safety practices to be followed in refineries are
1) Never drain water from the system to rain water sewer. It should always be drained into
closed oily water sewer.
2) Never bypass an Alarm or Trip system in an operating plant.
3) Any leakage should be attended immediately.
4) All HC detectors should be periodically tested & maintained regularly
5) All HC vapours or gases from Relief valve should be connected to flare headers or to a
safe location.
6) Always use Non sparking tools.
7) Rotary equipments should have guards
8) Operators should always stand on rubber mat while working with electricity or junction
box.
9) No operators should be allowed to work without PPEs
10) Good house keeping should be strictly followed.

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23.2 Important safety rules to prevent High Pressure Hazards:

1) Pressure gauges like Bourdon type should be free of air inside the tube. The gauges
should be installed above eye level. Tube should never be allowed to corrode. Too rapid
rise or fall of pressure must be avoided. Root valve must be opened only to the
required level & not wide open. Also it is safer to install EFCV (excess flow check vave)
for HP PG isolation.
2) Flammable gases at HP on rubbing against wall of metallic pipes cause static electricity
discharge. Good earthing is essential.
3) Bursting of rupture disc in vessels cause sudden high temperature which may ignite
flammable gases. Sufficient venting height is necessary, where it can cause no harm.
Discharge line must have sufficient diameter to carry the excess load release.
4) Direct-fired vessels should not be emptied suddenly. The fluid running in slow
velocities slowly cools down.
5) Two Safety valves, one operating at slightly lower pressure is advantageous in very
high pressure equipments.
6) HP tubings should be anchored securely at frequent intervals to prevent whipping in
case of break.
7) Welded equipment should be heat treated to relieve locked up stresses. Expert welders
should be engaged. Frequent radiography test of these equipment must be carried out
for any possible cracks developed during operation.
8) Oil should never be used as lubricant when oxygen is compressed.
9) Regular inspection should be carried out with experienced staff.
10) Too rapid raise or fall in temperature should be avoided.
11) Pressure joints should not be tightened under pressure.
12) It is often advisable to have more than one operating personnel in HP zone. Too many
persons also must be avoided.
13) All HP area should be clearly marked & guarded against unauthorized entry.
14) Design aspects like material selection, equipment layout, etc. should be considered
with extra care & should be made according to standards pertaining to HP systems.
15) Standard operating procedure for each of HP system should be evolved & strictly
followed.
16) Frequent training & education should be made to promote interest, better understanding
& for active participation.

23.3 STANDARDS
For comfort of normal human, the environment requirement is:
Temperture - 200C to 270C
Humidity - 50%
Velocity - 0.5 m/s
Dust - 1 micron
Noise - 90 dB

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Light - 65 lux
Electricity - 100 mA
Vibration - 500 Hz
Water - 4 ½ litres/day
O 2 Consumption - 40 litres/minute
Oxygen level in air - 20%

14.5 Personnel Protective Equipments (PPEs)

PPE is the last choice in preventing hazard, if unable to be controlled by engineering

method, but first choice in adopting. It is a barrier between person & hazard.
Importance of PPEs :
1) Iit should provide adequate protection
2) It should confirm BIS standards.
3) It should have minimum weight but maximum comfort.
4) It should not restrict essential movement
5) It should be durable & susceptible.
6) Aesthetic
7) It should be easy to use

PPE

Respirator on Respiratory

Eg:
1) Head protection (helmet)
2) Eye protection ( goggles)
Decontamination Segregated external supply 3) Leg protection (shoe / gum boot)
of local air, by of O2 deficient places. i.e 4) Hand protection (gloves)
filtration, Breathing Apparatus. 5) Ear protectionearplus, (earmuff)
absorption etc 6) Body protection (firesuit)
etc,.
Eg: Eg:
1) Canister Gas 1) SCBA
Mask 2) Compressed air line
2) Dust Mask breathing apparatus
3) Short distance breathing
apparatus

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23.4.1 Respiratory Protection:

Respiratory type PPEs are meant for protecting against contaminated air & provide clean
air. Some of the normally used respirators are discussed below

14.5.1.1 Canister:
This is a face piece connected through flexible hose to a container containing neutralizing
chemical. Chemicals in the container purify contaminated air not exceeding a
concentration of 2% by volume. Hence selection of chemicals is important. More than one
canister need to be interconnected at times.
Life time of canister falls from few minutes to hour based on concentration of the impurity,
exposure & amount inhaled by the user. Because of face piece leak, this is not
recommended. (life of small canister will be generally for 20 minutes).
Colour coding of some Canister types ( Source: IS 8318-1977)
1) Black - Organic vapour
2) White – Acid gases
3) Yellow – Organic vapour & Acid gases
4) Green – Ammonia
5) Brown – Ammonia, Organic vapour & Acid gases
6) White with Green strips – Hydrogen cyanide gas
7) White with yellow strips – Chlorine
8) Blue - Carbon Monoxide
9) Red - Carbon Monoxide, Ammonia, Organic vapour & Acid gases

23.4.1.2 Dust Mask

This is a face piece with single or double filters of lint, cotton, wool, etc, which can be
replaced when plugged with particulate matter. This is generally used for nuisance dust &
pneumoconiosis producing dust, powder, and mists having TLV less than 0.1 mg/m of air.
Resin impregnated wool filter can also be used for dust of 10 micron or less.
This is not suitable for toxic atmosphere.

23.4.1.3 SCBA:
Self contained breathing apparatus has a compressed air or oxygen cylinder which supplies
breathing air or oxygen required through a flexible hose to the face piece. Generally used
in oxygen deficient environment & toxic gas environment of high concentration. Different
types of SCBA are available like Regenerative type, Open circuit type, etc,. Regenerative
type is generally not recommended for normal usage, but only in special cases.

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Open circuit type:

This arrangement have a cylinder on the back with air regulated through hose to face
piece. SCBA in our refinery is 1840 litres of 204 bar pressure. Life time is for 36 minute at
a normal consumption of 40 LPM. 170-180 bar is minimum allowable pressure to use the
cylinder. Whistle will sound when the pressure reaches to low level.
Short distance fresh air breathing apparatus:
Face piece is linked by flexible hose to uncontaminated atmosphere. Air is supplied either
by self inspiratory method or by hand operated blower. Direction of wind
Note: Effects of O2 on human
1) 18% - Normal (for any vessel entry)
2) 17% - Loss of co-ordination
3) 10-14% - Faulty judgement
4) 6-10% - Loss of consciousness.

23.4.2 Non Respiratory Protection

23.4.2.1 Head Protection:

Head is the central nervous system of human. Helmets are used to protect the head from
the falling objects, accidents, Sparks etc.
As per IS 2925:1984 Helmets should withstand a lead ball of weight 500 gms falling from
3 m height, with brim radius not exceeding 0.5 mm from saddle & Peak angle < 360 .

HELMET PARTS DESCRIPTIO

Saddle Dissipates Load
Chin Strap Holds Helmet
Peak Protects Nose & Eyes from falling objects
Brim Deflects the falling objects on shoulder
Ventilation Ports Circulates Air
Head Band Shock Absorber

Different types of helmets and their brief description:

Type Material Protection

Safety Helmet PVC, Fibers, Aluminium Falling & Hitting objects
Electrical Helmet Non conducting Electric shock
Welders cap Leather with cloth lining Sparks
Crash Helmets Plastic, Fibers Road accidents ( prevents skull)

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23.4.2.2 Eye Protection:

Eye is the window between the world & individual. Goggles/Face shield are used to
protect the eyes from flying objects, radiation etc,.
As per IS 8521:1977, face shield should withstand a impact of steel ball whose radius is 22
mm & weight 44 gms dropped from a height of 1.5 m. It should withstand a temperature of
550C for a ½ hour period. It should also withstand UV radiation for 100 hours from a
Xenon lamp at a distance of 300 mm.

Different types of Eye protection and their brief description:

Type Material Protection

Spectacle Goggle Shatter proof toughened glass Flying objects
Pannoramma Light weight Oil, Paint splashes
Chemical goggles Acid/Alkali resistance Chemical dust & splashes
Welding goggles Fiber glass UV rays
Face shield Fiber glass Infra red
Gas tight goggles Air tight fitting Irritating fumes, vapour, etc.

Note: Goggles are cleaned with Formalin solution for 5 minute (1 part of 40%
formaldehyde in 9 parts of water). Expose to steam/hot water for 5 minute & finally clean
with soap in hot water.
Goggles should meet IS 2553:1977

23.4.2.3 Ear Protection:

Normal human audible range is between 20 – 20000 Hz. Optimum audible range is
between 500 – 5000 Hz. Ear plugs/ Ear muffs are used to protect the ears
from noise.

STADARDS
TIME (Hour) DECIBELS (Allowable)
8 90
6 92
4 95
2 100
1 105
1/2 110
1/4 115

Ear plugs – Ear plugs are used to reduce the noise level by 30 – 40 decibels.
Disposal, Semi disposable & reusable are different types available in ear plugs.

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Ear muffs – Ear muffs are used to reduce the noise level by 40-50 decibels. Cup, Cushion
&
Spring loaded head band are different parts of the ear muff.
(
ote: Tree reduces the noise level by 30 decibels.).

23.4.2.4 Foot Protection

Tool used to move human comfortably. Safety shoes are used to protect the foot.
As per standard IS 11226:1985 safety shoe should withstand a clearance of 13 mm when
14 kg mass is dropped from a height of 1 m. Toe caps plate thickness should be 1.4-1.6
mm. Ankle Height should be 12 cm & hardness 55A

Different types of Foot protection and their brief description:

Type Material Protection

Safety Shoe Leather shoe with metal cap & Falling & striking objects
neoprene soles
Electrical shoe Non conducting material Shock
Chemical shoe Rubber, Vinyl Chemicals
Fire Shoe Aluminized over the shoe Direct flames
Gum boots Rubber, vinyl Watery areas

23.4.2.5 Safety Belts & Lifelines:

Whenever any worker is engaged on work at a place from which he is liable to fall more
than 2 meters, he shall be provided with safety belts equipped with life lines which are
secured with a minimum slack, to a fixed structure unless any other effective means such
as provision of grand rails or ropes are taken to prevent his falling.
All safety belts & lifelines should be examined once in six months by a competent person
to ensure that all belts or lifeline are in good condition. Standards are made in IS
3521:1983.
Life jackets should confirm to the IS 6685:1972 which state that it should with stand
temperature of 13000 C for one hour with out water spray.

23.4.2.6 Hand protection:

Hand is a tool to perform all physical jobs. Adequate protection for the hands shall be
available for all workers when using cutting or welding apparatus, working in hot
atmosphere, handling chemicals etc,.
The protective device may be Gloves, Gantlets, Hand pads, Thumb & finger guard &
sleeves.
Gloves (Leather & Cotton) are as per IS6994:1973 standards

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Different types of Hand protection and their brief description:

Type Material Protection

Leather Gloves Leather with or without metal mesh Cuts, Abrasives, Heat, Flame
Aluminized Fabric Aluminium Flame & Heat
Gloves
Asbestos Padding Inside Flame & Heat
Rubber Gloves Acid, Alkali Proof Chemical
Electrical Gloves Non Conducting Electric Shock
Barrier Cream Mineral Oil with an inert base like Contact Dermatitis
zinc oxide (water soluble/ Water
Repellent)
Canvas Fabric Slipping, Oily, Grease
Lead Lined Gloves Plastic or Leather Ionising Radiation

23.4.2.7 Body Protection:

Body protection devices are Aprons, Overalls & complete head to foot suits. Nature of
potential hazard, degree of the hazard involved & nature of activities of the person
concerned are important considerations in the selection of safety clothings, although
complete coverage of the body and legs are not needed in many cases and unnecessary
safety clothing may hamper the efficiency of the worker. If a worker needs complete
coverage, he should have it.

Different types of Body protection and their brief description

Type Protection
Leather Hot Material
Asbestos Heat
PVC Chemical
Lead Radiation
Fire Suit Direct Flame
Water Gel Heat Shielding

As per IS6685:1972 fire proximity should with stand 13000 C for one hour without water
spray
Water Gel shelf- life period is 3 years & its general sizes are 8"*6", 6"*5"

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14.6 FIRE
Fire is the chemical reaction between combustible material & O2 to give heat & light.
(note: Oxidation is reaction with O2 which can be either endothermic or exothermic. If
exothermic it is called combustion)

FUEL
HEAT
HEAT
FUEL FIRE FIRE
TRIANGL TETRAHEDRO
E

OXYGEN
UNINTERUPTED
OXYGEN
CHAIN
REACTION

Chain Reaction: H2 – O2 combustion is taken as example.

The activation energy dissociates Hydrogen molecule into atoms. These atoms collide
with oxygen molecule to form OH radical. This radical in turn collides with hydrogen
molecule to form water molecule & releases the hydrogen atom to continue the reaction.
The oxygen atom released in the earlier collision now reacts with hydrogen molecule to
form OH radical & releases one hydrogen atom to carry on the reaction.
The combustion process of all other heavier molecules takes place in similar reactions &
influences the combustion.

COMBUSTIO

SLOW RAPID SPONTANEOUS

Only Heat, No light Rapid evolution of heat & Oxidation without
appreciable amount of any external source
Eg: Cotton waste light
combustion Eg: Phosphorous
Eg: Petroleum Products

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STAGES OF FIRE

ICIPIET SMOULDERIG FLAME HEAT

Invisible Visible products of Actual fire but Uncontrolled
products of combustion appreciable heat is heat & rapidly
combustion i.e No visible light not present but expanding in
i.e No visible or heat, but visible follows space
smoke, light or smoke instantaneously
heat

CLASSES OF FIRE

A B C D E
Combustible Flammable Gaseous fire Metals & Electrical
Solids Liquids Chemicals
Extinguisher:
Extinguisher: Extinguisher: Extinguisher: Extinguisher: Sand, DCP,
Water, Sand, Sand, DCP, DCP, CO2 Sand, DCP CO2, Halon
Soda Acid type Foam, CO2,
Halon

14.7 Fire Protection System:

Fire protection system is based on number of factors like class of fire, its toxicity,
explosive nature, reactivity nature, danger to personnel, availability of water, Effect
on plant etc.

FIRE PROTECTIO SYSTEM

DETECTIO TYPE EXTIGUISHIG TYPE

Flame detector All extinguishers
Smoke detector Sprinkler systems
Camera

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14.7.1 Fire Extinguishing Technique:

Starvation: Efforts directed to remove fuel

Smothering: Efforts directed to remove oxygen (either by dilution or substitution)
Cooling: Efforts directed to remove heat
Blanketing: Efforts directed to cut mixing of fuel & oxygen

23.6.2 Fire Water etwork:

Refer to utility system in OHCU manual topic o: 24.15

Fire water Hose Specification:

Material of construction – Synthetic
Operating Pressure - 10 KSC
Testing Pressure - 24 KSC
Length - 30 m

23.6.3 First aid fire fighting equipment

All first aid fire fighting equipment should conform to the relevant BIS standards. To
mention a few:
• All shall be in similar shape & appearance
• All shall have same method of operation
• All shall be placed such that they are easily & readily accessible.
• All shall be allotted a serial number
• Following details shall be painted 1) Serial Number, 2) Date of last filling, 3) Date
of last inspection

23.6.3.1 Water Type Extinguisher:

Water expelling fire extinguishers have water as an extinguishing agent, which is released
in the form of a jet by means of gas pressure in the upper part of the container. Gas
pressure may be induced by chemical reaction or by mechanical means. This type is
predominantly used for Class- A fire. On application water is converted into steam which
in turn will have smothering effect.
To operate the extinguisher, remove the extinguisher from the socket, position the
extinguisher at suitable location, remove the safety cap & strike the plunger, direct the jet
emerging from the nozzle on the base of the fire.
Soda Acid Water extinguisher: Gas pressure is developed because of reaction between
sulphuric acid (plunger strikes the acid bottle) & sodium bicarbonate solution to release
CO2. CO2 generated creates pressure, which forces the water out.
Gas pressure type: Gas catridge forming the inner container, with CO2 under pressure is
released when plunger is striked.

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Constant air line: Dry air is introduced through air line, till the desired pressure is built up
& sealed hermetically. While activation safety pin is withdrawn & valve lever is depressed
resulting in a jet of water through the hose.

23.6.3.2 Foam Type Extinguisher

This type is suited for class B fires. The foam expelled by actuating forms a blanket over
the surface of the liquid on fire & gets over the contact of the burning liquid with air thus
extinguishing the fire.

Construction – The foam type extinguisher consist of two containers, the inner & the outer.
The outer container holds a solution of sodium bicarbonate to which a foam stabilizer is
added. The inner container contains solution of Aluminum sulphate. When operated the
solution intermixes producing foam that is expelled from the extinguisher.
Note: CPCL reserves one Lakh liters of foam, which is sufficient for 2 major fire at a time.

23.6.3.3 Dry powder Type Extinguisher

This type is used for class B & C predominantly. The free radicals which are responsible
for sustaining any fire are put out of action by the dry chemical powder (i.e. undergoes
chemical reaction) & because of this, the fire dies out very fast.
Composition of DCP: Sodium bicarbonate – 97%, Magnesium sulphate – 1 ½,
Magnesium sterrate – 1%, Tri calcium phosphate 1/2%.
Composition of Ternary eutectic powder for Radioactive materials: Sodium chloride –
20%, Potassium chloride – 29%, Barium chloride – 51%.
The chemical powder is contained in the main shell & CO2 in sealed cartridge or in
separate storage vessel. Operation is similar to water type extinguisher.
(ote: Effective jet length – 3mt, duration 25-30 sec for a cartridge weight of 200 gms.
Stand 5 to 8 feet away & direct the stream near the seat of the fire, progress forward,
moving the nozzle rapidly with a side to side sweeping motion. Always operate from the
up wind side of the fire. Since wind forms a parabolic shaped cloud, prefer movement in
perpendicular direction.)

23.6.3.4 CO2 Type Extinguisher

This type of extinguisher extinguishes by smothering method. Predominantly used for
Class-C & Class-E (caution: not to be used in fire involving chemicals that contain their
own oxygen supply & fire involving reactive metal such as sodium potassium &
magnesium).
CO2 in liquid form is stored under pressure up to 2/3rd by weight of its total water capacity.
Carry the extinguisher to the place of fire, remove the safety pin, operate the discharge
device or unscrew the valve depending on the design. CO2 is discharged through HP
flexible hose & horn.
Direct the stream near the seat of the fire, progress forward, moving the nozzle rapidly
with a side to side sweeping motion. Always operate, from the up wind side of the fire.
Since wind forms a parabolic shaped cloud, prefer movement in perpendicular direction.

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ote: The gas at the time of discharge makes considerable noise. The user should therefore
be well conversant with its operation to prevent the jet from being misdirected during the
first few vital seconds. Performance duration will be 25-30 sec for 6.8 kg capacity).

23.7 FIRE ZONE CLASSIFICATION:

Class A: Zones having large quantities of air flowing past regular arrangements of similar
shaped obstruction
Class B: Zones having aerodynamics clean obstruction
Class C: Relatively small air flow
Class D: Very little or no air flow
Class X: large air flowing through them & are of unusual construction making
extinguishment very Difficult

According to NFPA (
ational Fire Protection Association), fire hazard identification

technique provides quick, on the spot information to protect the lives of fire fighting
personnel & identify any threats to the public safety during any fire

umber rating for hazard:

For Health
0 – Material pose no health hazard
1 – Material pose slight health hazard (PPE recommended for respiratory)
2 – Material pose moderate health hazard (PPE recommended for Eye & Nose)
3 – Extremely dangerous (full PPE recommended)
4 – Too dangerous to health –fire (evacuation)

For Reactivity
0 –Stable
1 – Unstable at elevated temperature
2 – Unstable at moderate temperature
3 – Unstable at low temperature
4 – Unstable at normal temperature

For Flammability
0 –Stable under fire
1 – Unstable at elevated temperature
2 – Unstable at elevated temperature but don't detonate
3 – Unstable at low temperature & detonate
4 – Unstable at normal temperature & detonate

FLAMMABILITY
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Flammable vapours are those, which exist below critical point & can be liquified by
pressure alone. Hence they are heavier than air & have low explosive range
Flammable gas are those which exist above critical point & can't be liquified by pressure
alone. Hence they are lighter than air & have wide explosive range
Flammable liquids are those which does not vapourises at atmospheric pressure &
temperature
Inflammable liquids are those, which vapourises at atmospheric pressure & temperature

Flammability:
It is that property of substance, which is capable of getting ignited when any ignition
source is available in the vicinity

Liquid classification

Flammable liquids: Combustible liquids: having

having flash point above flash point below 1000 F
1000 F

Gas classification

Flammable having Highly flammable having Extremely flammable having

Flash point Flash point Flash point
21 – 50 0 C 21 – 50 0 C 21 – 50 0 C

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Flammability Limit

Lower Flammable limit Upper Flammable limit

(LFL) (UFL)
Below which flame can't Below which flame can't
propagate propagate

SUBSTACE LFL % UFL %

Natural Gas 4.5 14.0
H2 4.1 74.2
NH3 16.0 25.0
Gasolene 1.3 7.6
JP5 0.8 6.2
H2S 4.4 46
Chlorine 4.0 8.1
Acetylene 2.5 81

Note: Formulae to find the LFL = P / 14.7

Where – P is the vapour pressure in psi(a) at flash point

14.8 Safety practices when working at height:

• when the height is more than 2 meter then safety belt & life line is must.
• For scaffolding, distance between cross bar should be 2 meter & between vertical bar
should be 1 – 1.5 meter.
• No work should be carried out without PPE.
• Machinery in the vicinity should be completely guarded, immobilized, power guarded
& affixed with warning notice.
• All means of access should be made clear before commencing.
• Crawling boards should always be used when working on roof.
• Ladder when used should have the toe distance placed at 1/4th of the height from the
wall.
• Openings should be guarded with railings.
• Lower edge of the floor should be provided with stoppers.
• Always breakfast before commencing work.
• Lock off electrical supply for overhead cranes.
• Always use tool kit.
• Barricade the area.

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23.9 APPEDIX

23.9.1 Terminology

TLV
Thresh hold limit value, which is the airborne concentration of substances & represent
condition under which it is believed that nearly all workers may be repeatedly exposed day
after day without adverse effect.

TLV-TWA: Time weighted average concentration, which is the concentration, where

nearly all workers in a normal 8 hours workday may be repeatedly exposed day after day
without adverse effect

TLV-STEL: Short term exposure limit, which is the maximum concentration to which
workers can be exposed for a period upto 15 minutes continuously without suffering from
irritation, chronic or irreversible tissue change or narcosis.

TLV-C: Ceiling, which is the concentration that should not be exceeded even
instantaneously.

Eg:

SUBSTACE TWA(ppm) STEL(ppm)

Ammonia 25 35
Carbon monoxide 50 400
Hydrogen sulphide 10 15
Gasoline 300 500
Oil Mist 0.1 0.3
Sulphur Dioxide 2 5
Chlorine 1 3
NOx 25 30

TLV is categorized into four major groups such as Category A, B, C & D.

Category A : No effect during life time
Category B : Reversible effect, but no definite state of disease
Category C : Reversible disease
Category D : Irreversible disease.

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23.9.2
ILLUMINATION:
Under factory act 1948 the standard for illumination is 65 lux measured in horizontal plane
at a level of 91.4 cm above the floor. 25 lux if the lighting mounted above 7.6 mts for
general illumination & 65 lux for working spot. If the artificial light source is less than 4.9
m above the floor level, no part of the light source or the light fitting having a brightness
greater than 1.5 candles per square centimeter shall be visible to the person at an angle of
200 with 30.5 meter distance.
DUST:
Fine particle suspended in air, produced due to disintegration of substances during
grinding, pulverizing, etc.
FUMES:
Fine particle suspended in air, produced due to condensation of Vapour State of solids.
VAPOURS:
Gaseous form of substances which are liquid at ordinary temperature.

23.10 COLOUR CODING IN REFINERY

23.10.1 Uninsulated Equipment

1) Furnaces, APH Duct, DFAH & Regenerators ( FCCU) – ALUMINIUM

2) Columns & Vessels, Heat Exchangers, Drums & Tanks – OPALINE GREEN
3) Motors, Pumps & Compressors - SMOKE GREY

23.10.2 Uninsulated pipelines

1) HC/Combustible lines - GOLDEN BROWN

2) FG/H2/H2S/N2/IG/CO/CO2/Amine services - GOLDEN YELLOW
3) Acids/Alkalies, Ammonia & Chlorine - WILD LILAC
4) All water lines other than fire water - AQUAMARINE
5) Fire water lines - POST OFFICE RED
6) Flare lines - ALUMINIUM

23.10.3 Uninsulated storage tanks, spheres & bullets

1) Crude, MS, HSD, Kero/ATF, Naptha & slop tank - ALUMINIUM

2) FO, LSHS tank - BLACK
3) Lube Oil tanks - GOLDEN BROWN
4) DM water tank - AQUAMARINE
5) Acid tank - WILD LILAC

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6) Solvent tanks - WHITE

7) LPG bullets & sphere - WHITE WITH
GOLDEN YELLOW BAND
8) Butylene bullets - WHITE WITH
LIGHT GRAY BAND
9) Ammonia bullets - WHITE WITH
WHITE LILAC BAND
10) Propane sphere - WHITE WITH BLACK BAND
11) Propylene & sphere - WHITE WITH
GOLDEN BROWN BAND

23.10.4 Valves, structural & cable trays

1) Alltypes of valves other than safety valve - ALUMINIUM

2) Safety / Relief valves - GOLDEN YELLOW
3) Pipe rack structure & all beams - OPALINE GREEN
4) Ladders, Platform, Hand rails - BLACK & GOLDEN YELLOW
5) Electrical & Instrument trays - ALUMINIUM

23.10.5 Cylinders

1) Chlorine - GOLDEN YELLOW

2) Ammonia, O2, CO2 - BLACK
3) Air, N2 - FRENCH GREY
4) Acetylene - MEROON
5) CO, H2, CH4 - SIGNAL RED
6) SO2 - LIGHT GREEN
7) Cyanide, Organic gas - PEACOCK BLUE
8) He - BROWN

23.11 Effect of dc current on human

DC Voltage Effect
0-5 No sensation
6-55 Mild shock
60-80 Painful shock
80-100 Loss of muscular control
110-350 Shock & loss of muscular control
400-800 Possible heart failure
Over 800 Fatal

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23.12 EFFECT OF RADIATION

Radiation level Effect

kW/m2
0.7 Nil ( solar radiation)
1.6 No discomfort
4.5 Cause pain & blister
12.5 Melt plastic & ignite wood
25 Ignite wood
62 Spontaneous ignition of wood

23.13 ACCIDET
Unplanned or unexpected event creating loss to men, material or machine. All accidents
can be attributed to either Unsafe acts or Unsafe condition. An injury invariably results
from a complete sequence of factors, the last one is injury itself.

The sequence of an injury is

1) Social environment
2) Fault of a person
3) Unsafe act or condition
4) Accident
5) Injury

Hence it is easier & most effective to remove the center domino unsafe act or condition.
Some of unsafe conditions & acts:

Unsafe Act: Making safety devices inoperative, operating the equipment without
authority, working on moving or dangerous equipment, failing to shut off or to secure
equipment, unsafe loading or placing, etc.

Unsafe Condition: Hazardous arrangements, Improper guarding, Equipment defects, etc,

If we deal only at the symptomatic level for any accident, the act or condition may be the
proximate cause, but invariably it is not the root cause. To effect permanent improvement
we must find out the root cause of any incident. Root cause is often related to the
management system. They may be due to management policy, its procedure, supervisions
& its effectiveness, training, etc.

Normally the cost involved or the losses in an accident is not evident to the full extent &
hence people don't have the awareness over it. The direct which could be explicitly
quantified & represent the compensation to the accident victims & medical expenses borne
by the management towards the injured persons in an accident are taken care of while
computing the cost of industrial accidents.. It is estimated that the direct cost amounts to
25% of the total cost and the rest i.e. indirect cost amounts to 75%)

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ACCIDET

WITH WITHOUT
INJURY INJURY

FIRST AID LOSS TIME

NON REPORTABLE
REPORTABLE (more than 48 hrs)
(within 48 hrs)

SERIOUS NON SERIOUS

(more than 24 hrs) (less than 24 hrs)

FREQUENCY RATE (F) = (Number of Injuries/disabling) / (Million Man hour) * 106

SVERITY RATE (S) = (Number of Days Lost) / (Million Man hour) * 106

FSI FACTOR = √(F*S)/1000.

This is used to find the performance of a company or used to compare the same between
different companies.

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23.14 BODY POSTURE STANDARDS

380 mm
TABLE

300 100 mm

Note: Heavy Work needs 8 – 10 kcal/min of energy at a pulse rate of 130 – 150 per minute.
Light Work needs 2.5 – 8 kcal/min of energy at a pulse rate of 90 – 130 per minute.

23.15 MSDS:
Material Safety Data Sheet which contains all information regarding that
substance/chemical. Refer chemical handled in this OHCU manual

23.16 TREM CARD:

Transport Emergency Card, is intended to meet the need for a uniform system, for
enabling the driver on a road in vehicle carrying dangerous hazardous substance to have
throughout the journey clear information in writing on the immediate action to be taken
either by the driver himself or by any personnel present in the event of emergency. This is
a legal requirement.
Eg:
W - Means don't use water

23.17 HAZCHEM PANEL:

Hazardous Chemical Panel is a panel placed in truck giving information like substance
carried, Its nature, contact number on emergency, action to be taken during emergency,
NFPA classification number, nature of the substance, extinguisher type to be used in case
of fire, etc.

EXPLOSIVES
RISK

RADIOACTIVE

OXIDISING

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As per NFPA IS1446:1959 HAZCHEM panel number description

• 1 - Explosives
• 2 – Gases compressed, Liquified under pressure
• 3 – Flammable Liquids
• 4 – Flammable Solids
• 5 – Oxidizing substance
• 6 – Poisonous substance
• 7 – Radioactive substance
• 8 – Corrosive substance
• 9 – Miscellaneous

Description of the number & letter (for eg: 2YE)

umber indicates the Letter indicates the PPE requirement

fire method Dilute with water Prevent Spillage
1 – Jet type applicant P- violently reactive Full PPE P- violently reactive Full PPE E - means
2 – Fog type applicant Req. Req. Evacuation
3 – Foam type R - Full PPE Req. R - Full PPE Req. preferred
applicant S- violently reactive BA Req. S- violently reactive BA Req.
4 – DCP type S* - violently reactive BA Req S* - violently reactive BA Req
applicant on fire on fire
T – violently reactive BA Req. T – violently reactive BA Req.
T* - violently reactive BA Req T* - violently reactive BA Req
on fire on fire

International MSDS number will also be painted on the panel for verification of the
detailed properties of the material transported (eg: 1203 for MS, 1075 for LPG, 1073 for
O2 etc)

H2S NH3 LPG CAUSTIC DEA Ni(CO)4

U.No 1053 1005 1075 1824 - -
H.CODE 2WE 2PE 2WE 2R - -
BP °C -60.4 -33.3 -40 102-140 217 42.8
AIT °C 260 651 466.1 - - 60
LEL % 4.5 16 1.9 5 1.6 2.0
UEL % 45 25 9.5 50 10.6 -
TLV PPM 10 25 1000 - - 0.5
STEL PPM 15 35 - - - -

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23.18 FIRST AID

A mandatory knowledge for all human in the world.
Its aim is to preserve life, assist recovery & prevent aggravation until the services of a
medical export can be obtained or during a shifting of the victim to the hospital in the
immediate vicinity.

Golden rules of First Aid:

• Do first things first without panic
• Give artificial respiration if breathing has stopped, as every second counts
• Stop any bleeding
• Treat for shock by moving the casualty as little as possible & handling him gently
• Do the minimum that is essential to save & prevent conditions from worsening
• Reassure the casualty to lessen the anxiety
• Arrange for the removal of the casualty to the care of a doctor or hospital

Let us discuss a few common issues & the rules to be followed.

WOUND:
Break in the continuity of the tissue & permit the escape of blood & disease producing
germs
Rules of First Aid treatment for wounds:
1) Place the casualty in a suitable position, such that blood escape from the wound is
least. It is less when the patient lies down
2) Elevate the bleeding part, except in case of fractured limbs
3) Do not remove any blood clot already formed
4) Remove carefully any foreign body visible with a clean dressing
5) Apply & maintain pressure with a clean pad so that blood flow will lessen
6) Apply a sterile dressing, pad or bandage
7) Immobilize the injured part so that blood flow will slowly stop
Internal wounds cannot be seen & should be treated by doctor only, hence remove the
patient to hospital quickly

SHOCK:
It is a condition of severe depression of vital functions
Rules of First Aid treatment for Shock:
1) Reassure the patient
2) Lay him on his back with the head low & turned to one side unless there is injury in
the head, abdomen or chest when the hand & shoulders should be slightly raised &
supported.
3) Loosen clothing about neck, chest & waist.
4) If thirst is there give sip of water, tea & not alcohol
5) Do not apply heat or friction to the limbs

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6) In severe bleeding, don't give any liquid beverage by the mouth. Remove urgently to
the hospital.

ASPHYXIA:
Any thing, which interferes with respiration, produces asphyxia
EARLY STAGE SIGNS
1) Dizziness & Weakness
2) Shortness of breath
3) Rapid Pulse
4) Giddiness
5) Congestion of the face with blueness of cheeks & lips.

Rules of First Aid treatment for Asphyxia:

1) Remove the casualty from the cause first
2) Ensure there is free passage of air
3) Apply artificial respiration if needed without any loss of time, every second counts
4) Provide warmthness of body
Rules of First Aid treatment for suffocation by Smoke
Protect by tying a towel or handkerchief preferably wet over mouth & nose. Remove the
casualty to fresh air.

ELECTRIC SHOCK:
It is the passage of electric current through body.
Rules of First Aid treatment for Electric shock:
1) Cut off electrical supply.
2) Rescuer should stand on a dry rubber mat.
3) Give artificial breathing.
4) Transfer the victim to hospital as quickly as possible.

BURNS & SCALDS:

Discontinuity of the skin due to fire, hot piece of hot metal, friction, chemicals, moist heat
like hot water etc.
Rules of First Aid treatment for Burns & Scalds:
1) Avoid handling the affected area more than is necessary
2) Do not apply lotion or ointments yourself.
3) Do not remove burned clothes sticking to the burned skin & do not break the
blisters.
4) Cover the area with dry sterile dressing if available.
5) Immobilize the affected area by suitable means, Treat for shock.
Rules of First Aid treatment for Burns by Corrosive chemicals.
1) Flood the area with plenty of cold water.

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2) Bathe the parts with dilute baking soda solution.

UNCONSCIOUSNESS:
It is the any disturbance to the brain function
Signs & symptoms are unconsciousness followed by a period of stupor, face is flushed,
breathing is noisy, pulse is slow, body & head temperature may be raised, eyes become
unequal & dilated and paralysis of one side of the body may be present.
Rule of First Aid treatment for unconsciousness:
Shift the casualty for immediate medical treatment

STROKE:
It is a disturbance to blood pressure or supply.
Signs & Symptoms:
Head ache, dizzeness, Vomiting, Abdominal cramp, Collapse, Temperature raise.
Rules of First Aid treatment for Stroke:
1) Place the casualty in a cool, airy place
2) Give cool salted water ( 4 gm in 400cc water)
3) Watch carefully & assist for medical aid

POISONS
Rules of First Aid treatment for Poison:
1) For injected poison send for medical aid at once
2) If the casualty is unconscious, place the head turned to one side on ground.
Give artificial breathing if feeble.
3) For swallowed poison, if casualty is conscious, induce vomiting. Emetic of 10 gms of
salt in one tumbler of water may help vomiting.
4) For alkali poison, do not induce vomiting. Give two spoon of lemon or orange juice
5) For acid poison, do not induce vomiting. Give plenty of water with milk of magnesium
6) For disinfectant, do not make vomit. Give two spoon of Epsom salt in a tumbler of
Water.
7) For other poison induce vomiting. Some antidotes may be activated char, egg white,
buttermilk, etc.

KNOW ABOUT FIRST AID KIT

Contents of Kit box A type

1) Assorted Sterile dressings 6) Scissors, safety pins
2) Paper tissue 7) Note book & pencil
3) Roll bandages (5cm * 8cm) 8) Smelling salt
4) Cotton wool (100gm) 9) Tincture Iodine
5) Measuring glass 10) Milk of Magnesia

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23.19 FIRST AID MEASURES

AMMOIA
Inhalation : Remove the victim to fresh air area, provide artificial respiration or
oxygen, if needed.
Eyes : Flush with plenty of water for 15 mins. Seek medical aid.
Skin : Remove the contaminated clothes and wash the affected area with plenty of
water and soap

H 2S
Inhalation : Remove the victim to fresh air area, Provide artificial respiration or
oxygen if needed .
Eyes: Irrigate with plenty of water for 15 mins.
Skin : Remove the contaminated clothing and wash the affected area with plenty of
water and soap. Seek medical aid immediately medical aid immediately

LPG
Inhalation : Remove the victim to open air area & artificial resuscitation may be
provided if required
Skin :Remove the Clothing & wash the affected area with plenty of water. Seek
medical aid

CAUSTIC
EYE: Flush eyes with water immediately while holding the eyelids open. Remove
contact lenses, if worn, after initial flushing, and continue flushing for at least
15 minutes. Get immediate medical attention.
Wash skin immediately with plenty of water and remove contaminated clothing and
shoes. Get medical attention. Discard contaminated clothing and shoes or thoroughly
clean before reuse.
IGESTIO: If swallowed, do not induce vomiting. Give the person a glass of
water or milk to drink and get immediate medical attention. Never give anything by
mouth to an unconscious person.
IHALATIO: Move the exposed person to fresh air. If not breathing, give
artificial respiration. If breathing is difficult, give oxygen. Get medical attention if
breathing difficulties continue.
OTE TO PHYSICIAS: Probable mucosal damage may contraindicate the use of
gastric lavage.

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i (CO)4
Eye: Flush eyes with water immediately while holding the eyelids open. Remove
contact lenses, if worn, after initial flushing, and continue flushing for at least 15
minutes. Get immediate medical attention.
Skin: Wash skin with water immediately and remove contaminated clothing and
shoes. Get medical attention if any symptoms develop. To remove the material
from skin, use soap and water. Discard contaminated clothing and shoes or
thoroughly clean before reuse.
Ingestion: If swallowed, do not induce vomiting. Give the person a glass of water
or milk to drink and get immediate medical attention. Never give anything by
mouth to an unconscious person.
Inhalation: For emergencies, wear a NIOSH approved air-supplying respirator.
Move the exposed person to fresh air. If not breathing, give artificial respiration.
If breathing is difficult, give oxygen. Get immediate medical attention.

23.20 HAZOP study

It is a fundamental method of hazard identification. HAZOP (Hazard & operability) study

is a procedure for the systematic, critical examination of the operability of the process.
When applied to a process design or an operating plant, it indicates potential hazard that
may arise from the deviation from the intended design conditions. (Hazard Analysis is the
technique for quantitative assessment of a hazard, after an operability study or similar
technique has identified it).

Basic principles:
It is the systematic study of the design vessel by vessel, line by line, using the guide word,
to help generate thought about deviations from the intended operating conditions can cause
hazardous situations. The seven guide words recommended by chemical industries
association are given below. In addition to these words the following words are also used
in a special way & have the precise meaning given below:

Intention: The intention defines how the particular part of the process was intended to
operate,
the intention of the designer
Deviation: These are departure from the designers intention which are detected by the
systematic application of the guide words
Causes: Reasons why & how the deviations could occur. Only if the deviation can be
shown to have a realistic cause, it is treated as meaningful
Consequences: Reasons the results that follow from the occurrence a meaningful
deviation .
Hazards: Consequences that can cause damage (loss) or injury

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Table of List of Guide Words

Guide Words Meanings Comments

No or Not The complete No part of the intentions is achieved but nothing else
negation of these happened
intentions
More Quantitative These refer to quantities & properties such has flow rates &
increases temperatures as well as activities like heat & react

Less Quantitative These refer to quantities & properties such has flow rates &
decreases temperatures as well as activities like heat & react
As Well As A qualitative All the design & operating intentions are achieved together
increase with some additional activity
Part Of A qualitative Only some of the intentions are achieved, some are not
decrease
Reverse The logical This is mostly applicable to activities. For eg: reverse flow
opposite of the of chemical reactions. It can also be applied to substances
intention eg: poison instead of antidote
Other than Complete No part of the original intention is achieved. Some thing
substitution quite different happens

Further explanation for other guide words:

As Well As: some thing in addition to the design, intention, such as impurities, side
reactions, ingress of air, extra phases present.

Part Of: some thing missing, only part of the intention realised, such as the change in
composition of a stream, a missing component.

Reverse: The reverse of, opposite to the design intention. This could mean the reverse
reaction. In heat transfer it could mean the transfer of heat in the opposite direction to what
was intended.

Other Than: An important & for reaching guide word but consequently more vague in its
application. It covers all conceivable situations other than that intended such as S/U, S/D
Maintenance, Catalyst regeneration, charging & failure of plant services.
When referring to time the guide words sooner than & Later than can also be used.

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Procedure:
A team of experienced people who have complementary skills & knowledge would
normally carry out an operability study, led by team leader who is experienced in the
technique. The team examines the process vessel by vessel, line by line, using the guide
word previously explained to detect any hazards. The information required for the study
will depend on the extent of investigation. A preliminary study can be made from a
description of the process & the process flow sheet. For a detailed final study of the design
the flow sheets, the P&ID, equipment specification & layout drawings would be needed.
For a batch process information on the sequence of operation will also be required, suc as
that given in operating instruction & flow charts.

A typical sequence of the events is given below. After each line has been studied, it is
marked on the flow sheet as checked.
Steps
1) Select a vessel
2) Explain the general intention of the vessel & its lines
3) Select a line
4) Explain the intention of line
5) Apply guide word
6) Develop meaningful deviation
7) Examine possible causes
8) Examine consequences
9) Detect hazards or operating problems
10) Make suitable annals
11) Repeat steps 6 to 10 for all meaningful deviations derived from the guide
word
12) Repeat steps 5 to 11 for all guide words
13) Mark line as having been examined
14) Repeat steps 3 to 13 for each line
15) Select an auxiliary (eg: engine heating system)
16) Explain the intention of the auxiliary system
17) Repeat steps 5 to 12 for auxiliary
18) Mark auxiliary as having been examined
19) Repeat steps 15 to 18 for all auxiliaries
20) Explain the intention of the vessel
21) Repeat steps 5 to 12 for the vessel
22) Mark the vessel as completed
23) Repeat steps 1 to 22 for all vessels on flow sheet
24) Mark flow sheet as completed
25) Repeat steps 1 to 24 for all flow sheets

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A written annals is normally made for each step in the study, only those deviations that
leads to a potential hazard are recorded. If possible the action needed to remove the hazard
id decided by the team and recorded. If more information of time, is needed to decide the
best action, the matter is referred to the design group for action or taken up at another
meeting of the study team. When using the operability study technique towards process
design the action to be taken to deal with potential hazard will often be modifications to the
control system & instrumentation, the inclusion of additional alarms, trips or interlocks. If
major hazard are identified, major design changes may be necessary: alternative processes,
materials or equipment.

LPG vapouriser
LPG vapouriser taken as sample to explain this concept.
Consider the simple example of the LPG vapouriser. The LPG is fed to the vapouriser from
the pump. For vaporization heating coil has been provided & steam is admitted to the coil
& steam condensate comes out through a trap. LPG vapour leaves through top of the
vapouriser. Now let us apply the guide words one by one systematically
1. Apply the guide word No or Not
a) Possible deviation: No steam flow
b) Possible causes: Blockage in the line, valve failure, failure of steam supply due to
boiler S/D. Clearly this is the meaningful deviation with several plausible causes.
c) Consequences: The main consequences is loss of LPG flow. The effect of this on
the D/S operation would have to be considered. This would be brought out in the
operability study of the D/S unit. It would be a possible cause of no LPG flow
2. Apply the guide word "More"
a) Possible deviation: More steam flow
b) Possible Cause: valve is struck open
c) Consequences: Due to more vapourisation of LPG there will be low level in the
vapouriser
d) Hazard: Depends on the possible effect of more flow of LPG vapour to the D/S
unit.

Note: Work Permit System & Emergency Preparedness plan for CPCL are detailed in
CPCL safety manual.

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CHAPTER-24

UTILITIES
Introduction:
Utility is a mandatory requirement of any refinery for smooth running. There are
varieties of utilities required for running a Refinery. Utilities required for OHCU are
Power, Steam (VHP, HP, etc.), Water (Service, Cooling etc,), Fuel, Air, Inert gas,
Flare, CBD, OWS, CRWS, FW network, Chemicals.
CBD, OWS, FW network, CRWS is dealt in Underground System of this Manual.
Chemicals are dealt in the topic Chemical Handled of this Manual
Rest of the Utilities is discussed below.

Utility conditions: Design Utility battery limit condition for OHCU is as

below:

Table 24.1
Pressure , kg / cm2 g Temperature, 0C
Fluid type
Minimum Normal Maximum Minimum Normal Maximum
Very high pressure
44.8 48 54.9 379 425 435
steam
High pressure steam 29.5 30.5 32.5 250- 270 280 290
Medium pressure steam 9.5 10.5 12.5 200 220 240
Low pressure steam 2.7 3.5 4.0 Saturated 170 190
Boiler feed water – HP 38.0 105
Boiler feed water – LP 19.0 105
Cooling water supply 4.5 33
Cooling water return 2.5 45
Ambien
Nitrogen 5.0 6.0 7.0
t
Fuel gas 2.6 3.5 3.8 40
Fuel oil 10.0 12.0 140 150 210

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24.2 RAW WATER

Raw water is used has Drinking Water, Service Water, Cooling Water & DM Water. The
Reservoir capacity is 36,000 m3 (storage of 2 days normal demand).

24.2.1 Raw Water Quality:

Table 24.2
pH 7.0 - 7.8
Turbidity 15 TU
TDS 496 – 757 mg / l
P-Alkalinity as CaCo3 il
Mo-Alkalinity 150 - 220 mg / l
Total Hardness 160 – 240 mg / l
Calcium Hardness 100 - 160 mg / l
Mg Hardness 60 – 80 mg / l
Total Silica as SiO2 20 – 40 mg / l
Chlorides as CaCo3 140 – 220 mg / l
Sulphates as CaCo3 70 – 110 mg / l
Dissolved Iron 0.3 mg / l
Conductivity 800 – 1200 micro mho / cm
COD 40 ppm
Kmno4 value @1000 C 19.5 mg / l

24.3 DM WATER:
DM water is mainly used for water washer vessel, Steam generation & for neutralization/
chemical tank.
3 Centrifugal Submersible Pump of 465 m3/hr capacity each ( 223 G 2A/B/C)is used for
this service, controlled by Utility Section. 2 DM tank of cone roof type with 3765 m3
capacity is available. Make up for DM water tank is made to & from Co-gen & OPH
Normal consumption of DM water is 323 m3 & Peak Load is 394 m3 .OHCU receive the
DM water by 4" line with FT 9203, PT 9204 ( HAL & LAL) & TI 9204 at plant B/L. DM
line is provided with isolation B/V & a Spectacle blind provision for positive isolation
from other units during M & C, P&ID of this system is attached at the end of this section

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24.3.1 DM water Quality:

Table 24.3
pH 7.0 - 7.8
Turbidity 15 TU
TDS 496 – 757 mg / l
Mo-Alkalinity 240 mg / l
Total Hardness as CaCo3 264 mg / l
Calcium Hardness as CaCo3 176 mg / l
Sodium as CaCo3 344 mg / l
Total Silica as SiO2 20 – 40 mg / l
Chlorides as Cl 172 mg / l
Sulphates as So4 121 mg / l
Dissolved Iron 0.3 mg / l
Total Cation / Anion as CaCo3 608 mg / l
Kmno4 value @1000 C 205 mg / l

24.4 SERVICE WATER:

Service water is used in the plant mainly for Washing purposes.
2 Centrifugal Submersible Pump of 50 m3/hr capacity each (223 G 1A/B)is used for this
service, controlled by Utility Section.
Normal consumption of SW water is 10 m3 & Peak Load is 40 m3 (i.e. for 4 HST)
OHCU receive the SW water by 3" line with FT 9202, PI 9203 & TI 9203 at plant B/L.
SW line is provided with isolation B/V & a Spectacle blind provision for positive isolation
from other units during M & C
P&ID of this system is attached at the end of this section

24.5 COOLING WATER:

Cooling water is used in the plant mainly for removing process heat. This is a closed
system mainly from Energy Conservation angle.
6 Centrifugal Pump of 3800 m3/hr capacity each (251 G 1A/B/C/D/E/F)is used for this
service, controlled by Utility Section.

ormal circulation rate of CW water is 15200 m3.

OHCU receive the CWS water by 30" line with FT 9001, PT 9002 & TE 9001 at plant
B/L. CWS line is provided with isolation B/V & a Spectacle blind provision for positive
isolation from other units during M & C. CWR is by 30" line with PI 9003 & TE 9003 at
plant B/L. CWR line is provided with isolation B/V & a Spectacle blind provision for
positive isolation from other units during M & C. P&ID of this system is attached at the
end of this section.
24.5.1 CW Quality:

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Table 24.4
pH 7.0 - 7.8
Turbidity 20 - 30 TU
TDS 1980 – 3030 ppm
Chlorides as aCl 398 – 625 ppm
Sulphates as So4 770 – 1210 ppm
Free Chlorine 0.2 – 0.3 ppm
Kmno4 consumption @ 1000 C 80ppm
Zinc Sulphate as Zn 1 – 2 ppm
HEDP as Po4 4 – 6 ppm
Polyphosphate as Po4 8 – 10 ppm
Silica as SiO2 80 – 160 ppm
Total Iron 10 ppm Max
Oil 10 ppm Max

24.6 COMPRESSED AIR SYSTEM

Compressed Air is used for HST for general usage of Cleaning, Blowing Operating
pneumatic systems etc,.
3 non-lubricating (2 Motor driven + 1 steam driven) centrifugal compressor (222K1A/B/C)
of 3100 Nm3/hr capacity each is used for this purpose, controlled by Utility section. The
compressed air is received in 2 LP receivers at 8.5 KSC & in 1 HP receiver at 32 KSC to
meet emergency.
222K-2 is another compressor of reciprocating type of 250 Nm3/hr capacity, used during
Emergency to supply Instrument Air at full load, to HP receiver at 32 KSC. This will be on
line when the HP receiver pressure falls below 6 KSC.
Interlock is provided for Air system in such a way that, Priority is given for Instrument Air
to operate various Control valves in the unit against Plant air during emergencies.

24.7 PLANT AIR:

Normal rate of PA is 480 Nm3.
OHCU receive PA by 6" line with PI 9303 & TI 9302 at plant B/L. PA line is provided
with isolation B/V & a Spectacle blind provision for positive isolation from other units
during M & C
P&ID of this system is attached at the end of this section.
Plant air requirement during catalyst regeneration:
First burn – 3490 Nm3 /hr (for 100 hrs.)
Second burn - 4800 Nm3 /hr (30 hrs.)
Third burn - 6120 Nm3 /hr (30 hrs.)

24.7.1 Plant air quality:

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Dew Point – Water Free

Oil content – Nil

24.8 INSTRUMENT AIR:

Normal consumption rate of IA is 340 Nm3 .
OHCU receive the IA by 3" line with FT 9302, PT 9306 (LAL) & TI 9303 at plant B/L.
IA line is provided with isolation B/V & a Spectacle blind provision for positive isolation
from other units during M & C
P&ID of this system is attached at the end of this section

24.8.1 Instrument air quality:

Dew Point – -400C
Oil Content – Nil

24.9 NITROGEN / INERT GAS SYSTEM

Nitrogen is used for Blanketing, During S/U & S/D( purging), Catalyst regeneration etc in
the units. Nitrogen is supplied from the N2 vaporizer (2 numbers of 100 Nm3 /hr each)
controlled in Utility section, to which 2 liquid N2 tank ( 75 m 3 ) is connected. Liquid N2 is
produced in N2 plant by compression & Cooling ( by refrigeration) of Atmospheric air .
N2 vaporizer is designed to meet the S/U demand of 56000 Nm3 of OHCU.
Normal consumption rate of N2 30 Nm3 .
OHCU receive the 2 by 6" line with FT 9301, PT 9302 (HAL &LAL) & TI 9301 at plant
B/L. 2 line is provided with isolation B/V & a Spectacle blind provision for positive
isolation from other units during M & C
P&ID of this system is attached at the end of this section

24.9.1 N2 Quality:
Oil Content- Nil
Dew Point - - 100 0C
O2 – 3 ppm
CO2 – 1 ppm
CO – 10 ppm
Purity – 99.99%

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24.10 BOILER FEED WATER

BFW is used in De-super heaters, Injection water Drum, For steam Generation etc, BFW is
of two type viz: HP & MP. 2 set of pump are used separately for these system HP BFW
centrifugal pump 221 G2A/B is 50 m3/hr capacity each (one steam driven & other
electrical driven). MP BFW centrifugal pump 221 G1A/B is 75 m3/hr capacity each (one
steam driven & other electrical driven). Normal consumption rate of BFW ( HP) 47.3
m3/hr.

OHCU receives the BFW by 4" line with FT 9204, PT 9206 (HAL &LAL) & TI 9205 at
plant B/L. BFW line is provided with isolation B/V & a Spectacle blind provision for
positive isolation from other units during M & C
P&ID of this system is attached at the end of this section

24.10.1 BFW Quality:

Table 24.5
pH 8.5 – 9.5
Cation Conductivity @ 250C 0.3 max micro mho
Total Hardness as CaCo3 Nil
Dissolved Oxygen 0.005
Total Iron + Cu 0.01 ppm
Kmno4 value @1000 C Nil
Total Silica < 0.02 ppm
Hydrazine 0.02
Morpholine 1 ppm app.

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24.11 STEAM SYSTEM

Steam is used for Process (Stripping steam & heating), Steam Drivers, Atomization, Steam
tracing, Snuffing, Purging, Soot Blowing etc,.
Different types of steam are available in refinery viz.: VVHP, VHP, HP, MP & LP.
Steam system is designed on 2 Soot blowers (4.55 TPH of MP), 1 Furnace snuffing (20
TPH of MP), 1 Furnace S/D (5 TPH of LP), & 1 Furnace decoking (5 TPH of MP) + 1
peak load of 20 TPH is considered.
New Boiler producing VVHP is tied up with existing NCPP with I/V. i.e. it only export
steam.

VHP steam is produced by PRDS 221-X3 from VVHP steam (95 KSC to 48 KSC)
MP steam is produced by PRDS 221-X4 from VVHP steam (95 KSC to 10.5 KSC)
HP steam is produced by PRDS 221-X5 from VHP steam (48 KSC to 30.5 KSC)
MP steam is produced by PRDS 221-X6 from VHP steam (48.5 KSC to 10.5 KSC)
LP steam is produced by PRDS 221-X8 from MP steam (10.5 KSC to 3.5 KSC)
All in Power Plant.

24.11.1 VHP Steam:

Normal consumption rate of VHPS 19.6 TPH .
OHCU receive the VHP by 6" line with PT 9108 (HAL &LAL) & TE 9108(HAL &
LAL) at plant B/L. VHP line is provided with isolation B/V & a Spectacle blind provision
for positive isolation from other units during M & C

24.11.2 HP Steam:
Normal consumption rate of HPS 4.1TPH
OHCU receive the HP by 4" line with PT 9106 (HAL &LAL) & TE 9106(HAL & LAL)
at plant B/L. HP line is provided with isolation B/V & a Spectacle blind provision for
positive isolation from other units during M & C.

24.11.3 MP Steam:
Normal consumption rate of MPS 19.8 TPH.
OHCU receive the MP by 12" line with FT 9102(HAL & LAL), PT 9104 (HAL &LAL) &
TE 9104 ( HAL & LAL) at plant B/L. MP line is provided with isolation B/V & a
Spectacle blind provision for positive isolation from other units during M & C.

24.11.4 LP Steam:
Normal consumption rate of LPS 8 TPH.

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OHCU receive the LP by 12" line with FT-9101(HAL & LAL), PT-9102 (HAL & LAL)
& TE-9102 (HAL & LAL) at plant B/L. LP line is provided with isolation B/V & a
Spectacle blind provision for positive isolation from other units during M & C.
P&ID of this system is attached at the end of this section.

24.12 CONDENSATE
Condensate obtained from the Surface condenser, Process exchangers, Reboilers etc., is
routed to Deareator –II. Condensate system has two streams viz: Surface condensate &
Atmospheric condensate.
Surface Condensate is coming from surface condenser of RGC ( in OHCU) which is
pure in quality and hence directly routed to steam generation.
Atmospheric Condensate from the process is routed first Flash drum in SRU & then to
Deoiler. Deoiled Condensate is routed to Deareator – II and then to steam generation using
pump. 2 centrifugal pumps of capacity 70 m3 each (one operating and other spare) is used
for transfer of condensate. Total condensate production in Ref – III is 66 TPH.

24.12.1 Surface condensate:

Normal generation rate of surface condensate is 28.5 TPH.
OHCU sends the surface condensate by 3" line with FT-9201, PI 9202 & TI 9202 at plant
B/L.Surface condensate line is provided with isolation B/V & a Spectacle blind provision
for positive isolation from other units during M & C.
P&ID of this system is attached at the end of this section.

24.12.2 Atmospheric condensate:

OHCU sends the atmospheric condensate by 4" line with PI 9201 & TI 9201 at plant
B/L.Atmospheric condensate line is provided with isolation B/V & a Spectacle blind
provision for positive isolation from other units during M & C.
P&ID of this system is attached at the end of this section.

24.13 FUEL SYSTEM

Fuel system is classified into two categories, viz: Fuel Oil & Fuel Gas system respectively.

24.13.1 Fuel Oil System:

Fuel Oil is used for firing in furnace ( F2 in OHCU) . FO system consist of one IFO tank
fed by Ref-III (PGVR), Ref-II( BHVR).
2 FO tanks of capacity 200m3 each ( 5 Days Reserve) is used for FO system. 2 FO Screw
pumps 226 G1 A/B ( 1 operating & other spare) of 42 m3/hr is available for circulating,
controlled by Utility section. FO after filtering upto 10 mesh particles in D/C. Circulation
rate of FO is 200% of requirement. i.e. 32 m3/hr.
Normal circulation rate of FO 2.45 TPH.

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OHCU receives FO by 3" line with PT 9503 & TE 9503 at plant B/L. FO line is
provided with isolation B/V & a Spectacle blind provision for positive isolation from other
units during M & C.
OHCU returns FO by 3" line with PT 9505 & TE 9505 at plant B/L. FO return line is
provided with isolation B/V & a Spectacle blind provision for positive isolation from other
units during M & C.
FO supply & return J/O is also provided at OHCU B/L.
P&ID of this system is attached at the end of this section.

24.13.1.1 FO Quality:
Flash Point : 660C
N2 : 3700 ppm
Vanadium : 200 ppm
Sodium : 80 ppm
H2: C ratio : 0.128
LHV :10000 Kcal
Temperature : 2000 C
Viscosity : 43cst
Sulphur for 2000 C : 4% wt.

24.13.2 Fuel Gas System:

Fuel Gas is used for firing in furnace ( F1 in OHCU), Purging etc,. FG system for Ref III is
independent. Sources of FG are from OHCU (C25 & CLPS off Gas), Sulphur plant after
treating sour gas, CDU/VDU, NHT/ CRU.

Header pressure ( 3.5 KSC) is maintained by LPG vaporizer in CDU-III, by vaporizing

LPG(from Merox or Storage) by controlling the flow of steam to vaporizer through PIC
Vaporiser capacity is designed to match S/U of CDU furnace (46.5 MMKcal/hr).
Normal rate of FG 3.56 TPH.

OHCU receives FG by 8" line with FT 9501(HAL & LAL), PT 9502 (HAL &LAL) & TE
9502( HAL & LAL) at plant B/L. FG line is provided with isolation B/V & a Spectacle
blind provision for positive isolation from other units during M & C.
P&ID of this system is attached at the end of this section.

24.13.2.1 Fuel Gas Quality:

Composition in Mole %
H2O : 0.76
H2 : 31.12

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C1 : 30.05
Ethylene : 0.48
C2 : 18.89
Propylene : 1.28
C3 : 10.37
IsoC4 : 1.85
Iso butane : 0.53
Normal C4 : 2.43
IsoC5 : 0.09
Normal C5 : 1.18
C6 + : 0.65
N2 : 0.32
LHV : 11701 Kcal/hr

24.14 FLARE SYSTEM

Flare system is used to dispose combustible toxic gases released from process units during
Normal, Emergency, Start up & Shutdown time safely to atmosphere. For this purpose
Flare stack of 52” dia & 100m height is constructed as per PCB norms, with Three Pilots
equally spaced, Molecular Seal, Purging system, etc,. Any Liquid HC discharged to flare is
separated in KOD of respective units as well in main flare KOD and Pumped to slop
header. OHCU flare header is sized to 26”, with Suitable Isolation valve with spectacle
blind at unit B/L. One local PI 9402 at unit B/L is also provided to check out the HDR
pressure at Peak load of OHCUP&ID of this system is attached at the end of this section.
Refinery main flare header is designed for a load of 277.7 TPH. Main flare header is 48” at
U/S & 52” at D/S of main isolation B/V. Another flare called “Sour gas flare header” runs
parallel to the main flare.

24.15 FIRE WATER NETWORK

3 MMTPA fire water capacity is 19,095 m3 with the break up as given below
New reservoir - 12656 m3
Sump - 770 m3
Co Gen - 4869 m3
Sump - 800 m3
Water sources for the fire water network is ETP-III & DM water plant Effluent are the
predominant one. There is a tie up with the present refinery for additional demands
Pump Details.
Totally 6 pumps are available out of which 3 are diesel & other 3 are motor driven. 4
pumps will be running & 2 will be spare. 2 more jockey pump are available. The capacity
of the jockey pump is 170 cum & the main pump is 900 cum.
Auto cut in pressure of different pumps are G101 – 11.5 ksc, G102 – 9.5 ksc, G103 – 9.0
ksc, G104 – 8.0 ksc G105 – 8.0 ksc, G107 – 7.5 ksc, G108 – 7.5 ksc & G109 – 7.0 ksc.

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The auto cut in pressure of jockey pump is 9.5 ksc & auto cut off pressure of jockey pump
is 11 ksc. Total fire water capacity for 4 hours duration will be 14,400 m3.

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CHAPTER-25

WORK ISTRUCTIO
25.1 CETRIFUGAL PUMP CHAGE OVER
(A TO B)
1) Ensure Safety Wears
 Helmet
 Safety Shoe
 Uniform
 Gloves
 Goggles ( Option )
 Apron (for Chemical handling )
2) Check Wind direction
3) Ensure availability and Working of Safety / Fire equipments
 Fire / Water Hose
 Fire Extinguisher
 Fire Blanket
 Eye Shower
 Water Sprinkler
 Canister
4) Check for Mechanical completion if any
• Strainer Cleaning
 Ensure Strainer for its position
 Ensure Bolts & Nuts for fastening, Type & Size
 Ensure Gasket for its Grade & Rating
• Seal Leak
 Ensure Pump fixed to bed rigidly
 Ensure Seal for its position & corresponding Bolts & Nuts are Fastened
 Ensure Coupling for its Fastening
 Ensure the Coupling Guard for its position
 Ensure Shaft for Free Rotation ( for LT Pumps only )
After Hot alignment
 Ensure the Reflector Ring for its position
 Ensure Chicken feed bottle for its position & Oil level ( for Holding )
 Ensure Bearing Oil top up Cap for its position
 Ensure Cooling Water flow through
• Valve Replacement / Gland Leak / Packing
 Ensure valve for Fastening

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 Ensure Bolts & Nuts for Fastening, Type & Size

 Ensure Gasket for its Grade & Rating
 Ensure Eye Bolt & Gland Follower for Fastening ( not for NRV )
 Ensure Wheel for its position ( not for NRV )
 Ensure Free rotation of Wheel ( not for NRV )
• Gasket Replacing / Flange Leak
 Ensure Bolts & Nuts for Fastening, Type & Size
 Ensure Gasket for its Grade & Rating
• Cooling Water Flow
 Ensure Strainer for its position
 Ensure all inter connection are Fastened (Flange Bolts, Union, etc,)
 Ensure outlet is to Chromate Water pit
 Ensure sufficient Flow of Cooling Water

5) Check for Electrical completion if any

 Ensure Motor fixed to bed Rigidly & Coupled to Pump
 Ensure Terminal box connected & M-Sealed
 Ensure Motor Energized / Meggared
 Ensure DOR ( for LT Motor only )
 Ensure Motor & Switch for Earthing completion
 Ensure Motor Bearing oil level ( for HT Motor only )
 Ensure Fan guard for its position
 Ensure rain Hood
6) Check the pump B for Spare condition
 Ensure drain is closed & suction valve is opened
 Ensure suction valve is opened for pump A
(only for common spare pump )
 Ensure cooling water flow
 Ensure pump Bearing oil level
 Ensure Motor bearing oil level(for HT Motor only )
 Ensure Bolts & Nuts for its position & Tightness
 Ensure Shaft for its free rotation ( for LT pumps only )
 Ensure Coupling & its Guard
 Ensure Earthing for Motor
 Ensure M-Seal around terminal box
 Ensure Seal balance line is live
 Ensure cooling water flow to seal cooler if any
 Ensure Discharge Pressure gauge & its commissioning
 Ensure pump is in Warm condition

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7) Get Panel clearance for changing to Pump B

 Panel Man will get Electrical clearance ( for HT Motor only )

 Panel Man will take a note of present related PV, MV, Pressure, etc,.

8) Note the discharge pressure of Pump A

9) Open the discharge block valve of Pump B say 10% ( Take care of
DOR. If rotating in reverse, close B/V )

10) Close the discharge block valve of Pump A say 40%

11) Switch on the Pump B
12) Check for DOR, any Flash, Leak, etc, simultaneously.
13) Open the d/c B/V of Pump B & Close the d/c B/V of Pump A
Simultaneously
14) When Pump A is say 80% closed stop Pump A.
15) Ensure D/C Pressure gauge reading of Pump for its
optimum value
16) Check Pump B for any Vibration
 Pump Bearing ( Inboard / outboard )
 Motor Bearing
 Fan
17) Check for any leak
 Seal
 Flanges
 Bearing Oil
18) Check for any abnormal sound
19) Check for any abnormal warming up of bearing
20) Inform Panel about the completion of C/O and get clearance
21) Close the discharge block valve of Pump A such that it is just
Sufficient to keep Warm
22) Open NRV bypass of Pump A and close NRV bypass in Pump B
23) Lock the Pump Switch of Pump A
24) Ensure the amperage of the pump is within safe limit
(For HT in particular)
Note: If any abnormality encountered sort it out and proceed to the steps.

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25.2 RECIPROCATIG COMPRESSOR START UP

1) Ensure Safety Wears

 Helmet
 Safety Shoe
 Uniform
 Gloves
 Goggles ( Option )
 Apron ( for Chemical handling )
2) Check Wind direction
3) Ensure availability and Working of Safety / Fire equipments
 Fire / Water hose
 Fire Extinguisher
 Fire Blanket
 Eye Shower
 Water Sprinkler
 Canister

4) Check for Mechanical completion if any

• Overhauling
 Ensure Flywheel for Fastening
 Ensure Flywheel Guard in its position
 Ensure Gear oil Pump is connected to Gear box
 Ensure cooling water flow to oil cooler
 Ensure no leak in Gear oil Tank & is Capped
 Ensure all Loader valves are operating and Fastened rigidly
 Ensure cooling Water flow through casing
 Ensure no leak in Crank Case oil & is Capped
 Ensure oil Filter in Fastened
• Valve Replacement / Gland Leak / Packing
 Ensure valve for Fastening
 Ensure Bolts & Nuts for Fastening, Type & Size
 Ensure Gasket for its Grade & Rating
 Ensure Eye Bolt & Gland Follower for Fastening ( not for NRV )
 Ensure Wheel for its position ( not for NRV )
 Ensure Free rotation of Wheel ( not for NRV )
• Strainer Cleaning
 Ensure Strainer for its position
 Ensure Bolts & Nuts for fastening, Type & Size
 Ensure Gasket for its Grade & Rating
• Gasket Replacing / Flange Leak
 Ensure Bolts & Nuts for Fastening, Type & Size

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 Ensure Gasket for its Grade & Rating

• Cooling Water Flow
 Ensure Strainer for its position
 Ensure all inter connection are Fastened (Flange Bolts, Union, etc,)
 Ensure outlet is to Chromate Water pit
 Ensure sufficient Flow of Cooling Water

5) Check for Electrical completion if any

 Ensure Motor fixed to bed Rigidly & Coupled to Compressor
 Ensure Terminal box connected & M-Sealed
 Ensure Motor Energized / Meggared
 Ensure Motor for Earthing completion
 Ensure Motor Bearing oil level ( for HT Motor only )
 Ensure Fan guard for its position
 Ensure rain Hood

6) Check the Compressor Spare condition

 Ensure Gear Box oil level
 Ensure cooling water flow (Lube oil cooler, Inter cooler & Cylinder)
 Switch on the Gear oil Pump
 Check for Normal Operation of Gear oil Pump
( for Vibration, Leak etc,.)
 Ensure drains are closed
 Ensure suction valve is opened
 Ensure Swift / Crank case oil level
 Ensure Bolts & Nuts for its position & Tightness
 Ensure Fly Wheel & its Guard
 Ensure Earthing for Motor
 Ensure M-Seal around terminal box ( for Compressor & Gear Pump )
 Ensure Pressure gauges & its commissioning
 Ensure Temperature gauges & its commissioning
 Ensure Compressor is fully unloaded
 Ensure no Liquid HC inside ( Drain if any )
 Ensure no leak of Gas
Get Panel clearance for starting Compressor
 Panel Man will get Electrical clearance
 Panel Man will take a note of present related PV, MV, Pressure, etc,.

7) Open the discharge block valve Fully

8) Drain the Cyclone Separator once Before starting Compressor
9) Ensure 30 Minutes run of Gear oil Pump
10) Start the Compressor

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11) Check for any abnormal sound

12) Check for any Vibration

13) Check Swift oil pressure for its optimum value
14) Load the Second Stage Outer Valve first
15) Load the First Stage Inner Valve Later
16) Ensure Pressure gauge readings for its Optimum value
17) Ensure Temperature readings for its Optimum value
18) Check for any abnormal sound after loading
19) Check for any Vibration after loading
20) Check for any leak
 Seal
 Flanges
 Valves
 Oil ( Gear oil & Crank Case oil)

21) Inform Panel about the completion of Compressor startup

with 50% load and get clearance ( Load 100% if Req. )
22) Check for any abnormal warming up of Bearings, Coolers
23) Commission Liquid to 1C8 line & ensure flow.
24) Ensure the amperage of the compressor for safe limit

Note : If any abnormality is encountered, sort it out and proceed the steps.

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25.3 SOOT BLOWIG

1) Ensure Safety Wears
 Helmet
 Safety Shoe
 Uniform
 Gloves
 Goggles ( Option )
 Apron (for Chemical handling )
2) Check Wind direction
3) Ensure availability and Working of Safety / Fire equipment’s
 Fire / Water Hose
 Fire Extinguisher
 Fire Blanket
 Eye Shower
 Water Sprinkler
 Canister
4) Check for Mechanical completion if any
5) Check for Electrical completion if any
6) Ensure all S/B for its close position individually
7) Ensure motor for Earthling
8) Ensure motor for Guarding
9) Ensure that all interlocks are in operating condition
10) Ensure the Retracting Chain for its position & Hand cranks Near by.
11) Inform panel and Get for clearance
12) Line up the soot blower steam lines (individual, Main, Drain B/V)
13) Open Condensate drain / bleeder valve gradually & UV4206 from panel
14) Open steam valve minimum and ensure dry steam thro’ drain (UV4207)
from panel
15) Open steam valve to required set pressure (UV4207) from panel
16) Start the S/B as per operating procedure in panel
17) Ensure the Box pressure for abnormal raise if any
18) Ensure the Flame for its aliveness
19) Check the S/B for steam leak if any
20) Check the motor for any vibration
21) Check the S/B for smooth operation
22) Tag the S/B switch for any abnormality and bypass
23) Switch of the S/B panel after sequence completion as per the
procedure in the panel
24) Ensure blower lances are in the home position
25) Close the individual steam B/V positively after completion one by one
26) Close the steam UV4207From panel
27) Close the drain / bleeder after depressurizing the S/B HDR & UV4206

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28) Inform panel about the completion

29) Ensure Box pressure and Flame for its normality
30) Check the Box for Tube leak if any

25.4 SAMPLIG SCHEME - 2 / 3

1) Ensure Safety Wears

S1 S2

S4

U1 U2

S3
C2

C1

C1

 Helmet
 Safety Shoe
 Uniform
 Gloves
 Goggles ( Option )
 Apron (for Chemical handling )
2) Check Wind direction (take position accordingly)
3) Ensure availability and Working of Safety / Fire equipments
 Fire / Water Hose
 Fire Extinguisher
 Fire Blanket
 Eye Shower
 Water Sprinkler
 Canister

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4) Open the Sample B/V (S1,S2 & S4) slowly & ensure minimum Flow
5) Open Cooling Water B/V (C1)& Ensure Minimum Overflow
6) Close S4 after ensuring the line is hot
(to confirm current sample in line)
7) Open S3 slowly till sample flows
8) Rinse the Sample Bottle Twice with the Warm sample
(to warm up the sample container)
9) Collect the Sample, Keeping the Bottle tilted aside slightly
10) Cap the Sample Bottle & Tag it
11) Close the Sample B/V S3 and Ensure no Passing
12) Close the sample B/V S1 & S2
13) Close the Cooling Water B/V and Ensure no Passing
14) Ensure sample pot free of water by opening & closing B/V C2
15) Clean the Area for Seepage if any

ote: If sample line is choked then follow the steps below after point 4
1) Close sample B/V S1, S2 & S4
2) Open Utility drain B/V U2
3) Open sample B/V S3
4) Open Utility B/V U1
5) After de-choking revert the above steps in note and follow from point 4 of sampling
work instruction.

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25.5 FURNACE LIGHT UP

1) Ensure Safety Wears

 Helmet
 Safety Shoe
 Uniform
 Gloves
 Goggles ( Option )
 Apron (for Chemical handling )
2) Check Wind direction
3) Ensure availability and Working of Safety / Fire equipments
 Fire / Water Hose
 Fire Extinguisher
 Fire Blanket
 Eye Shower
 Water Sprinkler
 Canister
4) Open the snuffing steam drain B/V's at B/L U/S to remove condensate
5) Inform Panel about taking the furnace on line
6) Check the stack damper operation & place it in open position
7) Line up the snuffing steam to furnace and ensure steam through stack
8) Ensure all Burners (including pilots) individual valves are closed
9) Activate the Fuel Gas (including pilot)system (check for leaks, drain liquid)
10) Close all the individual primary air register (Secondary open)
11) Check the Ignitor for its proper Functioning
12) Check draft inside the furnace (place a bit of paper through
peep hole or place your hand)
13) Insert the Ignitor and Position it if draft is normalcy (draft is O.K)

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14) Open the Pilot B/V and Simultaneously Switch on the Ignitor
(Pilot burner is firing)
15) Light up all pilots following the same procedure
16) Replace the Ignitor in its Position
17) Close the snuffing steam
18) Adjust Air Register if Required
19) Check the pilot system for any leaks
20) Open main gas burner B/V and light up the main burner
21) Check the Flame for Colour & Pattern
22) Adjust the primary air register
23) Check the Main gas system for any leaks
24) Adjust the draft through the stack damper
25) Inform Panel about the completion of Burner lighting
26) Record all the field readings & observation

Note: Since the coil is SS snuffing steam should be dry enough & to be for minimum
period to just develop draft. This is to avoid stress corrosion.

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25.6 BURER LIGHTIG (AFTER COKIG)

1. Ensure Safety Wears

 Helmet
 Safety Shoe
 Uniform
 Gloves
 Goggles ( Option )
 Apron (for Chemical handling
2. Check Wind direction
3. Ensure availability and Working of Safety / Fire equipments
 Fire / Water Hose
 Fire Extinguisher
 Fire Blanket
 Eye Shower
 Water Sprinkler
 Canister
4. Inform Panel about lining the Burner
5. Check the Igniter for its Functioning
6. Adjust the Air Register for Lighting the Pilot
7. Insert the Igniter and Position it
8. Open the Pilot B/V and Simultaneously Switch on the Igniter
9. Replace the Igniter in its Position
10. Ensure that Fuel lines are Free of Blockages
11. Ensure Jumpover B/V is Positively Isolated
12. Open the Atomising B/V of Oil Burner
13. Open the Fuel Oil B/V slowly till open wide
13. Check the Flame for Colour & Pattern
14. Adjust Air Register if Required
I5.Inform Panel about the completion of Burner lighting

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25.7 CAUSTIC ULOADIG

1) Ensure Safety Wears

 Helmet
 Safety Shoe
 Uniform
 Gloves
 Goggles
 Apron
2) Check Wind Direction
3) Ensure Availability and Working of Safety and Fire Equipments
 Fire / Water Hose
 Fire Blanket
 Eye Shower
 Fire Extinguisher
 Canister
 Fire Sprinkler
 First Aid Box
4) Check the MSDS from the Vehicle.
5) Check other relevant data from the vehicle(lab result etc,)
6) Check for Spark Arrestor.
7) Check the Inter connected Line and Isolate if any
8) Check the General Healthiness of the Pump ( Earthed,
Oil Level, etc
9) Permit the vehicle to Park Area and Ensure Wheel Locking
10) Connect the Hose to the Vehicle
11) Break the Carseal and open the Cock Valve slowly and
Ensure no leak in Flange
12) Open the Suction Valve of the Pump and Prime the Pump

13) Line the relevant Valve in the Tank

14) Open Pump D/C valve slowly.
15) Switch on the Pump and observe the performance
16) Note the Level Raise in the Tank and D/C Pressure.
17) Stop the Pump when the Vehicle becomes Empty.
(Pressure Hunting is the Sign)
18) Close the Valve Near Tank, Pump D/C, Valve at Hose receptively.
19) Close the Cock Valve in the Vehicle and bleed the hose content in ows.
20) Disconnect the hose and clean the area .
21) Close the Formality and ensure Vehicle has moved out of park area.

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PROCEDURE I THE EVET OF O AVAILABILITY OF HP LEA AMIE

PUMPS

PRESENT STATUS
HP Lean Amine Pump 207MG-5B is running at 210 m3/hr at OHCU feed rate of 240 m3/hr
HP Lean Amine Pump 207MG-5A not available
Reason: Three times tripping due to very high vibration: 207VAHH-3139A and 207VAHH-
3150A
Shop maintenance feedback: Being attended; available only for emergency

Emergency Procedure for Failure of pump 207MG-5B

1) Close the Amine flow control valve 207FIC-3103.

2) Ensure that the chopper valve 207FBV 3104 is closed.
3) Ensure that the Minimum Flow Recirculation valve 207FIC 3102 is 100 % open
4) Ensure 207C-4 level is at about 45 % (close LC and Block valve if required).
5) If 207C-4 Amine level is very low, ensure that 207LIC 2404 goes to Man mode and
is in unlatched condition.
6) Ensure that 207C-5 and 207C-6 pressures are normal.
7) Latch 207LIC 2404.
8) Keep 207C-4 bypass HIC 2502.
9) Eliminate the condition causing the trip.
10) Obtain electrical clearance.
11) Take the pump on line.
12) Normalize the flows.
13) Gradually establish Recycle gas flow through 207C-4 by closing HIC 2502 in
steps.

If both pumps 207G-5 A and 207G-5 B are not available

13) Inform SRU block about the failure of Amine.

14) Inform HGU non-availability of CLPS off gas and divert to flare.
15) Close the Amine flow control valve 207FIC 3103.
16) Ensure that the chopper valve 207FBV 3104 is closed.
17) Ensure that the Minimum Flow Recirculation valve 207FIC 3102 is 100 % open.
18) Ensure 207C-4 level is at about 45 % (close LC and Block valve if required).
19) If 207C-4 Amine level is very low, ensure that 207LIC 2404 goes to Man mode and
is in unlatched condition.
20) Keep 207C-4 bypasses HIC 2502.
21) Ensure that 207C-5 and 207C-6 pressures are normal.
22) Latch 207LIC 2404.
23) Send a sample of Recycle gas to lab for H2S and HC.

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24) Send a sample of CLPS Off gas to lab for H2S and HC.
25) CAUTION: As H2S content in Recycle gas is high, air mask must be worn before
taking Recycle gas sample.
26) As H2S accumulation is anticipated, start Recycle gas bleeding from 207C-7 PIC-
2601 such that system pressure is maintained at 153.8 Ksc g taking additional Hydrogen
from HGU.
27) After 4 hours again send a sample of Recycle gas for H2S content.
28) Observe conversion levels and product qualities for Sulfur content.

Sl. no. Condition Action

1 Product Sulfur levels ON Keep the same bleeding level
spec Maintain the same feed rate and CAT
2 Product Sulfur levels Reduce feed rate
OFF spec
3 Conversion levels drop Reduce the feed rate
4 Check H2 partial pressure If less than allowed, increase bleeding and
from Recycle gas Lab continue sampling and bleeding to achieve
analysis desired partial pressure
5 H2S slippage in product Increase stripping steam if DP permits
stripper
6 Check H2S levels in LPG Change Caustic frequently
7 Heavier Recycle gas Expect higher VHP steam consumption
8 Increased RGC DP Monitor for lower deviation and reduce RGC
speed such that H2/HC ratio is at optimum
level

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CHAPTER-26

PROCESS VALUES AD QUALITY COTROL

26.1 ACTUAL PROCESS VALUES - OHCU
Table 26.1
Description Flow Temp Pressure
m3/hr 0
C Kg/cm2
Hot feed from ref-3 125.7 170 12.0
Hot VB Feed 28.7 170 12.0
Cold VGO Feed 117.8 80 12.0
Mixed feed 249.2 131 11.0
Feed Surge Drum 207C-1 249.2 168 5.7
207F-1 O/L 356 177.8
207F-1 I/L 378 172.8
Reactor 207R-1 Inlet 378 172.5
Reactor R1 Outlet 411 169
Reactor 207R-2 Inlet 378 167.4
Reactor 207R-2 Outlet 411 163.9
CHPS 207C-2 H2O 6.2 153.9
CHPS 207C-2 HC 290 153.9
HP Centrifugal Separator 207C-3 (nm3/hr) 3,11,532
HP H2S Absorber 207C-4 (Nm3/hr) 3,07,521
Amine Flow to HP H2S absorber 207C-4 223.5 62
Amine Surge Drum 207C-5 61 6.8
Rich Amine Flash Drum 207C-6 66 6.0
RGC KO drum 207C-7 (nm3/hr) 3,07,521 153.1
RGC D/C 84 182.3
MUG D/C (nm3/hr) 69272 116 185.7
MUG S/C (nm3/hr) 68370 40 20.1
CLPS 207C-9 HC 285 38
CLPS gas (nm3/hr) 3116
Amine Flow to CLPS H2S absorber 5.8 61 38.8
CLPS Vapour KOD 207C-12 (nm3/hr) 3018 61 30
Degasser 207C-13 gas (nm3/hr) 36.1 6.1 40
Degasser 207C-13 H2O 14 5 40
Product Stripper 207C-14 feed 285 248
Product Stripper 207C-14 overhead gas (nm3/hr) 15485 146 14.1

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Description Flow Temp Pressure

m3/hr 0
C Kg/cm2
Product stripper 207C-14 Reflux 30.2 66
Product stripper 207C-14 Stripping Steam (Nm3/hr) 4555
Product stripper 207C-14 Bottom 263 243
Product stripper Reflux drum 207C-15 gas to 3781 66 12
dethanizer 207E-22 (nm3/hr)
Product stripper Reflux drum 207C-15 HC to 11.1 66 12.8
Dethanizer 207E-22
Product stripper Reflux drum 207C-15 H2O to 2.4
207C-13
207C-16 gas (nm3/hr) 18292 113 0.8
207C-16 reflux 41.3 55 15
207C-16 stripping steam (nm3/hr) 4261
207C-16 bottom 150.9 344
Hot UCO R/D 115.6 150 7.0
Cold UCO R/D 80
207C-17 55 0.7

Kero P/A 285 175 5.8

Kero P/A return 120
Kero draw 84.2 214 10.6
Kero R/D 67.2 40
Kero tray-2 temp 214

Diesel P/A 313 278 9.4

Diesel P/A return 223
Diesel draw 75 256 14.5
Diesel R/D 59.8 40
Diesel stripping steam (nm3/hr) 2273

207F-2 O/L 366 1.8

LPG R/D 7.8 40 14

Caustic circulation flow 5.8 40 18.5
Spent caustic 4.3 50 6
Water washer flow rate 0.3 40 18.5

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Description Flow Temp Pressure

m3/hr 0
C Kg/cm2
Naphtha splitter 207C-27
Feed 43.7 215 11.5
Top 63 94 1.3
Reflux Flow 51 55
Tray 2 temp 160
Light Naphtha R/D 11.9 40
Heavy Naphtha 15.5 40 7

Debutanizer 207C-27
Feed 51.4 111 11.1
Top 4218 80 10.7
Reflux Flow 11.2 40 18.4
Tray 2 Temp 215

De ethanizer 207C-20
Top 2277 52 12
Reflux 37.9 40 13.9
Bottom 31.5 145
Tray 2 Temperature 145

Sponge Oil Absorber 207C-22

Top (Nm3/hr) 3708 45 10.3
Reflux 18.4 40 12
FG H2S Absorber (Nm3/hr) 207C-25 2944 40 9.1
Amine Flow to 207C-25 53.9 46 12
Amine O/L Flow 54.9 49 7.3
Sponge Oil Absorber 207C-22 Bottom to 20.7 52 12.6
Dethanizer 207E-22

Naphtha to 207E-39 16.3 161 10.3

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26.2 OHCU DESIG VALUES (SOR & EOR)

Table 26.2
SOR EOR
Tag description Unit
Tag number value value
207FIC-1403 Total VGO mix flow m3/hr. 249.2 249.2
207FIC-1406 Ref-3 VGO feed flow m3/hr. 111.9 111.9
207FIC-1407 Ref-2 VGO feed flow m3/hr.
207FIC-1404 Cold VGO flow m3/hr. 111.9 111.9
207FIC-1402 VBVGO feed flow m3/hr. 25.5 25.5
207FIC-1408 UCO to Rx. Feed m3/hr. 0 0
207FI-2201 Recycle gas to 207E-7 nm3/hr. 210489.6 210425.2
0
207TI-1408 Mixed oil feed to 207E-1 C 131 131
0
207TI-1409 Oil feed from 207E-1 to 207E-2 C 148 148
0
207TI-1414 Rx feed to 207E-1 C 168 165
207PIC-1602 207C-1 feed surge drum pressure kg/cm2 4.5 – 4.8 4.5 – 4.8
0
207TI-1801 207E-3A/B feed I/L temp C 176 175
0
207TI-2205 Recycle gas from 207K-1 to 207E-7 C 93 94
0
207TI-1971 207F-1 feed O/L temp C 378 378
0
207TI-C1803 207F-1 feed I/L temp C 356 374
0
207TI-1809 207F-1 feed O/L temp C 378 396
0
207R-1/R-2 CAT 207R-1 / 207R-2 Catalyst average temp C 378 396
0
207R-1 CAT 207R-1 Catalyst average temp C 378 396
0
207R-2 CAT 207R-2 Catalyst average temp C 378 396
207PI-1901 Reactor-1 I/L pressure kg/cm2 172.5 176.0
207PDI-1903 Reactor-1 dp kg/cm2 3.5 7.0
0
207TIC-2003 Rx-2 feed I/L temp C 378 396
207FI-2001 Quench gas 207R-2 bed-1 I/L Nm3/hr. 22922.2 20469.2
207PI-2001 Reactor-2 I/L pressure kg/cm2 167.4 167.4
207FI-2002 Quench gas to 207R-2 bed-2 I/L Nm3/hr. 34184.4 32752.5
0
207TI-2050 Rx effluent from 207R-2 to 207E-3A/B C 411 429
207PDI-2003 Reactor-2 dp kg/cm2 3.5 3.5
0
207TI-1812 Rx. effluent 207E-3A/B O/L to 207E-4 temp C 279 281
0
207TI-2103 Rx effluent from 207E-4 to 207E-5 C 233 233
0
207TI-2106 Rx efflent from 207E-5 to 207E-7 C 213 213
0
207TI-2201 Rx efflent from 207E-7 to 207E-8 C 190 189
0
207TI-2301 Rx efflent from 207E-8 to 207E-9 C 136 135
0
207TIC-2306 207E-9 O/L to 207C-2 C 55 55
3
207FIC-3304 Inj.water flow to 207E-9 m /hr. 5.5 5.5
0
207TI-2503 207C-4 HP absorber gas I/L temp C 55 55
0
207TI-2504 Lean amine temp 207G-5A/B to 207C-4 C 62 62

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SOR EOR
Unit
Tag number Tag description value value
207FIC-3103 207G-5A/B d/c lean amine flow m3/hr. 223.5 223.5
207PIC-2702 207K-1 suction pressure (spillback) kg/cm2 153.1 153.1
207PIC-2601 207K-1 suction pressure (bleed) kg/cm2 153.1 153.1
207FI-2702 RGC suction flow (regn.) Nm3/hr. 306718.8 292809.7
0
207TI-2702 RGC suction temp C 62 62
207PI-2721 RGC suction pressure kg/cm2 153.1 153.1
207PI-2722 RGC discharge pressure kg/cm2 182.3 185.8
207PDI-2704 RGC suction / discharge dp kg/cm2 29.2 32.7
0
207TI-2713 RGC discharge temp C 84 85
207FI-2701 Make-up H2 flow Nm3/hr. 68370.2 69272.8
207PI-2701 Make-up H2 header pressure kg/cm2 185.7 185.7
0
207TIC-2102 207C-14 product stripper I/L temp C 248 249
0
207TI-2901 CLPS vapour from 207C-10 to 207C-11 C 55 54
207FI-2902 207C-11 vapour to 207C-12 flow Nm3/hr. 3017.3 3558.9
207FI-2903 207C-12 off gas to PSA-2 Nm3/hr. 3094.0 3626.9
0
207TI-2101 CLPS liquid from 207E-4 C 248 249
207FIC-4002 Product stripper stripping.steam flow Kg/hr. 3653 4110
207FIC-4003 207C-14 bottom to 207E-11 m3/hr. 263.7 257.5
207TIC-4003 207C-14 product stripper O/H temp m3/hr. 146 141
0
207TIC-4003 207C-14 product stripper O/H temp C 146 141
207PIC-4101 207C-14 product stripper O/H pressure kg/cm2 14.1 14.1
207FIC-4001 207C-14 product stripper reflux flow m3/hr. 30.2 44.7
207FIC-4101 207C-15 naphtha to deethaniser m3/hr. 11.1 14.6
0
207TI-4213 207C-14 bottoms to 207F-2 C 319 320
0
207TIC-4209 207F-2 O/L temp C 360 360
0
207TI-4310 207C-16 bottom to 207G-12A/B C 344 344
0
207TI-4304 207C-16 overhead temp C 113 113
207PIC-4501 207C-16 O/H pressure kg/cm2 0.8 0.8
0
207TI-4303 207C-16 reflux temp C 120 120
3
207FIC-4301 207C-16 reflux flow m /hr. 41.3 35.6
0
207TI-4801 Kero. Stripper 207C-18 temp C 175 174
0
207TI-4807 Kero P/A return temp C 120 118
3
207FIC-4801 Kero P/A flow m /hr. 238.6 239.4
207FIC-4702 SK / ATF R/D flow m3/hr. 67.2 66.70
0
207TI-5005 HSD draw temp C 272 269
0
207TI-5002 Diesel P/A return temp C 223 219
3
207FIC-5101 Diesel R/D flow m /hr. 59.8 55.0
207FIC-5003 Diesel P/A flow m3/hr. 313.1 314.9
207FIC-5202 Cold UCO flow from 207E-21 m3/hr. 30 15

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SOR EOR
Unit
Tag number Tag description value value
207FIC-5203 Hot UCO R/D flow to FCCU m3/hr. 115.6 115.4
207FI-4102 207C-14 off-gas to 207E-22 Nm3/hr. 3780.5 5100.5
207PIC-4101 207C-14 product stripper O/H pressure kg/cm2 14.1 14.1
207FIC-5701 Sponge oil absorber bottom to 207E-22 m3/hr. 20.7 23.8
0
207TI-5602 207E-22 O/L to 207C-21 C 40 40
3
207FIC-5601 Deethaniser reflux flow m /hr. 38 47
0
207TI-5501 Deethaniser reflux temp C 40 40
3
207FIC-5502 Deethaniser bottom flow m /hr. 31.5 38.9
207FIC-5501 207E-24 UCO flow m3/hr. 104 103.8
207FIC-5801 207E-39 O/L flow to 207E-23A/B m3/hr. 16.3 18.4
207FIC-5802 Sp.absorber reflux flow m3/hr. 18.4 20.6
0
207TI-5703 Sp.absorber overhead to 207E-23A/B C 45 45
207PIC-6701 207E-37 steam I/L press kg/cm2 2.5 2.5
207FIC-6801 Lean amine flow to 207C-25 m3/hr. 53.9 54.9
207PIC-6806 207C-25 Fuel gas absorber pressure kg/cm2 8.6 8.6
207FIC-4601 207C-17 naphtha to debutaniser m3/hr. 19.9 19.2
0
207TI-5906 207C-27 bottom to 207C-29 C 143 143
0
207TIC-5915 207C-27 debutaniser O/H temp C 80 81
3
207FIC-5901 Debutaniser reflux flow m /hr. 10.5 14.4
207FIC-6001 LPG to NaOH washer m3/hr. 7.8 12.2
207PIC-6003 Debutaniser reflux drum 207C-28 pressure kg/cm2 10.3 10.3
207FI-6603 Treated LPG R/D flow m3/hr. 7.8 12.1
207PIC-6601 LPG R/D pressure kg/cm2 14.7 14.7
207FIC-5902 Debutaniser bottom flow m3/hr. 43.7 46.0
207FIC-6302 Cold heavy naphtha to storage m3/hr. 0 0
207FIC-6301 Hot heavy naphtha to NHT / CRU m3/hr. 15.5 15.5
207FIC-5801 207E-39 O/L flow to 207E-23A/B m3/hr. 17.3 19.2
0
207TIC-6113 207C-29 naphtha splitter O/H temp C 94 94
3
207FIC-6101 Naphtha splitter reflux flow m /hr. 47.9 54.4
207PIC-6201 Naphtha splitter O/H pressure kg/cm2 1.3 1.3
0
207TIC-6202 207E-29 fin-fan O/L temp C 54 54
3
207TI-6205 Light naphtha to storage m /hr 12.3 12.9
207PIC-6202 207C-30 splitter refux drum pressure kg/cm2 0.9 0.9
207FI-6901 Make-up H2 flow Nm3/hr 68370.2 69272.8
207PIC-6902 H2 supply header pressure kg/cm2 20.1 20.1
207PIC-2702 207K-1 suction pressure (spillback) kg/cm2 182.3 185.8-
207PIC-6904 207K-2A/B/C discharge pressure kg/cm2 185.7 185.7

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SOR EOR
Unit
Tag number Tag description value value
207FI-2701 Make-up H2 flow to 207E-7 Nm3/hr 68370 69272
207TI-7003 207K-2A 1st stage intercooler 207E-32A/B 0
C 40 40
O/L temp
207PI-7001 207K-2A 2nd stage suction KOD pressure kg/cm2 42 42
207PI-7002 207K-2A 3rd stage suction KOD pressure kg/cm2 88.3 88.3
207PI-7101 207K-2B 2nd stage suction KOD pressure kg/cm2 42 42
207PI-7102 207K-2B 3rd stage suction KOD pressure kg/cm2 88.3 88.3
207PI-7201 207K-2C 2nd stage suction KOD pressure kg/cm2 42 42
207PI-7202 207K-2C 3rd stage suction KOD pressure kg/cm2 88.3 88.3

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26.3 QUALITY COTROL LOGIC CHART

Product Stripper
Product Increasing Increasing Increasing Increasing
Characteristics
Overhead Feed Overhead Stripping
Pressure Temp Temp Steam Rate
De-ethanizer Rate Decreases Increases Increases Increases
Overhead Gas C3 Content Decreases Increases Increases Increases
LPG Rate Increases Decreases Decreases Decreases
Vapor Decreases Increases Increases Increases
Pressure
C5 Content
H2S Content
.

Product Fractionator
Product Characteristics Increasing Increasing Increasing Increasing Increasing Increasing
Overhead Feed Strip Steam Overhead Kerosene Diesel
Pressure Temp Rate Temp P/A Rate P/A Rate
aphtha Rate Decreases Increases Increases
Final Cut Point Decreases Increases Increases
Vapor Pressure Increases Decreases Decreases
End Point Decreases Decreases (Note 3) Increases Increases Increases
Kerosene Rate
Initial Cut Point Decreases Increases Increases
Final Cut Point Decreases Increases Increases
Start Point Decreases Increases Increases
End Point Decreases Decreases (Note 3) Increases Increases Increases
Flash Point Worse Better Better
Freeze Point Better Better Worse Worse Worse Worse
Smoke Point Better Worse Worse
Diesel Rate
Initial Cut Point Decreases Increases Increases
Final Cut Point Decreases Increases Increases
Start Point Decreases Increases Increases
End Point Decreases Decreases (Note 3) Increases Increases
Flash Point Worse Better Better
Pour Point Better Better Worse Worse Worse
Cetane Index Worse Better Better Better

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Product Fractionator
Product Characteristics Increasing Increasing Increasing Increasing Increasing Increasing
Overhead Feed Strip Steam Overhead Kerosene Diesel
Pressure Temp Rate Temp P/A Rate P/A Rate
Fractionator Rate Increases Decreases Decreases
Bottoms Initial Cut Point Decreases Increases Increases
Start Point Decreases Increases Increases
Frac Reflux Rate Decreases Increases Decreases Decreases Increases
Frac. Rate Decreases Increases Decreases
Overflash

Kerosene Stripper Diesel Stripper

Product Increasing Increasing Increasing Increasing
Characteristics
Draw Reboiler Draw Reboiler
Rate Duty Ratio Rate Duty Ratio
aphtha Rate
Final Cut Point
Vapor Pressure
End Point Decreases
Kerosene Rate Increases
Initial Cut Point
Final Cut Point Increases
Start Point Increases
End Point Increases Decreases
Flash Point
Freeze Point Worse
Smoke Point
Diesel Rate Increases
Initial Cut Point Increases
Final Cut Point Increases Increases
Start Point Increases Increases
End Point Increases Increases
Flash Point Better Better Better
Pour Point Worse Worse
Cetane Index Better Better
Fractionator Rate Decreases Decreases
Bottoms Initial Cut Point Increases Increases
Start Point Increases Increases

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Product Increasing Increasing Increasing Increasing

Characteristics
Draw Reboiler Draw Reboiler
Rate Duty Ratio Rate Duty Ratio
Frac Reflux Rate (Note 4) Increases Increases
Frac Rate Decreases Decreases
Overflash

De-ethanizer
Increasing Increasing Increasing
Product Characteristics Column Feed Temp Tray 2 Temp
Pressure
Rate Decreases Increases Increases
Overhead Gas C3 Content Decreases Increases Increases
LPG Rate Increases Decreases Decreases
Vapor Pressure Increases Decreases Decreases
C5 Content
H2S Content Increases Decreases Decreases

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Sponge Oil
Absorber
Product Characteristics Increasing
Reflux Rate
Rate Decreases
Overhead Gas C3 Content Decreases
LPG Rate Increases
Vapor Pressure Increases
C5 Content
H2S Content Increases

Debutaniser
Increasing Increasing Increasing
Product Characteristics Column Tray 2 Temp Reflux Rate
Pressure
Rate Decreases Increases Decreases
LPG Vapor Pressure Increases Decreases Increases
C5 Content Decreases Increases Decreases
H2S Content Increases Decreases Increases
Rate Increases Decreases Increases
Light
aphtha Final Cut Point
Vapor Pressure Increases Decreases
End Point

aphtha Splitter
Increasing Increasing Increasing
Product Characteristics
Column Tray 2 Temp Reflux Rate
Pressure
Deethaniser Rate
Overhead Gas C3 Content
Light Rate Decreases Increases Decreases
aphtha Final Cut Point
Vapor Pressure Increases Decreases Increases
End Point Decreases Increases Decreases
Heavy Rate Increases Decreases Increases
aphtha Initial Cut Point

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aphtha Splitter
Increasing Increasing Increasing
Product Characteristics
Column Tray 2 Temp Reflux Rate
Pressure
Final Cut Point
Start Point Decreases Increases Decreases
End Point

otes:

1. The words in the cells indicate the directional change in the rate or property for an
increase in the indicated controller set point, assuming all other controllers are working and
no abnormal conditions or equipment limits are hit.

2. A blank cell indicates that little or no change is expected.

3. Increasing fractionator stripping steam raises product cut points (opposite to raising
pressure), but also increases L/V in each rectifying section (similar to raising feed
temperature). The opposing effects on end point may cancel. Increasing naphtha and/or
kerosene draw rate leads to higher temperatures on diesel pumparound draw tray, resulting
in more pumparound heat removal and less top reflux.

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CHAPTER- 27

EQUIPMET START UP PROCEDURE

27.1 START UP PROCEDURE FOR 207G3-A/B FEED PUMP

Inform panel about the operation.

Check the utility availability (Cooling water flow, Instrument air flow, etc,.)

Check the equipment in safety aspects (like earthling, coupling guard, etc,.)

Lubricating system start up
• Ensure oil level in the sump is sufficient to run the system.
• Ensure cooling water flow in the lube oil cooler
• Check the line up of the lube oil system.
• Keep AOP switch in manual mode
• Ensure pressure switch is lined up
• Inform panel about starting the lube oil pump
• Start the lube oil pump manually
• Check the lube oil system (for any leak, sufficient pressure, filter DP, etc,.)
• Normal MOP pressure 5 to 5.5 kg/cm2, Lube oil header pr. 1.8 to 2 kg/cm2,
filter DP 0.15 to 0.3 kg/cm2.
• Change the AOP switch to Auto mode.
• Inform to panel about the completion of operation.
Note: During regular change over operation the lube oil system is already on line.
Ensure the pump is already in warm up condition and close the warm up block
Valves; and skin temperatures are nearly same.

Before starting the pump, ensure that the pump is completely filled up with the
liquid.

Ensure the sealing fluid (steam) is in open condition.

Ensure recirculation block valves & control valve in wide-open condition.

Check all drains and vent valves are closed.

Verify that the suction MOV, suction and discharge block valves are opened.

After getting clearance from power plant and control room start the pump.

Check the motor & pump condition like vibrations and ensure flow (minimum
should be 130 m3 / hr) through the recirculation.

Open discharge MOV fully in "LOCAL" mode and put into REMOTE.

Check the suction and discharge pressures.

Check if seal system is operating properly and for seal leakage.

Check vibration and temperatures of pump and motor.

Stop AOP pump

If every thing is normal inform to panel for further proceedings
.

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27.2 START UP PROCEDURE FOR 207G5-A/B AMIE PUMP

Inform panel about the operation.

Check the utility availability (Cooling water flow, Instrument air flow, etc,.)

Check the equipment in safety aspects (like earthling, coupling guard, etc,.)

Lubricating system start up
• Ensure oil level in the sump is sufficient to run the system.
• Ensure cooling water flow in the lube oil cooler
• Check the line up of the lube oil system.
• Keep AOP switch in manual mode
• Ensure pressure switch is lined up
• Inform panel about starting the lube oil pump
• Start the lube oil pump manually
• Check the lube oil system (for any leak, sufficient pressure, filter DP, etc.)
• Normal MOP pressure 5 to 5.5 kg/cm2, Lube oil header pr. 1.8 to 2 kg/cm2,
filter DP 0.15 to 0.3 kg/cm2.
• Change the AOP switch to Auto mode.
• Inform to panel about the completion of operation.

ote: During regular change over operation the lube oil system is already on line.

Ensure the pump is already in warm up condition and close the warm up block
valves.

Verify that the suction block valves are opened. & ensure that the pump is
completely filled up with the liquid.

Verify that the discharge, drains and vent block valves are closed.

Ensure recirculation block valves & control valve in wide-open condition.

Ensure that the discharge block valve is closed condition.

After getting clearance from power plant and control room start the pump.

Check the motor & pump condition like vibrations and ensure flow (minimum
should be 110 m3 / hr) through the recirculation.

Open discharge block valve slowly.

Check the suction and discharge pressures.

Check if seal system is operating properly and for seal leakage.

Check vibration and temperatures of pump and motor.

Stop AOP

If every thing is normal inform to panel for further proceedings

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27.3 STARTUP PROCEDURE for 207K2-A/B/C Make Up Gas Compressor

Check all the instruments like pressure, temperature are lined up.

Check all drains and vents are in closed positions.

If required put barring as per procedure cylinder pr 5 kg/cm2, keep AOP & forced
lubricator online (check plant air pr.)

Then keep the barring device in disengaged position.

Check the level in lube oil sump, lubricator sump level and the level in cooling water
overhead reservoir and ensure the levels are upto the mark.

Ensure cooling water supply and return lines to cylinder jackets, all packings and
stuffing boxes are lined up.

Check the cooling water pumps AUTO CUT IN facility and then keep two pumps on
line (A or B, C or D in manual mode) and keep the other pumps on AUTO stand by.

Check the Lube Oil circuit and line up one of the lube oil filter.

Pressurize the compressor by slowly opening the suction block valve.

Start the AOP in ''MAN'' mode and run for ''2'' mts. Stop and then put into ''AUTO''
mode. [Check L.O .oil filter ''dp'']

Start the forced lubricator oil pump on MAN mode and ensure that the low low-
pressure alarm gets cancelled.

Once the pressure switch is normalized, stop the pump and put it on AUTO mode.

Open both the discharge block valves.

Confirm positive ‘‘dp’’ is maintained between all cylinders I.C and O.C. adjust the
N2 regulator accordingly.

Keep all cylinders I.C,O.C and stuffing box drain tanks drain in closed condition.

Ensure stuffing box drain tank vent line is lined up to flare.

Confirm in the local panel that the capacity selector switch is at zero percent.and also
selector switch in remote position.

Check for compressor start healthy condition. If it is O.K .Start the compressor by
pushing H.S 7001A.[After getting clearance from the PANEL and POWER
PLANT]

Now the timer sequence is started i.e., immediately AOP come on line, 30 sec after
lubricator is come on line. After 15 sec Compressor motor power will start.

The AOP will switched off automatically after MOP come on line app. 20 sec later.

"Start up sequence completed " indication will glow to indicate that compressor is
ready to load.

Load the compressor in step wise (i.e) 50%, 75%, 90%, and 100% respectively from
local or panel according to the instruction from panel.

After loading the compressor check for any abnormality and also watch the pressures
temperatures, Cylinder dp, suction strainer dp, etc.,

Local selector switch to remote only.

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27.4 RGC START-UP PROCEDURE:

1. Commissioning of Seal Gas System.

2. Commissioning of Lube Oil System
3. Commissioning of surface condenser 207E90.
4. Commissioning of Ejectors to Surface Condenser.
5. Commissioning of Gland Steam and its Condenser.
6. Preparation to start the Compressor RGC.
7. Start the Compressor RGC.

27.4.1 COMMISSIOIG OF RECYCLE GAS COMPRESSOR SEAL GAS

SYSTEM

Separation seal system & secondary dry gas seal gas system:
1. Check and confirm all maintenance jobs are completed in the secondary seal gas
system and the system is ready for start-up.
2. Confirm plant nitrogen header pressure is above 6.0 Kg/Cm2.
3. Confirm all the instruments are commissioned and working well.
4. Line up the nitrogen to the secondary seal gas filter 207T92 one by one and purge the
system to flare through the seal. Keep one filter on line the other as spare. Line up
secondary seal gas vents to flare.
Note:
a) After commissioning the nitrogen 207PAL-3754 came to normal.
b) If compressor primary seals are not leaking, FI-3751 & FI-3753 and FI-3752 &
FI-3754 should match.
c) Confirm all pressure switch alarms are cancelled.
5. Lines up the nitrogen to separation seal and purge it to atmosphere through the vent.
6. Now the compressor is ready for start-up.

PREPARATION OF PRIMARY SEAL GAS SYSTEM:

1. Check and confirm all maintenance jobs are completed in the primary seal gas system
and the system is ready for start-up.
1. Double block the
a) Make-up hydrogen to seal gas system.
b) Process gas from 207K1 discharge to seal gas system.
c) 207K1 suction and discharge block valves.
d) Spill back valves.
2. Line up the nitrogen to the seal gas system for purging and pressure testing. Line up the
Start-up filter (additional filter) one by one and purge it to flare & CBD.
3. Line up the nitrogen to duplex filter 207T-91 one by one through 207PDIC-3761 and
its bypass. Purge the filter one by one to flare and CBD. Confirm PDIC indication and
control valve is commissioned and working well.

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4. Line up the moisture / liquid free nitrogen to compressor primary seal system and
purge it to CBD / OWS / FLARE through casing drains and vents (check all the
drains).
5. Once purging is completed pressure test the system with nitrogen.
6. Pressure test all process flanges instrument fittings, and check the all instruments
working condition in nitrogen pressure.
7. Keep the 207PDIC-3761 on AUTO mode after pressure tests completed in the system.
If the pressure test is OK double block the nitrogen to seal gas system.
8. Now the primary seal is ready for start-up.
9. Line up the make-up gas compressor discharge to the seal gas system after the
compressor is started. Check the system for leaks for the increased pressure.

27.4.2. COMMISIOIG OF LUBE OIL SYSTEM:

1. Check and confirm all maintenance jobs are completed in the lube oil system and the
system is ready for start-up.
2. Check the lube oil reservoir 207D-90 level and confirm it is above 75% in gauge glass.
Confirm the following level instrument is commissioned and working well:
LI-3702 – lube oil reservoir level – should read 75% before start-up. Check with
gauge-glass also.
3. Commission nitrogen to lube oil tank for blanketing and confirm it’s self regulating
PCV is working and the tank pressure should be 100-200 MMWC.
4. Commission lube oil cooler 207E-91A/B is fully and keep one of the cooler online.
Open the vent in the cooling water and release the air.
5. Confirm the lube oil temperature control valve performance, line up the control valve
and keep setting at 40 Deg.C in “AUTO” mode.
6. Confirm the lube oil pump discharge pressure control valve (self regulating) lined up
condition.
7. Commission the lube oil duplex filter 207T-93 A/B, keep line up the one filter online
and keep lined up the lube oil header accumulators 207C-93 A/B/C.
8. Commission governor control oil and its CG accumulator 207C-91. Check and confirm
the following instruments are fully commissioned and are in working condition:
9. Commission the lube oil emergency pump 207G90C discharge line filter and line up
the filter O/L to the system.
10. Keep lined up the lube oil header pressure control valve and bypass is closed.
11. Keep close the overhead lube oil tank 207D-91 make up valve initially.
12. Line up the MOP turbine exhaust to LP steam and MP steam lines.
13. Start the MOP turbine and watch the speed and discharge header pressure.
(11.0 Kg/Cm2).

Note: -

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a) PAL-3754 secondary seal gas header pressure – start permissive for turbine
driven lube oil pump 207G90A.
b) PAL-3722 lube oil header pressure – auto start of motor driven stand by lube oil
pump 207G90B
c) PAL-3710 lube oil pump common discharge pressure – auto start of motor
driven stand by lube oil pump 207G-90B
14. If any leak observed in the system stop the pump and pull out the leaks. After attending
the leaks put back the pump online; Open the lube oil overhead tank 207D-91 fill up
valve, fill up the tank and keep continuos overflow (confirm with view glass).
15. Vent out lube oil duplex filters for some time to fill-up with oil, then close it.
16. Vent out EOP discharge line filter for some time to fill-up with oil, then close it.
17. Vent out both oil coolers one by one to fill-up with oil, and then close it.
18. Open the vents of lube oil header accumulators 207C-93 A/B/C one by one carefully
and fill-up oil during the initial start-up.
19. Open the vents of governor control oil CG accumulator 207C-91and fill-up oil during
intial start-up.
20. Confirm:
a) The control oil header pressure is 8.0 kg/cm2.
b) The lube oil header pressure is 2.0 to 2.5 kg/cm2.
c) At thrust bearing I/L is 0.3 to 0.8 kg/cm2.
d) At radial bearings I/L is 1.0 to 1.8 kg/cm2.
21. Watch the lube tank level, if required make-up the level.
22. Stop MOP and check SOP 207G90B cutting in condition and EOP 207G-90C cutting
in conditions. If interlocks are OK, Keep SOP and EOP in “AUTO” mode.
23. Observe for half an hour. If the lube oil duplex filter DP, control oil filter DP and
circulation is steady then go head for compressor start-up.

27.4.3 COMMISIOIG OF SURFACE CODESER 207E-90:

1. Check and confirm all maintenance jobs are completed in the surface condenser and
gland steam ejector system and the system is ready for start-up.
2. Commission the cooling water to the surface condenser 207E90.
3. Keep close the turbine gland steam control valves (PY-2748A & PY-2748B) down
stream block valves. Keep close the ejector condensers and gland steam condenser O/L
traps to surface condenser.
4. Fill-up the condenser up to 50% with DM water. Check the level indication of the
condenser in G.Glass and in DCS.
5. Line up the surface condensate LCV’s rundown to OWS and close the rundown. Keep
condenser level LIC-2740 in “AUTO” mode at 50%.
6. Keep close the condensate to valve glands and surface condenser safety valve.
7. Confirm LP and MP steam headers are commissioned.
8. Check the working condition of 207 ZLH-2740A & ZLL-2740A MOP 207G90A
turbine steam valve switches.

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9. Start the condensate extraction pump 207G92A turbine through the governor and set at
design speed.

Note:
a) LAL-2743 surface condenser 207E90 level – start permissive for condensate
extraction pump 207G92A or 92B.
b) LAH-2742 surface condenser 207E90 level – auto start of condensate extraction
pump 207G92A or 92B.
c) PAL-2764 discharge header pressure of condensate extraction pumps – auto
start of condensate extraction pump 207G92A or 92B.
d) LALL-2743 surface condenser 207E90 level – trip condensate extraction pump
207G92A and 92B.

10. If any leak observed, stop the pump and pull out the leaks. After attending the leaks put
back pump online.
11. Commission condensate to all valve glands and surface condenser safety valve and
confirm flow of condensate.
12. Check the auto cut-in of both condensate extraction pumps 207G92A/B.
13. Keep the motor driven condensate extraction pump 207G92B on “AUTO” mode.

27.4.4 COMMISSIOIG OF EJECTORS TO SURFACE CODESER 207E90:

1. Check and confirm all maintenance jobs are completed in the surface condenser ejector
system and the system is ready for start-up.
2. Commission cooling water to Ejector condensers 207E93A/B and keep close the
surface condenser vapour O/L’s to ejectors at ejector manifold. Keep open the
condenser vapour O/L to atmosphere. Commission the ejector condenser O/L traps
to surface condenser.
3. Line up surface condenser vapour O/L’s to start-up ejector 207H90 and ejector O/L to
atmosphere.
4. Drain condensate in MP header and line up the start-up ejector.
5. To improve the vacuum in surface condenser, line up the MP steam to ejectors
207H-91A and 92A. Keep as spare the ejectors 207H-91B and 92B. The required
minimum vacuum is - 0.8 kg/cm2.
6. Once the condenser vacuum became normal, cut off start-up ejector and close the
vapour I/L B/V to the ejector.

27.4.5 COMMISSIOIG OF TURBIE GLAD STEAM, ITS EJECTORS AD

CODESER

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1. Check and confirm all maintenance jobs are completed in the gland steam condenser &
ejector system and the system is ready for start-up.
2. Line up turbine gland exhaust to atmosphere and close gland steam condenser 207E-92
I/L block valve.
3. Fill up the all goosenecks in the system with DM water.
4. Commission the both gland steam pressure control valves and maintain gland steam
pressure at 0.5 kg/cm2.
5. Line up the gland steam condenser 207E92 vapours O/L to one of the ejector
207H-83A and ejector O/L to atmosphere. Keep the ejector 207H-83B as spare.
6. Put the gland steam ejector 207H83A on line and commission the condenser trap O/L
to surface condenser.
7. Close the gland steam atmospheric vent and open the gland steam to condenser
207E-92 I/L B/V.
8. Watch the turbine exhaust pressure & adjust gland steam pressure.

27.4.6 PREPARATIO TO START THE RECYCLE GAS COMPRESSOR:

BARRIG
1. Keep the compressor in barring condition 15 minutes before starting the compressor.

ote: PAL-3732 l start permissive for barring motor.
2. Confirm the barring switch in the local control panel is in “engage” condition.
3. Start the barring motor.
4. Put the barring switch in “engage” position. Confirm barring is taking place.

27.4.7 PURGIG AD PRESSURE TESTIG:

1. Confirm RGC suction, discharge and spill back valves and motorised valves are closed
and suction strainer is fitted with fine mesh for initial start-up.
2. Open nitrogen through seal equalise with system pressure with PDIC positive and
purge the compressor with all vents and drains. Close all vents and drains and pressure
test the compressor with nitrogen.
3. Once pressure with nitrogen is OK, open suction motorised valve, discharge and spill
back block valves and motorised valves slowly.
4. Open start-up nitrogen to primary seal gas system.
5. Raise the HP loop pressure to 21 Kg/Cm2 by injecting start-up nitrogen from make-up
hydrogen compressor, which is already running with nitrogen.
6. Once the pressure in the HP loop reaches 21 Kg/Cm2 open RGC suction block valve,
check the RGC casing drains for any liquid collection.
7. Now the compressor is ready for start-up.

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27.4.8 PROCESS CODITIOS TO START THE RGC 207K-1

1. ZLH-2701 compressor suction MOV full open. – compressor start permissive.

2. The suction block valve open condition.
3. ZLH-2705 RGC spill back block valve full open – compressor start permissive.
4. ZLH-2704 RGC spill control MOV full open – compressor start permissive
5. ZSH-2702 RGC spill back control valve full open in manual mode – compressor start
permissive.
6. LAH-3704 lube oil overhead tank 207D-91 level – compressor start permissive
7. PAL-3722 lube oil header pressure – compressor start permissive.
8. Minimum suction pressure 20.0 kg/cm2.
9.

27.5 207K-1 RGC HOT START-UP PROCEDURE

1. Check for alarm in annunciator panel. acknowledge the alarm.

2. Inform to panel and take corrective actions.
3. Reset the annunciator controller.
4. Ensure for the following
a. N2 to barrier seals (≈ 0.45 ksc)
b. CW supply pressures (≈.4 ksc)
c. IA supply
d. MP & VHP steam supply
e. Control oil pressure (≈ 9 ksc)
f. LO header pressure (≈ 3 ksc)
g. Primary seal gas pr. Positive.
5. Ensure gland steam header (≈ 200 mmWC).
6. Maintain surface condenser level (≈ 40 %).if required open dm water
Maintain surface condenser pressure (≈ -0.9 ksc). if required line up hogging ejector.
Keep open turbine casing drains to surface condenser
Ensure VHP steam temp >380 oC. if required open warm up vent (400C/hr).

ote: start barring gear while warm up is in progress

- Ensure the following
- MUGC is running.
- Suction, discharge and anti-surge MOVs are in open condition.
- Get permission from control room to start the compressor.
- Stop barring gear if it is running and disengage it.
- Ensure all trips logic is in healthy condition.Press trip reset push button (PB-2703B).
- Check for ready start indication.Press start push button (hs2702b) and check for S/U
oil pressure (≈ 8 kg/cm2.).

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ote:
1. If s/u oil pressure is insufficient, pump over speed tester and lift mechanical trip gear
lever to up position if required. Open s/u device (1841) gently to open ESV and inform
to panel.

2. Carefully watch start up oil and trip oil pressures while opening ESV trip oil will increase
to 8.5 kg/cm2 and simultaneously s/u oil will decrease to 0 ksc now turbine is ready to run
from panel. Close the turbine casing drains and DM water make-up.

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27.6 207G-12A/B CHAGE-OVER

27.6.1 CHAGE OVER FROM 207G-12B TO 207G-12A

1) Prime the pump and keep the pump warm up. Line up heating steam to stuffing box
jackets. Check the oil level in the seal flush reservoir. Confirm there is enough cooling water
flow through pump pedestal, bearing houses, seal flush coolers and cooling coils in the seal
flush reservoirs.

2 ) Keep open all the drains in the turbine and keep open all traps bypass valve i.e. from
to steam chest and from turbine casing.

3) Line up cooling water lines to and from turbine steam end bearing housing.

4) Confirm that MP steam inlet line and LP steam outlet lines are in warm up condition up
to the turbine isolation valve.

5) Slowly open MP steam 1" bypass valve across PBV –4403 to warm up the turbine.

6) Once the dry steam starts coming, close all the drains and steam bypass valve.

7) Ensure the suction & discharge B/Vs. are open condition. & min. flow C/V.

8) Keep the selector switch in local panel in man mode.

9) After getting clearance from panel and power plant then start the pump.

10) Press the start push button once, this will provide signal to the governor for
initialization. The trip lever shall be manually latched on to the knife-edge.

11) Second push of the same start push button will provide signal for the governor to
actuate the governor valve actuator to take the turbine to ramp speed and finally to set
speed.

12) Simultaneously, inlet solenoid valve PY 4403 will get a signal through PLC to open
the steam control valve PV-4403.

13) Now turbine will pick up speed to set value. Once set speed is reached check the
turbine and pump for any abnormalities.

14) After inform to panel stop the 207G-12B pump and put into the selector switch in
AUTO mode.

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27.6.2 CHAGE OVER FROM 207G-12A TO 207G-12B

1) Prime the pump and keep the pump warm up. Line up heating steam to stuffing box
jackets. Check the oil level in the seal flush reservoir. Confirm there is enough cooling water
flow through pump pedestal, bearing houses , seal flush coolers and cooling coils in the seal
flush reservoirs.

2) Line up cooling water lines to and from bearing housing.

3) Ensure the suction & discharge B/Vs. & min. flow C/V .are in open conditions.

4) Keep the selector switch in local panel in man mode.

5) After getting clearance from panel and power plant then start the pump.

6) Check the pump for any abnormalities.

7) After inform to panel stop the 207G 12 A pump and put into the selector switch in AUT
mode.

8) Keep the 207G-12A in warm up condition and open all steam drain valves, steam trap
bypass valve, Open the 1" bypass steam UV valve.

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27.7 CHAGE OVER PROCEDURE FOR WATER IJECTIO PUMP 207G-4A/B

 Check the spare pump conditions.

 Check gearbox oil level; crank case oil level & forced lubricator oil level.

 After inform to panel, Stop the running pump and close the discharge B/V.

 Now the chopper valve closed.

 Open the discharge block valve of the spare pump.

 Ensure that spill back valve 207PIC-3303 is in open condition.

 Start the pump checks the pump discharge pressure.

 Inform to panel to reset the chopper and latch it in field, now the chopper is
opening, simultaneously open the flow control valve and close the spill back to
make flow thro the chopper.

 Once flow is established check the pump conditions are normal.

ote: the chopper timer will actuate in 60 secs if flow fails.

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27.8 CHAGE OVER PROCEDURE

FOR SURFACE CODESOR CEP 207G-92A/B

27.8.1 CHAGE OVER FROM 207G-92A TO 207G-92B

 Ensure the 207G-92B suction and discharge B/V are open condition.
 If its returns from maintenance open the valve gland water, open the pump vent to
surface condenser slowly and check the casing pressure. It should be in
negativepressure. Slowly open the suction valve since it's connected with vacuum
condensor.

 Inform to panel, put selector switch of 207G-92B " MAN " mode and start the
pump.

 Check the discharge pressure of 207G-92B i.e. 9 to 10 kg/cm2.

 Stop the 207G-92A pump by pressing the local stop switch so that the steam
shut off valve gets closed and put the selector switch in AUTO mode.

 Open the Governor steam drain valve and upstream of governor steam drain valve
for warm up and ensure the M. P steam temperature should be 150 oC.

27.8.2 CHAGE OVER FROM 207G-92B TO 207G-92A

 Ensure the 207G-92A suction and discharge B/V are open condition.

 Ensure the M.P.Steam temperature should be 150o C or otherwise by opening the

steam drain valve to warm up.

 Close the all steam drain valve.

 After inform to panel, start the 207G-92A pump i.e. by pressing the LCS start
Button so that M.P.steam shut off valve get opened.

 Ensure the pump RPM will be 2900 to 3000 and discharge pressure will be 9 to
10 kg/cm2.

 After inform to panel stop 207G-92B and put the selector switch in AUTO mode.

 And confirm with panel for level is under control.

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CHAPTER -28
THERMAL DeOx
28.1 PROCESS DESCRIPTIO:
Thermal denox facility is designed to reduce NOx emission from OHCU –Fractioner feed
heater (207F2). The thermal denox process is a selective non-catalytic process for the
reduction of NOX emissions from stationery combustion sources.
The thermal denox process is based on the gas phase homogenous reaction between NO
and ammonia which produces nitrogen and water. For the process anhydrous ammonia is
injected into the flue gas by means of a carrier low pr.steam at a location selected to
ammonia into the flue gas results in numerous intermediate chain branching reactions
which can be summarized by the two simplified reactions.

NO + NH3 + O2 + (H2) N2 + H2O

NH3 + O2 NO + H2O

Since these two reactions are intended only to summarize the overall effect and not the
actual mechanism, they are not presented as balanced chemical reaction. The thermal
denox process can be applied to flue gas in the temperature range of 870 oC to 1090 oC
using ammonia alone. The first reaction is the desired NOx reduction reaction and is
favored at the lower end of this temperature range. As the temperature is increased, the
second reaction becomes more significant, finally dominating the process at the higher end
of the temperature range. If the temperature is too low, there will be very little NOx
reduction and the ammonia will pass through unreacted. If the temperature is too high, the
ammonia will be oxidized according to the second reaction, causing an increase in NOx
emissions. The fact is that in the practical temperature range these two process are always
competing, resulting in destruction of essentially all the excess ammonia. The effective
temperature range can be extended down to 700 oC by the injection of hydrogen along with
the ammonia. If the hydrogen injection is less than actually required, the ammonia will not
get reacted resulting in lower NOx reduction and higher ammonia slip. If the hydrogen
injection is slightly higher than required, more ammonia consumption will be there with
lower ammonia slip and if the hydrogen injection is too high as compared to desired value,
the ammonia will be oxidised causing an increase in NOx emissions. The reduction of
NOx by the thermal denox process is controlled by the kinetics of the numerous chemical
reactions. Therefore, the residence time of the flue gas at reaction temperature is an
important variable. In addition to temperature and residence time, flue gas composition
may also affect the performance of the thermal denox process. Oxygen, water vapour and
CO concentrations are particularly important. Other flue gas components also need to be
evaluated. For example, sulphur compounds, although not directly affecting the NOx
reduction performance, may react with excess ammonia to form ammonia salts. As the flue

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gases are cooled to about 230oC, ammonia react with sulphur trioxide to form ammonium
sulphate or bisulphate. These compounds could deposit on the surface of heat recovery
equipment operating in this temperature range. However, this has not been a problem when
the thermal denox process is operated within the prescribed design specifications. Sulphur
dioxide may also react with ammonia at temperature below 60 oC , but since this is usually
far below the stack temperature, it is not of concern.

28.1.1 SUPPLY OF AMMOIA FROM REF III SRU UIT (PLAT 231)

The anhydrous ammonia is vaporized in the heat exchanger with LP steam as heating
medium. The heat input to vaporizer will be automatically controlled with the help of
pressure controller at storage drum outlet. The anhydrous ammonia vaporizer is equipped
with safety relief valve.
LP steam is used as a carrier medium for injecting ammonia into firebox. Since, LP steam
is already available in respective units, the tap off is taken from existing lines and is
distributed to fire box.
To achieve desired NOX reduction at lower loads, hydrogen injection is also required. The
hydrogen produced in plant 205 H2 plant is used to meet this requirement.
The mixture of ammonia, hydrogen and carrier steam or ammonia and carrier steam is
injected into the firebox through a series of nozzles located in two levels. The choice of
injection level depends upon heater operating conditions and the required NOX reduction.
Carrier steam is needed to ensure that the ammonia/ hydrogen are adequately distributed in
the flue gases. As the mixture leaves the injection nozzles, it expands as a free jet inside
the heater. This action entrains flue gas, mixing it with the ammonia / hydrogen and
promotes the thermal denox reaction. The cooling /purge steam is also supplied to the
injection nozzle level not being used for ammonia injection.

28.1.2 AMMOIA FLOW COTROL

Ammonia flow is controlled via controller FIC-8801 whose set point is automatically
adjusted based on heater load and trimmed by feedback signal of NOX and O2 analyzers.
Ammonia flow rate is automatically regulated by a signal characterizing function
FY – 8802 translating from heater operating load (total fuel fired duty) as follows:
The fuel oil flow (kg / hr) is worked out based on signal FDI-4204
Fuel oil flow (kg / hr) = Fuel oil flow ( m3 / hr ) X Fuel oil density.
The fuel gas flow (kg / hr ) is worked out based on signal FI-4208.

Fuel Gas flow (nm3/ hr) X Fuel gas MW

Fuel gas flow (kg / hr) = ____________________________________
22.4

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Total fuel fired duty is worked out by adding fired duties of fuel oil and fuel gas

Heater load (MMKcal / hr) = [Fuel oil flow (kg / hr) x LHV of fuel oil (kcal / kg) +
Fuel gss flow (kg / hr) x LHV of fuel gas (kcal / kg)] x 10- 6

Provision shall be kept to input fuel oil density, fuel gas MW, LHV of fuel oil and LHV of
fuel gas manually also. The desired quantity of ammonia is determined as a function of
total heater operating load to provide set point for the ammonia flow controller FIC –8801.
In addition to the feed forward control on heater load, feedback control is provided by a
signal from the NOX analyser AIC – 8801. This signal compares the current NOX reading
to the set point and makes a small change to the ammonia injected to meet the set point (if
the current NOX is greater than set point, the ammonia injection is increased and vice
versa)
Similarly feedback control is provided by a signal from the O2 analyzer AIC 8802. This
signal compares the current O2 reading to the set point and makes a small change to the
ammonia injected to meet the desired NOX level. (If the current O2 is greater than set
point, the ammonia injection is increased and vice versa)

28.1.3 CARRIER STEAM FLOW COTROL.:

Carrier steam flow is controlled via flow controller FIC – 8802 whose set point is
automatically adjusted based on heater load. Carrier steam flow rate is automatically
regulated by a signal characterizing function FY 8805 translating from heater operating
load (total fuel fired duty) as described earlier. The desired quantity of carrier steam is
determined as a function of total heater operating load to provide set point for the carrier
steam flow controller FIC 8802.

28.1.4 HYDROGE FLOW COTROL:

Hydrogen flow is controlled via a flow controller FIC 8803 whose set point is
automatically adjusted based on heater load and ammonia flow rate. Hydrogen flow rate is
automatically regulated by a signal characterizing function AY 8803 translating from
heater operating load (total fuel fired duty) as follows.

The hydrogen flow (Nm3 / hr) is worked out based on signal FIC-8801.
Hydrogen flow (nm3 /hr) = Ammonia flow (nm3 /hr) x Hydrogen / Ammonia ratio

When the heater is operating below thermal denox achievable turn down load (50 % of
normal load), the NOX reduction is not expected to be effective and ammonia / hydrogen
& carrier steam flow is cut – off by pressing emergency shutdown push button HS – 8805
A / B but the injectors are cooled / purged by bypass steam line provided up–steam of
carrier steam shutdown valve. The cooling / purging steam must be kept on line regardless
of heater load and the NOX reduction facilities are in service or not. Additional

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instrumentation is required to monitor to operation of the thermal denox installation and to

assess its performance. The instrumentation are NOX analyzer AI – 8801 and NH3
analyser AI-8803 in the outlet flue gas. Selection of level is automatic function of heater
load FY 8804. Selection logic permits only one valve to be open at any time. Level
selection can also be done manually by the operator by hand switch HS 8807 in control
room based on the curves for level selection versus heater load.

28.2 ITERLOCK DETAILS:

Sl o. Actuated By Values Action taken By

1. FT / FALL – 8802 Close shutdown valves
207 – UV – 8801 / 8802 /8805
2. FT / FAHH – 8801 Close shutdown valves
207 – UV – 8801 / 8802
3. Hater shutdown Close shutdown valves
207 – UV – 8801 / 8802
4. Emergency shutdown Close shutdown valves
push button in field 207 – UV – 8801 / 8802
HS- 8805A and
Control room hardware
HS-8805B
5. FT/ FALL- 8801 Close shutdown valves
207 – UV – 8801 / 8802 /8805
6. HS – 8807/FY – 8804 Open shutdown value 207UV-8803 &
Close shutdown valve 207 UV-8804
or Open shutdown valve 207UV-
8804 & Close shutdown valve
207UV-8803
7. AY/ AALL - 8803 Close shutdown valves
207 – UV – 8801 / 8802 /8805

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ORMAL OPERATIO:
1. In normal operation the system control will be automatic.
2. Ammonia / Hydrogen & carrier steam rate will be established based on heater load.
3. Feedback control from the NOX and O2 analysers will optimize the ammonia rates to
meet NOX and ammonia slip limits.
4. When a major change in heater load occurs, a new level will be automatically selected,
the steps 2 & 3 are repeated to establish new ammonia / hydrogen & carrier steam rates.
5. During normal operation, the analysers (NOX, NH3, & O2) & flow instruments (NH3, H2,
LP Steam) should be frequently checked for correctness of readings.

28.3 SHUT DOW PROCEDURE:

• Extended heater operation at low load conditions that either does not required NOX
removal or does not provide sufficient flue gas temperature for the operation of the
thermal denox process.

• In the event of heater trip or thermal denox malfunction (ie low pressure in the NH3
vapor line or the NH3 storage tank ), the ammonia vaporizer and supply system is
isolated and shut down. From this condition the ammonia system can be restarted or
purged for maintenance.

• All other system shut down should follow the sequence below.
1) Close ammonia / hydrogen vapor & carrier steam flow control valve and shutdown
valve serving heater to be shut down. This will purge ammonia from the point
where it mixes with cooling / purging steam forward into the heater.
2) For individual heater to be shutdown, purge ammonia supply system with nitrogen.
a) Purge is accomplished by sending all ammonia to the injectors while the heater is
operating.
b) A system purge may not be required for short shutdown if no maintenance is
necessary on equipment containing ammonia.
c) The procedure for purging the system is as follows;
- Close ammonia isolation valve at heater or battery limit.
- Select last level used to be used for purging.
- Slowly open the ammonia flow control valve and shutdown valve.
- Open the N2 supply valve.
- When the purge is complete, close the ammonia flow control valve and
shutdown valve.
- Close the N2 supply valve
3) For total system shutdown additional steps needed are;
- Close ammonia isolation valves at ammonia storage tank
- Shut down vaporizer.
- Purge common ammonia supply system with nitrogen.

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- Isolate steam & hydrogen supply system

Emergency procedure:

Incase of Instrument air failure, power failure, & fire follow the shutdown procedure given
above

Ammonia leak:

Incase of ammonia leak the thermal denox system shall be shutdown by pressing
emergency push button provided in field and control room which will close ammonia,
hydrogen and stem supply to heater. The source of ammonia leak shall be identified and
affected section shall be isolated from rest of system by closing appropriate block valves.
Operating personnel working adjacent to the leakage area to be warned and should be told
to vacate the place if required. Then leak should attended by taking all necessary
precautions.

28.4 CLEAIG PROCEDURE FOR IJECTORS:

The level of injectors Two

The number of injectors 160 ( 80 per level, 20 on each side wall )

Following sequence to be followed for cleaning of injectors; -

• Open the 1 " NPT threaded cap provided at the end of individual injector assembly.
• Insert a wire of 3 mm dia. through this opening and clean out any depositions in the
entire nozzle length. The wire should be of sufficient length (1000 mm) to have
access up to nozzle tip.
• If the heater is shut down then nozzle tips can be cleaned from inside of heater. Also
in this case nozzle tip can be viewed as well, to observe damages, if any, to the nozzle
tip. If the tip is damaged the same should be replaced.
• If nozzles can not be cleaned with help of wire inserted through the end cap, the entire
injector assembly can be pulled out by opening two flange joints. One joint is
connecting the injector to main header and the other is connecting to heater sleeve.
After pulling out the assembly the same can be cleaned thoroughly with the help of
wire and steam.
• Before putting the injector back to operation the injector assembly should be
thoroughly flushed out with steam to clear remaining depositors, if any.

CHAPTER-29

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CALCULATIOS
There are several important parameters describing Hydrocracker performance which are
not available as simple instrument measurements. This section describes the methods to be
used to calculate these parameters. .

29.1 CATALYST TEMPERATURE

There are three steps to calculate CAT. The calculation procedure requires gathering
temperature information from the reactor thermocouples. The terminology definitions and
steps are shown below.

29.1.1 LAT
Level Average Temperature LAT is the average temperature at a given elevation. The
reactors should have eight bed thermocouples at a given elevation. A LAT needs to be
calculated for each elevation in the catalyst beds.

LAT, °C = [TI(1) + TI(2) + TI(3) + TI(4) + TI(5) + TI(6) + TI(7) + TI(8)]/8

When calculating the LAT use only reliable readings at an equal elevation, and discard any
unreliable readings. Examples of unreliable readings are those from thermocouples that are
known to be off-calibration or that provide unstable readings that are proven not to be
caused by the process.

30.1.2 BAT
Bed Average Temperature BAT is defined as the average of all LAT’s of a given bed. A
BAT needs to be calculated for each of the three catalyst beds in the first reactor and each
of the two catalyst beds in the second reactor.

BAT, °C (X) = [Inlet LAT (X) + Outlet LAT (X)] / 2, where X = Bed Number

29.1.3 CAT:
Catalyst Average Temperature CAT for each reactor is determined by averaging each
bed BAT after weighting them by the volume fraction of active catalyst in each bed. The
table below shows the weighting factors to be used to determine the CAT for each reactor.

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CAT, °C = [BAT(1) x ∈1] + [BAT(2) x ∈2] + [BAT(3) x ∈3]

For the design reactor loadings, the fractions are as follows:

Table 29.1
Volume Fraction Active
Catalyst in Each Bed
∈1 ∈2 ∈3
First Reactor (207-R1) 0.01 0.46 0.53
Second Reactor (207-R2) 0.50 0.50

In addition to temperature averages, delta bed temperatures are also useful for evaluating
the operation of the unit. “Bed Delta Ts” are simply the difference between the bed inlet
and outlet LATs and are an indication of how much reaction is taking place in the bed.
“Radial Delta Ts” are calculated as the difference between the maximum and minimum
reliable temperature readings at a level and are a measure of the quality of the flow
distribution across the reactor.

Another way to analyze flow distribution is to calculate the difference between the top and
bottom TIs along the same radial orientation of the reactor. If there is a low or high
temperature differential through a vertical plane along the same radial orientation, there
may be uneven flow distribution in that catalyst bed.

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29.2 HYDROGE PARTIAL PRESSURE

The hydrogen partial pressure (pH2) represents the concentration of hydrogen in the
reactor. Although in reality not all the mass in the unit is in the vapor phase, for this
variable Chevron uses the simplifying assumption that it is. This provides ease in
calculation, and in practice has shown to be suitable for data tracking, correlation, and
design work.

For routine plant monitoring and for programming into a process monitoring computer, it
is acceptable to monitor only the reactor inlet hydrogen partial pressure. Inlet hydrogen
partial pressure can be calculated following these steps:

1. Estimate the molar rate of oil feed.

2. The molar flow rates of recycle gas plus make-up gas from meter readings are needed.
Correct these for off-design conditions of temperature, pressure, and specific gravity at the
meter orifice as required.

3. Calculate the molar flow rate of hydrogen (H2) at the inlet from the hydrogen analyzer
on the recycle gas plus make-up hydrogen stream and molar flows from Step 2.

4. Determine the partial pressure of hydrogen at reactor inlet by multiplying the reactor
inlet pressure and the ratio of hydrogen molar flow to total gas plus oil molar flow (i.e.,
total moles at reactor inlet) as shown in the expression below:

Moles of H 2 at Reactor Inlet

pH 2 , kg / cm 2 (a) = Reactor Inlet Pressure, kg / cm 2 (a) x
Total Moles (Gas + Oil)
at Reactor Inlet
Example

The following example calculates the reactor inlet hydrogen partial pressure based on
design SOR case conditions. The streams are from the stream data sheet (Rev. 1), and the
component data sheet (Rev. 0).

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1. Determine the molar rate of oil feed (Stream 111):

Feed Rate (Standard Conditions) = 249.2 m3/Hr

Feed Gravity (Standard Conditions) = 929.1 kg/m3
Feed Molecular Weight = 378.0 kg/kg-Mole
Molar Rate of Oil Feed = 249.2 m3/Hr x 929.1 kg/m3
x 1 kg-Mole/378.0 kg
= 612 kg-Mole/Hr

2. Molar flow rate of recycle gas to the first reactor (Stream 128):

Recycle Gas Rate = 210,490 Nm3/Hr

Molar Rate of Recycle Gas = 210,490 Nm3/Hr / 22.405 Nm3/kg-Mole
= 9,395 kg-Mole/Hr
3. Molar flow rate of hydrogen at reactor inlet:

Mole % H2 Recycle Gas Stream = 93.8 Mole %

Molar Rate of H2 at Reactor Inlet = 0.938 * 9,395 kg-Mole/Hr
= 8,813 kg-Mole/Hr

4. Determine pH2 at reactor inlet:

Reactor Inlet Pressure, kg/cm2 (a) = 173.5

Molar Rate of H2 at Reactor Inlet = 8,813 kg-Mole/Hr
Total Moles at Reactor Inlet = 612 kg-Mole/Hr + 9,395 kg-Mole/Hr
(Sum of Oil + Gas Molar Rates)
= 10,007 kg-Mole/Hr

8,813 kg −Mole/Hr
pH 2 , kg/cm 2 (a) = 173.5 kg/cm 2 (a) x
10,007 kg −Mole/Hr
= 152.8 kg/cm 2 (a)

The pH2 at the reactor outlet is calculated in the same manner. The average hydrogen
partial pressure is calculated as:

pH 2 Inlet + pH 2 Outlet
pH 2 =
2

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29.3 COVERSIO
Conversion is a measure of how hard the catalyst is working. “T-Star” or T* is used to
characterize the front-end of the feed boiling curve. It is essentially an estimate of the true
boiling point (TBP) initial cut point of the feed and is a much more accurate parameter to use in
calculating first-stage conversion than the starting TBP of the feed.

T* is determined graphically by simply plotting the TBP feed curve, drawing a straight line
between the 30% and 50% points, and extrapolating that line back to 0%. T* could be simply
calculated from the 30% and 50% points without a plot, but preparation of a plot of the feed is
preferred so that possible errors in the distillation (as indicated by an unusual curve shape) can be
identified.

A stepwise method for calculating X(T*) is presented below. The TBP distillation assays of both
feed and product are required in order to calculate conversion. Note that ASTM distillations will
need to be converted to TBP distillations. (See Figure 13-1 for conversion method.)

1. Plot the feed TBP curve.

2. Locate T* as the intercept of TBP-axis with a line through the feed TBP 30% and 50%
points.

3. Determine the volume expansion, ∈, of feed to product.

The volume expansion depends not only on the actual conversion but also on the condition of the
catalyst. C5+ volume expansion is greater at start-of-run than at end-of-run. The following
estimated expansion factors may be used to simplify the calculations:

Table 29.2
Design Case Catalyst Condition ∈

SOR 8.3
EOR 6.3

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4. Adjust the product TBP discussion to account for the expansion according to the

100 + ∈
Adjusted LV % =  x Unadjusted LV %
 100 

formula:
Plot the adjusted product TBP curve.

5. Determine the amount of product boiling below T* from the adjusted product TBP curve.

6. Liquid conversion below T* is the value determined in Step 5 minus the expansion (∈).

29.4 AMMOIUM BI SULPHIDE

The Nitrogen present in the feed is (Design is max 1100 ppm) converted as ammonium bi
sulphide in the reaction and washed by injection water at 207E-9 and 207E-8 inlet. The
remaining ammonia goes along with CHPS gas and Hydro carbon phase.

Calculations for ammonium bi sulphide present in sour water:

Basis
Design feed rate = 249 m3/hr
Density =930 kg/m3
Feed rate in wt =249 x 930
= 231570 kg / hr
Design Nitrogen content = 1100 ppm
Nitrogen content in wt = 231570 x 1100 x 10-6
= 254.72 kg/hr

One mole of nitrogen with three moles of hydrogen will give two moles of ammonia.
Equivalent ammonia produced is in the ratio with nitrogen is 17/14

So, equivalent ammonia produced = 254 .72 x 17

14
= 309.31 kg/hr say 310 kg/hr

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• About 11.29 wt% (= 35/310) of ammonia lost in CHPS vapour

• About 14.84 wt% (=46/310) of ammonia lost in CHPS Hydrocarbon phase
• About 73.87 wt% (=229/310) collects in sour water as ammonium Bisulphide

Injection water
Vapour 11.29 wt% of NH3

310 kg/hr
HC 14.84 % wt of NH3
207E-9 207C-
NH4HS & 2
207E-8
NH3 SW 73.87 wt % NH4HS

In sour water NH3 content = 310 x 73.87 %

= 229 kg/hr

All 229 kg/hr NH3 is dissolved by injection water as ammonium bi sulphide.

One mole ammonia is produced one mole of ammonium bi sulphide.

Molecular weight of ammonium bi sulphide is 51

17 wt% of NH3 will produce 51wt% of NH4HS

2228.55 kg of NH3 will produce = 229 x 51

17
= 687 kg NH4HS/ hr

injection water = 6000 kg /he

sour water = 6000+ 687 kg/hr
= 6687 kg/hr

% of NH4HS in sour water = 687 x 100

6687
= 10.27 wt%

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Table 29.3
EGIEERIG UIT COVERSIOS

Multiply To Obtain
English by Metric
Temperature °F 5/9 x (°F-32) °C
Pressure psia 0.0703 kg/cm2 (a)
Volume Ft3 0.02832 m3
Gal. 3.785 L
Bbl 0.1590 m3
SCF 0.0268 Nm3
Length Ft 0.3048 m
In. 25.4 mm
Area Ft2 0.0929 m2
Mass or Weight Lb 0.4536 kg
Mass, Weight, or Volume Flow Lb/Hr 0.4536 kg/Hr
BPOD 0.00662 m3/Hr
gpm 0.2271 m3/Hr
MSCFD 1.1163 Nm3/Hr
Velocity Ft/Sec. 0.3048 m/s
Energy Btu 0.252 kcal
Power hp 0.7457 kW
Btu/Hr 0.252 kcal/Hr
Work Btu 0.252 kcal
Transport Properties
Enthalpy Btu/Lb 0.556 kcal/kg
Heat Capacity Btu/Lb/°F 1.0 kcal/kg/°C
Thermal Conductivity Btu/Hr/Ft/°F 1.488 kcal/Hr/m/°C
Heat Transfer Coefficient Btu/Hr/Ft2/°F 4.882 kcal/Hr/m2/°C
Density Lb/Ft3 16.02 kg/m3

Note:

Normal vapor conditions for metric units are 0°C and 1 atm. Standard liquid conditions for
metric units are 15.6°C and 1 atm. Standard vapor and liquid conditions for English units are
60°F and 1 atm.

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CHAPTER – 31
GUARATEE TEST RU (GTR) REPORT
Executive Summary
CPCL successfully commissioned its OHCU, a 1.65 MM Metric Ton/Year (221 m3/hr, 33,400
BPSD) CLG ISOCRACKING Unit, on August 4, 2004. This unit is part of a refinery expansion
project in Manali, Tamil Nadu, India, by Chennai Petroleum Corporation Limited (CPCL). The
hydrocracker is a single-stage, once-through unit that has been designed to produce middle
distillate fuel of superior quality. It is licensed by CPCL from Chevron Lummus Global LLC
(CLG).
The OHCU Unit Guarantee Performance Test (GTR) was carried out between 29th January 2005
to 4th February 2004. The Unit met all guarantees, namely Feed Processing Capacity, Product
Yield, Product Quality, Hydrogen Consumption, and Utility Consumption and Generation.

1. Unit Conditions Adjustment for GTR Conditions

Adjustments for GTR conditions began on January 29, 2005. It was observed during the test run
period that crude changes were taking place frequently resulting in changes in OHCU feed
quality. In view of the above, the unit operating parameters were required to be tuned frequently
for achieving the desired conversion. In addition, the above also required tuning the operation of
the Fractionator / Light End Recovery Section for yields and product quality. The following table
illustrates the frequency of crude change during the test run period.

Date Crude Type Combined Feed Sulfur, Wt %

29th January, 2005 Arab Mix 3.23
30th January, 2005 Arab Mix 3.23
31st January, 2005 Bombay High 0.63
1st February, 2005 Bombay High / Syrian Crude 0.63
2nd February, 2005 Bombay High / Arab Mix 0.81 / 0.86 / 1.04
3rd February, 2005 Bombay High / Arab Mix 0.94 / 1.56 / 2.13
4th February, 2005 Arab Mix 2.10 / 2.21

Another important issue during the test run was the feed distillation. CPCL was feeding heavier
VGO to the OHCU with much less diesel range material (370ºC minus) as compared to the
design feedstock composition. This results in much higher catalyst work load to meet the design
middle distillate yield and quality as almost all diesel yield must be made synthetically from
heavier components. The table below compares the feed distillations between the GTR and the
design.

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Sim. Dist. Design 1st Feb 2005 2nd Feb 2005 Remarks
0% 300°C 340°C 336°C
5% 330°C 391°C 376°C
10% 348°C 413°C 402°C
30% 387°C 441°C 436°C
50% 445°C 465°C 462°C
95% 556°C 542°C 536°C
% < 370°C 20.9 3.2 4.3 16% Lower than Design feed
1.1 % Variation in Diesel Impacts Diesel Quality & Yields
Components

A meeting was held between CLG and CPCL to finalise the approach for conducting the GTR
considering the varying nature of feed quality with respect to sulfur and diesel components in the
feed. It was also noted that the combined feed meter FIC 1801 and UCO meters were in error.
Based on the discussions, the following methodology was agreed upon between CLG and CPCL:

a. The overall Mid-Distillates (Kerosene + Diesel) yield would be used as guarantees as

against individual yields of Kerosene and Diesel.
b. Feed flow to Unit would be based on Battery Limit Fresh feed meter, FIC 1403,
adjusted for feed filter back wash.
c. UCO yields would be calculated by difference to close the mass balance.
d. Rich Amine flash gas meter (FI 3201) was in error and hence design values would be
used.
e. LPG run down meter at battery limit, FI 6603 was used for mass balance.
f. Cooling water supply and return temperatures were 31°C and 37°C, with an overall
∆T of only 6°C as against a design ∆T of 12°C. It was agreed that cooling water flow
rates would be pro-rated for a ∆T of 12°C.
g. Unit power calculations would be performed by CPCL based on individual motor
Amperage.
h. Data collection period would be shorter than 72 hours due to frequent changes in
crude mix resulting in change in feed quality to the unit.
i. Since the Guarantee performance test run was delayed beyond the agreed upon three
months after feed in, CPCL and CLG mutually agreed that yield guarantees would be
pro rated between SOR and EOR yields for a period of six months.

The meeting notes are attached for reference as Attachment 1.

2. Feed Processing Guarantees

The feed processing guarantee of 221 m3/hr was met within the permissible variations normally
observed in unit operations. It must be mentioned that subsequent to GTR, feed rates were raised
to 249 m3/hr and then to 260 m3/hr on 5th February, 2005 without any hydraulic limitations.

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Feed Rate Design 1st February Data 2nd February Data 5th February Data
221 m3/Hr 220 m3/Hr 221 m3/Hr 260 m3/Hr

3. Product Yield Guarantees

The unit met all conditions of product yield guarantee on LPG and Mid-Distillate yields:

Performance Parameter GTR Pass 1st February 2nd February Average GTR
Values Data Data Data
LPG Product , Wt % Yield 1.94 2.24 2.13 2.19
Kerosene + Diesel, Wt % Yield 44.99 45.99 45.18 45.59

4. Product Quality Guarantees

The unit met all conditions of product quality guarantees after adjusting catalyst temperatures
and achieving steady fractionation operation. The results are presented in the table below.
1st February 2nd February
Product Properties Guarantee Data Data Average
CLPS Offgas/Bleed H2
Hydrogen Sulfide Not Greater Than 20 mol wppm Nil Nil Nil
Chloride Content Not Greater Than 1 mol wppm Nil Nil Nil
LPG
n-Pentane/i-Pentane Not Greater Than 1 mol % 0.46 1.1 0.8
Free Water Nil Nil Nil Nil
Mercaptan Sulfur Not Greater Than 5 wppm 2.8 3.5 3.2
Copper Strip Corrosion Not Worse Than Number 1 No 1 No 1 No 1
(1 Hr @ 38°C)
Vapor Pressure @ 65°C Not Greater Than 16.8 kg/cm2 < 16 (Calc) <16 (Calc) <16 (Calc)
Vaporization @ 2°C & Not Less Than 95% > 95 > 95 > 95
Atm. Press.
Light Naphtha
Reid Vapor Pressure Not Greater Than 0.8 kg/cm2 0.7 ( 9.9 psia ) 0.7 ( 9.8 psia ) 0.7
Mercaptan Sulfur Not Greater Than 10 wppm Not Reported 4.5 4.5
Kerosene
ASTM D86 Recovery @ 200°C Not Less Than 20% ATF Mode > 25 > 25
Flash Point, Abel Not Less Than 35°C ATF Mode 35 35
Smoke Point Not Less Than 21 mm ATF Mode 26 26
Sulfur Not Greater Than 10 wppm ATF Mode < 10 < 10
Color Saybolt Not Less Than 10 ATF Mode + 29 + 29
Aviation Turbine Fuel
Freeze Point Not Greater Than -51°C -68 Kero Mode -68
Smoke Point Not Less Than 21 mm + 26 Kero Mode + 26
Flash Point, Abel Not Less Than 38°C 39 Kero Mode 39
Sulfur Not Greater Than 10 wppm < 10 Kero Mode < 10
Aromatics Not Greater Than 22 vol% 7.2 ( 2nd Feb ) Kero Mode 7.2
Naphthalene Not Greater Than 3 vol% 0.04 ( 2nd Feb ) Kero Mode 0.04
Mercaptan Sulfur Not Greater Than 3 wppm 2.7 Kero Mode 2.7

Water Tolerance Not Greater Than 1 mL < 1 ( 2nd Feb ) Kero Mode <1

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Copper Strip Corrosion Not Worse Than Number 1 No 1 Kero Mode No 1

(2 Hr @ 100°C)
Silver Strip Corrosion Not Greater Than 0 Zero Kero Mode Zero

3rd February 4th February

Product Properties Guarantee Data Data Average
Diesel
Density at 15°C, kg/m3 Between 820 and 870 0.8342 0.8360 0.8351
ASTM D86 85% Recovery Not Greater Than 350°C 329 342 336
ASTM D86 95% Recovery Not Greater Than 360°C 348 355 352
Cetane Number (ASTM Not Less Than 55 62 65 63
D613)
Flash Point, Abel Not Less Than 35°C 104 102 103
Pour Point Not Greater Than 3°C -3 +3 0
Sulfur Not Greater Than 10 wppm <10 <10 < 10
Viscosity @ 40°C Between 2.0 and 5.0 cSt 3.8 4.46 4.13
Unconverted Oil, Sulfur Not Greater Than 50 wppm <10 <10 < 10

Note for Diesel: As discussed in earlier sections, changing feed quality in the unit both in terms
of feed sulfur as well as varying content of diesel in feed resulted in time taken to adjust for the
correct Catalyst average temperatures as well as line out the Fractionator operation. Hence
diesel quality is reported for 3rd and 4th of February respectively. However, with available data
collected on Fractionator column temperature & pressure profiles during GTR and experience
gained by CPCL at design feed rate operation, Fractionator adjustment would be routine affair in
future operation.
5. Hydrogen Consumption Guarantees
The make-up hydrogen consumption, chemical plus dissolved, guarantee of 286 Nm3 Hydrogen/
SM3 of fresh feed was met within the permissible variations normally observed in Unit
operations.

MU H2 Guarantee, 1st February Data, 2nd February Data,

Nm3/m3 Nm3/m3 Nm3/m3
286 266 267

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6. Utility Guarantees
The utility consumption guarantees were met within the permissible variations normally
observed in Unit operations.
GTR Feb 1, Feb 2,
Performance Pass 2005 2005 Average
Parameter Guarantee Values Data Data GTR
Utilities Consumption 105% of Estimated Consumption
Fuel Fired, MMKCal/hr, With 23.94 20.2 21.6 20.9
105%
Power, kW, With 105% 13242 10642 10792 10717
Cooling Water, m3/Hr With 105 % 1350 1083 1080 1080
for 12°C ∆T
VHP Steam, M kg/Hr, With 105% 15.86 13.4 13.3 13.3
HP Steam, M kg/Hr, With 105% 4.31 3.6 3.6 3.6
LP Steam, M kg/Hr With 105 % 8.4 8.3 8.3 8.3
Net Steam Generation 100% of Predicted Value
MP Steam, M kg/Hr 22.8 23.1 23.1 23.1
Note: There is no direct LP steam generation in the unit. Generation of LP steam is only let
down of MP steam to LP steam in the Turbine of the Fractionator bottom pump. As there is no
individual steam flow meter for the above pump, Guarantee is indicated in terms of the LP steam
consumers

7. Unit Mass Balance

Unit Mass balance detailed work is provided in Table 1a for February 1st 2005 and Table 1b for
2nd February 2005. Each table consists of four sections, namely:
• As drawn mass balance
• Meter corrected mass balance
• Meter corrected and UCO fudged mass balance
• Normalized final yields
8. Consolidated Guarantee Tables as per Schedule B of CPCL – CLG Agreement
The consolidated guarantee tables as per Schedule B are given in Tables 2.
9. Utility Guarantee Calculations
Utility calculations are provided in Table 3.
10. Unit Power Consumption Calculations
Unit power consumption calculations were performed by CPCL based on Amperage readings
from Substation. The calculations are summarized in Table 4.
11. Consolidated Laboratory Data
Consolidated laboratory information from CPCL’s Quality Control as well as from the R&D lab
are provided in Table 5.
12. Unit Graphics During GTR
Unit graphics of key sections are presented for the following dates:
• 1st February, 2005 @ 221 m3/hr fresh feed

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• 5th February, 2005@ 260 m3/hr fresh feed

13. Comments on Catalyst Performance
Key catalyst parameters are given in the following table in comparison with design values. It
can be seen that compared to the design SOR Catalyst Average Temperatures of 394°C, the
actual values during GTR were around 383°C after six months of operation. This indicates
extremely good activity for the catalyst, especially since the catalyst must work harder than
designed to synthesize almost all diesel yield from heavier material.
2nd
st
Design 1 Feb. Feb.
Parameter Units (SOR) 2005 2005 Remarks
LHSV Hr -1 0.77 0.69 0.69
Stage Catalyst Average Deg C 394 383 383 Good Catalyst
Temp. Activity
Gas / Oil Ratio at RX1 Inlet Nm3/m3 845 1047 1032
Feed Distillation T* °C 300 405 397 T* High
Feed Distillation < 370°C Vol % 20.9 3.2 4.3 Low Diesel in Feed
Gross Conversion Below Vol % 54.0 59.0 60.3
370°C
Synthetic Conversion Below Vol % 33.1 55.8 56.0 High Syn.
370°C Conversion
Chemical Hydrogen Nm3/m3 256 246 248

14. Comments on Reactor Internals and Bed Radial Temperature Distribution

CLG had provided the state of the art “Nautilus” reactor internals for obtaining good flow
distribution over the catalyst bed. In addition, the efficient supervision during catalyst loading
has enabled very good bed temperature distribution profile, with very low radial distributions.

1st Feb. 2005 2nd Feb.2005 5th Feb 2005

Radial Spread, (Max. – (220 m3/Hr) FF (220 m3/Hr) FF (260 m3/Hr)
Min.) FF
Bed 1 Level 2 Radial Deg C 1 1 2
Spread
Bed 2 Level 1 Radial Deg C 2 1 2
Spread
Bed 2 Level 2 Radial Deg C 6 6 8
Spread
Bed 3 Level 1 Radial Deg C 2 2 2
Spread
Bed 3 Level 2 Radial Deg C 6 6 6
Spread
Bed 4 Level 2 Radial Deg C 2 2 3
Spread
Bed 5 Level 1 Radial Deg C 1 2 1

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Spread
Bed 5 Level 2 Radial Deg C 2 3 4
Spread

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Table -1a
PLANT MATERIAL BALANCE - AS PRODUCED
Feed Flow based on FIC 1403
CPCL Guarantee Test Run Yields for 1st February, 2005

As Produced Meter Corrected

M3/Hr SP.GR Kgs/Hr WT% VOL% Meter Correct M3/Hr Kgs/Hr WT% VOL%
NM3/hr (M.W) Factor NM3/hr
Battey Limit Feed less Backwash 219.6 0.9063 199009 100.00 100.00 1.0001 219.5 199021 100.00 100.00
Make-up Hydrogen 58512 2.09 5447 2.74 0.9963 58293 5427 2.73

TOTAL IN 204456 204448

CLPS Off Gas 2278 4.83 491 0.25 1.1633 2650 571 0.29
Recycle Gas Bleed gas 0 5.05 0 0.00 0.9986 0 0 0.00
Rich Amine Flash Gas 397 7.76 137 0.07 0.8888 353 122 0.06
Fuel Gas 1183 20.24 1068 0.54 1.1277 1334 1204 0.60
LPG 7.9 0.5570 4402 2.21 3.60 1.0121 8.00 4456 2.24 3.64
Light Naphtha to Storage 9.5 0.6829 6502 3.27 4.34 1.0105 9.62 6570 3.30 4.38
Light Naphtha to H2 Unit 0.0 0.6829 0 0.00 0.00 1.2014 0.00 0 0.00 0.00
Heavy Naphtha to Reformer 12.2 0.7480 9148 4.60 5.57 1.0287 12.58 9410 4.73 5.73
Heavy Naphtha to Storage 7.6 0.7480 5666 2.85 3.45 1.0158 7.69 5755 2.89 3.50
Kerosene 57.6 0.8077 46503 23.37 26.22 1.0081 58.04 46882 23.56 26.44
Diesel 53.2 0.8322 44275 22.25 24.23 1.0086 53.66 44657 22.44 24.44
Unconverted Oil to Storage 67.2 0.8296 55753 1.0126 68.05 56453 28.37
Unconverted Oil to FCCU 52.7 0.8296 43717 1.0083 53.13 44078 22.15
Back Wash 1.2 0.9063 1132 1.0404 1.30 1177 0.59
Total UCO, adjusted for Backwash 119.9 0.8296 99469 49.98 54.60 121.2 100532 50.51 55.20
Unmeasured H2S 1267 0.64 1266.89 0.64
Unmeasured NH3 166 0.08 166.51 0.08

TOTAL OUT 219095 110.09 122.01 221592 111.34 123.34

LPG Wt% 2.21 LPG Wt% 2.24

Kero + Diesel Wt% 45.61 Kero + Diesel Wt% 45.99

453
Table -1a (Continued)
PLANT MATERIAL BALANCE - AS PRODUCED
Feed Flow based on FIC 1403
CPCL Guarantee Test Run Yields for 1st February, 2005

Meter Corrected and UCO Fudged Normalised yields

Fudge M3/Hr Kgs/Hr WT% VOL% WT% VOL%
Factor NM3/hr
Battey Limit Feed less Backwash 1.00 220 199021 100.00 100.00 100.00 100.00
Make-up Hydrogen 1.00 58293 5427 2.73 0.00 2.73 0.00

TOTAL IN 204448 0.00 0.00 102.73 0.00

0 0.00 0.00 0.00 0.00
CLPS Off Gas 1.00 2650 571 0.29 0.00 0.29 0.00
Recycle Gas Bleed gas 1.00 0 0 0.00 0.00 0.00 0.00
Rich Amine Flash Gas 1.00 353 122 0.06 0.00 0.06 0.00
Fuel Gas 1.00 1334 1204 0.60 0.00 0.60 0.00
LPG 1.00 8.00 4456 2.24 3.64 2.24 3.64
Light Naphtha to Storage 1.00 9.62 6570 3.30 4.38 3.30 4.38
Light Naphtha to H2 Unit 1.00 0.00 0 0.00 0.00 0.00 0.00
Heavy Naphtha to Reformer 1.00 12.58 9410 4.73 5.73 4.73 5.73
Heavy Naphtha to Storage 1.00 7.69 5755 2.89 3.50 2.89 3.50
Kerosene 1.00 58.04 46882 23.56 26.44 23.56 26.44
Diesel 1.00 53.66 44657 22.44 24.44 22.44 24.44
Total UCO, adjusted for Backwash 0.83 100.52 83393 41.90 45.79 41.90 45.79
Unmeasured H2S 1266.89 0.64 0.00 0.64 0.00
Unmeasured NH3 166.51 0.08 0.00 0.08 0.00

TOTAL OUT 204454 102.73 113.93 103 113.92

NRMZ. FACTOR 1.000
LPG Wt% 2.24 2.24
Kero + Diesel Wt% 45.99 45.99

454
Table -1b
PLANT MATERIAL BALANCE - AS PRODUCED
Feed Flow based on FIC 1403
CPCL Guarantee Test Run Yields for 2nd February, 2005

As Produced Meter Corrected

M3/Hr SP.GR Kgs/Hr WT% VOL% Meter Correct M3/Hr Kgs/Hr WT% VOL%
NM3/hr (M.W) Factor NM3/hr
Battey Limit Feed less Backwash 221.3 0.9112 201674 100.00 100.00 1.0007 221.4 201814 100.00 100.00
Make-up Hydrogen 59632 2.09 5552 2.75 0.9919 59149 5507 2.73

TOTAL IN 207226 207321

CLPS Off Gas 2244 5.82 583 0.29 1.0622 2384 619 0.31
Recycle Gas Bleed gas 0 3.65 0 0.00 1.1741 0 0 0.00
Rich Amine Flash Gas 397 7.76 138 0.07 0.8885 353 122 0.06
Fuel Gas 1172 18.42 963 0.48 1.1831 1387 1139 0.56
LPG 7.6 0.5570 4250 2.11 3.45 1.0128 7.73 4304 2.13 3.49
Light Naphtha to Storage 9.2 0.6842 6284 3.12 4.15 1.0098 9.28 6346 3.14 4.19
Light Naphtha to H2 Unit 0.0 0.6842 0 0.00 0.00 1.1977 0.00 0 0.00 0.00
Heavy Naphtha to Reformer 10.4 0.7462 7755 3.85 4.70 1.0282 10.69 7973 3.95 4.83
Heavy Naphtha to Storage 9.2 0.7462 6867 3.40 4.16 1.0161 9.35 6977 3.46 4.22
Kerosene 52.4 0.8046 42167 20.91 23.68 1.0108 52.97 42621 21.12 23.93
Diesel 57.6 0.8387 48344 23.97 26.04 1.0046 57.91 48568 24.07 26.16
Unconverted Oil to Storage 76.6 0.8355 63971 1.0076 77.15 64458 31.94
Unconverted Oil to FCCU 36.3 0.8355 30303 1.0049 36.45 30451 15.09
Back Wash 2.0 0.9112 1806 1.0384 2.06 1875 0.93
Total UCO, adjusted for Backwash 112.8 0.8355 94274 46.75 50.98 113.6 94909 47.03 51.31
Unmeasured H2S 1990 0.99 1991.25 0.99
Unmeasured NH3 159 0.08 159.06 0.08

TOTAL OUT 213772 106.00 117.15 215730 106.90 118.12

LPG Wt% 2.11 LPG Wt% 2.13

Kero + Diesel Wt% 44.88 Kero + Diesel Wt% 45.18

455
Table -1b (Continued)
PLANT MATERIAL BALANCE - AS PRODUCED
Feed Flow based on FIC 1403
CPCL Guarantee Test Run Yields for 2nd February, 2005

Meter Corrected and UCO Fudged Normalised yields

Fudge M3/Hr Kgs/Hr WT% VOL% WT% VOL%
Factor NM3/hr
Battey Limit Feed less Backwash 1.00 221 201814 100.00 100.00 100.00 100.00
Make-up Hydrogen 1.00 59149 5507 2.73 0.00 2.73 0.00

TOTAL IN 207321 0.00 0.00 102.73 0.00

0 0.00 0.00 0.00 0.00
CLPS Off Gas 1.00 2384 619 0.31 0.00 0.31 0.00
Recycle Gas Bleed gas 1.00 0 0 0.00 0.00 0.00 0.00
Rich Amine Flash Gas 1.00 353 122 0.06 0.00 0.06 0.00
Fuel Gas 1.00 1387 1139 0.56 0.00 0.56 0.00
LPG 1.00 7.73 4304 2.13 3.49 2.13 3.49
Light Naphtha to Storage 1.00 9.28 6346 3.14 4.19 3.14 4.19
Light Naphtha to H2 Unit 1.00 0.00 0 0.00 0.00 0.00 0.00
Heavy Naphtha to Reformer 1.00 10.69 7973 3.95 4.83 3.95 4.83
Heavy Naphtha to Storage 1.00 9.35 6977 3.46 4.22 3.46 4.22
Kerosene 1.00 52.97 42621 21.12 23.93 21.12 23.92
Diesel 1.00 57.91 48568 24.07 26.16 24.07 26.16
Total UCO, adjusted for Backwash 0.91 103.53 86503 42.86 46.76 42.86 46.76
Unmeasured H2S 1991.25 0.99 0.00 0.99 0.00
Unmeasured NH3 159.06 0.08 0.00 0.08 0.00

TOTAL OUT 207324 102.73 113.57 103 113.57

NRMZ. FACTOR 1.000
LPG Wt% 2.13 2.13
Kero + Diesel Wt% 45.18 45.18

456
 Table 2
Process Guarantees

GTR Feb 1,
Performance Pass 2005 Feb 2, 2005 Average
Parameter Guarantee Values Data Data GTR
Unit Capacity 100% of Design Capacity, m3/Hr 221 220 221 221
LPG Product Yields Not Less Than 80% of Predicted Wt % 1.94 2.24 2.13 2.19
Yield
Kerosene + Diesel 100 % of Predicted Wt % Yield 44.99 45.99 45.18 45.59
Yield
Hydrogen Not More Tan 105% of Predicted 286 266 267 267
Consumption Nm3 Hydrogen per Sm3 of Feed
Utilities Consumption 105% of Estimated Consumption
Fuel Fired, MMKCal/hr, With 105% 23.94 20.2 21.6 20.9
Power, kW, With 105% ( Note 1 ) 13242 10642 Note 1 10792 Note 1 10717
Cooling Water, m3/Hr, With 105 % 1350 1082 1080 Note 1

VHP Steam, M kg/Hr, With 105% 15.86 13.4 13.3 1080

HP Steam, M kg/Hr, With 105% 4.31 3.6 3.6 13.3
LP Steam, M kg/Hr With 105% ( Note 2 ) 8.4 8.3 8.3 3.6
8.3
Net Steam 100% of Predicted Value
Generation MP Steam, M kg/Hr 22.8 23.1 23.1 23.1

Product Qualities Per Exhibit 1

Note 1 : Power calculation is by CPCL based on amperage readings from electrical substation
Note 2: There is no direct LP steam generation in the unit. Generation of LP steam is only let down of MP steam to LP
steam in the Turbine of the Fractionator bottom pump. As there is no individual steam flow meter for the above pump,
Guarantee is indicated in terms of the LP steam consumers

457
 Table 2 (Continued)
Product Quality Guarantees
1st February 2nd February
Product Properties Guarantee Data Data Average
CLPS Offgas/Bleed H2
Hydrogen Sulfide Not Greater Than 20 mol wppm Nil Nil Nil
Chloride Content Not Greater Than 1 mol wppm Nil Nil Nil
LPG
n-Pentane/i-Pentane Not Greater Than 1 mol % 0.46 1.1 0.8
Free Water Nil Nil Nil Nil
Mercaptan Sulfur Not Greater Than 5 wppm 2.8 3.5 3.2
Copper Strip Corrosion (1 Hr @ 38° C) Not Worse Than Number 1 No 1 No 1 No 1
Vapor Pressure @ 65°C Not Greater Than 16.8 kg/cm2 < 16 (Calc) <16 (Calc) <16 (Calc)
Vaporization @ 2° C & Atm. Press. Not Less Than 95% > 95 > 95 > 95
Light Naphtha
Reid Vapor Pressure Not Greater Than 0.8 kg/cm2 0.7 ( 9.9 psia ) 0.7 ( 9.8 psia ) 0.7
Mercaptan Sulfur Not Greater Than 10 wppm Not Reported 4.5 4.5
Kerosene
ASTM D86 Recovery @ 200°C Not Less Than 20% ATF Mode > 25 > 25
Flash Point, Abel Not Less Than 35°C ATF Mode 35 35
Smoke Point Not Less Than 21 mm ATF Mode 26 26
Sulfur Not Greater Than 10 wppm ATF Mode < 10 < 10
Color Saybolt Not Less Than 10 ATF Mode + 29 + 29
Aviation Turbine Fuel
Freeze Point Not Greater Than -51°C -68 Kero Mode -68
Smoke Point Not Less Than 21 mm + 26 Kero Mode + 26
Flash Point, Abel Not Less Than 38°C 39 Kero Mode 39
Sulfur Not Greater Than 10 wppm < 10 Kero Mode < 10
Aromatics Not Greater Than 22 Vol % 7.2 ( 2nd Feb ) Kero Mode 7.2
Naphthalene Not Greater Than 3 Vol % 0.04 ( 2nd Feb ) Kero Mode 0.04
Mercaptan Sulfur Not Greater Than 3 wppm 2.7 Kero Mode 2.7
Water Tolerance Not Greater Than 1 ml < 1 ( 2nd Feb ) Kero Mode <1
Copper Strip Corrosion (2 Hr @ 100°C) Not Worse Than Number 1 No 1 Kero Mode No 1
Silver Strip Corrosion Not Greater Than 0 Zero Kero Mode Zero

458
 Table 2 (Continued)
Product Quality Guarantees

Product Properties Guarantee 3rd February Data 4th February Data Average
Diesel
Density at 15°C, kg/m3 Between 820 and 870 0.8342 0.8352 0.8347
ASTM D86 85% Recovery Not Greater Than 350°C 329 347 338
ASTM D86 95% Recovery Not Greater Than 360°C 348 363 356
Cetane Number (ASTM D613) Not Less Than 55 62 66 64
Flash Point, Abel Not Less Than 35°C 104 109 106
Pour Point Not Greater Than 3°C -3 +3 0
Sulfur Not Greater Than 10 wppm <10 <10 < 10
Viscosity @ 40°C Between 2.0 and 5.0 cSt 3.8 3.96 3.9
Unconverted Oil
Sulfur Not Greater Than 50 wppm <10 <10 < 10

Note for Diesel: As discussed in earlier sections, changing feed quality in the unit both in terms of feed sulfur as well as
varying content of diesel in feed resulted in time taken to adjust for the correct Catalyst average temperatures as well as
line out the Fractionator operation. Hence diesel quality is reported for 3rd and 4th of February respectively. However,
with available data collected on Fractionator column temperature & pressure profiles during GTR and experience gained
by CPCL at design feed rate operation, Fractionator adjustment would be routine affair in future operation.

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Table 3
CPCL GTR Utility Calculations

Item 1 Fuel Fired

ST
Oil Units Tags 1 Feb 2005 2nd Feb 2005
Fuel Oil Supply Kgs/hr 207 FI 4204 3225 3324
Fuel Oil Return Kgs/hr 207 FI 4205 2006 2074
Net Oil Fired Kgs/hr 1219 1250
Oil Calorific Value KCal/Kg 10000 10000
Oil Fired Duty MMKCalHr 12.19 12.50

Gas
FG To Unit NM3/hr 207 FI 9501 737 837
Gas Molecular Weight 19.7 19.7
Gas Density Kg/NM3 0.879 0.879
Gas Mass Flow Kgs/Hr 648 737
Gas Calorific Value KCal/Kg 12407 12407
Gas Fired Duty MMKCalHr 8.04 9.14

Total Fired Duty MMKCalHr 20.2 21.6

Item 2 Cooling water

Cooling Water supply Flow M3/hr 207 FI 9001 2094 2089

Cooling Water Supply Temperature Deg C 207 FI 9002 31 31
Cooling Water Return Temperature Deg C 207 FI 9004 37 37
Cooling Water Temperature Differential Deg C 6 6
Required Cooling water Temperature Differential Deg C 12 12
Cooling Water flow, pro rated for ξ T of 12 Deg C M3/hr 1082 1080

Item 3 MP steam Generation

E-5 MP Steam Generation Kgs/Hr 207 FI 2101 5998 6252

E-18 MP Steam Generation Kgs/Hr 207 FI 5002 14085 13684
E-36 MP Steam Generation Kgs/Hr 207 FI 5204 2952 3153

Total Kgs/Hr 23035 23089

Item 4 VHP Steam Consumption

VHP STEAM to RGC Kgs/Hr 207 FI 2706 13357 13285

Item 5 HP Steam Consumption

HP STM to C14 Product Stripper Kgs/Hr 207 FIC 4002 3600 3600

Item 6 Lean Amine Heater LP steam consumption

LP Steam to E10 Kgs/Hr 207 FI 3002 7939 7936

LP Steam to DS2 Kgs/Hr 208 FI 6701 320 320

Total LP steam to Leam Amine Heaters Kgs/Hr 8259 8256

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Table 4
CPCL GTR Power consumption Data

Power consumption Data for 01.02.2005

Pumps Power kW Amperage Voltage Power kW

(EDP) (Actual)

207-G3A 1577 210 6600 1920.5

207-G4B 29.6 55.3 415 31.8
207-G5B 1039 140 6600 1280.3
207-G6A 7.5 39.9 415 22.9
207-G7A 10.6 23.5 415 13.5
207-G8A 40 70 415 40.3
207-G9B 119 16.5 6600 150.9
207-G10A 1.5 9.9 415 5.7
207-G11B 30 98 415 56.4
207-G13A 31.6 105 415 60.4
207-G14A 42 142 415 81.7
207-G16A 4.7 14.4 415 8.3
207-G17B 7.5 18.2 415 10.5
207-G18B 2.5 7.5 415 4.3
207-G19B 3.2 8.3 415 4.8
207-G20A 15 56.1 415 32.3
207-G21A 8.1 34.6 415 19.9
207-G23B 1 9.5 415 5.5
207-G24B 21 44.4 415 25.5
207-G26 0.6 Spent caustic (intermittent)
207-G27A 0.13 1.4 415 0.8
207-G28 2 Make up caustic (intermittent)
207-G30 12.5 Sulfiding pump (not on line)
207-G31A 4.3 0.7 415 0.4
207-G32 51.6 Quench recirculation (regeneration only)
207-K2B/C 10400 600 6600 6858.9
207-K2G80B 5.3 415 3.0
207-K2G80C 5.0 415 2.9
207-K2G84B 0.5 415 0.3
207-K2G84C 0.9 415 0.5

Total 13462 10642

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Table 4 ( continued )
CPCL GTR Power consumption Data

Data of 02.02.2005

Pumps Power kW Amperage Voltage Power kW

(EDP) (actual)

207-G3A 1577 205 6600 1874.8

207-G4B 29.6 54 415 31.1
207-G5B 1039 135 6600 1234.6
207-G6A 7.5 39 415 22.4
207-G7A 10.6 28 415 16.1
207-G8A 40 76 415 43.7
207-G9B 119 16 6600 146.3
207-G10A 1.5 10 415 5.8
207-G11B 30 114 415 65.6
207-G13A 31.6 94 415 54.1
207-G14A 42 140 415 80.5
207-G16A 4.7 14 415 8.1
207-G17B 7.5 22 415 12.7
207-G18B 2.5 7.3 415 4.2
207-G19B 3.2 8 415 4.6
207-G20A 15 54 415 31.1
207-G21A 8.1 33 415 19.0
207-G23B 1 9.3 415 5.3
207-G24B 21 42 415 24.2
207-G26 0.6 Spent caustic (intermittent)
207-G27A 0.13 1 415 0.6
207-G28 2 Make up caustic (intermittent)
207-G30 12.5 Sulfiding pump (not on line)
207-G31A 4.3 24 415 13.8
207-G32 51.6 Quench recirculation (regeneration only)
207-K2B/C 10400 620 6600 7087.6
207-K2G80B 5 415 2.9
207-K2G80C 5.0 415 2.9
207-K2G84B 0.4 415 0.2
207-K2G84C 0.5 415 0.3

Total 13462 10792

Guaranteed power consumption is 12612 kW.

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QC LAB RESULTS
Gas Samples
Sample Date : 1st Feb, 2005
Sample Time : 14 00 Hr
Sl. o. Samples/Tests Make-up H2 C6 Offgas CLPS Offgas Fuel Gas LPG
1 Density @ 15°C 0.5550
2 Composition:
C1 -- 5.78 02.38 6.41 --
C2 -- 2.90 00.95 12.00 --
C3 -- 4.92 01.85 32.40 23.74
iC4 -- 1.07 01.35 00.05 52.17
nC4 -- 00.52 00.54 00.12 23.63
iC5 -- 00.70 00.42 00.24 00.46
nC5 -- 00.11 00.11 00.08 --
3 H2 S -- -- Nil -- Nil
4 RSH -- -- -- -- 2.8
5 Chlorides -- -- Nil -- --
6 W, Test -- -- -- -- Zero
7 VP @ 65°C -- -- -- --
8 Free Water -- -- -- -- Nil
9 Cu Corrosion -- -- -- -- No.1
10 H2 97.2 84.00 92.4 48.70 --

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Middle Distillates
Sample Date : 1st Feb, 2005
Sample Time : 14 00 Hr

Sl. o. Samples/Tests Lt. aphtha Hy. aphtha Kerosene HSD

1 Density @ 15°C, g/cc 0.6829 0.7480 0.8077 0.8322
2 Distillation, D86
3 IBP, °C 30 75 138 234
05% 46 91 156 261
10% 48 93 158 267
20% 52 97 165 281
30% 55 101 173 294
40% 59 103 182 306
50% 64 106 192 319
60% 69 110 202 333
70% 76 113 211 347
80% 82 119 222 361
90% 91 131 237 375
95% -- -- 249 --
FBP, °C 97 163 257 355
4 Flash Point, °C -- -- 39 >105
5 RSH -- 3.7 2.7 --
6 RVP 9.9 2.4 -- --
7 Sulfur 10 ppm 10 ppm <10 ppm 10 ppm
8 P/O 71.45 / Nil 38.43 / Nil --/-- --
N/A 28.00 / 00.55 58.88 / 02.69 --/-- --
9 Color -- -- Plus 27 --
10 Cetane Number -- -- -- --
11 K.V. @ 40°C -- Negative -- 5.73
12 Copper Corrosion -- -- Number.1 --
13 Ag Corrosion -- -- Zero --
14 Freezing Point, °C -- -- Minus 68 --
15 Smoke Point, mm -- -- 26 --
16 Moisture -- -- -- --
17 Pour Point/Cloud Point, °C -- -- -- +18 / +24
18 Naphthalene -- -- -- --

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Heavy Distillates
Sample Date : 1st Feb, 2005
Sample Time : 14 00 Hr

Sl. Comb.FL. Comb.UF Hot VGO Hot VGO- Cold

o Samples/Tests Fr. Feed Fr. Feed II III VGO UCO
1 Density @ 15°C, g/cc 0.9063 0.9065 -- 0.9118 0.9134 0.8296
2 Asphaltenes 45 65 -- 130 110 --
3 Sulfur 0.60 0.63 -- 0.58 -- <10 ppm
4 Aniline Point -- -- -- -- -- --
5 CCR, Wt % 0.11 -- -- -- --
7 Chlorides -- -- -- -- -- --
9 K.V.@ 40°C -- -- -- -- --
K.V. @ 50°C 31.25
10 K.V.@ 100°C 6.91 7.45 06.54 4.40
11 K.V.@ 60°C 24.54 20.87
12 K.V. @ 200°C
13 K.V.@ 250°C
14 Wax-Free Particulates -- -- -- -- -- --

Middle Distillates
Sample Date : 4th Feb, 2005
Sample Time : 08:00, 16:00 Hr

Sl.
o Samples/Tests Lt. aphtha Hy. aphtha Kerosene/ATF HSD
08:00 16:00 00:00 08:00 16:00 00:00 08:00 16:00 00:00 08:00 16:00 00:00
1 Density @ 15°C, g/cc 0.6829 0.6827 0.7482 0.7471 0.8052 0.8040 0.8360 0.8373
2 Distillation, D86
3 IBP, °C 39 42 78 78 134 132 220 231
05% 48 48 92 91 150 149 251 256
10% 51 50 95 93 152 153 252 261
20% 52 52 96 96 159 155 268 272
30% 55 55 100 99 167 164 279 286
40% 60 59 103 103 176 172 290 290
50% 66 65 105 104 185 187 301 299
60% 69 70 108 106 196 194 311 308
70% 75 76 112 109 208 205 323 318
80% 83 84 116 113 219 216 335 330
90% 92 91 125 120 235 231 349 346
95% 94 93 136 130 248 242 355 355
FBP, °C 98 96 146 145 255 247 356 360
85%, 342 338
4 Flash Point, °C -- 37 36 102 112
5 RSH 1.8 3.0 2.4 2.9 1.6 2.4
6 RVP 9.17 9.27 2.25 2.4 --
7 Sulfur, ppm -- -- -- <10 <10 <10 <10
8 P, Vol % 40.40
O, Vol % 00.00
N, Vol % 56.20
A, Vol % 03.40 6.80
9 Color (Saybolt) -- -- +27 +28
10 Cetane Number -- -- -- 65.4 65.3
11 K.V. @ 40°C -- -- -- 4.46
12 Copper Corrosion -- -- No.1 No.1 --
13 Ag Corrosion -- -- Zero Zero --
14 Freezing Point, °C -- -- -67 -69

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Sl.
o Samples/Tests Lt. aphtha Hy. aphtha Kerosene/ATF HSD
15 Smoke Point, mm -- -- 25 25
16 Water Tolerance: -- --
a. Separation Sharp --
b. Interface Condition 1b
17 Pour Point, °C -- -- -- -- +3 -3
19 Cloud Point, °C -- +9 +6
20 Naphthalene -- -- 0.06 -- -- --
21 RON 75.6 -- -- 64.8 -- -- -- -- -- --

Heavy Distillates
Sample Date : 4th Feb, 2005
Sample Time : 08:00, 16:00 Hr

Samples/Tests Comb. FL. Fr. Feed Hot VGO II Hot VGO III Cold VGO UCO
08:00 16:00 08:00 08:00 08:00 08:00 16:00
Density @ 15°C, g/cc 0.9123 0.9176 0.9250 0.9298 0.8936 0.8398 0.8415
C7 Asphaltenes, ppm 47 45 40 55 50 -- --
Sulfur, Wt % 2.10 2.21 2.73 2.78 1.12 0.0010 0.0010
CCR, Wt % 0.40 0.39 -- -- -- -- --
Chlorides Traces Traces Traces Traces Traces
K.V. @ 50°C 33.95 34.02 -- -- --
K.V. @ 100°C 7.74 7.82 8.34 8.79 5.72 4.68 4.72
K.V. @ 200°C -- -- -- -- -- -- --
K.V. @ 250°C -- -- -- -- -- -- --
Wax-Free Particulates -- -- -- -- -- -- --

CPCL R&D LAB RESULTS

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OHCU OHCU
Combined OHCU Combined OHCU Ref II Ref III Cold
Feed dt UCO dt Feed dt UCO dt VGO VGO VGO
3/2/05, 3/2/05, 3/2/05, 3/2/05, dt. 3/2/05 dt. 3/2/05 dt. 3/2/05
Characteristics 08:00 Hr 08:00 Hr 16:30 Hr 16:30 Hr 08:00 Hr 08:00 Hr 08:00 Hr
Nitrogen, ppm 760 BDL 810 BDL 990 780 600
Nickel, ppm 0.21 - 0.14 - 0.18 0.27 0.23
Vanadium, ppm 0.19 - 0.10 - 0.15 0.20 0.19
Iron, ppm 0.02 - 0.09 - 0.03 0.02 0.03
PCI 0.19 - 0.23 - 0.23 0.19 0.18
Sim. Dist., %OFF Temperature, ºC
IBP 351 350 349 341 352 384 345
5 392 392 397 395 399 427 412
10 415 417 411 410 412 437 427
20 430 432 429 426 431 449 443
30 443 443 443 437 445 460 456
50 466 464 470 459 468 477 471
70 490 484 496 480 493 497 488
80 506 496 512 493 511 510 501
90 526 514 533 513 532 527 519
95 540 527 546 527 545 539 535

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MIS REPORT DURIG GTR PERIOD

Table 6
MIS Report
1st February 2005 2nd February 2005
FEED SECTION
207FIC1406PV VGO F. CRUDE III 77.85 72.48
207FIC1407PV VGO F. CRUDE II 47.45 42.68
207FIC1404PV COLD VGO FR.STRG TO E1 89.83 103.77
207FIC1402PV HOT VGO FR.VBU TO E1 0.00 0.00
207FIC1408PV UCO TO E1 0.00 0.00
207FI2201PV RECY GAS FROM K1 TO E7 230000.00 228427.98
207TI1408PV MIXED OIL FEED TO E1 134.47 127.82
207TI1409PV OIL FEED FROM E1 TO E2 148.23 141.01
207TI1414PV RX FEED TO T-1 160.21 159.06
207PDI1504PV dP across T1 0.24 0.22
207PIC1602PV N2 TO C1 5.49 5.45
207LIC1601PV OIL FEED C1 73.31 71.36
207FIC1801PV RX FEED FR G3A/B TO E3A/B 236.63 239.75
PREHEAT AND FURNACE SECTION
207TI1801PV RX FEED G3A/B TO E3A/B 167.71 167.65
207FI2201PV RECY GAS FROM K1 TO E7 230000.00 228427.98
207TI2205PV RECY GAS FROM K1 TO E7 57.07 57.56
207TIC1803PV OILGAS FEED FR.E3A/B TO F1 337.90 337.92
207TI1804PV INSERT TO F-1 339.46 339.53
207TI1805PV RX FEED FROM F1 TO R1 364.39 364.32
207TI1807PV RX FEED FROM F1 TO R1 360.45 360.14
207TI1809PV FEED TO 207-R1 363.09 362.86
REACTOR - I
207TI1971PV RX FEED FR. F1 TO R1 363.52 363.35
207TI1901PV RX R1 BED1 BOT. LAYER TEMP 365.58 365.43
207TI1902PV RX R1 BED1 BOT. LAYER TEMP 364.56 364.42
207TI1903PV RX R1 BED1 BOT. LAYER TEMP 364.06 363.89
207TI1904PV RX R1 BED1 BOT. LAYER TEMP 365.72 365.57
207TI1905PV RX R1 BED1 BOT. LAYER TEMP 364.42 364.26
207TI1906PV RX R1 BED1 BOT. LAYER TEMP 365.64 365.44
207TI1907PV RX R1 BED1 BOT. LAYER TEMP 365.42 365.25
207TI1908PV RX R1 BED1 BOT. LAYER TEMP 364.83 364.71
207TIC1911PV RX R1 BED 1 362.96 363.18
207TIC1911MV RX R1 BED 1 45.76 44.95
207FI1901PV QNCH GAS FROM R1 TO E6 0.00 0.00
207TI1911PV RX R1 BED2 I/L TEMP. 362.29 362.53
207TI1912PV RX R1 BED2 I/L TEMP. 363.66 363.87
207TI1913PV RX R1 BED2 I/L TEMP. 362.89 363.12
207TI1914PV RX R1 BED2 I/L TEMP. 363.03 363.20
207TI1915PV RX R1 BED2 I/L TEMP. 363.79 364.03
207TI1916PV RX R1 BED2 I/L TEMP. 362.58 362.77
207TI1917PV RX R1 BED2 I/L TEMP. 362.43 362.67
207TI1918PV RX R1 BED2 I/L TEMP. 363.02 363.25

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Table 6 ( Continued )
MIS Report
1st February 2005 2nd February 2005
207TI1931PV RX R1 BED2 LAYER 2 TEMP 386.91 387.59
207TI1932PV RX R1 BED2 LAYER 2 TEMP 386.46 387.35
207TI1933PV RX R1 BED2 LAYER 2 TEMP 383.25 383.50
207TI1934PV RX R1 BED2 LAYER 2 TEMP 384.63 384.49
207TI1935PV RX R1 BED2 LAYER 2 TEMP 385.11 385.15
207TI1936PV RX R1 BED2 LAYER 2 TEMP 388.18 388.89
207TI1937PV RX R1 BED2 LAYER 2 TEMP 383.94 384.63
207TI1938PV RX R1 BED2 LAYER 2 TEMP 388.76 389.39
207TIC1941PV RX R1 BED 3 I/L TEMP. 381.05 380.61
207TIC1941MV RX R1 BED 3 I/L TEMP. 37.40 40.37
207FI1902PV MUH2 FROM R1 TO MIX 14504.36 17511.07
207TI1941PV RX R1 BED 3 I/L TEMP. 380.91 380.50
207TI1942PV RX R1 BED 3 I/L TEMP. 380.11 379.66
207TI1943PV RX R1 BED 3 I/L TEMP. 381.51 381.07
207TI1944PV RX R1 BED 3 I/L TEMP. 379.68 379.26
207TI1945PV RX R1 BED 3 I/L TEMP. 381.86 381.41
207TI1946PV RX R1 BED 3 I/L TEMP. 381.34 380.89
207TI1947PV RX R1 BED 3 I/L TEMP. 381.01 380.55
207TI1948PV RX R1 BED3 I/L TEMP. 381.96 381.49
207TI1961PV RX R1 BED3 LAYER 2 TEMP 394.17 393.25
207TI1962PV RX R1 BED3 LAYER 2 TEMP 399.01 397.69
207TI1963PV RX R1 BED3 LAYER 2 TEMP 397.07 396.01
207TI1964PV RX R1 BED3 LAYER 2 TEMP 398.94 397.52
207TI1965PV RX R1 BED3 LAYER 2 TEMP 396.46 395.38
207TI1966PV RX R1 BED3 LAYER 2 TEMP 400.80 399.47
207TI1967PV RX R1 BED3 LAYER 2 TEMP 398.42 397.24
207TI1968PV RX R1 BED3 LAYER 2 TEMP 395.12 394.10
207TI1970PV RX EFFL FROM R1 TO E6 408.44 407.15
207TIC2002PV RXEFFL FR. E6 TO QNCHMIXER 366.18 364.63
REACTOR - II
207TIC2003PV RX EFFL.FROM E6 TO R2 366.97 366.37
207TIC2003MV RX EFFL.FROM E6 TO R2 32.97 32.25
207FI2001PV RECY GAS FROM K1TO R2 17284.57 16609.42
207TI2011PV RX R2 BED1 LAYER2 TEMP 392.12 393.05
207TI2012PV RX R2 BED1 LAYER2 TEMP 392.41 393.96
207TI2013PV RX R2 BED1 LAYER2 TEMP 392.31 393.34
207TI2014PV RX R2 BED1 LAYER2 TEMP 392.06 393.05
207TI2015PV RX R2 BED1 LAYER2 TEMP 392.67 393.71
207TI2016PV RX R2 BED1 LAYER2 TEMP 391.00 391.90
207TI2017PV RX R2 BED1 LAYER2 TEMP 392.41 393.45
207TI2018PV RX R2 BED1 LAYER2 TEMP 391.79 392.84
207TI2021PV RX R2 BED2 I/L TEMP. 384.54 383.56
207TI2022PV RX R2 BED2 I/L TEMP. 383.85 382.91
207TI2023PV RX R2 BED2 I/L TEMP. 384.24 383.28
207TI2024PV RX R2 BED2 I/L TEMP. 383.96 383.01
207TI2025PV RX R2 BED2 I/L TEMP. 384.10 383.17
207TI2026PV RX R2 BED2 I/L TEMP. 383.69 382.78
207TI2027PV RX R2 BED2 I/L TEMP. 384.11 383.20

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Table 6 ( Continued )
MIS Report
1st February 2005 2nd February 2005
207TI2028PV RX EFFL FM. E9 TO C2 383.90 382.98
207TIC2002PV RXEFFL FR. E6 TO QNCHMIXER 366.18 364.63
207TIC2002MV RXEFFL FR. E6 TO QNCHMIXER 32.64 33.09
207FI2002PV RECY GAS R2 TO E3A/B 21953.76 25901.56
207TI2041PV RX R2 BED2 LAYER2 TEMP 395.28 395.85
207TI2042PV RX R2 BED2 LAYER2 TEMP 395.13 395.68
207TI2043PV RX R2 BED2 LAYER2 TEMP 394.27 394.82
207TI2044PV RX R2 BED2 LAYER2 TEMP 394.45 395.01
207TI2045PV RX R2 BED2 LAYER2 TEMP 393.95 394.45
207TI2046PV RX R2 BED2 LAYER2 TEMP 394.99 395.39
207TI2047PV RX R2 BED2 LAYER2 TEMP 393.12 393.45
207TI2048PV RX R2 BED2 LAYER2 TEMP 394.35 394.84
207TI2050PV RX EFL FROM R2 TO E3A/B 394.01 394.60
REACTOR EFFLUENT COOILING SECTION
207TI2050PV RX EFL FROM R2 TO E3A/B 394.01 394.60
207TI1812PV RX EFFL FM E3A/B TO E4 245.71 246.96
207TI2103PV RX EFFL FROM E4 TO E5 209.89 210.97
207FIC2102PV BFW TO E5 17.93 18.49
207FI2101PV 207 E-5 MP 5997.76 6252.33
207TI2106PV RX EFFL FROM E5 TO E7 199.68 200.20
207TI2201PV RX EFFL FROM E7 TO E8 172.73 173.91
207TI2301PV RX EFFL FROM E8 TO E9 124.03 124.55
207TIC2306PV RX EFFL FR.E9 TO C2 54.99 55.00
207FIC3304PV INJ.WTR FR. G4A/B 6.21 6.23
207LI3302PV INJ. WTR DRUM C8 LVL 64.92 64.93
HP GAS RECOVERY SYSTEM
207TI2307PV RX EFFL FM. E9 TO C2 53.95 54.04
207LI2403PV COLD HI PR SEPR C2LVL 35.61 35.28
207LI2404PV CHPS WTR FRM C2 TO C13 60.00 60.00
207LIC2501PV CLPS OIL FROM C3 -0.09 -0.65
207TI2503PV KERO TO G8 A/B 53.05 53.05
207TI2504PV LEAN AMINE G5A/B TO C4 62.07 61.98
207TDI2504PV DIFF TEMP ALRM 9.67 9.62
207FIC3103PV LEAN AMINE G5A/B 215.02 214.98
207LIC2601PV RICH AMINE FR. C7 -0.62 -0.62
207PIC2601PV RECY GAS TO K1 152.88 152.87
207FIC2601PV RECY GAS TO FLARE 0.00 0.00
RECYCLE GAS COMPRESSOR SECTION
207FI2702PV COMPRESSOR SUCTION FLOW 151729.09 151573.90
207PIC2702PV COMPRESSOR SUCTION PRESSURE 153.00 153.00
207TI2702PV COMPRESSOR SUCTION TEMP. 63.95 63.78
207PI2721PV COMP SUCTION PRESS 153.77 153.76
207PI2722PV COMP DISCHARGE PRESS 181.89 181.75
207PDI2704PV DIFFL PR. ACROSS COMP. SUCTION & 27.55 27.44
207SI2701PV LOCAL DISPLAY FOR SPEED 12097.38 12097.54

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Table 6 ( Continued )
MIS Report
1st February 2005 2nd February 2005
207HIC2703PV 207 K1 Turbine Speed 0.00 0.00
207PI2740PV VHP STEAM INLET PRESSURE 49.48 49.33
207FI2705PV COMPRESSOR RECYCLE GAS FLOW 0.00 0.00
207FI2701PV MUH2 FROM K2 TO E7 58512.21 59631.64
207TI2701PV MUH2 FROM K2 TO E7 108.08 111.22
207PI2701PV MUH2 FROM K2 TO E7 180.24 180.14
LP GAS RECOVERY SECTION
207TI2307PV RX EFFL FM. E9 TO C2 53.95 54.04
207LIC2801PV CLPS OIL FR. C9 TO E8 51.81 52.60
207FIC2801PV CLPS LIQ FROM C9 TO E8 240.44 234.72
207TI2203PV CLPS LIQ. FROM E8 TO E4 142.88 143.16
207TIC2102PV CLPS LIQ. FR. E4 224.43 225.13
207FIC2901PV CLPS VAP FR.G6A/B TO C11 5.50 5.50
207TI2901PV CLPS VAP FR.C10 TO C11 58.17 57.96
207TI2902PV I/L TO CLPS VAP ABS C-11 61.51 61.43
207TDI2902PV DIFF TEMP CLPS -3.34 -3.46
207FI2902PV CLPS VAP FROM C11 TO C12 0.00 0.00
207FI2903PV CLPS VAP FROM C12 TO PSA 2278.46 2244.42
PRODUCT STRIPPER
207TI2101PV CLPS LIQ FR.E4 222.25 223.03
207FIC4002PV HP STM TO C14 PROD.STR. 3599.78 3600.10
207LIC4003PV C14 PROD.STR.LVL 50.87 48.77
207FIC4003PV FRACBTMS FRG12A/B TOC14 277.73 258.76
207TIC4003PV NAP C14 RFLX 155.03 150.76
207PDI4004PV PROD STR C14 DP 0.00 0.00
207TIC4003PV NAP C14 RFLX 155.03 150.76
207PIC4101PV PROD STR VAP E12 TO C15 13.00 13.25
207LIC4101PV NAP FROM C15 TO E22A/B 62.26 58.57
207FIC4001PV NAP TO C14 15.06 19.54
207FIC4101PV Stripper rflx. to De-ethaniser 27.08 27.94
FRACTIONATOR FEED FURNACE
207TI4213PV C14 BTMS TO F2 319.33 319.14
207TI4201PV FRAC FEED FROM F2 TO C16 361.19 361.66
207TI4203PV FRAC FEED FROM F2 TO C16 357.90 358.88
207TI4205PV FRAC FEED FROM F2 TO C16 357.39 357.41
207TI4207PV FRAC FEED FROM F2 TO C16 356.28 356.52
207TIC4209PV C14 BTMS FR.F2 TO C16 360.06 360.45
207FI4204PV MASS FLOW FO SUPLY 3225.24 3323.75
207FI4205PV MASS FLOW TO RETURN 2006.09 2073.76
207FI4206PV C14 BTMS TO F2 9.16 8.73
207PI4226PV C14 BTMS TO F2 0.78 0.78

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Table 6 ( Continued )
MIS Report
1st February 2005 2nd February 2005
FRACTIONATOR & REFLUX
207LIC4301PV C16 LVL 65.00 65.00
207TI4310PV C16 O/L TO G12A/B 339.46 339.88
207TI4304PV C16 OVHD FROM C16 TO E13 99.40 97.80
207PIC4501PV FRAC OVHD FR E13 T C17 0.85 0.85
207TI4303PV REFLUX PUMP TO C16 95.46 94.67
207PDI4303PV PROD FRAC C16 FLSH ZONE 0.14 0.23
207PDI4303PV PROD FRAC C16 FLSH ZONE 0.14 0.23
207TIC4302PV KERO FROM C16 96.93 96.08
207LIC4501PV FRAC.RFLX DRUM C17 LVL 44.68 45.07
207FIC4301PV RFLX FR. G11A/B TO C16 34.05 39.96
FRACTIONATOR PRODUCT STRIPPERS AND P/A
207TI4801PV LEAN AMINE TO C25 161.92 156.63
207TI4807PV KERO FR E14 TO PROD.FRC 99.71 97.93
207FIC4801PV KERO FR. E14 TO PROD.FRAC 215.01 221.90
207FIC4702PV KERO FR. E17A/B TO STRG 57.57 52.41
207TI4804PV KERO FR E38 TO E14 135.96 132.68
207TI5005PV HSD P/A DRAW TEMP 266.34 261.46
207TI5002PV DIESEL P/A TO C-16 200.99 196.73
207FIC5101PV HSD FR. C36 TO HDR 53.20 57.64
207FIC5003PV HSD FROM E18 TO C16 300.00 307.35
207FI4701PV 76.95 84.04
207FIC5202PV UCO FROM E21 67.20 76.57
207FIC5203PV HOT UCO R/D FLOW TO FCCU 52.70 36.27
207FIC1408PV UCO TO E1 0.00 0.00
LIGHT ENDS RECOVERY SYSTEM
DE-ETHANISER
207FI4102PV OFF GAS FROM C15 TO E22 1208.09 1166.74
207PIC4101PV PROD STR VAP E12 TO C15 13.00 13.25
207FIC5701PV RICH SPNG OIL FR.G18A/B 20.68 21.69
207TI5602PV C20 OVHD FR. E22 TO C21 43.76 41.43
207LI5606PV 207-C-21 LVL -0.62 -0.62
207FIC5601PV DEETH RFLX FR.G17A/B TO C28 39.67 42.18
207TI5501PV DEETH.RFLX TO C20 44.60 42.37
207TIC5512PV C20 BTMS 84.35 83.63
207LIC5502PV C20 BTMS TO C27 53.42 54.98
207FIC5502PV C20 BTMS TO C27 18.19 17.55
207FIC5501PV C16 BTMS TO UCO A/C 1686.39 1546.44
207TI5511PV DEETN REB TO FRACT BOT 135.94 138.37
207TI5509PV C16 BTMS TO E24 187.24 187.89

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Table 6 ( Continued )
MIS Report
1st February 2005 2nd February 2005
SPONGE OIL ABSORBER
207FIC5801PV NAP FROM E39 TO E23A/B 8.00 7.18
207TI5805PV SP.OIL FR.C23 TO C24 34.33 33.88
207FIC5802PV RFLX FR.G19A/B 0.00 0.00
207PDI5702PV SPONGE OIL ABS C22 DP 2.24 2.47
207PDI5703PV SPONGE OIL ABS C22 DP -1.00 -0.89
207TI5703PV C22 OVHD TO E23A/B 40.44 39.73
207LIC5701PV SP.OIL ABS FR. C22 TO E22A/B 49.99 46.80
207FIC5701PV RICH SPNG OIL FR.G18A/B 20.68 21.69
207PIC6701PV LP STM TO DS2 0.36 0.20
207FIC6801PV LEAN AMINE TO C25 45.00 45.00
207TI6801PV FG TO C25 46.67 46.25
207TI6803PV RX R1 BED 3 I/L TEMP. 33.01 32.68
207TDIC6801PV E37 BYP LINE TEMP CON 13.66 13.57
207LIC6801PV FG H2S ABS C25 52.00 51.49
207PIC6806PV OFF GAS FR. C25 TO FLARE 10.40 10.40
DEBUTANISER / LPG TREATING SECTION
207FIC5501PV C16 BTMS TO UCO A/C 1686.39 1546.44
207FIC4601PV NAP FR. G11A/B TO C27 23.77 23.51
207TI5905PV DEBUTANISER TEMP 159.13 158.10
207TI5908PV C27 BTMS FR. E26 TO C27 189.15 190.08
207TI5906PV C27 BTMS TO C29 188.42 188.51
207LIC5901PV C27 BTMS TO C29 49.96 49.99
207FIC4601PV NAP FR. G11A/B TO C27 23.77 23.51
207TIC5915PV C27 OVHD TO E25 71.96 72.79
207FIC5901PV C27 RFLX 12.64 14.71
207LIC6001PV SOUR WTR FR.C28 TO C13 64.89 64.86
207FIC6001PV SOUR LPG FR. 7.57 6.91
207PIC6003PV OFFGAS FR. C28 TO FLARE 10.72 10.69
207FI6603PV TRT LPG FROM C41 TO STRG 7.90 7.63
207PIC6601PV TRTD.LPG FR.C41 TO STRG. 12.00 12.00
207LI6406PV MUCAUS.SRG DRUM C45 LVL 48.74 48.72
NAPTHA SPLITTER
207FIC5902PV C27 BTMS 41.31 39.92
207TI5906PV C27 BTMS TO C29 188.42 188.51
207LIC6101PV C29 LVL 54.35 55.05
207FIC6302PV COLD HVY NAP FR.E31A/B 7.57 9.20
207FIC6301PV HVY NAP TO NHT/CRU 12.23 10.39
207FIC5801PV NAP FROM E39 TO E23A/B 8.00 7.18
207PDI6102PV NAP SPLT C22 DP 0.02 0.01
207PDI6101PV NAP SPLT C22 DP -0.03 -0.03
207TIC6103PV C29 BTMS 124.50 125.09
207TIC6113PV C29 OVHD TO E29 94.95 95.01
207FIC6101PV NAP RFLX TO C29 12.59 12.11
207PIC6201PV C29 OVHD TO C30 1.28 1.29
207TIC6202PV C29 OVHD TO E29 48.05 48.06

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Table 6 ( Continued )
MIS Report
1st February 2005 2nd February 2005
207LIC6201PV C30 NAP SPLTR.RFLX DRUM 59.92 60.01
207FIC6202PV LTNAP.FR. G24A/B TO H2UNIT 0.00 0.00
207TI6205PV LT.NAP FR. E30A/B TO STRG. 32.71 32.74
207FIC6201PV LTNAP FR.E30A/B TO STRG 9.52 9.19
207PIC6202PV OFFGAS FR.C30 1.30 1.30
MAKE-UP GAS COMPRESSOR
207FI6901PV MUH2 TO C32 55038.11 57348.47
207LIC6901PV 207-C-32 LVL -0.62 -0.62
207PIC6902PV MUH2 FR. H2PLANT TO FL 20.97 20.77
207PIC2702PV COMPRESSOR SUCTION PRESSURE 153.00 153.00
207PIC6904PV MUH2 TO RX 180.61 180.52
207FI2701PV MUH2 FROM K2 TO E7 58512.21 59631.64
207PI2701PV MUH2 FROM K2 TO E7 180.24 180.14
207 K2-A
207TI7001PV Ist STG. I/C 207-E32 A/B INLET 35.06 35.11
207TI7003PV Ist STG. I/C 207-E32 A/B OUTLET 32.79 32.86
207LI7001PV DIFF LVL IInd STAGE SUCT K2A -0.56 -0.55
207PI7001PV II STG SUCT 207-K2A 20.94 20.69
207TI7005PV IInd STG. I/C 207-E33 A/B INLET 26.67 26.78
207TI7007PV IInd STG. I/C 207-E33 A/B OUTLET 27.44 27.45
207LI7004PV DIFF LVL IIIrd STAGE SUCT K2A 1.35 1.33
207PI7002PV III STG SUCT 207-K2A 20.99 20.74
207TI7009PV IIISTG DISCHG TEMP 207-K2A 31.83 31.56
207 K2-B
207TI7101PV ISTG I/C 207-E32 C/D INLET 116.76 107.98
207TI7103PV ISTG I/C 207-E32 C/D OUTLET 42.01 42.98
207LI7101PV DIFF LVL 2ND STG SUCT K2B -0.07 0.19
207PI7101PV II STG SUCT 207-K2B 44.30 40.52
207TI7105PV IISTG I/C 207-E33 C/D INLET 118.36 125.15
207TI7107PV IISTG I/C 207-E33 C/D OUTLET 32.14 33.98
207LI7104PV DIFF LVL 3RD STG SUCT K2B -0.63 -0.35
207PI7102PV III STG SUCT 207-K2B 96.71 93.70
207TI7109PV IIISTG DISCHG 207-K2B 112.70 117.47
207 K2-C
207TI7201PV 207K2C IST Stage d/c Temp. 111.10 112.28
207TI7203PV ISTG I/C 207-E32 E/F OUTLET 41.28 41.19
207LI7201PV DIFF LVL 2ND STG SUCT K2C 1.41 1.44
207PI7201PV II STG SUCT 207-K2C 44.57 44.59
207TI7205PV IISTG I/C 207-E33 E/F INLET 120.98 121.62
207TI7207PV IISTG I/C 207-E33 E/F OUTLET 37.65 37.54
207LI7204PV DIFF LVL 3RD STG SUCT K2C 3.62 3.64
207PI7202PV III STG SUCT 207-K2C 96.32 95.72
207TI7209PV IIISTG DISCHG 207-K2C CYL4 108.54 109.26

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Table 6 ( Continued )
MIS Report

1st February 2005 2nd February 2005

Additional Tags added for GTR
207FI1803APV PILOT FG TO F1 35.84 32.94
207FI1804APV MAIN FG TO F1 663.83 645.04
207PI1901PV H2 PUR FCV1903 TO R1 I/L 167.44 167.56
207PDI1903PV Reactor I dP 2.78 2.76
207PDI1904PV H2 PUR FCV1905 - R1 BED1 0.03 0.04
207PI1906PV H2 PUR FCV1903 TO R1 O/L 164.79 164.92
207TIC1910PV FEED FM F1 TO REACTOR 365.31 365.05

207TI1921PV RX R1 BED 2 359.99 360.32

207TI1922PV RX R1 BED 2 362.23 362.47
207TI1923PV RX R1 BED 2 361.86 362.16
207TI1924PV RX R1 BED 2 361.32 361.59
207TI1925PV RX R1 BED 2 361.89 362.20
207TI1926PV RX R1 BED 2 359.94 360.18
207TI1927PV RX R1 BED 2 360.29 360.59
207TI1928PV RX R1 BED 2 359.97 360.29

207TI1951PV RX R1 BED 1 379.57 379.21

207TI1952PV RX R1 BED 1 378.48 378.13
207TI1953PV RX R1 BED 1 379.08 378.72
207TI1954PV RX R1 BED 1 378.21 377.84
207TI1955PV RX R1 BED 1 379.61 379.24
207TI1956PV RX R1 BED 1 378.61 378.26
207TI1957PV RX R1 BED 1 379.01 378.64
207TI1958PV RX R1 BED 1 379.77 379.37
207PI2001PV H2 PUR FCV 2003 TO R2 I/L 163.38 163.49
207PDI2003PV Reactor II dP 3.86 3.88
207PI2004PV H2 PUR FCV2004 TO R2 O/L 159.45 159.53
207TI2031PV RX R2 BED2 382.61 381.77
207TI2032PV RX R2 BED2 380.08 379.24
207TI2033PV RX R2 BED2 381.27 380.42
207TI2034PV RX R2 BED2 382.95 382.07
207TI2035PV RX R2 BED2 382.85 382.02
207TI2036PV RX R2 BED2 382.87 382.02
207TI2037PV RX R2 BED2 383.65 382.82
207TI2038PV RX R2 BED 2 382.26 381.43
207TIC2021PV RX R2 BED2 I/L TEMP 384.05 383.11
207TIC2021MV RX R2 BED2 I/L TEMP 39.93 45.20
207FI3002PV LP STM TO E10 7938.88 7935.65
207FI2706PV VHP STEAM INLET FLOW 13357.36 13285.08
207TI2906PV CLPS VAP FROM C12 TO PSA 47.10 46.18
207PIC2903PV CLPS VAP FR.C12 TO FG 22.54 22.60
207FI3201PV HP BLEED 0.00 0.00
207TI3201PV RICH AMINE T C6 59.11 59.37

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Table 6 ( Continued )
MIS Report
1st February 2005 2nd February 2005
207PIC3201PV SOUR GAS FR. C6 TO O/PLOT 6.20 6.20
207FI4204PV MASS FLOW FO SUPLY 3225.24 3323.75
207FI4205PV MASS FLOW TO RETURN 2006.09 2073.76
207FDI4204PV MAIN FG TO F2 -1219.13 -1249.94
207FI4206APV C14 BTMS TO F2 9.16 8.73
207FI4208PV FG TO F2 181.68 178.46

207TI4711PV KERO FR. E17 TO STRG. 35.04 33.16

207TI4904PV HSD FROM E20 TO E2 38.31 38.11
207TI5202PV FRACT.BOT. TO HDR 90.73 96.02
207TI5205PV C16 BTMS FR.E21 TO IFOSTRG 162.64 165.42

207FI3401PV BKWH OIL FROM G31 TO E21 0.00 0.00

207TI3401PV BKWH OIL FR C39 TO G31A/B 119.81 119.14
207FIC4305PV MP STM TO C16 3000.21 3000.04

207FI2101PV 207 E-5 MP 5997.76 6252.33

207FIC2102PV BFW TO E5 17.93 18.49
207PI2104PV RX EFFL MP STM GEN.E5 11.61 11.63
207TI2104PV MP STM FROM E5 188.29 188.35
207FI5002PV 207 E-18 MP 14.09 13.68
207FIC5001PV BFW TO E18 12.56 12.16
207FI5204PV 207 E-36 MP 2952.09 3153.40
207FIC5201PV BFW TO E36 3.95 4.17

207FI9001PV CWS DISTN. FLOW 2093.96 2088.56

207TI9002PV CWS DISTN. 30.80 30.79
207PI9002PV CWS DISTN PR. 4.72 4.71
207FI6802PV OFF GAS FROM C25 TO O/P 1182.52 1172.21
207TI6805PV FG FROM C25 TO OFFPLOT 43.92 43.39

207TI5901PV C27 REFLUX 52.55 52.65

207TI6101PV NAP.RFLX TO C29 37.71 37.46
207TI6205PV LT.NAP FR. E30A/B TO STRG. 32.71 32.74
207TI6304PV C29BTMSFR.E31A/B TO RFTK 31.28 32.51
207TI6104PV C29 BTMS TO G20A/B 129.30 130.18
207TI2701PV MUH2 FROM K2 TO E7 108.08 111.22

207TI1601PV OIL FEED FROM C1 TO G3A/B 159.89 158.74

207TI1407PV HOT VGO CDU/VDU2 TO E1 178.58 177.57
207TI1406PV HOT VGO CDU/VDU3 TO E1 163.86 161.83
207TI1402PV HOT VB VG FROM VBU TO E1 85.98 84.94
207FFIC4901PV MP STEAM TO DIESEL STRIP 1000.01 1000.00
207FI9102PV MP STM DISTN.FLOW 11792.18 12106.87
207FI9101APV LP STM DISTN.FLOW 1917.42 1644.75
207FI9501PV FG TO C60 737.16 837.48

207FI6701PV LP STM TO DS2 320.00 320.00

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CATALYST LOADING DIAGRAM FOR 207-R1 AS MODIFIED IN 2012

empty space 0.100 0.300

Penta-ring Sock 0.151 0.151 1.60 1.60 3/4"wheel 3/4"wheel
Macrotrap1.5 Sock 0.124 0.124 1.30 1.30 8mm ring 8mm ring
TK-711 (3/16") Sock 0.115 0.115 1.20 1.20 3/16" 3/16"
TK-711 (1/8") Sock 0.158 0.158 1.70 1.70 1/8" 1/8"
GSK-6A Sock 0.111 0.111 1.20 1.20 1/4" rings 1/4" rings
1/12" x 1/12" x
BED 1

ICR161NAQ Dense 0.303 0.303 3.20 3.20 1/14" 1/14"

1/12" x 1/12" x
ICR132NAQ Dense 0.100 0.100 1.00 1.00 1/14" 1/14"
1/12" x 1/12" x
ICR131NAQ Dense 2.488 2.488 26.20 26.20 1/14" 1/14"
Denstone 2000 (1/8") Sock 0.100 0.100 1.10 1.10 1/8" 1/8"
Denstone 2000 (1/4") Sock 0.100 0.100 1.10 1.10 1/8" 1/8"
3.75 3.95 39.60 39.60
Internals
empty space 0.10 0.08
ICR131NAQ Dense 0.971 0.971 10.20 10.20 1/12 x 1/14 1/12 x 1/14

ICR511NAQ Dense 4.029 4.029 42.40 42.40 1/14 x 1/18 1/14 x 1/18
BED 2

Denstone 2000 (1/8") sock 0.100 0.100 1.10 1.10 1/8" 1/8"
Denstone 2000 (1/4") sock 0.100 0.100 1.10 1.10 1/8" 1/8"
5.30 5.28 54.80 54.80
Internals
empty space 0.11 0.11
B E D 3

ICR511NAQ Dense 2.220 2.220 23.40 23.40 1/12 x 1/14 1/12 x 1/14

ICR142NAQ Dense 0.064 0.064 0.70 0.70 1/12 x 1/14 1/12 x 1/14

ICR180 Dense 3.382 3.382 35.60 35.60 1/12 x 1/14 1/12 x 1/14

Denstone 2000 (1/8") sock 0.100 0.100 1.10 1.10 1/8" 1/8"
Denstone 2000 (1/4") sock 0.971 0.971 1.10 1.10 1/8" 1/8"
6.85 6.85 61.90 61.90
Reactor ID : 3.66 meter
2
Area : 10.5 m

Catalyst Height : 15.13 m

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The following modifications were carried out during August

2013 shut down:

1. OHCU feed filter backwash oil to FCCU hot feed:

A 2" line from 207G-31A d/c FV-3403 d/s to hot UCO R/D FV-5203 d/s was
provided to route OHCU feed filter backwash oil to FCC as hot feed.
This would help FCCU personnel to ensure better control over their gasoline sulfur
content and thus ensure on-spec products consistently. Refer the attached drawing
for details.

2. LPG and Light Naphtha to Deethaniser 207C-20:

A provision to route LPG and Light aphtha to Deethaniser was made to avoid
delay and ensure smooth stabilization of LER section during plant startup.
Refer the attached drawing for details.

3. 207C-26 drain to flare:

Draining of the high H2S containing liquid from Fuel gas amine absorber
centrifugal separator 207C-26 to CBD results in corrosion of the underground CBD
lines. The leaks from the corroded CBD lines result in oil seepage into the ground.
Hence a ¾” drain line from 207C-26 LV-6702 d/s to flare was provided thus
avoiding corrosion of the underground CBD line. Refer the attached drawing for
details.

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Subject: Provision for routing Feed filter backwashed material from G3

as hot feed inside OHCU B/L.

Chennai Petroleum Corporation Ltd

Flare

4"

Feed filter backwash from 207 T1 Feed filter

4" Back wash oil surge drum

207C39
LI3402
Min circulation line

CBD OWS

Backwash oil pumps

207 G31A 207G31B

FO/Tk.312/313
3"

3"
FI3403

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Note: LPG & Light Naphtha to 207C-20

2" Hot tapping to be taken in hot UCO rundown line for hook up.
2" line from donwstream of FIC 3403 to be taken and routed at hot UCO rundown line at downstream of 207 FIC5203
G31A to be operated for based on LI 3402 and will be feeding to FO blend header or to TK312/313 by operating the respective valv
G31B always in line and will be feeding to FCC using FIC3403 and spike at controlled rate based on FCC requirement.

Propoesd line

Normally Valve in closed condition

R/D

Flare

R/D
LPG

2”

2”
PV-6601 2” New line FV-6201
2”

2”
207G-11A / B
2”

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481