Professional Documents
Culture Documents
Project Specification
OPERATING MANUAL
FOR
Unit : 810
AMINE TREATING PROCESS UNIT
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Since the Amine Treating Process Unit consists of Amine Treating Section and Sour
water Stripping Section which are quite different processes from each other, this
operating manual is divided into two PARTs as below:
PART AMINE TREATING SECTION
from page 3
from page 84
OF 126
PART
AMINE TREATING SECTION
CONTENTS
PAGE
1. GENERAL DESCRIPTION.......................................................................................................
1.1. PLANT DUTY....................................................................................................................
1.2. DISCUSSION OF PROCESS..................................................................................................
1.3. DESIGN BASIS FOR FEED AND PRODUCTS...........................................................................
1.3.1. Feeds.............................................................................................................................
1.3.2. Products........................................................................................................................
1.3.3. Design Considerations...................................................................................................
1.4. MATERIAL BALANCE / B.L. CONDITIONS...........................................................................
1.4.1. Material balance............................................................................................................
1.4.2. B.L. conditions..............................................................................................................
1.5. UTILITY AND CHEMICALS REQUIREMENTS.........................................................................
1.5.1. Utility requirements.......................................................................................................
1.5.2. Chemical requirements..................................................................................................
2. OPERATING CONDITIONS AND CONTROLS.....................................................................
2.1. DISCUSSION OF PROCESS VARIABLES.................................................................................
2.1.1. Absorption.....................................................................................................................
2.1.2. Regeneration.................................................................................................................
2.2. PROCESS FLOW AND CONTROL.........................................................................................
2.2.1. Description of process flow...........................................................................................
2.2.2. Control Flow Plan.........................................................................................................
3. EMERGENCY EQUIPMENT...................................................................................................
3.1. SAFETY VALVES................................................................................................................
3.1.1. Summary of Safety Valves.............................................................................................
3.1.2. Summary of Flare Loads...............................................................................................
3.2. CAR SEALED VALVES........................................................................................................
3.3. REMOTE OPERATING VALVES.............................................................................................
3.4. INSTRUMENT ALARMS......................................................................................................
3.5. INSTRUMENT TRIP SETTINGS.............................................................................................
3.6. PROCEDURES FOR SETTING PROTECTIVE RELAYS..............................................................
4. PREPARING UNIT FOR PRE-COMMISSIONING.................................................................
4.1. PRE-COMMISSIONING........................................................................................................
4.2. COMMISSIONING OF UTILITIES..........................................................................................
4.3. PRESSURE TESTING..........................................................................................................
4.4. FLUSHING OUT.................................................................................................................
4.5. ACID CLEANING OF RECIPROCATING COMPRESSOR LINES..................................................
4.6. INSPECTION AND RUN-IN OF PUMPS AND FANS.................................................................
4.7. LEAK TEST.......................................................................................................................
4.8. INSPECTION AND RUN-IN OF RECIPROCATING COMPRESSOR..............................................
4.9. INSPECTION AND RUN-IN OF CENTRIFUGAL COMPRESSOR.................................................
4.10. LOADING INTERNAL MATERIAL REQUIRED FOR ABSORBERS, VESSELS, PACKED COLUMNS.
4.11. DRYING OUT FIRED HEATER...........................................................................................
OF 126
OF 126
General Description
This manual covers the operation of the Amine Treating Process Unit of PARCO MIDCOUNTRY REFINERY PROJECT for PAK-ARAB REFINERY LIMITED (PARCO)
in Pakistan.
Plant duty
The Amine Treating Process Unit shall consist of an Amine Absorber Section to treat
fuel gas, an Amine Regeneration Section, and a Sour Water Stripper Section ( See Part
II - Sour Water Stripper Section )..
The Amine Treating Process Unit will be designed to remove H2S from off gases derived
from various process units in the Refinery. Treated gas from the Fuel Gas Amine
Absorber shall not exceed 100 mol ppm H2S.
The Amine Treating Process Unit will be designed to regenerate rich amine from
various process units, and to provide lean amine back to those units. Acid gas from the
regeneration section will be routed to the Sulfur Recovery Process Unit (hereinafter
called SRU).
Discussion of process
Amine solution of 20 wt % DEA (di-ethanol amine) employed for acid gas removal.
For simplicity, only the chemistry involved in H2S removal will be discussed. It should
be realized, however, that other acid gases ( such as CO2 ) will also undergo similar
reactions.
Hydrogen sulfide, H2S or HSH, is a weak acid and ionizes in water to form hydrogen
ions and sulfide ions:
H2S
H+
+
HSSince it is a fairly weak acid, only a fraction
of the H2S will ionize. Similar ionization
reversible
will occur for the other acidic compounds present, for example CO 2:
CO2 + H2O
H+
+
HCO3Ethanol amines are weak bases and ionize
in water to form amine ions and hydroxyl
reversible
ions:
(HOCH2CH2)2NH + H2O (HOCH2CH2)2NH2+ + OHWhen H2S dissolves into the solution containing the amine ions, it will react to form a
weakly bonded salt of the acid and the base.
(HOCH2CH2)2NH2+ + HS
(HOCH2CH2)2NH2SH
The disulfide ion is thus absorbed by the amine solution.
This salt formation reaction does not go to completion. As the arrows indicate, an
equilibrium level of hydrogen sulfide remains in the hydrocarbon stream. The overall
reaction can be summarized by the following equations:
(HOCH2CH2)2NH + H2S
(HOCH2CH2)2NH2SH
Operating variables are adjustable to favor the forward reaction of the equation above
in the absorption step of the process and, conversely, adjusted to favor the reverse
reaction in the amine regeneration step of the process. It is the reversibility of this
reaction that permits solvent regeneration and continuous removal of H2S by amine
treating.
Design basis for feed and products
Feeds
The Fuel Gas Amine Absorber ( 810-V2 ) in the Amine Treating Process Unit shall be
designed to process off gases from the following:
Absorber at the Gas Concentration Process Unit
Additional gas streams, if any, to be determined during the process design
Stripper Off Gas from a future Distillate Hydrotreating Process Unit.
The Amine Treating Process Unit shall be designed to provide lean amine to, and to
regenerate rich amine from, the following:
Amine Absorber at the LPG Merox Process Unit
Recycle Gas Scrubber at the DieselMax Process Unit
Fuel Gas Amine Absorber at the Amine Treating Process Unit
Products
Off gas from the Fuel Gas Amine Absorber ( 810-V2 ) shall be sent to the refinery fuel
gas system. The design H2S level in the treated fuel gas shall not exceed 100 mol ppm.
Acid gases from the Amine regenerator shall be routed to the Sulfur Recovery Process
Unit ( SRU ).
Design Considerations
1.
2.
3.
4.
5.
6.
Rich amine will be loaded to no more than 0.33 mol H2S/mol DEA. Lean amine
will be regenerated to 0.03 mol H2S/mol DEA.
The Fuel Gas Amine Absorber ( 810-V2 ) will be designed to produce a treated gas
having no more than 100 mol ppm H2S.
wt% DEA will be used in the Amine Treating Process Unit.
An acid gas flare will be provided as a means to dispose of H2S rich gas when the
Sulfur Recovery Process Unit is shut down.
Mechanical and carbon filtration will be included on the lean amine stream leaving
the Amine Treating Process Unit.
An allowance for future Distillate hydrotreating Process Unit will be provided in
the design of the Fuel Gas Amine Absorber. This allowance will be 0.85 MMSCFD
and be of the same composition as the gas from the Gas Concentration Process
Unit.
38
42
Future Use
Rich Amine
from
L-MRX
1.531
0.505
35.634
0.00004
0.004
0.003
0.00002
Rich Amine
from DieselMax
24.98
80.98
1.74
148.76
99.49
5.76
0.76
0.20
6.3
20.51
0.44
37.68
25.2
1.46
0.19
0.05
276.761
0.045
91.372
5.450
6455.59
0.400
0.433
0.077
0.033
0.008
SHEET 9
C6+
C2H4
C3H6
C4H8
C2H6S
0.01
0.84
0.35
0.01
0.00
0.21
0.09
0.02
-
0.0002
0.00005
0.0003
0.004
-
92.16
1,715
18.61
37.68
821
21.78
6830.17
148,569
21.75
0.81
144
8,618
2,183
1,031
-
1,032
137
0.786
0.786
0.28
OF 126
363.80
6,773
18.62
Stream Number*
12
99
97
111
Lean Amine
to L-MRX
Lean Amine
to DieselMax
Gas to
SRU
DEA
NH3
H2S
H2
H2O
CH4
C2H6
C3H8
C4H10
C5H12
C6+
C2H4
C3H6
C4H8
C2H6S
Treated Gas to
Fuel Gas
System
0.0003
0.012
101.413
8.615
186.275
124.572
7.215
0.948
0.250
0.012
1.047
0.439
0.012
-
1.544
0.002
0.033
0.000
36.037
-
276.75
0.03
5.73
6458.57
-
0.003
0.0007
117.07
0.09
10.66
0.01
0.01
0.002
0.003
0.0006
0.0003
0.0003
0.0001
0.00002
0.0003
430.81
7,535
17.49
10,206
0.738
37.61
813
21.6
0.81
1,024
-
6,741.08
145,665
21.6
142.3
1,024
-
127.85
4,183
32.7
3,029
1.381
B.L. conditions
Fluid
1) Incomings
Off Gas
Rich Amine
Sour Water
2) Outcomings
Lean Amine
Sour Gas
Origin / Destination
Available Pressure
( kg/cm2G )
Temperature
( oC )
9.51
9.16
9.86
-
42
38
54
60
13.73
1.05
61
61
61
10
OF 126
H2S
(HOCH2CH2)2NH2SH
The H2S loading of the amine solution is controlled by adjustment of the amine
circulation rate. In most cases, unless special design considerations have been
employed, the rich amine acid gas loading ( H2S plus CO2 ) should not exceed 0.3 to 0.4
mols total acid gas per mol of amine present.
High Amine Concentration
The concentration of uncombined amine is favored by high amine solution, good
regeneration, and freedom from strong acids. Practical and economical considerations
confirmed by field experience have generally shown that the optimum amine
concentration is 20 wt% for DEA. This is based on the lowest heat requirement for the
desired H2S removal, the lowest chemical losses, and the fewest operational problems.
The available amine concentration in the lean amine is mainly affected by the efficiency
and control of amine regeneration. The lower the sulfide content of the lean amine, the
greater the available amine concentration for removal of H2S. In most cases, properly
regenerated lean amine will not contain more than 0.03 mol H2S per mol amine nor
more than 0.1 mol CO2 per mol amine.
Regeneration
The regeneration of the amine solution, actually the breakdown of the weakly bonded
amine-hydrosulfide salt, is favored by :
1. High Temperature
2. Low pressure
3. High stripping steam rate
4. Low amine concentration
5. Intimate contacting
These conditions are controlled in the amine stripping column, subject to the following
limitations. Item 5 is not an operating variable and is fixed during plant design.
High Temperature
The breakdown of the amine-hydrosulfide salt into H2S and amine, the reverse reaction
of the equation below, is promoted by higher temperatures.
(HOCH2CH2)2NH +
H2S
(HOCH2CH2)2NH2SH
12
OF 126
The Amine Treating Section also includes an Amine storage facility. Pure Amine ( 99 wt%
DEA ) will be periodically delivered in bulk amounts and pumped directly to the Make-up
Tank ( 810-TK1 ). The pure amine is diluted with cold condensate to the 20 wt% solution in
the Amine Storage Tank ( 810-TK2 ).
14
OF 126
FRC
Fuel Gas Amine
Absorber
810-V1
Amine Regenerator
810-V5
F
R
C
1
3
4
Rich Amine
Flash Drum
810-V4
Lean
Amine
Trim
Cooler
810-E9
2
PDIC
Lean Amine
Cooler
810-EA2
2
3
Lean Amine
Carbon Filter
810-V7
F
R
Lean Amine
Sock Filter
810-ME2A/B
Lean Amine
to
DieselMax
Lean Amine
to LPG
Merox Unit
Rich-Lean
Amine
Exchanger
810-E3
Lean Amine
Mechanical Filter
810-ME1A/B
Rich
Amine
Lean Amine
Pump
810-P3A/B
2
0
L
I
C
P
I
C
L
I
C
A
u
t
o
S
t
o
p
Slop Oil
Pumps
810-P1A/B
Rich Amine
Flash Drum
810-V4
L
e
a
nL
AI
mC
i
n
e
Lean Amine
to Lean
Amine Pumps
M
Rich Amine
Pumps
810-V2A/B
16
Rich-Lean
Amine
Exchanger
810-E3
SHEET 17
OF 126
Emergency Equipment
Safety valves
Summary of Safety Valves
Summary of the safety valves provided for this unit is shown below. Refer to DATA
SHEET FOR SAFETY RELIEF VALVES ( S-810-1374-301 ) .
Tag. No.
810-PSV-001A/B
810-PSV-002A/B
810-PSV-003
810-PSV-004A/B
810-PSV-005A/B
810-PSV-006A/B
810-PSV-007
810-PSV-013
810-PSV-014
810-PSV-016
Set
Size and
kg/cm2g
Type
11.3
3.5
9.3
6.0
26.9
26.9
26.5
10.0
18.3
6.0
3K4
6Q8
3/4*1
3L4
3/4*1
3/4*1
1E2
4N6
3/4*1
1.1/2F2
Service
Location
Governing Relief
Case
810-V2
810-V4
810-E3
810-V5
810-ME1
810-ME2
810-V7
810-V4
810-E9
810-ME4
Top mounted
Top mounted
Outlet
Top mounted
Inlet
Inlet
Top mounted
Inlet
Inlet
Outlet
Blocked Outlet
Blow by
Thermal
Fire
Fire
Fire
Fire
Blow by
Thermal
Blow by
Size
Equipment /
Line No.
P&ID No.
Open
Open
Open
Open
Open
Open
Open
Open
810--FA-0301-A1A2P-ST
810--FA-0302-A1A2P-ST
810--FA-0303-A1A2P-ST
810--FA-0304-A1A2P-ST
810--FA-0305-A1A2P-ST
810--FA-0306-A1A2P-ST
810--FA-0307-A1A2P-ST
810-PSV-103 inlet line
D-810-1225-103
D-810-1225-103
D-810-1225-103
D-810-1225-103
D-810-1225-103
D-810-1225-103
D-810-1225-103
D-810-1225-111
Open
Open
810-6-SSW-1101-A1A2
Open
Open
Open
Close
810--FA-1301-A1A2P-ST
810-PSV-001A inlet line
810-PSV-001A discharge line
810-PSV-001B inlet line
4
4
4
810-P7A/B
810-P8A/B
810-P11A/B
810-P1A/B
810-P2A/B
810-P4A/B
810-P10A/B
100-6-SSW-3403A1A2
100-6-SSW-3403A1A2
100-6-SSW-3403A1A2
810-V1
810-V2
810-V2
810-V2
D-810-1225-111
D-810-1225-111
D-810-1225-113
D-810-1225-113
D-810-1225-113
D-810-1225-113
Open
Open
Open
4
2
6
Open
Open
Open
Open
Close
Open
Open
Open
Open
Open
Open
Open
Open
Open
Open
Open
Open
Close
Open
810--FA-1404-A1A2P-ST
810-PSV-002A inlet line
810-PSV-002A discharge line
810-PSV-002B inlet line
810-PSV-002B discharge line
810-2-FA-1402-A1A2P-ST
810-PSV-006A discharge line
810-PSV-006B discharge line
810-PSV-007 discharge line
810-PSV-005A discharge line
810-PSV-005B discharge line
810-2-N2-1701-A1A1
810-1-N2-1701-A1A1
810-2-N2-1702-A1A1
810-1-N2-1702-A1A1
810-4-FA-1702-A1A2P-ST
810-3-AM-1707-A1A1P
810-PSV-003 inlet line
10
8
10
8
2
1
1
2
1
1
2
1
2
1
4
3
1
Open
Open
Open
Close
Open
Close
Open
6
4
6
4
1
810-V2
810-V9
810-10-AM-1101A1A2P
810-10-AM-1101A1A2P
810-SN-8
810-V4
810-V4
810-V4
810-V4
810-V4 stack
810-ME2A
810-ME2B
810-V7
810-ME1A
810-ME1B
810-TK1
810-TK1
810-TK2
810-TK2
810-V8
810-V8
810-8-AM-1803A1A2P-IH
810-8-AM-1803A1A2P-IH
810-V5
810-V5
810-V5
810-V5
810-P4A/B
810-SN-10
D-810-1225-113
D-810-1225-113
D-810-1225-114
D-810-1225-114
D-810-1225-114
D-810-1225-114
D-810-1225-114
D-810-1225-114
D-810-1225-114
D-810-1225-114
D-810-1225-115
D-810-1225-115
D-810-1225-115
D-810-1225-116
D-810-1225-116
D-810-1225-117
D-810-1225-117
D-810-1225-117
D-810-1225-117
D-810-1225-117
D-810-1225-117
D-810-1225-119
D-810-1225-119
D-810-1225-119
D-810-1225-119
D-810-1225-119
D-810-1225-119
D-810-1225-120
D-810-1225-120
Service
LI-019
LIC-007
LIC-010
LI-020
Unit: %
ALL
AL
AH
7
19.7
9.8
68.8
66.7
80.1
89.9
AHH
P&ID No.
D-810-1225-113
D-810-1225-113
D-810-1225-114
D-810-1225-114
18
SHEET 19
OF 126
18.8
9.3
14.9
20
22.5
92.5
95
85.1
80
84.3
D-810-1225-117
D-810-1225-117
D-810-1225-117
D-810-1225-119
D-810-1225-120
Unit:
ALL AL
AH
Service
TI-013
TI-011
TI-028
56
140
AHH
66
137
150
P&ID No.
D-810-1225-116
D-810-1225-119
D-810-1225-119
Tag No
Service
FI-004
FI-015
FIC-031
FIC-032
4825
15
2.8
2.8
P&ID No.
D-810-1225-113
D-810-1225-116
D-810-1225-119
D-810-1225-119
22
(4O)Pressure Alarm
Unit: kg/cm2g
ALL AL AH AHH
Tag No
Service
PIC-002
8.6
P&ID No.
D-810-1225-113
Tag No
Service
PDI-079
PDI-080
PDIC-014
PDI-081
1.3
AHH
1.0
1.0
1.7
1.0
P&ID No.
D-810-1225-115
D-810-1225-115
D-810-1225-116
D-810-1225-116
Service
ALL
VSH-108
VSH-125
810-EA2 Vibration
810-EA1 Vibration
AL
AH
x
x
AHH
P&ID No.
D-810-1225-116
D-810-1225-120
Tag No.
Service
P&ID No.
XA-918A/B/E/F
XA-919A/B/E/F
XA-920A/B/E/F
D-810-1225-114
D-810-1225-114
D-810-1225-120
Controller SP
Alarm SP
PID Tuning Constants
OtherParameters (e.g. dir/rev)
Operator
Supervisor
Engineer
x
x
x
x
x
Access control to various manipulations on ESD PLC for this project is shown below
and details of operating procedures is shown in the DCS vendor's
operating manual:
Operator
Trip SP
Other Parameters (e.g. Timer)
Supervisor
Engineer
x
x
20
OF 126
6.
22
OF 126
3.
Alignment of pump and driver for cold operation. No undue strain by the piping on
the pump or driver is allowable.
4. Cooling fluid piping and seal or gland oil piping:
Conventionally packed pumps in hot service are generally furnished with
gland oil. Verify that this installation is correct and complete.
For pumps with mechanical seals, verify that all of the components of the
flushing system ( such as strainers, separators, restriction orifices, and coolers
) have been correctly installed and are clean. Loss of flush or dirty flush may
cause the failure of seals.
1. Packing or seals are installed.
2. Bearings and shafts have been cleaned prior to final lubrication.
3. Pump and driver are lubricated according to lubrication instructions.
4. Rotation of electric motor drivers uncoupled from the pump. Run-in uncoupled for
a minimum of four hours, verifying good motor operation.
During run-in, many pumps are delivering a higher density liquid ( water ) than the
normal process fluid. But the pumps drivers are sized for the normal pumping fluid.
Consequently, there is potential for the overload of many electric motors. To avoid
overloading the motor of a centrifugal pump, the flow must be limited by throttling the
pump discharge valve. When doing so, if possible, check the amperage usage against
design.
The following procedure is suggested for pump run-in:
1. Rotate pump and driver by hand, verifying that they roll freely.
2. Check that run-in water circulation is lined up.
3. Open suction valves fully, venting air from piping and pumps, completely filling
with liquid.
4. Establish flow of cooling fluid, where required.
5. Check that lubrication is satisfactory.
6. Make sure that electric power is available from the switch gear to the starter of the
electric motor driver.
7. Barely open the discharge valve on the centrifugal pump.
8. Start the pump; if the pressure does not build immediately, stop and resolve the
problem.
9. When the discharge pressure has increased satisfactorily after starting, gradually
open the discharge valve to obtain the desired flow rate.
10. In the event of unusual noise, vibration, overheating, or other abnormal conditions,
shut the pump down immediately. Correct the cause before resuming use of
the pump. Continue to check for abnormal conditions as these may occur after
prolonged operation.
11. Check shaft sealing; mechanical seals should show no leakage. Conventionally
packed stuffing boxes must always be permitted to leak slightly to provide
some lubrication and to prevent overheating. Stuffing box gland nuts are
generally only finger tight. A leaking mechanical seal will show some leakage
on start-up. However, after the pump is started and stopped a few times, the
leakage may stop.
12. Operate the pump, directing flows through all suction and discharge piping
circuits.
13. Inspect and clean screens as required.
14. Recheck and realign if required, after any disturbance of piping, such as required
for suction screen inspection if pipe flanges have to be parted for screen
removal.
15. When shutting down, close the discharge valve first, maintaining discharge
pressure while the pump rolls to a stop. This will protect against the pump rolling
24
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backwards should the discharge check valve leaks, and gives the wearing rings a
quick flush.
After all lines available to a pump have had suitable flushing, the temporary screen may
be removed, but only after it has shown free of debris on two successive examinations.
The permanent strainers may then be installed where required.
Leak Test
The purpose of the leak test is to check the piping and equipment for tightness of
flanges, connections, and fittings. These tests should not be confused with the
hydrostatic tests made during construction. Generally plant air or nitrogen is used for
this test.
Prior to test, all the instruments which have been unmounted in the previous steps must
be remounted.
The temporary isolating blinds must be removed for a final pressure test, but the battery
limit blinds must remain in the closed position.
The tightness test must be conducted within certain blocks divided according to the
design pressure of each vessel.
The recommended pressure for the tightness test is about 7.0 kg/cm2G ( available
pressure in air system ) or the normal operating pressure, whichever is
smaller.
Leakage shall be checked with soap solution.
All flanges shall be checked for leakage and re-tightened, if leakage is found.
During the tightness test, the operating pressure shall be maintained as shown
above.
A final leak/pressure test with process fluids at working pressure is made as part
of the plant start-up described in the next section.
The test pressure should be held for a minimum of one hour, while every flange and
joint in the system is closely examined for leaks. Stubborn flange leaks may often be
stopped by simply unbolting and rebolting the flanges. Screwed connections may
require Teflon tape.
Inspection and Run-in of Reciprocating Compressor
Not applicable to this unit.
Inspection and Run-in of Centrifugal Compressor
Not applicable to this unit.
Loading internal material required for absorbers, vessels, packed columns
Not applicable to this unit.
Drying out Fired heater
Not applicable to this unit.
Drying out Reactor section
Not applicable to this unit.
Preparing Reactors
Not applicable to this unit.
Loading Catalyst
Not applicable to this unit.
Degreasing for Amine Circulating System
The presence of heavy hydrocarbon, such as grease or rust inhibition coatings on vessel
walls and internals, could cause serious amine emulsification problems if allowed to
remain. Also any rust present will quickly react with H2S on start-up to form particulate
iron sulfide.
Accordingly, all piping and equipment that will be in contact with the amine solution
must be thoroughly cleaned and degreased. The preferred cleaning solution is 2 wt%
solution of sodium carbonate ( Na2CO3, also called soda ash ). This degreasing and
cleaning solution is prepared in the Amine Storage Tank (810-TK2) and circulated
throughout the amine treating unit, employing the normal amine circulation flow path.
While circulating, the solution is mildly heated with the stripper reboiler to 60 oC to
aid in the grease removal.
Following thorough cleaning, the soda ash solution is drained and replaced by
condensate water and the circulation scheme repeated to rinse the equipment. A detailed
degreasing procedure follows.
Note:
This procedure presumes that the amine treating unit pre-commissioning activities are
complete, all utilities are available, and instrumentation has been checked out and is
ready for service. The gas blanketing system for Amine Storage Tank can be
commissioned at this time to have it ready when amine solution is prepared.
Preparation of Degreasing Solution
Prepare a 2 wt% solution of soda ash with steam condensate in the Amine Storage
Tank.
The volume of soda ash solution required will be approximately equal to the volume of
amine inventory in the bottom of the stripper, plus each absorber to a 50% gauge glass
level, plus 20 percent of the Amine Storage Tank volume, plus approximately 25% of
this total volume to allow for line volumes, vessel tray inventories and complete column
flooding, one at a time. This quantity of solution is easily prepared using the amine
make-up facilities and the amine storage tank. The amine storage tank can be used to
dissolve the soda ash in water as a concentrated solution. The soda ash should be
completely dissolved to avoid lumping of the solid which would cause pumping and
pump screen plugging problems.
The amine transfer pump is used to circulate the soda ash solution in the storage tank to
provide a homogeneous solution. Sample and analyze the solution to determine the soda
ash concentration. Add more water or soda ash as indicated by the sample result to
adjust the soda ash concentration to approximately 2 wt%.
Temporary Modifications to the Unit
1. Remove the filter elements from the amine filters. If activated charcoal has already
been loaded into the filter, isolate the filters with block valves and blinds to
avoid circulation of soda ash solution through them.
2. Connect plant air or nitrogen hoses fitted with temporary pressure regulators to the
overhead line of each absorber column. This will provide a pressure source
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9.
10.
11.
12.
13.
14.
15.
16.
With the circulation flows stabilized, carefully commission the amine regenerator
reboiler and gradually increase the circulating soda ash temperature to 60 oC.
NOTE: The lean amine cooler should not be in service.
Maintain soda ash solution circulation for a minimum of four hours, preferably 24
hours, to assure that all surfaces are contacted by the soda ash solution.
Remember to route a slipstream through the empty filter housings.
After the soda ash solution has circulated four hours, flood each absorber with
soda ash solution until it is completely full to make sure that all internal
surfaces have been wetted and degreased. Make sure that no equipment is
over-pressured during this step. Also flood the amine storage tank when
appropriate.
Sample and analyze the soda ash solution during circulation to assure that the soda
ash is not totally consumed. If this is the case, additional soda ash should be
added to the circulating solution.
Slowly reduce the steam flow to the regenerator reboiler but continue the soda ash
circulation for a few additional hours to allow it to gradually cool to
approximately 38 oC .
Shut down the lean amine circulation pump and discontinue circulation. Pressure
the soda ash solution from each absorber to the amine regenerator. If the
regenerator foundation loading will permit, it too can be flooded with soda ash
solution for the most effective degreasing.
As soda ash solution is drained from pumps, lines, and vessels, the amine sump
will be filled with the used soda ash solution. The sump is pumped out via a
temporary hose to the refinery oily water sewer system.
Finally, drain all vessels, tanks, pumps, and lines of the dirty soda ash solution
making sure some residual pressure remains on all columns to avoid any chance of
a vacuum.
Water Rinse
1. Reestablish working levels in the regenerator and absorber(s) as before but this
time use cold condensate instead of soda ash solution. This may be done as
previously outlined for the soda ash solution or by multiple hose connections
to the treated water supply header, whichever is more convenient. Do not
forget to rinse the regenerator overhead system.
2. Proceed as outlined for the soda ash solution except that circulation of the water
for four hours can be done at ambient temperature unless climatic conditions
favor slight warming.
3. When rinsing is complete, drain the water to the sewer, again taking care to
maintain positive pressure on all equipment.
4. Reinstall the amine filter elements when washing and rinsing is complete.
5. Check and clean up pump screens one final time.
Purging and gas blanketing
Before admitting hydrocarbons into any process lines or vessels, safe refinery practice
requires that the unit be freed of air. The air may be displaced with water, steam, or
inert gas, such as nitrogen. The system must be purged to prevent formation of
explosive mixed gas prior to admitting flammable materials.
If steam is used, precautions should be taken to avoid the following potential problems
or hazards:
1. Collapse Due to Vacuum: Some of the vessels may not be designed for vacuum.
This equipment must not be allowed to stand blocked in with steam since the
condensation of the steam will develop a vacuum. Thus, the vessel must be
28
2.
3.
OF 126
vented during steaming and then immediately followed up with fuel gas or
nitrogen purge at the conclusion of the steam-out.
Flange and Gaskets Leaks: Thermal expansion and stress during warm-up of
equipment along with dirty flange faces can cause small leaks at flanges and
gasketed joints. These must be corrected at this time.
Water Hammering: Care must be taken to prevent water hammering when
steam purging the unit. Severe equipment damage can result from water
hammering.
The following steps briefly outline air freeing by steam purging:
4. Portions to be steam purged include all the columns, vessels, heat exchangers,
and lines.
5. Pumps, sight glasses, level gauges and instruments are not to be steamed-out.
This can be done by closing their inlet and outlet valves.
6. When the unit is divided into a number of sections for steam purging, it must
be so arranged that steam is injected from one end of the section and
blown out from the other end.
7. Open high point vents and low point drains on the vessels to be steam purged.
After opening all vents and drains, steam purge is conducted by opening
the valve at the steam outlet and blowing in steam from the steam out
connection. Care must be taken not to cause hammering when
introducing steam. It may be necessary to make up additional steam
connections to properly purge some piping which may be dead-ended.
8. Thoroughly purge all equipment and associated piping of air. The progress of
the steam purge can be followed by marking up the P&I diagram to
indicate the lines purged. Verify that sufficient drains are open to drain
the condensate which will collect in low spots in the unit.
9. When the steam purging is completed, start to close all the vents and drains.
To prevent the creation of negative pressure within the system, the
injection of a little steam must be continued until the subsequent filling of
fuel gas or nitrogen is started.
10. After steam purging all the sections of the unit, open all the block valves that
has been closed during the steam purging operation to enable the
subsequent fuel gas or nitrogen filling throughout the system.
11. Start to introduce fuel gas or nitrogen into all vessels and then cut back the
steam flow until it is stopped. Regulate the fuel gas or nitrogen flow and
the reduction of steam so that vacuum due to condensing steam is not
created in any vessel or that the refinery fuel gas system pressure is not
appreciably reduced. Introduce fuel gas or nitrogen into the system to
prevent vacuum. Maintain the pressure within the system at 0.5 ~ 1.0
kg/cm2G. When the system is under fuel gas pressure, check the O2
content. ( O2 content shall be less than 1.0 vol%. ). At every purging
step, the pressure of each equipment must be kept under its respective
design pressure.
12. Drain any residual condensate from the unit.
3.
4.
5.
6.
7.
8.
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Commissioning
General overall commissioning plan
With the unit degreased, rinsed, and under an oxygen-free gas positive pressure, the unit
is now ready for start-up. The amine solution can be prepared and inventoried into the
unit. The actual volume of amine solution required can be best ascertained from the
data obtained during the degreasing operations.
The initial start-up consists of the following sequential activites:
1. Preparation of amine solution.
2. Inventorying amine to Regenerator and Absorbers.
3. Introduction of feed to unit.
4. Establishing Amine circulation.
5. Commissioning of Regenerator Reboiler.
6. Commissioning of Amine filters.
7. Final Adjustments of Operating parameters.
Detailed step-by-step start-up procedure
Preparation of Amine Solution
Refer to the section 11.5.
Inventorying Amine to Regenerator and Absorbers.
1. Confirm that the acid flare system has been air freed and is in service. Also
confirm that any isolation blinds previously installed to isolate the unit from
the flare system have been removed.
2. Transfer the amine solution from the Amine Storage Tank ( 810-TK2 ) to the
Amine Regenerator ( 810-V5 ) with the Amine Transfer Pumps ( 810P6A/B ). As the amine level in the Regenerator increases, periodically start
the Lean Amine Pumps ( 810-P3A/B ) and transfer amine to the absorbers
until a visible working level is obtained in each absorber column.
3. With a working level ( ca. 50% ) in the absorber level glass, continue to inventory
fresh amine to an 85% level in the Regenerator bottom. This additional
volume of amine, and probably more, will be required when hydrocarbon flow
to the absorber causes an increase in amine inventory on the absorber trays.
4. Verify that the amine regenerator off-gas line steam jacketing is commissioned and
that all steam traps are passing condensate. These will require checking each and
every shift. Initially, expect to clean these steam traps frequently until all of the dirt
has been dislodged from the pipe jacket.
Introduction of Feed to Unit
1. Introduce the hydrocarbon feed to each absorber, slowly pressuring each absorber
to the design operating pressures.
2. Commission the pressure controller ( PIC-002 ) for the Fuel Gas Amine
Absorber(810-V2).
3. Refer to the Operating Manual of the LPG Merox Process Unit for the Amine
Absorber(802-V1) and that of the Dieselmax Process Unit for the Recycle Gas
Scrubber(284-V5).
Establishing Amine Circulation
1.
Start the Lean Amine Pumps ( 810-P3A/B ) and send lean amine to each absorber.
Set the flow controller ( FIC-016 ) at mid scale and verify its operation for the
Fuel Gas Amine Absorber(810-V2).
2. Verify that each absorber bottom has a working level, unblock the level control
valve ( LV-007 ), and verify that the level control is operating correctly and
rich amine is being returned to the Rich Amine Flash Drum(810-V4).
3. When 810-V4 has a working level, commission the Rich Amine Pump(810-P2A/B)
and then put LIC-010 into auto.
4. Transfer amine solution from the Amine Storage Tank(810-TK2) to the Amine
Regenerator(810-V5) as required to maintain an adequate working level in the
Amine Regenerator bottom. This is the surge reservoir for the entire amine system
and must never be so low that the pump loses suction, or so high that the reboiler
return line is flooded.
Note:
If the commission of the Dieselmax Unit is delayed and it is difficult to
maintain sufficient amine circulation to operate the pumps, some of the lean amine shall
be Bypassed to the Rich Amine Flash Drum(810-V4) by using a bypass line(810-6AM-1503-A2A1P).
Commissioning of Regenerator Reboiler
1. With the amine circulation established, commission the steam flow to the Amine
Regenerator Reboiler ( 810-E2A/B ). Introduce the steam slowly so as to heat
up the reboiler yet avoid water hammer caused by rapid
condensation/expansion.
2. Commission the Lean Amine Cooler ( 810-EA2 ) and the Amine Regenerator
Condenser ( 810-EA1 ).
3. As the Amine Regenerator pressure rises, commission the amine regenerator acid
gas pressure control ( PIC-043 ) to send the acid gas to the acid gas flare. The
Amine Regenerator Receiver ( 810-V6 ) operating pressure will be set
between 0.35 and 0.7 kg/cm2G.
4. When condensed liquid begins accumulating in the Amine Regenerator Receiver,
prepare the Regenerator Reflux Pumps ( 810-P4A/B ) for operation. When a
working level is obtained, start the reflux pump and begin refluxing back to
the Regenerator. Commission the Amine Regenerator Receiver level control
( LIC-041 ), verify its operation, and place it on automatic control.
5. Continue increasing the heat input to the Amine Regenerator Reboiler by
increasing the steam rate until the design reflux rate is achieved. At this time,
verify that the proper temperatures have been achieved; typical temperatures are
often as follows:
Regenerator Feed
88-93 oC
Reboiler Vapor
110-121 oC
Regenerator Top
106-116 oC
Reflux
61 oC
Lean Amine
61 oC
Commissioning of Lean Amine Filters
1.
2.
3.
Verify that the amine filter elements were installed in the filters.
Crack open the filter inlet and slowly fill with lean amine while venting any gas
present.
With the filters liquid full, fully open the inlet and outlet gate valves. Adjust the
differential pressure or flow controller to send the design amount of amine
solution through the filters. Do not exceed the manufacturers recommended
maximum pressure differential across this filters. Typically, this maximum
differential is 1.5 kg/cm2.
32
4.
OF 126
Be prepared to clean the filters quite frequently during the first or two of week
operation.
Lab Method
UOP 9
UOP 212
UOP 212
Analysis
H2S
H2S, RSH, COS
H2S, RSH, COS
It is also useful to have a feed composition analysis for reference if an upset occurs.
Therefore, a GLC analysis of each absorber feed is also required on a daily basis.
Operation Conditions Monitoring
In order to maintain good H2S removal, the amine concentration, H2S content, and
visual appearance of the lean amine must be continuously monitored. It is also
important to monitor the mole ratio of acid gas to amine, or acid gas loading, of the rich
amine solution from each absorber. When this mol ratio exceeds about 0.5 or 0.6, the
amine solution becomes increasingly corrosive toward carbon steel piping, particularly
at elevated temperatures. It is desirable to keep the mol ratio of acid gas to amine in the
rich amine below 0.4 by increasing the amine circulation rate to each absorber until this
ratio is attained.
The recommended analytical methods for simple monitoring of these streams are listed
below:
Stream
Lab Method
Analysis
Lean Amine
UOP 824 or 825
Free Amine
UOP 827
Apparent H2S
Rich Amine
UOP 827
Apparent H2S
34
OF 126
The apparent H2S content of the amine solution is generally reported in grains
( abbreviated gr ) of H2S per gallon of amine solution. This value is converted to the
mole ratio of H2S to amine by the following expressions:
( H2S, gr / gal ) x ( 5.3 x10-3 / DEA, wt% ) = mole ratio
Routine operation
Trouble shooting
There have been many papers published on the subject of analytical control of amine
solution. Sophisticated procedures have been published to analyze and overcome
chronic problems. It is beyond the scope of these operating instructions to reproduce
those papers, but their existence should be mentioned for those who seek additional
information. The following items are furnished as a guide for assistance when routine
analytical tests intended for monitoring plant performance seem confusing or
inconsistent.
Total Amine
The UOP test methods 824 and 825, referred to previously in the Operations
Monitoring discussion, mention free amine.
These methods merely titrate all basic compounds present in a sample with standardized
acid to the methyl red indicator endpoint and call them free amine by calculating them
as if they were all amine; this is quite suitable for routine control purposes, for example
the need for water make-up, but is chemically incorrect, except for fresh solutions.
Periodically, therefore, the lean amine should be checked for total amine by UOP
Method 828 and free amine by UOP 824 or 825 is an indication of the presence of
amine degradation products.
As an initial goal and until plant operation dictates otherwise, do not let the total
amine content to exceed the free amine content by more than 2 wt%.. This is
controlled by partial purging and partial replacement of the plant inventory with fresh
20 wt% DEA solution.
Thiosulfate
Oxygen entering the amine system in any manner quickly reacts with aminehydrosulfide to form amine-thiosulfate. Unlike amine-hydrosulfide, amine thiosulfate is
heat-stable under Regenerator conditions and will gradually increase in concentration
unless removed by purging.
Thiosulfate will react with iodine in the test to apparent H2S, UOP 827, and be included
as H2S in the calculation. Therefore, thiosulfate should be determined weekly by the
analytical test method UOP 818 to make certain that any high apparent H2S
concentration in the lean amine is not thiosulfate.
Thiosulfate concentration should be kept low and should not exceed 50 grains/gallon
when calculated as apparent H2S.
Apparent H2S
As just discussed, UOP Method 827 for apparent H2S does not discriminate between
true H2S and thiosulfate; both are included in the analysis. High values of apparent H2S
in the lean amine could be wrongly interpreted as poor Regenerator performance when,
in fact, thiosulfate or other compounds are at fault. For example, sodium sulfide,
present because of caustic contamination, is also titrated as apparent H2S. There is a
simple test that can quickly determine if inadequate Regenerator performance or other
compounds are the case of the high apparent H2S.
Determine the apparent H2S content in a portion of a lean amine sample using UOP
827. Add 100 ml of the same lean amine sample to a 500 ml flask, add 100 ml of
distilled water, drop in a few boiling stones, and boil the sample over a hot plate in a
laboratory fume hood until the volume of sample is reduce to 100 ml. Remove the 500
ml flask from the hot plate, add distilled water if necessary to reconstitute the original
sample volume, cool, and again determine the apparent H2S content of the resultant
sample by UOP 827. If the sample after boiling now indicates a much lower
concentration of apparent H2S, inadequate stripping in the plant Regenerator may be a
problem; increase the reboiler steam rate. If, however, the apparent H2S concentration
has not greatly diminished, the amine solution is probably contaminated with
thiosulfate, sodium sulfide, or some other material which titrates as apparent H2S.
additional laboratory work can pinpoint the problem.
Foaming
Foaming in the Regenerator or gas absorber and emulsification of amine and
hydrocarbon in the liquid/liquid absorber are sometimes problems. These problems can
be largely avoided by good quality control of the amine solution to keep amine and acid
gas concentrations in the proper range and by good filtration system maintenance so
that the amine solution is always clear and visibly free of particulate matter when a
grab sample is viewed in direct light. Good plant maintenance to quickly remove any
liquid hydrocarbon accumulation from knockout pots and absorber skim lines are
essential. If foaming or emulsification occurs despite these precautions, judicious use
of silicon antifoam agents will usually eliminate the problem.
The simple foam test can be of benefit when used routinely to monitor plant solutions
for foaming tendency, particularly taking note of any changes, and if used to
predetermine minimum antifoam injection rates, should a plant foaming problem
develop.
There are effective antifoam agents for injection into the amine solution to suppress
foaming. High boiling alcohols such as oleyl alcohol have been used as antifoam
agents. Current practice favors the use of the highly effective and easily handled
silicone antifoam agents, such as Dow Antifoam A.
Antifoam agents should not be injected unless foaming experience in the plant indicates
their need. When needed, only a few parts per million, usually less than 10 parts by
weight of the silicone compound per million parts by weight of plant amine solution,
will effectively suppress foaming.
In the case of gas treatment, the silicones cannot escape the unit; thus, continuous
addition is not required. Antifoam agents applied indiscriminately when plant operation
does not require them can actually promote foaming and lead to operating difficulties.
Miscellaneous procedures
Filter operation
To maintain the differential pressure across the entire filtering system( a series of
mechanical filter, carbon filter and sock filter) from exceeding or failing below 1.5
kg/cm2, PDV-014 is opened or closed. The filters are for slip-stream flow and pass
whatever flow is possible with a 1.5 kg/cm2 differential.
The design flow is 21 m3/h, but when the cartridges are clean, more flow will pass
through the filters.
When the flow through the filters drops to 19 m3/h,at a differential pressure of 1.5
kg/cm2, the filters should be changed over and cleaned.
36
OF 126
Antifoam injection
Antifoam agent should be injected if foaming experience in the plant indicates its need.
Continuous addition is not required.
Injection Points
Rich amine line upstream of Rich-Lean Amine Exchanger(810-E3) for Amine
Regenerator(810-V5)
Lean Amine line upstream of Lean Amine Trim Cooler(810-E9) for Fuel Gas
Amine Absorber(810-V2)
Skimming operation
To avoid foaming troubles it is important to remove liquid hydrocarbon accumulation in
Fuel Gas Amine Absorber(810-V2).
Monitor LG-T 003 periodically. And discharge liquid hydrocarbons to Fuel Gas
Absorber Interface Pot(810-V9)
Routine control tests to be performed by operators
Refer to section 11.7.
General overall shutdown plan
Normal shutdown consists of the following sequential activities:
1. Cutting off feed streams
2. Regeneration of amine solution
3. Recovery of the regenerated amine solution
4. Water circulation
Detailed step-by-step shutdown procedure
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Throttle the feed flow rates to each absorber down to 50 % load. And also throttle
lean amine flow rates to each absorber down to 60% of design.
Commission lean amine bypass line to 810-V4 to maintain amine solution
circulation after shutting down each absorber..
Divert the acid gas discharge to acid gas flare.
Block in feed stream to each absorber. And maintain enough pressure in each
absorber to force rich amine to the Rich Amine Flash Drum( 810-V4).
Stop the lean amine supply to each absorber.
Maintaining at least one circulation.
Stop the steam input to the Amine Regenerator Reboilers(810-E2A/B).
Open the bypass of FV-039 to pump as much liquid as possible to the Amine
Regenerator(810-V5) and then shut down the Amine Regenerator Reflux
Pumps(810-P4A/B) . Shut down the Amine Regenerator Condenser( 810EA1) as well.
When circulating amine solution has cooled to 55 to 60 , transfer lean amine to
Amine Storage Tank(810-TK2) by using amine pumpout line.
Shut-down the amine circulating loop( Rich Amine Pumps(810-P2A/B), Lean
Amine Pumps(810-P3A/B) and Lean Amine Cooler(810-EA-2)).
Drain out remaining amine in all equipment and piping
Conduct water circulation of overall amine circulating loop to wash out remaining
amine inside the system.
Steam out all vessels and drums for inspection.
Blanking off
Every line connecting to a nozzle on the vessel to be entered must be blinded off at the
vessel. This includes drains connecting to a closed sewer, utility connections and all
process lines. Install additional blinds at the battery limits as necessary for safety. The
location of each blind should be marked on a master piping and instrumentation
diagrams (P&IDs), each blind should be tagged with a number and a list of all blinds
and their locations should be maintained. One person should be given responsibility for
the all blinds in the unit to avoid errors.
Opening equipment
The area around the vessel manways should also be surveyed for possible sources of
dangerous gases which might enter the vessel while the person is inside. Examples
include acetylene cylinders for welding and process vent or drain connections in the
same or adjoining units. Any hazards found in the survey should be isolated or
removed.
Safe access must be provided both to the exterior and interior of the vessel to be
entered. The exterior access should be a solid, permanent ladder and platform or
scaffolding strong enough to support the people and equipment who will be involved in
the work to be performed.
Access to the interior should also be strong and solid. Scaffolding is preferred when the
vessel is large enough to permit it to be used. The scaffolding base should rest firmly
on the bottom of the vessel and be solidly anchored. If the scaffolding is tall, the
scaffolding should be supported in several places to prevent sway. The platform boards
should be sturdy and capable of supporting several people and equipment at the same
time and also be firmly fastened down. Rungs should be provided on the scaffolding
spaced at a comfortable distance for climbing on the structure.
If scaffolding will not fit in the vessel, a ladder can be used. A rigid ladder is always
preferred over a rope ladder and is essential to avoid fatigue during lengthy periods of
work inside a vessel. The bottom and top of the ladder should be solidly anchored. If
additional support is available, then the ladder should also be anchored at intermediate
locations. When possible, a solid support should pass through the ladder under a rung,
thereby providing support for the entire weight should the bottom support fail. Only
one person at a time should be allowed on the ladder.
When a rope ladder is used, the ropes should be thoroughly inspected prior to each new
job. All rungs should be tested for strength, whether they be made of metal or wood.
Each rope must be individually secured to an immovable support. If possible, a solid
support should pass through the ladder so that a rung can help support the weight and
the bottom of the ladder should be fastened to a support to prevent the ladder from
swinging. As with the rigid ladder, only one person should climb the ladder at a time.
Also refer to Section 10.12 Entering tanks, drums or other vessels.
Special precautions
When draining out the amine solution from the Amine Regenerator, make sure that the
amine solution in it has already cooled down to 60 . Then open the drain valve for
the closed amine recovery.
Otherwise, the underground pipe might be broken due to thermal expansion.
38
OF 126
Emergency Shutdown
General instructions
Emergency shutdown, capacity reduction, or modified operation of the Amine Treating
Section can result from any of the following causes:
Loss of Utilities - loss of low pressure steam, cooling water, electrical power, or
instruments air.
Equipment failure of some equipment items the plant require plant shutdown or
capacity reduction.
Loss of Feed
Fire and other Emergencies
Loss of pump external flushing fluid
The extent to which the plant will have to be shut down depends on the specific
emergency. In any emergency, determine the extent of the emergency condition, and
decide how to cope with it. Then proceed with one of the following actions as warranted
by the emergency:
Handle the emergency as a localized condition without shutting down the rest of
the plant. For example, in the case of a faulty control valve. Block in and bypass
the malfunctioning item until repairs can be made.
OR
Shut down the unit using the normal shutdown procedure described in Section 6.2.
OR
Shut down the unit using the emergency procedures given below for a specific
emergency. In executing emergency shutdown steps, the normal shutdown
procedure detailed in Section 6.2 should be followed as closely as possible.
Fire
Consequence
If a fire occurs in the plant, that section of equipment in which the fire has occurred
must be isolated to confine fire and depressured to eliminate the source of combustible
material. Unless the fire is small and can be handled quickly the plant will shutdown.
Operating supervisor on duty will advise on shutdown, based on refinery procedures in
place.
Actions
Follow operation supervisors orders on shutdown and firefighting procedures.
If plant must be shutdown:
Remove all heat input to the plant.
Block in feeds and product streams.
Isolate section or area where fire is occurring, to remove combustion source.
Depressure various columns and vessels to flare.
Shutdown remaining portions of plant as time and circumstances permit or require.
Power failure
When and electrical power failure occurs, the Amine Treating Section will be shut
down. The plant is designed to fail safe when loss of power occurs,. A true emergency
exists when an electrical power failure occurs.
Consequence
The plant will have to be shut down. Feed will be lost , reflux to columns will be lost,
and temperatures and pressures in columns will rise.
Actions
Make sure all pumps are down (all electric driven).
Block in manually steam inlet valves to the reboiler and block in outlet valves.
Block in all feed and product streams in the plant.
Block in all pumps.
Follow the preceding action with an orderly shutdown using the normal shutdown
procedures described in Section 6.2.
Caution
Maintain a positive pressure in the regenerator as it cools by using nitrogen.
Instrument Air failure
A true emergency exists when instrument air is lost.
Consequence
When an instrument air failure occurs the plant will shutdown. The plant is designed to
fail safe when instruments air is lost.
Actions
Block feed inlet valve at battery limits.
Follow the preceding action with an orderly shutdown using the normal shutdown
procedure described in Section 6.2.
Maintain a positive pressure on the plant as it cools by using nitrogen. Do not let
the regenerator go under a vacuum.
LP Steam failure
A true emergency exists when steam is lost
.
Consequence
If low pressure steam is lost, amine stripping steam and heating steam to the reboilers
will be lost. Therefore plant will be shut down.
Actions
Proceed with a normal shutdown when the emergency steps are complete.
Water failure
Cold Condensate failure
Condensate is used intermittently in this unit, therefore, there is no serious consequence
foreseen when it fails. However, a condensate failure when it is required will have an
effect on the amine dilution operation of the unit..
Cooling Water failure
When a cooling water failure occurs, the plant operation conditions must be adjusted.
Consequences
40
OF 126
Cooling for lean amine coolers will be lost resulting in a slight increase in lean amine
temperature to the absorber.
Pump cooling will be lost.
Actions
Monitor the H2S content in the treated streams.
Monitor the relevant pumps. If any pump has to be shut down, whole section will
be shut down.
Feedstock failure
Consequence
If feed is lost because of a power failure, the plant must be shut down as outlined under
Electrical Failure. If lost because of feedstock failure then a unit shut down could
happen.
Action
When loss of feed occurs, the following action should be taken:
Maintain plant in hot standby mode until feed is available.
When feed is available, proceed with the plant start-up as discussed in Section 6.6.
If feed is lost for a long time period, follow emergency steps with and orderly
shutdown using the normal shutdown procedure described in Section 6.2.
Equipment failure
Consequence
A major equipment failure will shut down the unit for repairs.
Action
Under this emergency condition, immediately initiate the following procedure:
Proceed with a normal shutdown when the emergency steps are complete.
Have maintenance blind the involved equipment following the normal blinding
procedure.
Await instructions from operating supervisor.
42
OF 126
Rich Amine Flash Drum where any liquid hydrocarbon is separated from the rich
amine.
An inlet distributor is provided to avoid excess inlet turbulence and promote an even
flow distribution through the vessel. It consists of a single pipe arranged vertically
through nearly the full width of the vessel diameter with one full length slot facing the
nearest vessel partition.
Liquid hydrocarbon is separated into a reservoir in the vessel and can be periodically
pumped to the Light Slop Oil Tank.
Hydrocarbon vapor separated in the Rich Amine Flash Drum, which contain H2S, is
scrubbed with a small lean amine slipstream in the stack portion. The stack is packed
with 25 mm diameter carbon Raschig rings for contact and the lean amine enters
through a distributor located at the top end of the stack.
Rich amine from the bottom of the Rich Amine flash Drum is pumped to the Amine
Regenerator for regeneration.
Amine Regenerator Receiver ( 810-V6 )
The Amine Regenerator Receiver is a vertical vessel that is made up of KCS. It is
provided to separate the partially condensed ( two-phase ) stream from the Amine
Regenerator condenser. The stream enters the vessel through a distributor located less
than a meter below the mesh blanket. The vessel is provided with a thick mesh blanket
to remove any entrained liquid from the acid gas stream. The liquid water from the
receiver is pumped as reflux to the top tray of the Amine Regenerator. The acid gas
flows on back-pressure control to the Sulfur Recovery Unit.
Lean Amine Carbon Filter ( 810-V7 )
The Lean Amine Carbon Filter is a vertical vessel ( made up of KCS ) filled with
granular carbon to a height of 2100 mm from bottom tangent line. The Carbon Filter is
provided to remove chemical impurities from the slipstream of cooled lean amine.
The regenerated lean amine solution enters the vessel through a 4 distributor at the top
end of the vessel and flows downwards through the carbon bed, removing the
impurities. The product stream goes out from the bottom of the vessel and sent to the
final filtration system.
The vessel is designed for both vacuum and liquid-full conditions.
Amine Sump Tank ( 810-V8 )
An underground sump tank is provided to be the end destination ( final storage ) of
lean/rich amine solutions discharged from the unit during normal operation, emergency
situations and unit shutdown. The vessel will be made mainly from KCS and to be
provided with 6 mm corrosion allowance. The indicated vessel and associated piping
will be below grade.
The vessel is provided with a dedicated pump for transferring amine solution to the
Rich Amine Flash Drum.
Fuel Gas Amine Absorber Interface Pot ( 810-V9 )
The Fuel Gas Amine Absorber Interface Pot is provided for hydrocarbon skimming and
amine drainage to the Amine Sump Tank.
The Interface Pot is a small vertical vessel made from KCS. The vessel is attached to
the bottom-side of the Fuel Gas Amine Absorber to remove liquid hydrocarbon
accumulating from the Absorber.
The vessel is supplied with stripping steam to vaporize the skimmed hydrocarbons from
the Amine Absorber. Hydrocarbon vapor is sent to the acid gas flare from the top of the
vessel and the rich amine solution drained to the Amine Sump Tank.
Reactor summary
Not applicable to this unit.
Fired heater summary
Not applicable to this unit.
Exchanger summary
Amine Regenerator Reboilers ( 810-E2A/B )
The Amine Regenerator Reboilers are tubular heat exchangers provided to supply heat
to the Amine Regenerator. LP steam goes through the tube side while the lean amine is
vaporized on the shell side.
The two horizontal reboilers arranged in parallel are of BJU type heat exchangers with
its shell and cover constructed with KCS and the tubes and other internals with
Stainless Steel ( SS ). Both the shell side and tube side of the exchangers will be
provided with insulation.
Rich/Lean Amine Exchanger ( 810-E3 )
The Rich/Lean Amine Exchanger is a horizontal, AES type tubular heat exchanger
which is provided for heat recovery purposes. The rich DEA solution from the Rich
Amine Flash Drum, before entering the Amine Regenerator, is heated as it passes
through the SS tube side of the exchanger while the lean DEA solution from the
Regenerator bottom is cooled down on the KCS shell side.
Lean Amine Trim Cooler ( 810-E9 )
The Lean Amine Trim Cooler is provided to give the necessary cooling to the lean amine
solution prior to entering the Amine Absorber. This horizontal exchanger will be of type
AES and will be constructed with KCS. Cooling water will be passed through the tube
side and the lean amine to the shell side.
Amine Regenerator Condenser ( 810-EA1 )
The Amine Regenerator Condenser is an air cooled exchanger used for cooling the
overhead vapor of the Amine Regenerator from 107 oC to 61 oC. This condenser will be
constructed with KCS with 5.0 mm corrosion allowance on the headers. Post-weld heat
treatment is required. Fans in the air bay shall be the standard type ( SP ) where blade
pitch can be adjusted manually when fan is stopped.
Lean Amine Cooler ( 810-EA2 )
The Lean Amine Cooler is an air cooled exchanger provided for cooling the lean amine
solution from the Amine Regenerator from 101 oC to 61 oC. This air fan cooler will be
constructed with KCS and to be post-weld heat treated. One half of fans in the air bay
shall be auto-variable ( AV ) type where the blade pitch is automatically adjusted to
44
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Service
Failure
P&ID No.
Action
810-FV-016
Fail Close
D-810-1225-113
810-PV-002
Fail Close
D-810-1225-113
810-LV-007
Fail Close
D-810-1225-113
810-PV-008
Fail Open
D-810-1225-114
810-FV-017
Fail Close
D-810-1225-114
810-PDV-014
Fail Open
D-810-1225-116
810-PCV-026
NA
D-810-1225-117
810-LV-010
Fail Close
D-810-1225-119
810-FV-029/30
Fail Close
D-810-1225-119
810-FV-031/32
Fail Close
D-810-1225-119
810-TV-027
Fail Close
D-810-1225-119
810-FV-039
Fail Open
D-810-1225-120
810-PV-043A
Fail Close
D-810-1225-120
810-PV-043B
Fail Open
D-810-1225-120
Fired heaters
Not applicable to this unit.
Miscellaneous
Refer to the Attachment 8.1.
46
OF 126
( S-810-1371-401 )
Safety
To prevent accidents it is of the utmost importance that all personnel be instructed
properly of the following subject;
The leaks and responsibilities of the operators
The methods to accomplish this in a safe manner.
The following safety regulation cover operations of particular concern to the personnel
responsible for the Amine Treating Process Unit. They are intended to supplement any
existing general refinery safety regulations which cover all units; reference should be
made to the latter for all points not mentioned below;. Mechanical craftsmen working
on his unit will be governed by their own departmental safety regulations, but the
operator should see that none of the following safety regulations are violated by
mechanical workers.
In addition to specifically defined rules and practices, the exercise of good judgment by
every person involved is essential to safe operation by every person involved is essential
to safe operation. An operator should be alert for any situation which might present a
personnel hazard. It should also be the responsibility of each person familiar with the
plant to warn other workers who enter the plant of possible hazards they could
encounter.
All personnel must know the location and use of safely shower, fire extinguisher, plant
fire alarm, and main isolation valves, fire hoses and hydrants, fire blankets, gas masks
and respirators, and other protective equipment such as hard hats, rubber gloves, etc.
Soda acid or foam type extinguisher must not be used on fire around electrical
equipment because the water solution will conduct electricity and may aggravate the
difficulty or result in the electrocution of personnel.
Carbon dioxide or dry powder extinguisher may be used safely on electrical fires. The
carbon tetrachloride extinguishers liberate poisonous fumes and should not be used in a
confined space, unless precautions are taken to avoid breathing the vapors.
Gas masks or breathing apparatus must be worn whenever toxic fumes are encountered.
Safety hats must be worn when outdoors.
Gloves and goggles or face shields should be worn where toxic or hot vapor or liquid is
encountered, and are recommended for use while samples are being withdrawn and
solutions made up.
Fire extinguishers must be recharged immediately after use. All steam and water hose
equipment must be put back in place after use. Access to such equipment must not be
obstructed.
Gas masks must have fresh cartridges installed after use.
Emergency fire plan
The fire protection system of the plant is designed to prevent fire occurrence, control
fire escalation, or extinguish fire within short period of time, assuming there will be no
outside fire fighting assistance, with only one major fire at a time.
Fire fighting and protective equipment
There are five water hydrants with monitors and live hose reels in the process area.
Suitable fire extinguisher must be readily available. The area around an extinguisher or
hydrant must be clear so that equipment is readily accessible in case of emergency.
For details, see the relevant drawing for the fire fighting system.
In case of fire in the process facility, there is a chance that vessels or drums will fall
down because of overheating of the supports. The fire fighting should be done from the
windward.
48
OF 126
In order to prevent the spread of fire, it is necessary to cool down near equipment using
the fire water system, special equipment for fire fighting and also fire fighting trucks.
If the process unit is in operation, it is necessary to shut down the unit.
DO NOT EVACUATE or VENT any hydrocarbon to atmosphere.
Refer to FIRE PROTECTION SYSTEM LAYOUT FOR PROCESS AREA, D926-1225-003 ( Attachment 9.6) for details.
Fire alarm system
Refer to ARRANGEMENT OF FIRE ALARM SYSTEM EQUIPMENT FOR
WHOLE REFINERY AREA , D-926-1225-021 ( Attachment 9.9).
Also, Refer to FIRE EXTINGUISHER LAYOUT FOR PROCESS & UTILITY
AREA , D-926-1225-011 ( Attachment 9.7 ).
Fixed Water Monitors
Provision for fixed water monitors shall be per LAYOUT FOR WHOLE FIRE
PROTECTION SYSTEM, D-926-1225-002 ( Attachment 9.10 ).
Fixed water monitors have an effective nozzle range of at least 30 m and a discharge
capacity of 1900 liter per minutes. Monitors are arranged so that any equipment to be
protected may be covered by two fixed monitors with a radius of at least 30m. Monitors
are located approximately 15 m from the equipment being protected.
Fire Hydrants
The maximum distance between fire hydrants serving the process units shall be 50
meters or less as determined by the equipment served.
Live Hose Reel Stations
Heavy duty hose reels having 40 meters of 32 mm hard booster hose equipped with 38
mm couplings and contain straight stream/fog nozzle, shall be provided as means for
quick water application by one man.
Fire Protection
Refer to LAYOUT FOR WHOLE FIRE PROTECTION SYSTEM, D-926-1225002 ( Attachment 9.10) for details.
Structure steel, Pipe racks, Equipment Supports, main supports of heater are
fireproofed. ( Refer to S-000-13B0-001. )
The following are precautions to avoid fire:
1. Leaking flanges, glands, or broken gauge glasses can release any hydrocarbon gas
or liquid to the area, creating a fire hazard. All equipment should be tested for
leaks before start-up.
2. All systems are to be purged to give a non-explosive atmosphere.
3. Trash and rubbish are a fire and stumbling hazard. Pick it up, an operator should
be proud of a clean unit.
4. Overheating vessels by steam may cause damage to the internal assembly.
5. Spilled oil or chemicals around units or in trenches should be cleaned up at once.
6. Smoking in the process area can cause fires and explosions. Smoke only in
designated areas.
7. Welding or other work which can cause sparks in the process area can cause fires
and explosions. Make the area safe for such work and obtain the necessary permit
from the proper authorities before commencing work.
2.
3.
4.
5.
6.
7.
8.
9.
Repair work
1.
2.
3.
4.
5.
6.
7.
8.
9.
Mechanical work around and operating unit must be kept to a minimum, and the
minimum number of men should be used.
No mechanical work on the equipment is to be done without a properly authorized
work permit.
Safety hats must be worn by all personnel in all areas at all times.
No burning, welding, open fires, or other hot work shall be allowed in the area unless
authorized by a work permit. Catch basins, manholes, and other sewer
connections must be properly sealed off to prevent the leakage of gases which
may ignite upon contact with an open flame.
No personnel shall enter a vessel for any purpose whatsoever until it has been
adequately purged, blanked off, then tested to ensure freedom from noxious or
inflammable gases and an entry permit issued.
When flushing equipment with a fire hose, the fire hose must be equipped with a check
valve to prevent backflow into the fire main.
Lines operation at a low temperature might fracture if unduly stressed; therefore, do
not physically strike these lines and avoid operation conditions which would
cause a water hammer to start.
Do not use light distillates such as gasoline or naphtha to clean machinery or for any
other cleaning purposes.
Equipment should not be left open overnight. At the end of each days work blanks or
spades should be installed to prevent entry of flammable materials due to valve
let-by.
50
OF 126
10. Welding cylinders should be removed from site to a designate safe area at the end of
each working day.
52
2.
OF 126
Compressed air line trolley breathing apparatus. This breathing apparatus is also
completely independent of outside air. It is principally used where the fresh air
line breathing apparatus would be unsuitable.
Poisonous Material
A matter of utmost concern for all operating personnel is the presence of H2S in
streams.
Refer to ARRANGEMENT OF GAS DETECTORS FOR PROCESS AREA ( D926-1225-023).
Hydrogen Sulfide (H2S)
H2S is a colorless gas slightly heavier than air (it accumulates in low spots- be aware!).
It is highly flammable and a dangerous fire risk. Hydrogen sulfide is an explosive gas
which will explode in concentrations of 4.3% (3.4% at 149 ) to 45% by volume in
air. Hydrogen sulfide explosions are most likely to occur in the vapor space over liquid
sulfur, because as liquid sulfur is cooled or agitated, it evolves H2S into vapor space
above it. Such vapor exists above the liquid sulfur in the sulfur pit, which must be
swept with air to prevent a buildup of H2S to explosive. H2S is easily identified in very
low, non-fatal concentrations (0.13 ppm) by the strong pungent odor of rotten eggs.
However, since H2S deadens your sense of smell, do not rely on its odor to warn you of
its presence in lethal concentrations.
Note
H2S is extremely poisonous, (more poisonous than the hydrogen cyanide gas used in
the gas chambers) and breathing any concentration must be avoided. Symptoms of
poisoning vary with the concentration and length of exposure.
H2S is present in the feed from the fractionator overhead system and in many lines and
vessels in the plant.
Note
H2S leaks should never be approached without self contained breathing gear and a
stand-by man in position with breathing gear.
H2S monitors have been provided to detect H2S leaks in particular areas of moderate to
high concentrations. Become familiar with the location of this safety equipment and its
operation.
Precautions to Avoid Danger from Hydrogen Sulfide Gas
Working in any concentration of hydrogen sulfide is not desirable. Where necessary,
work can be done for an eight hour period in a concentration up to 10ppm (0.001%) by
volume in a air, providing continual checks are made by a qualified gas tester using an
approved H2S Gas Detector. Under no circumstances should anyone work in
concentration greater than 10 ppm without proper respiratory equipment and approval
of a supervisor.
Because of the dangerous from the release of hydrogen sulfide gas, the following
precautions must be strictly observed:
Do not work or permit anyone to work in an area suspected of containing a
concentration of hydrogen sulfide gas without first having the area tested by a qualified
gas tester, using an approved H2S detector.
Report at once any leakage of gas or any gaseous areas as soon as discovered.
Keep out of gaseous areas and keep others out.
Stay on the windward side of the area as long as the condition exists.
Nitrogen
N2 is an inert gas used for purging equipment or maintaining a positive pressure inert
gas blanket on a vessel.
N2 is neither poisonous nor flammable, but care must be exercised when working inside
equipment that has beenN2 purged. Adequate ventilation must be provided and
appropriate breathing devices worn. To breathe an atmosphere high in N2, could result
in suffocation.
Before entering vessels that have been purged with N2, a check must be made for
proper oxygen content prior to entry. Rapid vaporization of liquid nitrogen can cause
severe burns on contact with the skin.
Ammonia
Ammonia is a colorless gas with an extremely pungent odor May cause varying degrees
of irritation to the eyes, skin, or mucous membranes.
Refer to MSDA Sheets for the above materials for more detailed information.
Sodium Hydroxide ( NaOH Caustic Soda )
Refer to the appropriate safety bulletin published by the National Safety Council or the
Manufacturing Chemists Association.
Caustic solution, commonly called lye, and technically known as sodium hydroxide, is
used so widely in petroleum refining, that its potential hazards are often carelessly
overlooked. Certain general precautions should be observed.
54
OF 126
Goggles or face shields should be worn at all times in the processing area. Painful
injury and possible blindness can result if caustic reaches the eyes. A bubbler fountain
should be provided for the purpose of washing the eyes if an accident should occur.
Boric acid solution should be available for first aid after washing the injured eye with
copious quantities of water. All eye injury cases, even slight, should be referred to a
physician.
Workmen should be impressed that caustic does not give immediate warning of its
presence on the skin by burning or irritation, as in the case of many other chemicals. A
severe burn can result from caustic before the individual realizes its presence on the
skin. However, the presence of caustic on the skin before burning sensation develops
can be recognized by its slippery and soapy feeling. A physician should be consulted in
case of a severe skin burn. Some refiners keep a tub of diluted vinegar handy to
neutralize caustic on tools, rubber gloves, etc., after washing in water.
In view of the foregoing, workmen should be instructed to wear, in addition to face
shields or goggles, rubber gloves and rubber aprons when performing any work which
exposes them to caustic. Depending upon conditions, it may be advisable to wear
protective rubber footwear, as caustic is destructive to leather. Incidentally, cotton
material is more resistant to caustic than wool, and therefore is preferable for clothing.
Although it should not be considered as a protective material.
When caustic has come into contact with the skin, the area should be immediately
flushed with water for several minutes, and depending upon the severity of the
exposure, this an be followed by a two percent acetic acid wash to neutralize any last
traces of caustic. Facilities for quick action in the matter of water washing should be
available.
A treadle operated safety shower equipped with a quick opening valve should be
installed in the area. In cold seasons provisions should , of course, be made to supply
with warm water.
Preparing for entering process equipment
Anyone entering a vessel which may contain an inert or contaminated atmosphere must
follow safety precautions and rules which apply. The vessels may contain H2s or other
toxic material in addition to hydrocarbons.
Therefore, the following precautions should be included in the standard procedure.
The vessels should be isolated by positive action, such as blinding, to exclude all
sources of hydrocarbon, fuel gas, steam, air, etc.
the refinery safety officer and supervisory personnel will give their permission for
vessel entry after they have made the appropriate tests.
Install an air mover outside the vessel to sweep away any vapors.
The man entering the vessel must be equipped with a fresh air mask in proper working
condition, with a fresh air supply.
There should be available and ready for immediate use and transfer to the man in the
vessel, a separate air supply which is independent of electrical power.
The man entering the vessel should wear a safety harness with properly attached safety
line.
If the work involves a large distance above the floor of the vessel, scaffolding or
support flooring must be built to prevent dangerous falls.
There should be a spare fresh air mask complete with its own separate air supply, to
allow a second man to enter the equipment quickly in case of an emergency. This spare
equipment must e compact enough to allow the second man to enter through the
manway while entering the equipment.
The API publication Guide for Inspection of Refinery Equipment or the NIOSH
publication No. 87-113; A Guide to Safety in Confined Spaces can be referred to for
additional information on safety procedures for vessel entry and accident prevention
measures.
Opening equipment
Every line connecting to a nozzle on the vessel to be entered must be blinded at the
vessel. This includes drains connecting to a closed sewer, utility connections and all
process lines. The location of each blind should be marked on a master piping and
instrumentation diagram ( P&ID ), each blind should be tagged with a number and a list
of all blinds and their locations should be maintained. One person should be given
responsibility for the all blinds in the unit to avoid errors.
The area around the vessel manways should also be surveyed for possible sources of
dangerous gases which might enter the vessel while the person is inside. Examples
include acetylene cylinders for welding and process vent or drain connections in the
same or adjoining units. Any hazards found in the survey should be isolated or
removed.
Safe access must be provided both to the exterior and interior of the vessel to be
entered. The exterior access should be a solid, permanent ladder and platform or
scaffolding strong enough to support the people and equipment who will be involved in
the work to be performed.
Access to the interior should also be strong and solid. Scaffolding is preferred when the
vessel is large enough to permit it to be used. The scaffolding base should rest firmly on
the bottom of the vessel and be solidly anchored. If the scaffolding is tall, the
scaffolding should be supported in several places to prevent sway. The platform boards
should be sturdy and capable of supporting several people and equipment at the same
time and also be firmly fastened down. Rungs should be provided on the scaffolding
spaced at a comfortable distance for climbing on the structure.
If scaffolding will not fit in the vessel a ladder can be used. A rigid ladder is always
preferred over a rope ladder and is essential to avoid fatigue during lengthy periods of
work inside a vessel. The bottom and top of the ladder should be solidly anchored. If
additional support is available, then the ladder should also be anchored at intermediate
locations. When possible, a solid support should pass through the ladder under a rung,
thereby providing support for the entire weight should the bottom support fail. Only
one person at a time should be allowed on the ladder.
When a rope ladder is used, the ropes should be thoroughly inspected prior to each new
job. All rungs should be tested for strength, whether they be made of metal or wood.
Each rope must be individually secured to an immovable support. If possible, a solid
support should pass through the ladder so that a rung can help support the weight and
the bottom of the ladder should be fastened to a support to prevent the ladder from
swinging. As with the rigid ladder, only one person should climb the ladder at a time.
Working in columns or vessels
It is recommended that any man working in a vessel which has an inert or contaminated
atmosphere not be permitted to move too far away or into any tight areas, such as
through a fractionator tray manway. The reason for this precaution is that should the
man develop some difficulty while below a tray, for example, to a point where he could
not function properly or lost consciousness, it would be extremely difficult for the
surveillance team outside the vessel to pull the man up through the small tray manway
by use of the safety line.
Any one working in the bottom of the column or vessel should be aware of the hazard
of falling objects. Hard hats should be worn , but these will not provide total protection
against heavy objects. The workmen should be warned to pay attention, to look, and
56
OF 126
listen. The maintenance supervisor should be careful when scheduling work, to avoid
having people in the bottom of the vessel when there is heavy work going on in the top
of the column or vessels.
A communication system should be provided for the manway watch so that they can
quickly call for help in the event that the personnel inside the vessel encounter difficulty.
A radio, telephone, or public address system is necessary for that purpose.
Entering tanks, drums or other vessels
Before entering a vessel, the refinerys safety precautions should be observed. These
usually include the following: sampling the vessel for toxic vapors and oxygen
concentration, wearing a safety harness, and having an attendant outside the vessel.
An unattended vessel should never be entered
Procedure for removing safety valves
Before removing the safety valve, it is required to confirm that both side of isolation
valve are blocked and depressured safely. It is also required to confirm that the set
pressure of spare safety valve is properly adjusted on the testing facility in warehouse
and block valve of both inlet and outlet line in field are car-sealed-open.
Work permit procedure and work permit formats
Before entering the vessel, a vessel entry permit must be obtained. A vessel entry permit
insures that all responsible parties know that work is being conducted inside of a vessel
and establishes a safe preparation procedure to follow in order to prevent mistakes
which could result in an accident The permit is typically issued by the safety engineer or
by the shift supervisor.
The permit should be based on a safety checklist to be completed before it is issued.
The permit should also requires the signatures of the safety engineer, the shift
supervisor, and the person that performed the oxygen toxic and explosive gas check on
the vessel atmosphere. Four copies of the permit should be provided. One copy goes to
the safety engineer, one to the shift supervisor, one to the control room, and one copy
should be posted prominently on the manway through which the personnel will enter the
vessel.
The permit should be renewed before each shift and all copies of the permit should be
returned to the safety engineer when the work is complete. Additional requirements or
procedures may be imposed by the refiner, but the foregoing is considered the minimum
acceptable for good safety practice.
Recommendation
No.
R-22
Oper. Manual
Section No.
3 and 6.9
58
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Miscellaneous
Conversion tables
length
area
volume
English Unit
Abbrev.
Multiplied
By .
inch
foot
in
ft
25.4
304.8
millimeter
millimeter
mm
mm
square foot
ft2
0.09290
square meter
m2
cubic foot
standard cubic
feet of gas*
gallon
barrel
ft3
SCF
0.02832
0.02826
m3
std m3
gal
bbl
0.003785
0.1590
cubic meter
standard cubic
meters of gas
cubic meter
cubic meter
temperaturedegrees Fahrenheit OF
Metric Unit
Abbrev.
m3
m3
O
6.895
0.1333
0.2491
0.07030
kilopascal
kilopascal
kilopascal
kilograms per
square centimeter
kPa
kPa
kPa
kg/cm2
mass
lb or lbm
0.4536
kilogram
kg
Btu
1.055
kiloJoule
kJ
hp
Btu/hr
0.746
0.2931
kilowatt
watt
kW
W
pound mass
horsepower
British Thermal
Units per hour
*UOP calculates standard cubic feet of gas at 60 F and 14.696 psia. UOP proposes to
calculate standard cubic meters of gas at 15 C and 101.325 kPa.
General pre-start up procedures
Refer to S-xxx-xxxx-xxx.(Hold)
Overall start-up and shutdown outlines
Refer to S-xxx-xxxx-xxx.(Hold)
Offsite systems
There is no interconnection between the amine treating section and the offsite system.
Test Method
Normal
Start-up
Composition
GLC
As req.(1) As req.(1)
H2S
Detector tube or UOP 212
As req.(1) As req.(1)
CO2
Deleted (2)
Note(1) This stream is the same as sponge absorber lean off gas in unit 411.
A sample will be normally taken from 411-SN5.
Note(2) CO2 does not exist.
(2O Treated sweet gas from Fuel Gas Amine Absorber (810-SN2)
60
OF 126
Item
Test Method
Normal
Start-up
H2S
1/D
1/D
Test Method
Normal
Start-up
Apparent H2S
UOP 827
As req.
As req.
Normal
Start-up
1/D
1/D
1/W
1/W
1/D
1/D
1/W
1/W
1/D
As req.
1/D
As req.
Test Method
Diethanolamine
UOP 824
Apparent H2S
UOP 827
Thiosulfate
UOP 818
Total Amine
UOP 828
Carbon Dioxide
Deleted (1)
Appearence
Visual
Foam Test
See this manual
Note (1) CO2 does not exist.
(7O Lean Amine from Lean Amine Sock Filters(810-SN6)
(8O
Normally no test is required.
(9O Rich Amine from Fuel Gas Amine Absorber Interface Pot(810-SN7)
(10O
Normally no test is required.
(11OSlop Oil from Rich Amine Flash Drum (810-SN8)
Normally no test is required.
(12OReflux water from Amine Regenerator Reflux Pumps (810-SN9)
Normally no test is required.
(13OAcid Gas to SRU (810-SN10)
Item
Test Method
H2S
CO2
Hydrocarbons
Note(1) highly Toxic.
Deleted (1)
Deleted (1)
Deleted (1)
Normal
Start-up
Test Method
Normal
Start-up
Diethanolamine
UOP 824
As req.
As req.
62
OF 126
FIGURE 11.7
FOAMING APPARATUS
AIR IN
NO. 12
STOPPER
FLOWMETER,
MONOMETER TYPE
AIR
OUT
AIR IN
CAPILLARY
TUBE
GAS
DISPERSION
TUBE
GRADUATED
CYLINDER
1000 MILLILITER
1
0
0
0
7
5
m
0
l
5m
0l
0
2
m
l5
0
m
l
64