Professional Documents
Culture Documents
Mathura Refinery
OPERATING MANUAL
CONTINUOUS CATALYTIC REFORMING
UNIT (CCRU)
UPDATED MARCH 2016
PREPARED BY
REVIEWED BY
APPROVED BY
Sh.BrijeshYadav,
Sh. B.S.Pachahara,
DMPN
CPNM
AMPN
FOREWORD
The Continuous Catalyst Regeneration type of Reforming Unit (CCRU)
commissioned on 18th May 1998 at Mathura Refinery Is a new feather in the cap of
Indian Oil Corporation. Its process is based on advanced technology from IFP
(France), which allows continuous regeneration of catalyst unlike in earlier semiregenerative type of CRU s operating with limited cycle length between two
consecutive regenerations.
Installed at the cost of about Rs. 360 crores (inclusive of power plant), the CCRU
is serving us to produce high octane reformate (up to 98 RON) from straight run
(C5145 0C cut) naphtha through catalytic reforming process.
Reformate so
Date: 31.03.2016
ADDENDUM 2016
1.
ADDENDUM 2015
1.
2.
3.
4.
5.
6.
10.
11.
12.
13.
14
15.
ADDENDUM 2014
INDEX
PART A:
PART B:
PART C:
PART D:
PART E:
PART F:
PART G:
PART H:
MISCELLANEOUS
PART A
NAPTHA SPLITTING UNIT (UNIT 9)
S NO
DESCRIPTION
PAGE NO.
1.0
Introduction
NSU-01-01
2.0
Process description
NSU-02-01
NSU-02-01
NSU-02-01
NSU-02-02
2.1
2.2
2.3
3.0
Normal operations
3.1
3.2
4.0
Feed Supply
Splitter Section
Re-boiling Heater
Operating Parameters
Process Variables
Start up procedure
4.1
4.2
4.3
NSU-03-01
NSU-03-01
NSU-03-02
NSU-04-01
NSU-04-01
NSU-04-01
NSU-04-01
5.0
NSU-05-01
6.0
NSU-06-01
NSU-06-01
NSU-06-01
NSU-06-01
NSU-06-02
NSU-06-02
NSU-06-02
NSU-06-02
NSU-06-02
NSU-06-03
NSU-06-03
NSU-06-03
6.1
6.2
6.3
6.4
6.5
7.0
8.0
Loss Of Feed
Reflux Pump Failure
Splitter Bottom Pump Failure
Heater Tube Failure
Utilities Failure
6.5.1
Power Failure
6.5.2
Steam Failure
6.5.3
Fuel Oil Failure
6.5.4
Cooling Water Failure
6.5.5
Instrument Air Failure
6.5.6
DCS Failure
Stationary Equipment List
PSV List
Interlocks
NSU-07-01
NSU-07-01
NSU-07-02
NSU-08-01
PART B
NAPTHA HYDROTREATER UNIT (UNIT 14)
S NO
DESCRIPTION
PAGE NO.
1.0
Introduction
NHTU-01-01
2.0
Process Description
NHTU-02-01
NHTU-02-01
NHTU-02-01
2.1
2.2
2.3
2.4
2.5
3.0
Basis Of Design
3.1
3.2
3.3
3.4
4.0
Operating Variables
4.1
4.2
4.3
4.4
4.5
5.0
Feed Supply
2.1.
Off-Sites
1
2.1.
Inside CRU
2
Charge Heater (14F-01)
Reaction Section
Stripping Section
Stripper Reboiler (14F-02)
Reactor Temperature
4.1.1
14-R-2
4.1.2
14-R-1
Space Velocity
Hydrogen Partial Pressure And H2/HC Ratio
4.3.1
14R1
4.3.2
14R2
Feed Quality
Stripper Bottom Temperature
Chemical Reactions
5.1
14-R-1 Reactions
5.1.1
Hydro-refining Reactions
5.1.1.
De-sulfurisation
1
5.1.1.
De-nitrification
2
5.1.1.
Hydro De-oxygenation
3
NHTU-02-01
NHTU-02-02
NHTU-02-02
NHTU-02-04
NHTU-02-05
NHTU-03-01
NHTU-03-01
NHTU-03-01
NHTU-03-01
NHTU-03-06
NHTU-03-07
NHTU-03-07
NHTU-03-07
NHTU-03-08
NHTU-04-01
NHTU-04-01
NHTU-04-01
NHTU-04-01
NHTU-04-02
NHTU-04-02
NHTU-04-02
NHTU-04-02
NHTU-04-03
NHTU-04-03
NHTU-05-01
NHTU-05-01
NHTU-05-01
NHTU-05-01
NHTU-05-02
NHTU-05-02
5.2
5.1.2
Hydrogenation
5.1.3
Elimination of arsenic and metals
14-R-2 Reactions
5.2.1
Hydrogenation of Di-olefins
5.2.2
Iso Di-olefins
5.2.3
Olefin Hydrogenation
S NO
DESCRIPTION
5.2.4
6.0
6.2
7.0
Catalyst Contaminants
7.1.
Inhibitors
1
7.1.
Temporary poisons
2
7.1.
Permanent poisons
3
Utility Requirement
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
9.0
Catalyst Characteristics
7.1
8.0
Sulfur reaction
Electric Power
Fuel Gas
Cooling Water
Steam
Treated Feed Water
Nitrogen
Hydrogen
Intermittent Steam Requirement
Preliminary Operations
9.1
NHTU-05-03
NHTU-05-03
NHTU-05-03
NHTU-05-04
NHTU-05-04
NHTU-05-05
PAGE NO
NHTU-05-05
NHTU-06-01
NHTU-06-01
NHTU-06-01
NHTU-06-01
NHTU-06-02
NHTU-06-02
NHTU-06-03
NHTU-06-03
NHTU-06-03
NHTU-06-03
NHTU-07-01
NHTU-07-01
NHTU-07-01
NHTU-07-02
NHTU-07-02
NHTU-08-01
NHTU-08-01
NHTU-08-01
NHTU-08-02
NHTU-08-02
NHTU-08-02
NHTU-08-02
NHTU-08-02
NHTU-08-02
NHTU-09-01
NHTU-09-01
NHTU-09-01
NHTU-09-01
9.2
9.3
10.0
9.1.
Reaction Section
3
9.1.
Stripper Section
4
Drying
9.2.
General
1
9.2.
Feed section Drying
2
9.2.
Reaction section Drying
3
9.2.
Stripper section Drying
4
Catalyst Loading
9.3.
Preliminary
1
9.3.
14R1 Catalyst Loading
2
9.3.
14R2 Catalyst Loading
3
9.3.
Leak Test
4
First Start Up
10.1
10.2
10.3
S NO
DESCRIPTION
10.4
10.5
10.6
11.0
12.0
Emergency Procedures
12.1
12.2
12.3
12.4
12.5
12.6
12.7
Introduction
General
Loss Of Feed
Recycle Compressor (14k-1) Failure
Hydrogen Rich Gas Make-Up Failure
Stripper Reboiler Pump 14-P-4a/B Failure
Utilities Failure
12.7.1 Fuel Gas
12.7.2 Cooling Water
NHTU-09-02
NHTU-09-02
NHTU-09-03
NHTU-09-03
NHTU-09-03
NHTU-09-03
NHTU-09-03
NHTU-09-04
NHTU-09-04
NHTU-09-05
NHTU-09-07
NHTU-09-08
NHTU-10-01
NHTU-10-01
NHTU-10-01
NHTU-10-02
NHTU-10-02
PAGE NO
NHTU-10-03
NHTU-10-04
NHTU-10-05
NHTU-10-05
NHTU-10-05
NHTU-10-06
NHTU-10-07
NHTU-10-08
NHTU-10-12
NHTU-11-01
NHTU-11-01
NHTU-11-02
NHTU-12-01
NHTU-12-01
NHTU-12-02
NHTU-12-02
NHTU-12-03
NHTU-12-04
NHTU-12-04
NHTU-12-05
NHTU-12-05
NHTU-12-05
12.7.3
12.7.4
12.8
13.0
14.0
Safety Devices
15.1
15.2
15.3
16.0
Troubleshooting
14.1
14.2
14.3
14.4
14.5
15.0
Power Supply
Instrument Air And/Or Instrument Power
Supply Failure
Major Leak Or Fire
Emergency Sequences
Alarm List
Process Safety Interlock
Catalyst Regeneration
16.1
In-Site Regeneration
16.1.1 Heating The Catalyst Bed
16.1.2 Catalyst Bed Steam Stripping
16.1.3 Pre-Oxidation
S NO
DESCRIPTION
16.1.4
16.1.5
17.0
Catalyst Unloading
17.1
17.2
18.0
Coke Burning
Cooling
NHTU-12-05
NHTU-12-06
NHTU-12-07
NHTU-13-01
NHTU-13-01
NHTU-13-01
NHTU-13-02
NHTU-14-01
NHTU-14-01
NHTU-14-01
NHTU-14-02
NHTU-14-02
NHTU-14-02
NHTU-15-01
NHTU-15-01
NHTU-15-03
NHTU-15-04
NHTU-16-01
NHTU-16-01
NHTU-16-01
NHTU-16-01
NHTU-16-01
PAGE NO
NHTU-16-02
NHTU-16-02
NHTU-17-01
NHTU-17-01
NHTU-17-01
NHTU-18-01
PART C
CONTINUOUS CATALYST REGENERATION UNIT
1.O
Introduction
1.1
1.2
1.3
1.4
2.0
Design Capacity
Feed Specification
1.2.1
Distillation
Product Specifications
1.3.1
C5+ cut
1.3.2
Hydrogen rich gas
1.3.3
Fuel Gas
Utilities
Process Description
2.1
Feed Section
CRU-01-01
CRU-01-01
CRU-01-01
CRU-01-03
CRU-01-04
CRU-01-04
CRU-01-04
CRU-01-05
CRU-01-06
CRU-02-01
CRU-02-01
2.2
2.3
2.4
2.5
2.6
2.7
2.8
Reaction Section
2.2.1
Heaters
2.2.2
Burners
2.2.3
Pilot Burners
2.2.4
Reactors
Re-contacting Section
Debutaniser Section
2.4.1
Stabiliser reboiler
Catalyst Regeneration
2.5.1
Coke Burning
2.5.2
Calcination
2.5.3
Oxy-chlorination
2.5.4
Dryer
Catalyst circulation
2.6.1
Catalyst level control
2.6.2
Sequence transfer
Catalyst Circulation and regeneration
2.7.1
Dryer
Catalyst circulation and regeneration
2.8.1
Catalyst flow control
2.8.2
Isolation of reaction section
2.8.3
Regeneration loop
2.8.4
Catalyst regeneration procedure
2.8.5
Nitrogen lift gas system
S NO
DESCRIPTION
2.8.6
2.8.7
2.8.8
2.8.9
3.0
3.2
3.3
4.2
5.0
CRU-03-01
CRU-03-02
CRU-03-04
CRU-03-04
CRU-03-04
CRU-03-05
CRU-03-05
CRU-03-06
CRU-03-06
CRU-03-07
PAGE NO
CRU-02-23
CRU-02-24
CRU-02-27
CRU-02-29
CRU-03-01
CRU-03-01
Chemical Reactions
3.1
4.0
Catalyst replacement
Procedure for Regenerator Cleaning/Repair
Steam Generation System
Process Variables
CRU-02-02
CRU-02-02
CRU-02-02
CRU-02-02
CRU-02-03
CRU-02-05
CRU-02-05
CRU-02-06
CRU-02-07
CRU-02-08
CRU-02-09
CRU-02-09
CRU-02-11
CRU-02-11
CRU-02-11
CRU-02-12
CRU-02-14
CRU-02-14
CRU-02-14
CRU-02-14
CRU-02-15
CRU-02-16
CRU-02-18
CRU-02-22
Catalyst (Cr-201)
4.1.1
CR-201
Chemicals (C2Cl4, NaOH, N2)
4.2.1
Per-chloro ethylene
4.2.2
Caustic soda
4.2.3
Nitrogen
CRU-04-01
CRU-04-01
CRU-04-01
CRU-04-02
CRU-04-02
CRU-04-02
CRU-04-02
CRU-05-01
5.1
5.2
5.3
5.4
5.5
5.6
5.7
6.0
7.0
7.3
Introduction
Loss Of Feed
7.2.1
Recycle gas compressor
7.2.2
Absorber feed pump failure
7.2.3
Reboiler pumps
Utilities Failure
7.3.1
Fuel Gas
7.3.2
7.3.3
7.3.4
7.3.5
7.3.6
S No
8.0
DESCRIPTION
9.0
Trouble Shooting
9.1
9.2
9.3
General
Unexpected Decrease In Ron (Research Octane
Number
Leak In The Feed/Effluent Heat Exchanger
9.2.1
Presence Of Nitrogen In Feed
9.2.3
9.2.3
Presence Of Sulfur In The Feed
9.2.4
Presence Of Metals In The Feed
9.2.5
Low Chlorine Content Of The Catalyst
9.2.6
Partial By-Pass Of The Catalyst
Loss Of Reformate Yield
9.3.1
Presence Of Sulfur In The Feed
9.3.2
Presence Of Metals In The Feed
CRU-05-01
CRU-05-02
CRU-05-03
CRU-05-04
CRU-05-05
CRU-05-07
CRU-05-07
CRU-06-01
CRU-06-01
CRU-06-02
CRU-06-03
CRU-06-04
CRU-06-04
CRU-06-05
CRU-07-01
CRU-07-01
CRU-07-02
CRU-07-03
CRU-07-04
CRU-07-04
CRU-07-04
CRU-07-04
PAGE NO
CRU-07-04
CRU-07-05
CRU-07-06
CRU-07-07
CRU-07-08
CRU-08-01
CRU-08-01
CRU-08-02
CRU-08-02
CRU-08-03
CRU-09-01
CRU-09-01
CRU-09-01
CRU-09-02
CRU-09-02
CRU-09-02
CRU-09-02
CRU-09-02
CRU-09-03
CRU-09-03
CRU-09-03
CRU-09-03
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
9.13
S No
10.0
DESCRIPTION
Equipment List
10.1
10.2
10.3
10.4
10.5
10.6
11.0
Safety Interlocks
11.1 Unit-15
11.2 Unit-17
11.3 Process safety interlocks (Unit 15&17)
CRU-09-04
CRU-09-04
CRU-09-05
CRU-09-05
CRU-09-06
CRU-09-06
CRU-09-07
CRU-09-07
CRU-09-07
CRU-09-07
CRU-09-08
CRU-09-08
CRU-09-09
CRU-09-09
CRU-09-09
CRU-09-10
CRU-09-10
CRU-09-10
CRU-09-10
CRU-09-10
CRU-09-11
CRU-09-11
PAGE NO
CRU-10-01
CRU-10-01
CRU-10-03
CRU-10-04
CRU-10-05
CRU-10-06
CRU-10-06
CRU-11-01
CRU-11-01
CRU-11-02
CRU-11-08
PART D
NITROGEN PLANT
S No
1.0
Introduction
DESCRIPTION
N2-01-01
2.0
Design Basis
N2-02-01
N2-02-01
N2-02-01
N2-02-01
2.1
2.2
2.3
Nitrogen Requirement
Air Requirement
Product Quality
PAGE NO
2.4
Production Pattern
N2-02-01
3.0
Principle Of Operation
N2-03-01
4.0
Process Description
N2-04-01
N2-04-01
N2-04-01
N2-04-02
N2-04-03
N2-04-03
N2-04-03
N2-04-04
N2-04-05
N2-04-05
N2-04-06
N2-04-06
N2-04-07
4.1
4.2
4.3
4.4
4.5
5.0
Regenerations Of Adsorbers
5.1
6.0
Air Compressor
6.1
6.2
6.3
6.4
Lubrication System
Control System
Air Compressor Start-Up
Stopping The Air Compressor
6.5
Inter Locks
S No
7.0
8.0
DESCRIPTION
Refrigeration Section
7.1
7.2
7.3
Refrigeration Compressor
Starting Procedure
Stopping Procedure
7.4
Trouble Shooting
Expansion Turbine
8.1
8.2
8.3
9.0
Start Up Of Plant
9.1
9.2
9.3
9.4
9.5
9.6
Preparation Of Adsorbers
Drying Of The Circuits (Cold Box)
Putting In Cold (Before Placing The Insulation)
9.3.1
Start Up Of The Unit
9.3.2
Shut Down Of The Plant
Tightening Of Nut & Bolts Inside The Cold Box
Placing the Insulation Inside The Cold Box
Final Start Up
9.6.1
First Stage
9.6.2
Second Stage
9.6.3
Third Stage
N2-05-01
N2-05-01
N2-06-01
N2-06-01
N2-06-03
N2-06-07
N2-06-08
PAGE NO
N2-06-09
N2-07-01
N2-07-01
N2-07-04
N2-07-04
N2-07-05
N2-08-01
N2-08-02
N2-08-03
N2-08-03
N2-09-01
N2-09-01
N2-09-01
N2-09-02
N2-09-02
N2-09-03
N2-09-04
N2-09-04
N2-09-04
N2-09-04
N2-09-04
N2-09-05
9.6.4
10.0
10.2
N2-09-05
N2-10-01
N2-10-01
N2-10-01
N2-10-01
N2-10-01
11.0
N2-11-01
12.0
Danger Of Impurities
N2-12-01
N2-12-01
N2-12-01
N2-12-01
12.1
12.2
12.3
13.0
Dangers Of Acetylene
Dangers Of Oxygen
Dangers Of Nitrogen
Miscellaneous Information
13.1
13.2
N2-13-01
N2-13-02
N2-13-02
N2-13-02
N2-13-03
N2-13-03
PART E
AMMONIA REFRIGERATION SYSTEM (15-X-1)
S No
1.0
Introduction
DESCRIPTION
PAGE NO
NH3-01-01
2.0
Process Description
NH3-02-01
3.0
Operating Parameters
NH3-03-01
4.0
Equipment Description
NH3-04-01
5.0
6.0
NH3-05-01
NH3-05-01
NH3-05-02
NH3-06-01
7.0
NH3-07-01
8.0
NH3-08-01
9.0
NH3-09-01
5.1
5.2
Starting Procedure
Stopping Procedure
PART F
AIR PREHEATER SYSTEM
09F-1 / 14F-1 / 14F-2 / 15F-4
S No
1.0
DESCRIPTION
General Description
1.1
1.2
1.3
1.4
1.5
2.0
3.0
Design Data
Process Parameters
3.2
Interlock Scheme
3.1.1 FD fan failure
3.1.2 ID fan failure
3.1.3 High arch pressure
3.1.4 High temperature of ID fan inlet
3.1.5 Low combustion Air flow/pressure
3.1.6 Fuel cut-off to furnace
3.1.7 Stack damper
3.1.8 Turndown operation
Set Point
PAGE NO
APH-01-01
APH-01-01
APH-01-02
APH-01-02
APH-01-03
APH-01-04
APH-02-01
APH-02-01
APH-02-01
APH-03-01
APH-03-01
APH-03-01
APH-03-02
APH-03-02
APH-03-02
APH-03-03
APH-03-03
APH-03-03
APH-03-03
APH-03-04
PART G
OFF-SITE HYDROGEN STORAGE FACILITY
S No
1.0
Introduction
DESCRIPTION
H2-01-01
2.0
H2-02-01
3.0
Hydrogen Compressor
H2-03-01
H2-03-01
H2-03-02
H2-03-04
H2-03-05
H2-03-05
H2-03-05
3.1
3.2
3.3
3.4
3.5
Lubrication System
Initial Start-Up Procedure
Start-Up Procedure
Stopping Procedure
Emergency Stopping Procedure
3.6
Interlocks
PAGE NO
4.0
H2-04-01
5.0
H2-05-01
6.0
H2-06-01
H2-06-01
H2-06-02
6.1
6.2
Properties
Hazards Involved
PART H
MISCELLANEOUS
S No
1.0
DESCRIPTION
Utility System (NSU, NHTU, CRU, N2 Plant)
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
Instrument Air
Drinking Water
Steam
1.3.
LP Steam
1
1.3.
MP Steam
2
1.3.
HP Steam
3
Cooling Water
Dm Water (De-Mineralised Water
Boiler Feed Water
Fuel Gas System
Nitrogen System
Plant Air
Service Water
Flare System
PAGE NO
MISC-01-01
MISC-01-01
MISC-01-01
MISC-01-01
MISC-01-01
MISC-01-02
MISC-01-03
MISC-01-04
MISC-01-05
MISC-01-05
MISC-01-05
MISC-01-07
MISC-01-09
MISC-01-09
MISC-01-10
2.0
Standing Instructions
MISC-02-01
3.0
MISC-03-01
MISC-03-01
MISC-03-01
3.1
3.2
Introduction
Scope
3.3
S No
DESCRIPTION
3.3.1 Definitions
General Requirement
Responsibilities
3.5.1 Issuing Authority
3.5.2
Executing Authority
Procedures
3.6.1 Issue Of Permit
3.6.2 Explanatory Notes To Permit Forms
3.6.3 Explanatory Notes To Permit At Height
3.6.4 Surveillance And Permit Withdrawal
3.6.5 Surrendering The Permit
3.6.6 Training And Awareness
MISC-03-02
PAGE NO
4.0
MISC-03-02
MISC-03-02
MISC-03-04
MISC-03-04
MISC-03-04
MISC-03-05
MISC-03-06
MISC-03-07
MISC-03-11
MISC-03-13
MISC-03-13
MISC-03-14
MISC-04-01
5.0
MISC-05-01
6.0
MISC-06-01
7.0
MISC-07-01
8.0
MISC-08-01
MISC-08-01
MISC-08-06
MISC-09-01
MISC-09-01
MISC-09-01
MISC-09-02
MISC-09-04
MISC-09-04
MISC-09-05
MISC-09-05
MISC-09-06
MISC-09-06
MISC-09-06
MISC-09-07
MISC-09-08
MISC-09-08
MISC-09-10
MISC-09-10
MISC-09-10
MISC-09-12
MISC-09-14
MISC-10-01
MISC-10-01
MISC-10-02
MISC-10-03
MISC-10-04
MISC-11-01
MISC-11-01
3.4
3.5
3.6
8.1
8.2
9.0
9.5
9.6
9.7
9.8
9.9
10.0
Introduction
Operating principle
Compressor
Compressor shaft and sealing system
9.4.1
Seal related data
9.4.2
Gas filter system
9.4.3
Leakage gas system
9.4.4
Separation gas system
Turbine
9.5.1
Turbine operating data
9.5.2
Trip & throttle valve
9.5.3
Turbine gland seal system
9.5.4
Lube oil system
9.5.5
Lube oil specifications
Turbine governor
Compressor anti-surge control
Guidelines for start-up
Guidelines for shutdown
11.0
Compressors
Furnaces
Pumps
Heat exchangers
Vessels
Columns
Check Lists
11.1
Furnace light-up
11.3
S No
DESCRIPTION
11.4
12.0
13.0
14.0
15.0
16.0
17.0
18.0
19.0
20.0
MISC-11-03
11.2
PAGE NO
MISC-11-05
MISC-11-05
MISC-11-06
MISC-11-08
MISC-11-08
MISC-11-10
MISC-11-11
MISC-11-12
MISC-11-12
MISC-11-16
MISC-12-01
MISC-12-01
MISC-12-06
MISC-12-10
MISC-12-14
MISC-12-17
MISC-12-21
MISC-12-25
Alarm List
MISC-13-01
MISC-14-01
MISC-14-01
MISC-14-01
MISC-14-01
MISC-14-03
MISC-14-06
MISC-14-09
MISC-14-12
MISC-14-13
MISC-14-13
MISC-14-13
MISC-14-14
MISC-14-14
MISC-14-14
MISC-14-14
MISC-14-14
MISC-14-15
MISC-14-18
MISC-14-18
MISC-14-19
MISC-15-01
MISC-16-01
MISC-17-01
MISC-18-01
MISC-19-01
MISC-20-01
MISC-20-01
MISC-20-01
MISC-20-01
21.0
22.0
20.4
DCS/PLC Failure
20.5
CRU IFP heater tripping
20.6
BFW Failure
20.7
Screen damage in Reactor
20.8
Screen damage in Regenerator
20.9
Runaway Temperature in Regenerator
20.10 Network Hydrogen Failure
20.11 Condensate in FG Header
20.12 Nitrogen Leak
20.13 Ammonia Leak
20.14 Hydrogen Sulphide Leak
20.15 Hydrogen Leak
20.16 14E3A/B tube leak
20.17 Critical pump seal leak
20.18 CRU separator bottom pump Failure
20.19 NHTU Reactor Furnace 14F1 trip
20.20 Stripper reboiler furnace 14F2 trip
20.21 Oil back-up from OW&S
20.22 Nitrogen plant air compressor Failure
20.23 Freon refrigeration Compressor Failure
20.24 Chemical Leakage
List Of Critical Equipments in CRU Unit
NSU, NHTU and CRU Equipment Process Data Sheets
MISC-20-03
MISC-20-03
MISC-20-03
MISC-20-03
MISC-20-04
MISC-20-04
MISC-20-04
MISC-20-05
MISC-20-05
MISC-20-05
MISC-20-05
MISC-20-05
MISC-20-06
MISC-20-06
MISC-20-06
MISC-20-06
MISC-20-06
MISC-20-06
MISC-20-07
MISC-20-07
MISC-20-07
MISC-21-01
INTRODUCTION:
Naphtha splitting unit produces feed of required TBP range for the
reforming unit by splitting wide cut naphtha from CDU. The selected cut is
then Hydrotreated before feeding to the Reforming Unit.
This unit has been designed to split SR naphtha (144 MT/hr for BH or 95
MT/hr for AM) to C5-80 oC and 80-115 oC cut. Due to the restriction on
Benzene content in the final product (motor spirit), the IBP of the heavier cut
is raised to approximately 105 oC. The present operating cut range of NSU
for light naphtha is C5-105 oC and for heavy naphtha is 105-160 oC. NSU
can be operated with naphtha directly from AVU (hot feed) and from OM&S
(Cold feed), it can also be operated using both the feed simultaneously.
Light naphtha stream can be routed from splitter to R/D naphtha tanks
through AVU, directly to HGU feed tanks, directly to R/D naphtha tanks
through slop header. The heavier cut is routed to Hydrotreating unit as hot
feed and balance to hydrotreater feed tanks. The off spec naphtha is
routed to R/D naphtha tanks using slop header.
Naphtha Splitting Unit (designed by EIL) comprises of a single column with
on-stream factor of 8000 hours and has an operating flexibility of 50% of the
design capacity.
Naphtha Splitting Unit was commissioned on 08.03.98.
Subsequently Naphtha splitter was revamped during July 2010.
Again Naphtha splitter revamped for inclusion of Side cut facility
during Nov. 2013.
Light naphtha is used as feedstock for penex unit and heavy naphtha for PXPTA and CCRU.For current crude processing capacity of 8.5 9 MMPTA,
NSU needs to be operated at more than design capacity that in turn affects
product qualities.Henceforth, NSU capacity augmentation from 144MT/hr to
200MT/hr in BH case was carried out to maintain product quality and also to
avoid naphtha spillover in AVU.
CCRU OPERATING MANUAL
NSU- 01- 01
PART-A
NSU- 01- 02
PART-A
STREAM
TBP at 760MM
HG
IBP
5%
10%
30%
50%
70%
90%
95%
FBP
DENSITY@150C
(Kg/M3)
Bz & Bz
Precursor(%)
C7+(%)
NSU
NSU TOP
NSU
Bottom
Light
Side Cut
Heavy
Naphtha
Naphtha(
Naphtha(
0
0
( C)
C)
0
C)
29
47
63
84
102
122
140
147
150
12
31
36
62
70
78
85
91
93
82
93
98
110
119
134
146
150
152
37
62
69
81
91
99
110
111
118
744.2
705.1
747.1
670.9
<3
<9
NSU- 01- 03
PART-A
PROCESS DESCRIPTION:
NSU splits C5-150 oC cut naphtha into three streams Light NaphthaC5-90
oC cut , Heavy Naphtha 90-150 oC cut and Side Cut Naphtha 40-115 oC.
Heavier cut forms the feed for reformer. Cut pt. of 90 oC has been chosen
to get required octane number with moderate severity and also to exclude
out the benzene precursors from the reformer feed.
2.1
FEED SUPPLY:
For normal operation of the plant, the feed naphtha will be supplied by AVU
stabilizer section at a temperature of about 60 OC. This naphtha is received
directly on tray number #19 of 09-C-1 via 09-FRC-1101 (cascaded with 11LIC-14, stabilizer level control in AVU) after getting preheated to about 100
O
C in 09-E-5. The controller 09-FRC-1101 is being operated by AVU and in
NSU the flow is available. The splitter column bottom product exchanges
heat along with the feed naphtha in 09-E-5, before being routed to rundown
or HTU feed via 9-LIC-1101.
In case of pre-planned AVU shutdown, stabilized naphtha (C5-150 oC) will
be stored in the existing naphtha tanks (101,102 for BH and 103, 104 for
AM) and processed in NSU. New pump 81-P-5A with capacity of 200 M3/hr
is provided in off-sites to supply this cold feed through flow controller 09FRC-1104.This cold feed was joining NSU at the d/s of 9E-05 which was
latter routed via 9E-05 (Process scheme MR/TS/PS/CRU/2009/03). The
stream was routed via 9E-05 for energy conservation purpose.
In order to improve the paraffin quantity in PNCP naphtha, it was proposed
to process 30m3 of BH SRN ex Tk -107 in 9C1 during HS run.BH SRN
stored in Tk-107 will be processed in 9C1 during HS run after reducing the
unit
thrput
by
equivalent
quantity.(Process
scheme
MR/TS/PS/CRU/2009/04
NSU- 02- 01
NSU- 02- 02
Top temp
range, deg C
90-91
80-83
88-90
83-85
NSU- 02- 03
PART-A
2.3
REBOILING HEATER:
Splitter re-boiler 09-F-01 supplies the heat necessary for 09-C-01 re-boiling.
It is a six pass vertical cylindrical heater with 6 burners having provision for
combination firing of both fuel gas and fuel oil. However they are designed
for 100 % of fuel gas or fuel oil firing also.
The circulation through 09-F-01 is provided by splitter Bottom pumps, 09-P2 A/B/C and the pass flows are controlled by 09-FIC-1201/ 1202 / 1203 /
1204 / 1210 / 1211.
Desired temperature at outlet is maintained by controlling the fuel firing
through 09TIC-1201A (09-F-1 COT) or by 09-TIC-1103A (09-C-1 36 tray
temperature). HS1201 has been provided to select 09-TIC-1201A or 09TIC-1103A for furnace firing control. HS1203 has been provided for furnace
firing control on F.G. or F.O. The F.O. has not been used in 09-F-1 till now.
Individual temperatures at convection outlet are indicated by 15-TI-138 (A to
F) and at radiation section outlet by 09-TI-1203, 4, 5, 6, 17and 18.
The radiant section of the heater is provided with 12 bare tubes per pass
(CS of diameter 6 NB sch.40). The convection section has studded as well
as bare tubes. The permissible maximum tube skin temperature for the
heater is 253 oC.
This heater is part of Non IFP heaters and integrated in one block with 14F-01, 14F-02, and 15-F-04. ID, FD fans and APH system is also a part of
this block. In the heat recovery system, FD fan supplies hot air for
combustion through APH and hot flue gases are discharged to stack using
ID fan after exchanging heat in APH. Refer to the APH section later in the
manual for detailed information about its operation and construction.
NSU- 03- 01
PART-A
The MP steams condense in 9E-102 by giving its latent heat for naphtha preheating to Mp steam condensate pot 9V-102 under its own pressure. The
MP steam condensate pot is floating with MP steam header thru 1.5line at
its top. The level in MP condensate pot is maintained at 50% by level control
valve 9LV-102, which transfers the condensate to condensate recovery drum
by 9V-103 by its own pressure.
3.1
OPERATING PARAMETERS:
The designed operating parameters for the unit in the case of designed
feed quality are given below. Established Operating parameters for all the
three types of feed viz. BH, Nigerian and AM to have Heavy Naphtha IBP of
105 oC are also given as actual operating parameters.
3.2
PROCESS VARIABLES:
NSU- 03- 02
PART-A
4.1
4.2
NSU- 04- 01
PART-A
4.3
NSU- 04- 02
NSU- 05- 01
6.1
Loss of feed:
Feed to the unit is normally supplied from Naphtha stabilizer of CDU.
Provision for cold feed ex storage tanks 101,102,103 and 105 by pump 81P-5A, is also available. Interruption in NSU feed supply can be due to
a)
CDU shutdown
b)
6.2
6.3
NSU- 06- 01
PART-A
6.4
6.5
a)
Cut off fuel firing in 09-F-1 (fuel gas and pilot gas) and isolate.
b)
c)
d)
e)
f)
g)
h)
Stop FD / ID fan.
UTILITIES FAILURE:
STEAM FAILURE:
NSU operation will not be affected with steam failure as normally gas
burners are kept in line. However, if oil burners are in line then switch over
to gas firing.
6.5.3
NSU- 06- 02
6.5.4
6.5.5
6.5.6
DCS FAILURE:
Total DCS failure, that is console and controller failure, will bring all the
control valves to their fail-safe modes. In that case isolate all the burners
and go for plant shutdown immediately. For complete details refer to
MISC-19 section
6.5.7
LP STEAM FAILURE:
LP steam will not be available for preheating naphtha in 9E-101.LP steam
flow to naphtha pre-heater 9E-101 to be closed and unit t put to be
reduced accordingly to maintain the desired reflux ratio.
6.5.8
6.5.9
S No
1
2
3
4
5
6
Details of action
Action
By
PO
SI &
PO
SI &
PO
PO
PO
FO
FO &
PO
FO &
PO
FO &
PO
NSU- 06- 03
7.0
7.1
EQUIPMENT DETAILS:
Sr. No.
Equipment No.
Equipment Description
9-AC-1A
2
3
9-AC-1B
9-AC-1C
9-AC-1D
5
6
7
8
9
10
9-AC-1E
9-AC-1F
11
12
13
14
9-A C-1K
9-AC-1L
9-AC-3A
9-AC-3B
15
9C1
16
17
18
19
20
21
22
23
24
25
26
27
28
29
9E1
9E4
9-E-5
9V1
9V5
9F1
9 E 101
9 E 102
9 V101
9 V102
9 V 103
9 E 104
9 E 103
9V-105
30
9E-105
9-AC-1G
9-AC-1H
9-AC-1I
9-AC-1J
NSU- 07- 01
7.2
Sr.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
PSV Details:
PSV Tag No.
9 PSV 1101A
9 PSV 1101B
9 PSV 1101C
9 PSV 1101D
9PSV 101E
9PSV 101F
9 PSV 1102
9 PSV 1301A
9 PSV 1301B
9 PSV 1303A
9 PSV 1303B
9 PSV
101A/B
9 PSV 102
A/B
Set
Pressur
e
Kg/cm2g
3.8
3.8
3.8
3.8
3.8
3.8
7.0
3.8
3.8
17.3
17.3
Isolation B/V
On 9V- 101
On 9V-102
PSV Location
On 9-C-1
On 9-C-1
On 9-C-1
On 9-C-1
On 9-C-1
On 9-C-1
On CWR EX 9-E-4
On 9-V-1
On 9-V-1
On 9-V-5
On 9-V-5
I/L
O/L
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
N
Y
Y
Y
Y
18
TAG NO.
Bellow
Bellow
Bellow
Bellow
Bellow
Bellow
CONV.
CONV.
CONV.
NSU- 07- 02
PART-A
ABNORMALITY
Type
SET VALUE
INTERLOCK
1.
09-FD-1201
09-FD-1202
09-FD-1203
09-FD-1204
09-FD-1210
09-FD-1211
20 m3/hr
20 m3/hr
20 m3/hr
20 m3/hr
20 m3/hr
20 m3/hr
2.
FG to 09-F-01 Pressure
low
09-PD-1210
0.37
Kg/cm2g
3.
15-FD-3101
8000 Kg/hr
15-PD-3110
+20mmwc
5.
XL-3111 &
XL-3114
6.
15-PU-3103A
15-PU-3103B
15-PU-3103C
(Combination
of any two
Tags)
HS-1202A
4.
7.
8.
HS-1202B
9.
Non-IFP Heaters
Emergency Stop (Field)
HS-3119
10.
Non-IFP Heaters
Emergency Stop (H / W
console)
HS-3120
8.0
INTERLOCKS:
+5mmwc
+5mmwc
+5mmwc
NSU- 08- 01
NHTU- 01- 01
2.1
FEED SUPPLY:
2.1.1 OFF-SITES:
Feed naphtha (NSU Product) is stored in tanks 105 and 106 each of 10,000
M3 nominal capacities. The low sulfur naphtha is stored in Tank 106 and
high sulfur naphtha is stored in Tank 105. Tank 106 contains neat low sulfur
naphtha, but the interface of high and low sulfur naphtha is received in Tank
105. Three pumps, 602-P-4 A/B/C each having a capacity of 52 M 3/hr and
discharge pressure of 8.8 Kg/cm2 have been provided to supply feed to
Hydrotreating unit. High Sulfur naphtha and Low sulfur naphtha feed will be
supplied to the unit through the flow control valve in OM&S, the controllers
for which are operated from CRU-DCS.
There was a facility to store desulfurised Naphtha in Tank 107, which can be
processed directly to stripper for further processing in CRU. Tank 107 is now
being used in other service and this facility no more existing.
2.1.2 IN-SIDE CRU:
Feed naphtha ex storage tanks enters the feed surge drum 14-V-1 under
level control 14LIC-1401 through filter 14G-1. Filter stops gum compound. A
shutdown valve is provided in the feed line ahead of the filter to shut-off feed
when LAHH 1418 (14V1 high level) and PAHH1451 (2/3 of PT 1451 A/B/C)
get actuated. Surge drum pressure is maintained by fuel gas and controlled
by split controller 14-PIC-1401; excess pressure is released to flare.
VBN is taken directly from VBN R/D through 14-FC-1434; there is a facility to
receive VBN from OM&S through 14-FC-1440 and Heavy FCC Gasoline
from FCC Gasoline splitter through 14-FC-1433. The VBN and Heavy FCC
Gasoline joins the feed surge drum u/s of S/D valve UV-1415.
From surge drum 14V-01, feed is pumped by 14-P-1A/B under flow control
of 14FIC-1402 and is mixed with make-up gas ex 14K2A/B before being preheated in Reactor Feed / Effluent Exchangers 14-E-1 D/E/F. The shell side
outlet of 14E1D is taken to the Di-ene saturation reactor 14R2. The 14-R-2
effluents enter the shell side of 14-E-1A/B/C and further heated in heater 14F-1 before reaching the main hydrotreater reactor 14R1. The recycle gas
after exchanging heat with reactor effluent in 14-E-1G enters the shell side of
14-E-1 A/B/C.
OHCU heavy naphtha is taken directly thru FCC gasoline line via FC1433.
In case of emergency like feed failure from OM&S NTHU feed can be
managed directly from 9V5 outlet. Before doing so ensure the quality of the
feed.
CCRU OPERATING MANUAL
PART-B
NHTU- 02- 01
2.2
2.3
REACTION SECTION:
The saturation of di-olefins takes place in the diene saturator reactor 14R2.
Reactor contains HR-945 catalyst (22 m3). The catalyst is NickelMolybdenum oxide impregnated on Alumina. Inert alumina balls are used
above and below the catalyst bed.
The Reactor inlet temperature is maintained at 160 oC (195 oC at EOR) and
is controlled by the temperature controller TC1443, which has a selector
switch for SOR and EOR. During SOR mode temperature is controlled with
the operation of TV-1443 A/B and during EOR mode temperature is
controlled with the operation of TV-1444 A/B. TV-1443 A/B has been
provided at the tube side of 14-E-1 D/E/F and its bypass line respectively,
whereas TV-1444 A/B has been provided at the tube side of 14-E-1 A/B and
its bypass line respectively.
NHTU- 02- 02
The rector pressure is maintained at 25.6 Kg/Cm 2g on the outlet through 14PC-53. The reactor bed temperatures are measured by 20 nos
thermocouples along the height of the reactor.
Hydrorefining and hydrogenation reactions are conducted in the
Hydrotreater Reactor 14R-1.It is cylindrical vessel of dia 2.5 meters, height 4
meters and is made up of 1-1/4 Cr. and 1/2 Mo with SS type 321 cladding on
shell and heads.
Two catalyst beds, upper of 475-mm height (1.90 m 3) of LD-145 and lower of
3935-mm height (19.1 m3) of HR-348 catalysts are used. Above the upper
layer and below the lower layer of catalyst, Alumina balls are used.
Reactor inlet temperature is maintained at 290 oC (340 oC at EOR) and is
controlled by 14-TIC-1404, which resets the fuel gas firing in feed heater.
Reactor pressure is to be maintained at 20 Kg/cm 2g. However due to low
Sulfur level in the feed, lower H2 partial pressure and hence lower system
pressure can be maintained.
14-R-1 inlet temperature is indicated by 14TI-1403 and outlet by 14TI-1406.
Reactor bed temperature are measured by 14TI-1405 A/B/C/D/E/F/G/H.
14PDT-1406 indicates the pressure drop across catalyst bed.
The reactor effluent is cooled down successively in 14-E-1 A/B/C/D/E/F,
followed by the recycle gas pre heat exchanger 14-E-1G and the stripper
feed preheat exchanger 14-E-7 before getting cooled in the air cooler 14AC-1 (A To C) and water cooler 14-E-2. It is then routed to separator drum
14-V-02.
Make up hydrogen gas from the Hydrogen network is supplied at a pressure
of 15.58 Kg/cm2g through a pressure reducing valve 14-PCV-85, to the
suction of make up compressor 14-K-2 A/B. The purity of Hydrogen is
99.9%. In case of non-availability of hydrogen from the network there is a
facility to line up hydrogen bullet through 14-PC-86 to supply hydrogen at
constant pressure of 15.6 Kg/cm2g.
Water Injection is done (@ of 5% of hydrocarbon flow) in the process line at
air cooler inlet in order to wash the chlorides, sulphides and ammonium
salts, which may deposit in solid form when the temperature is low. A makeup of deaerated water (10% of water recycle equivalent to 365 kg/hr) and the
circulation of water is achieved at constant flow by separator water recycle
pumps 14P-5 A/B. 14-P-5 takes suction from 14V-2 boot and injects at 14E1F inlet and 14AC1 A/B/C inlet. Sour water from 14V-2 boot is taken out
under level control 14LIC-1406. For water injection HP BFW(T=110Deg. and
P=80Kg/cm2) was available with manual control. This may lead water
carryover. To avoid this MP BFW(T=110Deg.and P=30kg/cm2) provided for
NHTU wash water section with new HIC to Control water injection.
NHTU- 02- 03
2.4
STRIPPING SECTION:
The function of the stripper is to eliminate the light ends and the impurities
hydrogen sulphide and moisture from the reformer feed.
Stripper feed ex 14P-2A/B is preheated in 14-E-7 against 14-R-1-reactor
effluent and then in 14-E-3 A/B (Feed / Bottom exchanger). Pre-heated feed
enters a 27 tray stripper at tray #08 at a temperature of 174 oC. Stripper is
operated at a pressure of 14 Kg/cm 2g and top temperature of 172 oC (127 oC
for feed II i.e. Arab Mix). Its overhead vapors are condensed and cooled in
Stripper Air Condenser 14-AC-2, Stripper trim cooler 14-E-4 A/B and
collected in stripper reflux drum 14-V-4. Corrosion inhibitor solution (10PPM
by wt.) is injected by pumps 14-P-7 A/B to the overhead products at column
outlet. A 10% weight solution of Corrosion inhibitor is prepared with
reformate and stored in 14-T-3.
A gas purge of 283 Kg/hr with H2S of 2.28 kg/hr is done from 14V-4 under
pressure control 14PIC-1411 to H2S scrubbing unit (Amine wash unit). The
stripper is operated on total reflux using reflux pump 14-P-3 A/B. Sour water
recovered in 14V-4 boot is taken out under level control 14LIC-1415 for sour
water treatment.
Stripper bottom product after cooling in feed / bottom exchanger 14E-3 A/B
is sent to Reforming unit through temperature controllers TC1453 A/B, to
maintain the CRU feed temperature at 110 oC. Another stream goes to
storage tank 107 under 14C-1 level control 14LIC-1412 through stripper
bottom water cooler 14E-05. Due to change in service of Tank 107 the R/D
line has been kept blinded. There is a facility to divert off spec R/D to storage
tanks 105 and 106.
A new line has been installed to route the excess DSN FROM 14V4 TO
14V1/AVU.This line to be used only during acute emergency in order to
maintain 14V4 level.This line has been provided with a C/V.
NHTU- 02- 04
2.5
NHTU- 02- 05
Attributes
Compressor amps
Power consumption by
compressor
Saving by reducing 1
KWH of electricity
Total saving
(considering
compressor used to run
at 30% of load)
Quant
ity
50
30
KW
11.3
Rs
2.7
Unit
Amps
NHTU- 02- 06
3.0
BASIS OF DESIGN
3.1
3.2
FEEDS SPECIFICATION:
AM
VB
BH
SPGR
0.7327
0.7318
0.710
70.3 wt%
44 vol%
35.5 wt%
---
32
---
18
13
32.6
11.7
---
---
Bromine number
---
50
---
11
31.9
NHTU- 03- 01
Origin:
AM naphtha
VBU naphtha
BH naphtha
89
45
56
10
92
75
70
30
101
89
90
50
119
102
106
70
129
115
119.5
90
145
134
139.5
FBP
154
161
148
AM naphtha
VB naphtha
BH naphtha
Sulfur
(wt ppm)
270
3000
10.9
H2S
(wt ppm)
NIL
40
NIL
Nitrogen
(wt ppm)
1.5
50
1.5
Arsenic
(wt ppb)
10
-----
10
50
-----
50
Lead
(wt ppm)
20
-----
20
Copper
(wt ppb)
20
-----
20
Nickel
(wt ppb)
20
-----
20
(wt ppb)
NIL
-----
Nil
Others
(wt ppb)
NIL
-----
Nil
NHTU- 03- 02
feed
specifications
are
as
follows
Sp gr.
0.7326
0.7325
P wt%
65
64
O wt%
N wt%
18
17
A wt%
12
12
Diene value
0.2
0.4
Bromine number
10(*)
(normal
1043 /
1816(*)
11
12
50 max
23
26
58
96
23
26
V (wt ppb)
10
5 max /
Others
nil
10 max
(*) The design has been checked so that the unit is able to handle a feed
containing 10% VB naphtha with the following properties (Diene value: 4;
IBr: 90; Total Sulfur content: 1200 wt ppm; H 2S content: 40 ppm wt). This
case is the controlling case for stripping section.
NHTU- 03- 03
Normal Operation
PARAFFIN
OLEFINS
NAPTHENES
AROMATIC
Turndown
C4
0.07
0.14
C5
0.50
0.99
C6
0.70
1.40
C7
25.08
23.83
C8
28.07
26.12
C9
12.94
11.86
C10+
0.08
0.16
O4
0.00
0.00
O5
0.27
0.54
O6
1.15
2.30
O7
1.05
2.10
O8
0.56
1.13
O9
0.07
0.13
O10
0.10
0.20
N5
0.01
0.02
N6
0.21
0.42
N7
4.82
4.98
N8
10.21
9.61
N9
2.30
2.10
N10
0.00
0.00
A6
0.03
0.05
A7
3.40
3.43
A8
6.84
6.88
A9
1.55
1.59
A10
0.00
0.00
--------------------100.0
--------------------100.00
NHTU- 03- 04
MAKE-UP GAS
99.5
C1
0.5
136
MAX. IMPURITIES
CO + CO2
50 ppmv max
HCl
1 ppmv max
PROCESS WTAER
A water stream is foreseen at the inlet of the reactor effluent air cooler
De aerated water must be used for this service
The process water recycle rate is around 5% of the hydrocarbon feed flow
rate
The water make-up flow rate is 10% of the water recycle rate
Water make-up: 364 Kg/Hr
CASE STUDIES
In this design, SOR and EOR operations have been considered. SOR and
EOR referring to start of run and end of run (or cycle) of the hydrotreating
catalyst. These cases are reviewed throughout the design for their impact
on equipment size and operating severity.
NHTU- 03- 05
3.2.2
PRODUCT SPECIFICATIONS:
All the detailed compositions are given in the section:
0.5
Nitrogen
0.5
1 wt ppb
Olefins
Diolefins
Metals
5 wt ppb
Halogens
This stream contains H2S and is preferably sent to an H2S scrubbing unit
(amine unit)
Normal Operation
Turndown
Flow rate
Kg/H
283 Kg/H
161
MW
19.8
21.2
H2S
%
27 wt %
24.2
NHTU- 03- 06
wt
3.2.3
YIELDS:
They are expressed in wt%
Origin:
Normal Operation
Turndown
H2S/NH3
0.112
0.194
Hydrogen
-0.080
-0.156
Methane
0.016
0.026
Ethane
0.017
0.032
Propane
0.020
0.035
Isobutane
0.0085
0.016
N-butane
0.0085
0.016
C5+
99.899
99.838
----------------------------100.0
3.3
3.3.1
DESCRIPTION:
100.00
Pressure Kg/cm2
Feed stock -SR naphtha
----------------------------
Temperature C
5.0
40
6.0 to 8.0
40
19.5(1)
40
40 to 17
40
7.0
46
-Hydrotreater purge to AU
7.0
43
-Reformer feed
12.9
110
4.5
45
-VB naphtha
-H2 from network
(Make-up)
-Hydrogen from bullets
(Start-up)
Products
(1) MU gas compressor inlet is designed for 15.6 Kg/cm2g suction pressure to suit the
new duty conditions with a suction pressure reduction valve 14-PCV-85.
NHTU- 03- 07
3.4
STREAM
UNITS
FEED
Kg/cm2g
T/Hr
3.5
T/H
11
HYDROGEN EX NETWORK
Kg/cm2g
15.58
Kg/cm2g
1.5
MT/hr.
69.9
KG/hr.
2306
Deg. C.
84
Deg. C.
165
10
Kg/cm2g
25.6
11
Deg. C.
169
12
Kg/cm2g
25.2
13
Kg/cm2g
22.7
14
Deg. C.
290/340
15
Deg. C.
290/340
16
Kg/cm2g
18
17
Kg/cm2g
27
18
Deg. C.
75
19
Kg//hr.
169
NHTU- 03- 08
20
Deg. C.
65
21
Kg/cm2g
17.5
22
Deg.C.
43
23
Kg/hr
15
24
Deg. C.
165
25
FEED TO STRIPPER
M3/hr.
91
26
Deg. C.
150
27
Deg. C.
65
28
Deg. C.
47
29
Kg/cm2
14
30
REFLUX FLOW
M3/hr.
10.8
31
Deg. C.
47
32
Kg/hr
283
33
Deg. C.
236
34
Deg. C.
239
35
Kg/cm2g
14.9
36
DEG C
110
NHTU- 03- 09
4.0
OPERATING VARIABLES:
The independent variables, which can be fixed by the operator with in the
operating range of the equipment, are:
4.1
REACTOR TEMPERATURE:
4.1.1 14R2:
Thermodynamics for selective hydrogenation of di-olefins are very favorable.
Di-olefin hydrogenation to olefins is completed even at a relatively very high
temperature and low H2 content
The Hydrogenation reaction rate is increased at higher temperature.
Hydrogenation selectivity however is favored by lower temperature. For
catalyst stability the operation must take place at a lower temperature to
prevent polymerization of gum precursor compounds.
Lower operating temperature keeps the reactants in the liquid phase by
minimizing vaporization.
The reactor exotherm is a function of the di-olefins content of the fresh feed
and make-up hydrogen rate.
4.1.2 14-R-1:
The hydrotreating reactions are favored by an increase of temp. But at the
same time this increase of temperature increases the coke deposit on the
catalyst.
The chosen range of temperature is a compromise between long catalyst
life, optimal quantity of catalyst and an hydrotreatment as complete as
possible. The optimum reactor inlet temperature is between 290 (new
catalyst) to 340 oC (At the end of the cycle) for the designed feed cut. In case
of lower sulfur content, the values can be reduced.
NHTU- 04- 01
4.2
SPACE VELOCITY:
Space velocity is defined as:
Hourly feed flow rate in M3/hr at 15 OC
------------------------------------------------------Volume of catalyst in M 3
LHSV =
4.3
4.3.1 14R1:
An increase in hydrogen partial pr. favors the hydrogenation reactions and
reduces polymerization reactions and coke deposits. As the unit pr. is fixed,
the only way to modify the hydrogen partial pr. is either by increasing recycle
gas flow rate of by modifying hydrogen purity by increasing the make up gas.
H2/HC ratio
NHTU- 04- 02
FEED QUALITY:
Although the feed is not an operating variable, knowing its properties allows
the adjustment of operating conditions to meet the specifications. In case of
high impurities or olefins in the feed, or higher final boiling point, the severity
of the operation needs to be increased.
Higher olefin content in the feed will result in higher exothermicity across the
catalyst bed and coke deposits on the catalyst will increase. It is desired to
control the olefin content to limit the exothermicity. If the feed stays too long
into the storage, the dissolved oxygen content in the feed increases and
thereby increased risk of gum formation leading to the fouling of the
exchanger. Anti-polymerization inhibitor thus must be used.
4.5
NHTU- 04- 03
14R1
The different kinds of Reactions that occur in hydrotreating are:
Hydro refining reactions
Hydrogenation reactions
5.1.1
HYDROREFINING REACTIONS:
5.1.1.1 DESULFURIZATION
Mercaptides, sulfides and disulfides easily react, leading to the
corresponding saturated or aromatic compounds:
R-SH + H2
RH + H2S
R-S-R' + 2H2
RH + R'H + H2S
R-S-S-R' + 3H2
RH + R'H + 2H2S
+ 4H2
C4 H10 + H2S
S
Thiophene
NHTU- 05- 01
5.1.1.2 DE-NITRIFICATION:
Nitrogen compounds inhibit considerably the acidic function of the
reforming catalyst. They are eliminated by production of ammonia. The
nitrogen compounds of SR naphtha are methylpyrol and quinoline.
HC
CH
HC
4H2
C5H12 + NH3
C-CH3
N
Methyl pyrrol
n-Pentane
HC CH
HC
CH
CH
HC
CH
+ 5H2
HC
Ammonia
CH
+ C3H8 +
HC
NH3
CH
HC N CH
CH
Quinoline
Benzene
Propane
5.1.1.3 HYDRO-DEOXYGENATION:
Oxygen or oxygen compounds modify the acidic function of the reforming
catalyst. They are eliminated by production of water. The oxygen
compounds of straight-run are peroxides and phenols.
Oxygen is almost completely transformed into water. It is then necessary
to adjust the conditions of the stripper column so as to limit to 4-PPM wt
water content of the treated naphtha product.
HC
HC
CH
C-OH
HC
CH
+ H2
HC
CH
HC
Phenol
+ H2O
HC
CH
CH
Benzene
NHTU- 05- 02
PART-B
5.1.2
HYDROGENATION:
1)
2)
5.1.3
Cn H2n+2
(highly exothermic)
5.2
14R2
The VB naphtha contains the following unsaturated components:
Di-olefins
Olefins
Aromatics
Several chemical reactions can take place during the diolefin
hydrogenation. The most important reactions are as below:
NHTU- 05- 03
PART-B
into
corresponding
olefins
with
some
A) Cyclodiolefins
A typical example is cyclohexadiene, which is hydrogenated into
cyclohexene with no further hydrogenation with the catalyst and the
operating conditions.
+ H2
Cyclohexadiene
Cyclohexene
B) Normal or Iso-Diolefins:
Normal Di-olefins:
Their hydrogenation produces several isomers, for example:
CH3-CH2-CH2-CH2-CH2-CH=CH2
CH3-CH=CH-CH2-CH2-CH=CH2 + H2
1-Heptene
1,2-Heptadiene
CH3-CH=CH-CH2-CH2-CH2-CH3
2-Heptene (cis & trans)
5.2.2
ISODIOLEFINS
Isodiolefins hydrogenation produces also various isomers. Moreover, double
bond migration can also occur within the new generated isomer.
Diolefins are very unstable compounds, which polymerize easily into gums.
Therefore conversion of diolefins to olefins, improves the product quality.
These reactions are highly exothermic. The differemce between the diene
value (DV) or the Maleic anhydride value (MAV) of the feed and the diene
value or MAV of the product measures the extent of these reactions and this
could be related to the hydrogen consumption. Refer, to section Operation
of the unit.
NHTU- 05- 04
PART-B
Isomerisation of Olefins
CH2=CH-CH2-CH2-CH2-CH3
1- Hexene
CH3-CH=CH-CH2-CH2-CH3
2- Hexene
OLEFIN HYDROGENATION:
The Hydrogenation of diolefins is faster than olefin hydrogenation. This
reaction is also exothermic.
The difference between the feed bromine number (BrN) and the product
bromine number measures the conversion rate of this reaction and is related
to the hydrogen consumption.
Thermal and catalystic polymerization of unstable compounds:
These reactions are undesirable because polymer deposits reduce both the
catalyst activity and cycle duration.
The catalytic polymersiation of olefins and even diolefins remains negligible
in the range of the selected operating condition when the appropriate
catalyst is used.
Thermodynamic and kinetic analysis:
The hydrogenation of unsaturated hydrocarbons is characterized by an
important heat release (exothermic reaction) and a reduction of volume.
Consequently from a thermodynamic viewpoint, these reactions are favored
by low temeperature and high pressure.
From a kinetic view point with a proper catalyst, and temperature in the
range of 160 deg C, the rate of diolefin hydrogenation is high enough for
almost complete hydrogenation.
5.2.4
Sulfur reaction:
In cracked naphtha the principal sulfur compounds include
mercaptants(RSH), aliphatic sulfides (RSR), aliphatic disulfide and
thiophenes. In the presence of selective hydrogenation catalyst, light
mercaptants and light sulfides are converted to heavier sulfur species. In
addition, H2S is also converted to heavier sulfur compounds. The
combination of selective hydrogenation and VBN fractionation allows the
production of a gasoline stream with very low sulfur content provided that
thiophene carry over in the system is controlled. The sulfur shift reactions
are faster reactions than the diolefin hydrogenation reactions.
NHTU- 05- 05
PART-B
RSR
RH + H2S
Step 2
H2S + (R- C5 TO C7 OLEFIN)
RSH
+H2
C2H5 S-CH3
H2S + (R-C5 TO C7 OLEFIN)
RSH
RSH
NHTU- 05- 06
PROCATALYSE
Presentation
Particle size
3 mm (dia. )
Bulk density
Pore Volume
0.45 cm3/g
Surface area
140 m2/g
Quantity
1.9 m3
Packing
The use of the LD 145 as the top of the catalytic bed achieves a total
selective hydrogenation of the minor proportion of diolefins (coming with
cracked material). This leads to longer cycles at lower operating pr.
PROCATALYSE
Presentation
Particle size
Loading density
Pore volume
0.42 cm3/g
1.2 MPa
Composition (wt%)
Loss on ignition
Quantity
19.1 m3
Packing :
HR 348 catalyst is for the hydro refining of naphthas, kerosenes, gas oils,
and either straight run or from thermal treatments.
The specific property of this catalyst is a very high activity in de-nitrification
and aromatic hydrogenation, besides desulfurization.
NHTU- 06- 01
Void fraction
0.3
6 mm diameter
0.55m3
20 mm diameter
1.45m3
AXENS PROCATALYSE
HR 945
Alumina content impregnated with
Nickel and Molybdenum oxides
2 to 4 mm
0.77 +-0.05 g/cm3
22m3 for HR945
Particle Size
Loading Density
Quantity Volume
0.3
Quantity in m3
6 mm diameter (1/4)
0.4 m3
20 mm diameter (3/4)
0.46 m3
NHTU- 06- 02
6.2
CHEMICALS:
NHTU- 06- 03
7.0
CATALYST CHARACTERISTICS:
Cobalt-molybdenum and Nickel molybdenum catalysts are used to
promote the hydrodesulfurization and hydrodenitrification reaction.
Active form of the catalyst are their sulphided state. Metals are
deposited on high purity, high area alumina. The active sulphide form is
maintained, in normal operation, by the H 2S partial pressure in the
reactor. Before start-up a special procedure allows to transform the
metal oxides into sulfides.
The choice of the catalyst and the associated operating conditions are
essential for the performance of any catalytic process.
Catalyst to be used in VB naphtha hydrogenation must meet the
following criteria:
A hydrogenation activity to fully hydrogenate the diolefins and other gum
precursor compounds at the lowest possible temperature
A low polymerization activity to reduce gum formation to a minimum and
to allow long enough operating cycles even with highly polymerizable
feeds. The HR 945 is a mix of Nickel and Molybdenum oxides on a
special support
7.1
CATALYST CONTAMINANTS
Catalyst contaminants are classified in three categories:
NHTU- 07- 01
7.1.2
TEMPORARY POISONS:
Temporary poisons are contaminants, which are so strongly adsorbed
that they accumulate over the active surface. Specific treatment
applicable either in-situ or ex-situ is needed to remove the temporary
poisons and restore activity. Free water is a typical temporary poison and
hot hydrogen stripping enables recovery of the catalyst activity.
7.1.3
PERMANENT POISONS:
Are those which induce a loss of activity which can not be recovered,
even with regeneration and catalyst must be replaced. The most
common permanent poisons are metals like silicon, lead, sodium etc .
i)
Arsenic :
ii)
Silicon
iii)
Lead
iv)
Sodium: the catalyst can fix up to 0.6 wt% and the activity is not
recovered by the regeneration.
NHTU- 07- 02
8.0
UTILITY REQUIREMENTS
UTILITY FOR NORMAL OPERATION IN SOR
8.1
127.0
14P2
11.0
14P3
6.0
14P4
70.0
14P5
2.5
AIR COOLERS
14AC1
39.0
14AC2
19.0
COMPRESSORS
8.2
14K1
361.0
14K2
53.0
TOTAL (KWh/h)
688.5
3.643
14F2
3.918
NHTU- 08- 01
8.3
8.4
COOLING WATER
Inlet temperature
35 deg C
45 deg C
189 m3/Hr
16 m3/Hr
105 m3/Hr
14 m3/Hr
TOTAL (m3/Hr)
324
STEAM
8.5
0.4 m3/h
8.6
Nitrogen
Start-up:
112 m3
Hydrogen
Start-up:
8.8
2240 m3
3920 m3
Steam
MP steam:
Catalyst regeneration:
Decoking operations:
14 T/Hr
32 T/Hr (16 T/Hr for each
heater)
NHTU- 08- 02
PART-B
9.0
PRELIMINARY OPERATIONS:
9.1
9.1.1
GENERAL:
The initial leak test can be performed using air. The test pressure will be
the air system pressure or the unit (or section of unit) design pressure,
which ever is lower.
Unit is isolated with blinds from adjacent sections containing hydrocarbons
(liquid or gaseous) and from utilities systems where pressure is lower than
air pressure.
The pressure change must be checked on several manometers. Leaks
must be carefully located and tightened. Their location must be recorded.
The leak test is satisfactory when the pressure decrease is lower than 0.2
Kg/cm2 / hour during 4 hours.
For the purpose of leak tests the unit will be divided into sections of approx.
the same design pressure. Air will be injected at different locations.
For the reaction section, the tests can be followed by a vacuum test at
maximum vacuum. The pressure increase must be lower than 25 mm
Hg/hour.
The unit is divided into following sections for the purpose of leak testing.
9.1.2
FEED SECTION :
Naphtha surge drum (14-V-1) with its connected piping. The section is
isolated at pressurisation line (B/L), at water drain lines, at feed pumps
suction and discharge, at feed FCV's, at start-up lines to stripper feed, at
polymerization inhibitor line.
The tightness test shall be performed with air at the operating pressure of
2.0 Kg/cm2g.
NHTU- 09- 01
9.1.3
REACTION SECTIONS :
Reactor heater (14-F-1), Reactor (14-R-1), Reactor (14-R-2), Feed / effluent
exchanger (14-E-1 A to F), Air cooler (14-AC-1A/B/C), Trim cooler(14-E-2),
Separator drum (14-V-2), Recycle compressor KO drum(14-V-3).
The section is isolated at feed pumps discharge, at separator purge gas
lines to fuel gas, flare and ejector, at separator liquid feed to stripper, at
separator water drain, at recycle compressor KO drum drain line, at recycle
compressor suction and discharge valves, at H 2 rich gas makeup gas line,
at regeneration inlet and outlet valves or blinds, at N 2 connection to
process.
STRIPPER SECTION:
Stripper feed / bottom exchanger, Stripper feed preheat exchanger (14-E7), stripper column, stripper heater reboiler, overhead air cooler, overhead
trim cooler, Reflux drum.
The section is isolated at stripper feed line (FCV), at start-up line, at MP
steam, at pressurisation lines, at corrosion inhibitor pumps discharge
valves, at reflux pumps suction and discharge valves, at reboiler pumps
suction and discharge valves, at separator purge gas lines to flare and fuel
gas, at separator water LCV, at stripper bottom line FCV.
The tightness test can be performed with air at 7 Kg/cm 2g or with N2 if the
test is to be performed at higher pressure (12 kg/cm 2g).
NOTE: Even though pumps & compressors shall be isolated during
tightness test ,they must be submitted to the test pressure prior to the test
period.
NHTU- 09- 02
9.2
DRYING :
9.2.1
GENERAL :
Reaction section must be dried out prior to catalyst loading to avoid
damaging the catalyst with water. Free water shall be removed from the
column to avoid damaging the trays during heating period.
FOR GENERAL PROCEDURE ON HEATERS REFRACTORY DRY OUT,
PLEASE REFER GENERAL DRYING PROCEDURE IN LICENSOR
MANUAL PAGE 52, AND FOR SPECIFIC GUIDELINES, REFER
MANUFACTURER'S INSTRUCTION.
9.2.2
9.2.3
9.2.4
NHTU- 09- 03
9.3
CATALYST LOADING :
9.3.1
PRELIMINARY :
If nitrogen has been used for initial leak test, the reactor shall be blown with
air before loading. Breathable atmosphere into the reactor shall be checked
using a portable oxygen analyzer.
Check that the reactor is properly isolated (blinds in closed position)
Open the top manhole. Aerate and check that the atmosphere inside the
reactor is suitable for entering
Remove the reactor inlet elbow. Check the good conditions of the mesh on
the outlet collector. Check again the catalyst dumping nozzle is equipped
with its closure device, that the K wool plug has been installed and that the
internal pipe is well fixed
Make sure that the catalyst and alumina drums are gathered in a sheltered
place close to the reactor
Alumina balls and catalyst levels are marked-up in the reactor
Catalyst baskets with their wood covers and their retaining rings and inlet
distributor are made available in the vicinity of the reactor
Check that all the internal parts to be installed during loading are available.
Check their conformity to the drawings and numbering done during
preliminary assembling.
All the reactor internals are made of parts, which can be dismantled in order
to allow passage through the manhole.
Check the quality of the alumina balls. If they are broken, they must be
sorted and fines must be removed
Ensure that all necessary safety and personnel protection equipment is
available as well as means of communication.
Before loading the catalyst drums must be stored in a safe place and
protected from rain.
A final check on cleanliness of the inside of the reactor is made and
cleaning is performed if necessary.
NHTU- 09- 04
9.3.2
NHTU- 09- 05
PART-B
o Remove from the top manhole platform excess of 6mm alumina balls
o Adjust the length of the loading sleeve to allow a catalyst free fall
equal to 1 meter
o At ground level fill-up one of the mobile hoppers with catalyst and lift it
above the fixed hopper
o Load the mobile hopper catalyst into the reactor, modulating the
catalyst flow with the mobile hopper slide valve. One man, provided
with an air mask and a walky-talky will monitor the sleeve to equally
level the catalyst. During this operation the second mobile hopper is
filled-up with catalyst
o When the first mobile hopper is empty it is sent to the ground level for
refilling then the second one, full of catalyst is installed above the
fixed hopper and the loading into the reactor is resumed
o When the loading of HR348 catalyst (2 nd bed) is complete, then send
one rigger to equalize the level
o Load a quantity of LD145 equivalent to the level lower than 400mm
below the final catalyst level. Adjust the loading sleeve to allow
always a catalyst free fall lower than 1 meter
o The baskets covered with wooden covers are then carefully installed
and secured with rings by stainless steel wire. After that the catalyst is
loaded manually to reach the normal level
o The 20mm alumina balls loading can now take place. The balls will be
loaded with a bucket. The rigger in the reactor will receive the buckets
full of balls and spray the balls above the catalyst bed, leveling and
loading in the same time until the upper level has been reached.
Note: All the above mentioned operations must be witnessed by an IFP
representative.
NHTU- 09- 06
PART-B
9.3.3
NHTU- 09- 07
9.3.4
NHTU- 09- 08
10.0
FIRST START UP
The sequence of the first start-up is as follows:
Purging and oxygen removal and gas back-up
(O2 content is reduced to < 0.2% vol. for all the sections)
Receiving oil in feed section and establishing circulation in stripper
(reaction section bypassed) with total reflux.
Pressurization of the reaction section with H2-Tightness test.
Reaction section oil-in with desulfurized naphtha.
Catalyst sulfiding.
10.1
block
NHTU- 10- 01
10.1.2
REACTION SECTION:
The section is isolated from the rest of the unit by closing B/V's at:
Feed control valves,
H2 make-up,
Separator liquid HC,
Seperator gas to FG
Separator liquid water,
Separator gas to flare,
Water make-up discharge.
The recycle compressor is isolated (air will be removed only by
nitrogen sweeping).
A.
B.
C.
D.
Break the vacuum with N2 and increase the pressure upto 0.3
kg/cm2 g.
E.
STRIPPER SECTION:
Open vent on top of the column and on top of the reflux drum. Through
the steam out connection inject very slowly LP steam at the bottom of the
column. Also inject LP steam at the bottom of the reflux drum through a
hose connected to a drain point.
NHTU- 10- 02
10.2
NHTU- 10- 03
o Light up pilots and one or two burners of the reboiler furnace in order
to increase the stripper bottom temperature at a rate of 30deg C/Hr
o Let the pressure increase in the column, and follow the temperature
increase until a level appears in the reflux drum. If necessary, makeup some desulfurised naptha/SR naptha, to maintain the bottom level
between 60 and 80%.
o When the reflux drum level reaches 50%, start the reflux pump and
start the reflux to the column
o Compensate for the cooiling effect of the reflux by increasing the firing
in the reboiler heater, stabilize the unit and set the temperature
control in auto mode
o Keep the column in these conditions until hydrogen rich gas is
available, then through the pressurization line increase slowly the
pressure upto the design value and increase top and bottom
temperatures as close as possible to the design values.
10.3
NHTU- 10- 04
10.4
run
and
desulfurized
naphtha
available
as
per
specification.
o Oil circulation, by-passing the reaction section, is in service and the
reformer is in early operation (low severity operation at reduced
capacity).
o Start recycle compressor 14-K-1A/B at 100% capacity.
o Start to introduce desulfurized naphtha in the reaction section at 60%
of the design value.
o When level reaches 50% in the separator drum 14-V-2, start 14-P2A/B to feed the stripper from separator drum.
o Stabilize the stripper conditions. Never forget that during this
operation and during the sulfiding operation the pretreater product
feeds the CCR reformer.
o Prepare a solution of 10wt.% corrosion inhibitor in desulfurized
naphtha. Then start the pump 14-P-7A/B and inject this solution to
the stripper overhead line.
The unit is now ready for catalyst sulfiding.
10.5
CATALYST SULFIDING
10.5.1
INTRODUCTION:
It is for transforming the metals from their oxide form (new catalyst) to
sulfide form (active form). It is required after catalyst replacement or after
catalyst regeneration. The safest and easiest way for sulfiding the
catalyst is the use of dimethyl disulfide (DMDS), which is thermally
cracked to H2S and methane according to the following reaction:
2CH4 + 2H2S
NHTU- 10- 05
The H2S combines with the metal oxides to form sulfides according to
the following reactions:
3 NiO + H2 + 2H2S
Ni3S2 + 3H2O
MoO3 + H2 + 2H2S
MoS2 + 3H2O
Light-up the reaction heater pilots, then one burner. Increase the
temperature at reactor inlet upto 180oC at a rate of 30oC/hr.
At 180oC, start to inject DMDS at a rate to give 0.5wt.% sulfur in
the feed and keep increasing the temperature at reactor inlet up to
220oC.
NHTU- 10- 06
NOTES:
1.
2.
3.
4.
During the step at 220oC the total sulfur in the feed shall be
analyzed one time to check if the DMDS injection rate is correct.
5. During the sulfiding operation the delta T of the reactor should be
limited to few deg.C. If the delta T exceeds 30 oC reduce the
DMDS injection.
NHTU- 10- 07
6.
10.5.4
NHTU- 10- 08
PART-B
shell
side, line
P-014-014,
14F1
hydrotreater reactor feed heater, lines P-014-015, P-014-178, P014-167, 14R2 diene saturator, lines P-014-170, P-014-016,
exchangers 14E1 A/B/C/D/E/F, tube side, lines P-014-171, P-014017, exchanger 14E1G tube side, lines P-014-179, exchanger
14E7 tube side, lines P-014-180, and then to the 14V2
hydrotreater seperator drum via the 14AC1 reactor effluent air
cooler and 14E2 reactor effluent trim cooler.
The reactor 14R1 is isolated as follows:
-Blind on the inlet line P-014-015 and on the outlet line P-014-016
Inert raw naptha at 60% of operating flow circulates through the
reaction section bypass to the stripper
Crack open the feed control valve to 10% of design rate and start
feeding raw naptha to the reactor. The hydrogen gas is mixed with
naptha at the inlet of the exchanger 14E1F, shell side
As the level increases in the 14V2 hydrotreater seperator drum,
commission level controller, to feed naptha to the stripper. Pinch
back on the reaction section by-pass.
Continue increasing the naptha to the reactor in 10% increment
and cut back on the strat-up reaction section bypass until closed.
Stabilise the unit at 60% capacity while circulating through the
reactor and stripper.
Catalyst Sulfiding:
Light the reactor feed heater and increase the reactor inlet
temperature up to 180 deg C at a rate of 20 deg C/Hr
Start the sulfiding agent injection at 180 deg C. Adjust the
injection flow rate. A moderator temperature rise should be
noticed in the reactor.
NHTU- 10- 09
PART-B
NHTU- 10- 10
PART-B
NHTU- 10- 11
PART-B
10.6
Pressurize 14V1 hydrotreater feed surge drum using fuel gas and put
PIC-1401 pressure control loop on auto mode at 1.5 Kg/cm2g
NHTU- 10- 12
PART-B
Light the burners of the HDT reactor feed heater, 14F1 and
commission all control loops on reactors including:
NHTU- 10- 13
PART-B
11.0
NORMAL SHUTDOWN:
Shut-down planned long time in advance or due to unexpected event
which is not of emergency nature leads to normal shut down.
11.1
(ii)
(iii)
NHTU- 11- 01
PART-B
(v)
(vi)
Set the stripper column 14-C-1 at total reflux conditions. Stop the
corrosion inhibitor injection pump 14-P-7 A/B.
The unit is now in the following stand-by conditions:
i. Recycle compressor in service at 100% capacity.
ii. Reactor inlet temperatures are at 180oC.
iii. Minimal make-up to maintain the section pressure (purge gas
closed).
iv. Stripper column at total reflux conditions.
11.2
(ii)
(iii)
(iv)
(v)
NHTU- 11- 02
PART-B
(vii)
Cool down the stripper column 14C-1, Stop reflux pumps 14-P-3
A/B the reboiler heater 14F-2 and circulation pumps 14-P-4A/B.
Unless maintenance is to be carried out, the column is kept with
its hydrocarbon level under 2kg/cm 2 of fuel gas or nitrogen.
(viii)
NHTU- 11- 03
12.0
EMERGENCY PROCEDURES:
12.1
INTRODUCTION :
The objective which will govern the steps to be taken in such a situation
are :
To protect the operating personnel.
To protect the catalyst.
To protect the equipments.
NHTU- 12- 01
12.2
GENERAL :
The general course of actions to be followed in an emergency situation is
summarized hereunder:
Cut-off fire to reaction heater 14-F-1
In the same time shut off the liquid feed
Route the products to feed tank / slop
Isolate by block valves, the control valves at the bottom of the
vessels
Keep the stripper column in total reflux
Note :
12.3
1.
2.
LOSS OF FEED:
The occurrence can be due to either a failure of the upstream unit or to
the failure of the two naphtha feed charge pumps :
Decrease immediately the reactor inlet temperature of 14R1
down to 180oC at a rate of 50 oC per hour, keeping the recycle
compressor at full capacity.
Close the separator purge gas FIC-1406 but keep the
hydrogen rich gas make-up in service to maintain the reaction
pressure at design value.
Stop water injection and circulation pump 14-P-5 A/B,
polymerization inhibitor injection pump 14-P-8A.
Isolate separator bottom block valves of FIC-1407 when the
level LIC-1405 reaches 50%.
NHTU- 12- 02
PART-B
12.4
NHTU- 12- 03
PART-B
12.5
Shut down feed charge pumps 14-P-1A/B and close FCV-1402 if makeup gas flow is not restored till the system pressure reduces less than
80% operating pressure. Stop the polymerization inhibitor injection
pump 14-P-8 A/B.
Close the separator bottom, block valves on FIC-1407 when the level
reaches 50% on LIC-1405.
Same for the stripper bottom products, set the column at total reflux
conditions. Stop the corrosion inhibitor injection pump 14-P-7 A/B
12.6
NHTU-12- 04
12.7
UTILITIES FAILURE:
12.7.1
FUEL GAS
Reaction and columns heaters 14F-1 / 14F-2 will shut down and the
temperatures will decrease in reaction and stripper section:
12.7.2
Shut down the feed charge and follow the procedure described
12.3 above
COOLING WATER
For this unit, essentially the reaction and column trim cooler will be
affected and the separator and reflux drums temperature will increase to
about 50-60oC. But upstream and down stream unit will be shut down
which will lead in our case to feed and hydrogen rich gas failure:
Shut down the feed charge pumps 14-P-1A/B and follow the procedure
described at 12.3 above.
12.7.3
POWER SUPPLY:
This failure will immediately stop the recycle compressor 14-K-1A/B, the
feed pumps 14-P-1A/B water injection and circulation pumps 14-P-5A/B,
the inhibitors pumps 14-P-7A/B, the stripper reboiler and reflux pumps
14-P-4A/B / 14-P-3A/B reaction and columns air coolers fans and
interrupt the H2 rich make-up gas.
This emergency shutdown cumulates the inconvenience of loss of
compressor plus loss of hydrogen rich make-up gas.
NHTU- 12- 05
The reflux pump of the column in order to bring under control the
overhead temperature and pressure
This shutdown can be rather long as the upstream and downstream units
shall be restarted and stabilized.
The initial start-up procedure, without catalyst sulphiding shall apply.
12.7.4
Close separator purge gas and H2 rich make-up gas block valves.
NHTU- 12- 06
12.8
Shut the naptha feed pump, close the stripper feed and block-in
Isolate the unit. Block the feed, product and make-up hydrogen gas
lines
Isolate the reaction section from the feed and stripper sections
Depending on the severity of the leak and its location, shutdown the
hydrogen recycle compressor immediately, block-in and depressurise
the reaction section to flare.
As the depressurized hot vessels cool down, watch the pressure and
inject nitrogen as necessary to avoid vacuum
Nitrogen purging and steam out should be considered for the stripper
circuits
If a fire has occurred, then all the steps above will be taken while the fire
fighting is taking place. Note, however, that the de-pressurising step may
be needed sooner than described above depending upon the gravity of
the situation. If a small leak occurs in the heater, the hydrocarbons will
ignite immediately in this confined area. Open the snuffing steam and the
damper and maximize the draft to keep the fire under control within the
heater box.
In the case of an extreme emergency, the reaction section can be
depressurized to the flare using the quick de-pressurisation valve. This is
typically part of the I-1404 system, which is activated by push button in
the control room (HS-1404).
NHTU- 12- 07
Details of action
Inform S/I and alert FO about emergency
Inform Unit Incharge and RSM about disturbance
Inform MSQ, OM&S regarding change in Routing
System taken out from APC Mode
Action By
PO
SI & PO
SI & PO
PO
FO & PO
15FC01\02 to be isolated
FO & PO
FO & PO
13.0
SI & PO
13.1
NHTU- 13- 01
13.2
13.3
NHTU- 13- 02
14.0
TROUBLESHOOTING
The main causes of concern related to process besides failures of
equipment or utilities (which have been covered under emergency
procedures) for the Naphtha Hydrotreater are:
High pressure drop in the reactors
Feed/.effluent or feed/bottom exchanger leaks
Chemical/Hydrogen consumption increase
Presence of water or H2S in the Reformer feed
Presence of total Sulfur in the Reformer feed
14.1
14.2
NHTU- 14- 01
14.3
14.4
14.5
NHTU- 14- 02
NHTU- 14- 03
15.0
SAFETY DEVICES:
15.1
EMERGENCY SEQUENCES:
High High pressure in line P-014-009 will trip the naptha feed pumps and
feeds to NHTU will be cut off.
High level in feed surge drum UV1415 will cut the feeds to naptha
hydrotreating unit at the surge drum inlet (14V1)
NHTU- 15- 01
HAND SWITCHES:
Dedicated hand switches are provided for following actions:
Shut off of the feed heater main F.G & pilot HS-1421.
Shut off the stripper re-boiler main F.G & pilot HS-1431.
NHTU- 15- 02
15.2
ALARM LIST:
SN
O
ITEM
SIGNAL
FROM
SERVICE
ALARM
VALUE
FAL 1402
FIC 1402
NAPTHA FEED
25 T/Hr
FAL 1407
FIC 1407
14P2A/B OUTLET
25 T/Hr
FAL 1411
FI 1411
RECYCLE GAS
1500
Kg/Hr
FALL 1411
FSLL 1411
14 K1 A/B OUTLET
767.7
Kg/Hr
FAL 1435
FI 1435
14K2A/B DISCHARGE
100
Kg/Hr
FALL 1416
FSLL 1416
STRIPPER REBOILER
FLOW
15 m3/Hr
FAL 1416
FIC 1418
14 F 2 INLET
15 m3/Hr
FALL 1419
FSLL 1419
14 F 2 INLET
14 m3/Hr
LAH 1401
LT/LTC 1401
14 V 1
45%
10
LAHH 1401
LT 1418
14 V 1
40%
LEVEL
PRESSURE
11
PAH 1450
PT 1450
NAPTHA FEED
30.5
Kg/cm2
12
PAHH 1451
PT 1451
NAPTHA FEED
31.5
Kg/cm2
TEMPERATURE
13
TAH 1443
TIC 1443
160 oC
14
TAL 1443
TIC 1443
210 oC
15
TAH 1445
TT 1445
130 oC
NHTU- 15- 03
TAG NAME
DESCRIPTION
SOFT SWITCHES
1.
HS1401 (S.W.)
2.
HS1404 (S.W)
3.
HS1405 (S.W.)
HARDWARE SWITCHES
4.
SSPOS2 (H.W.)
5.
HS1421 (H.W.)
6.
HS1431 (H.W.)
7.
SSPOS1(H.W.)
8.
HS 1441
9.
HS 1442
BY-PASS SWITCHES
10.
PSLL1442 (H.W.)
11.
12.
PB4CPSH3102
PB-4(C)
13.
PB-24
FSLL1404 (14FD04)
15.
14FD11
16.
14-PD22
17.
14LD13
18.
14FD16
19.
14FD19 A, B, C, D
20.
14PD42
21.
PSH 3101
22.
PSH 3102
NHTU- 15- 04
TAG NAME
DESCRIPTION
PD1002 A/B
PSL1001 A/B
LSHH 1409
PSLL 1004 A/B
TSHH 1002 A/B
TSHH 1004 A/B
PSLL 1006
TAG NAME
DESCRIPTION
1.
HS1406 (S.W.)
2.
PSLL1474A
3.
PSLL1474B
4.
PSLL2007
5.
TSHH1477A
6.
TSHH1477B
7.
PAHH1476A
8.
PAHH1476B
9.
PSLL2002A
10.
PSLL2002B
11.
PSL2001A
12.
PSL2001B
NHTU- 15- 05
Over a period of time, if the unit has not experienced frequent operating
problems, the catalyst will slowly deactivate as carbon or coke builds up. It
will become necessary to remove this carbon to restore the activity. There
are two alternative ways to regenerate.
Exsitu:
location.
Insitu:
16.1
IN-SITU REGENERATION:
Regeneration refers to coke burning-off by injecting a controlled amount of air
into a flow of steam through the catalytic bed.
Shut down the unit as for a long duration normal shutdown.
Line-up the regeneration circuit and isolate the reactor from the reaction
section by swinging the blinds. Purge the air circuit. Heat-up the steam
header to avoid water going on the catalyst. Air injection shall be lined to the
heater inlet.
16.1.1
16.1.2
16.1.3
16.1.4
NHTU- 16- 01
Slowly increase the air flow rate to achieve 3% volume oxygen content,
keeping the temperature below 60 deg C
When the reactor temperature rise drops below 20 deg c begin to slowly
increase the reactor inlet temperature to 460 deg C
The coke burning is monitored by the thermocouples located inside the
reactor and by analyses at reactor outlet (CO 2 content).
Oxygen content is gradually increased up to 8% vol. during 4 hours, the
reactor temperature being set to 490oC min (500oC max.).
16.1.5
16.1.6
NHTU- 16- 02
STRIPPING
N2
STEAM
PRE-OXY
BURNING
STEAM
STEAM
+AIR
+AIR
O2 = 0.3
VOL%
O2 UPTO 3
VOL%
3 T/HR
PER M2
OF
SECTION
AREA
3 T/HR
PER M2
OF
SECTION
AREA
18.2
250 DEG C
GAS
COMPONEN
TS
SPECIFICAT
IONS
CCRU OPERATING MANUAL
FLOW RATE
FOR EACH
REACTOR
(KG/H)
GAS
MOL.WT
3 T/HR
200
PART-B
PER M2
NM3/HR
OF
PER NM3
SECTION
OF CAT
AREA
28
18
UPTO 200
DEG C
UPTO 250
DEG C
COOLING 1
COOLING 2
STEAM
N2
NHTU- 16- 03
3 T/HR
PER M2
OF
SECTION
AREA
200
NM3/HR
PER NM3
OF CAT
19.6
18
28
FROM 400
TO 460
DEG C
DOWN TO
250 DEG C
50 DEG C
TEMP
DEGC
REACTOR
CATALYST
BULK
REACTOR
OUTLET
PRESSURE
(BARG)
EFFLUENTS
DIRECTED
FLARE
DECOKIN
G DRUM
DECOKIN
G DRUM
DECOKIN
G DRUM
DECOKIN
G DRUM
FLARE
8 TO 10
8 TO 10
8 TO 10
8 TO 10
TO
TIME IN
HRS AT
PROPER
TEMP
ESTIMATED
DURATION
17.0
2 DAYS
CATALYSTS UNLOADING:
Catalysts may be unloaded for various reasons:
The catalyst is used (not regenerable).
The catalyst is unloaded for an ex-situ regeneration.
The catalyst is still active but must be dumped for the
reactor.
17.1
inspection of
Prior to unloading, the catalyst must undergo hot H2 stripping and cooling
steps. When dumped, if the catalyst warms up due to ambient air oxidation, it
can be watered.
If there is no need to enter the reactors, they will be left under nitrogen
pressure. Otherwise a man equipped with a adequate breathing apparatus
must enter to clean the reactor from the remaining catalyst prior to aerating.
17.2
NHTU- 17- 01
PART-B
Equipment No.
14AC1A
14AC1B
14AC1C
14 AC 2
14 C 1
14 E 1A/B
Description
REACTOR EFF. AC (SOUTH ELEMENT)
REACTOR EFF. AC (MIDDLE ELEMENT)
REACTOR EFF. AC (NORTH ELEMENT)
STRIPPER AIR CONDENSER
STRIPPER
FEED/ EFF. EXCHANGER (A-TOP, B-BOTTOM)
7
8
9
10
14 E 1C/D
14 E 1E/F
14 E 1G
14 E 2
11
14 E 3 A/B
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
14 E 4A
14 E 4B
14 E 5
14 E 7
14 E 8
14 F 1
14 F 2
14 G 1
14 RX 1
14 RX 2
14 V 1
14 V 2
14 V 3
14 V 4
14 V 5
14 VT 1
14 VT 2
14 VT 3
NHTU- 18 - 01
PART-B
Sr.
No.
PSV No.
14 PSV 1412 B
Location
Isolation B/V
I/L
O/L
Set
Pressure
Type
14 PSV 1411 A
ON 14-K-2B DISCHARGE
ON 14-K-2A SUCTION
32
17.23
14 PSV 1411 B
ON 14-K-2B SUCTION
17.23
14 PSV 1414
ON 14-P-7A
21.5
14 PSV 1415
ON 14-P-7B
21.5
14 PSV 1416
ON 14-V-4
16.4
BELLOW
14 PSV 1417
ON 14-C-1
16.1
BELLOW
14 PSV 1423 A
ON 14P1A/B DISCHARGE
32.0
14 PSV 1423 B
ON 14P1A/B DISCHARGE
32.0
10
14 PSV 1424 A
ON 14R1 OUTLET
22.1
11
14 PSV 1424 B
ON 14R1 OUTLET
22.1
12
14 PSV 1425 A
ON 14R2 INLET
32.0
13
14 PSV 1425 B
ON 14R2 INLET
32.0
14
14 TSV 1418
ON CWR EX-14E-2
7.0
CONV.
15
14 TSV 1419
ON CWR EX-14E-6
7.0
CONV.
16
14 TSV 1420
ON CWR EX-14E-5
7.0
CONV.
17
14 TSV 1421
ON CWR EX-14E-4B
7.0
CONV
18
14 TSV 1422
ON CWR EX-14E-4A
7.0
CONV.
19
14 PSV 1401
ON 14-V-1
3.5
BELLOW
20
14 PSV 1402
ON 14-P-8B
4.9
21
14 PSV 1403
ON 14-P-8A
4.9
22
14 PSV 1404
ON 14-P-6B
4.9
23
14 PSV 1405
ON 14-P-6A
4.9
24
14 PSV 1406
ON 14-M-1
-----
25
14 PSV 1408
ON 14-V-2
18.7
BELLOW
26
14 PSV 1409
ON 14-K-1A DISCHARGE
30.0
BELLOW
27
14 PSV 1410
ON 14-K-1B DISCHARGE
30.0
BELLOW
28
14 PSV 1412 A
ON 14 K 2A DISCHARGE
32
NHTU- 18 - 02
PART-B
1.1
Design Capacity
The normal capacity of the CCR Unit is 466,000 MT based on a stream factor of
8000 hours/year with 120% over design factor.
The normal operating flexibility of the CCR is 60% of 466,000 MT.
1.2
Feed Specification
Naphtha from Bombay high crude oil 80 1400C TBP cut (Feed I)
95/5 blend of naphtha from Arab mix (80-145 0C TBP cut) and visbroken
Naphtha (Feed II)
***
Composition:-wt%
Feed
Feed I
Feed II
PARAFFIN
iC5
0.20
0.00
nC5
0.3
0.04
iC6
3.80
4.29
nC6
4.98
5.61
C7
20.76
9.88
C9
5.88
5.55
C10+
0.89
0.27
CRU- 01 - 01
PART-C
NAPHTHENE
N5
0.26
0.24
N6
7.97
8.91
N7
13.33
13.07
N8
3.81
7.78
N9
2.39
2.55
N10
0.00
0.00
A6
6.87
8.14
A7
7.85
12.38
AROMATIC
A8
4.21
11.39
A9
0.32
0.07
A10
0.00
0.00
TOTAL
100.00
100.00
CRU- 01 - 02
PART-C
1.2.1 Distillation
B.H.
A.M.
VBN
TBP Cut 0C
60-145
80-145
Sp. Gr 15 0C
TBP distillation
0.7703
0.7327
B.H.
A.M.
VBN
Deg. C
Deg. C
Deg. C
IBP
56
89
39.5
5%
63
90
0.7057
10%
70
92
66
30%
90
101
78
50%
106
119
100
70%
119.5
129
120
90%
139.5
144.5
141
95%
140.5
146
FBP
148
154
167
B.H.
A.M.
VBN
35.47
70.31
35.7
32.55
17.99
15.1
31.98
11.70
15.4
33.8
PONA wt %
CRU- 01 - 03
PART-C
1.3
PRODUCT SPECIFICATIONS
1.3.1 C5+ cut:
This product is taken as stabilizer bottom and sent to storage.
FEED
CASE I
CASE II
(SOL)
(EOL)
(SOL)
(EOL)
63486
62487
65453
64450
78.9
77.6
80.3
79.1
Sp gr at 15oC
.805
.805
.815
.815
RVP
<0.4
<0.4
<0.4
<0.4
RON
98
98
98
98
CASE I
CASE II
Vol%
(SOL)
(EOL)
(SOL)
(EOL)
H2
92.3
89.5
93.7
90.3
C1
2.2
3.2
2.0
3.2
C2
2.5
3.5
1.9
3.1
C3
1.6
2.2
1.3
1.9
C4
0.8
1.1
0.6
0.9
C5+
0.6
0.5
0.5
0.6
TOTAL
100
100
100
100
M.WT
4.6
5.4
4.1
5.1
3802
4145
FLOW RATE(Kg/Hr)
5190
5547
CRU- 01 - 04
PART-C
CASE I
CASE II
Vol%
(SOL)
(EOL)
(SOL)
(EOL)
H2
45.7
50.0
23.9
33.3
C1
12.5
16.5
6.8
14.0
C2
25.7
21.0
32.9
31.5
C3
11.8
8.8
30.9
16.0
C4
3.8
2.6
3.2
3.6
C5+
1.3
1.1
2.3
1.6
TOTAL
100
100
100
100
M.WT
18.7
16.3
28.7
22.9
57
44
160
90
FLOW RATE(Kg/Hr)
CASE I
CASE II
Vol%
(SOL)
(EOL)
(SOL)
(EOL)
C2
8.7
8.9
6.6
8.6
C3
45.5
40.2
67.2
48.0
C4
45.8
50.9
26.2
43.4
C5+
TOTAL
100
100
100
100
1092
1747
458
1190
FLOW RATE(Kg/Hr)
CRU- 01 - 05
PART-C
1.4
Utilities
1.4.1 Steam
Pressure / Temp
(Kg/cm2)
Cons/Gen
HP Steam (T/Hr)
65
420
25.3
MP Steam (T/Hr)
10
250
00.8/12.5
LP Steam (T/Hr)
150
03.0/25.3
1300
24
460
106/125
3.3 (consumption)
0 (Generation)
nil
15000
CRU- 01 - 06
PART-C
FEED SECTION:
Feed for the Reforming unit (94 m3/hr at 14 kg/cm2g and 110 oC) is received directly
from Hydrotreater stripper after heat exchange in 14E-3A/B. Feed is filtered in 15G-1
A/B to remove any foreign particles. Each filter is designed for flow of 106 M3/hr to
remove particles larger than 0.8 mm. Maximum allowable pressure drop across the filter
is 1.0 kg/cm2 and is indicated by PDI-1501. At the D/S of the feed filter, chloriding
agent and water injection facilities are provided. C 2Cl4 solution of 1% in reformate is
prepared in tank 15T-2 (capacity 2M3) and is dosed by pump 15P-9 A/B, (capacity 9.5
litres/hr). Dosing @ 1 ppm wt C 2Cl4 in feed is done when continuous Regeneration unit
is down.
DM water injection can be done through tank 15T-1 by 15P-8A/B. 15T-1 has a capacity
of 100 litres. Water injection is done to maintain Cl - OH equilibrium on the catalyst
when regenerator is out of service. But, water injection is generally not done, as feed
moisture content is sufficient to meet design requirements.
15FIC-01 and 15FIC-02 controls feed to unit. Two control valves are provided for better
control. Downstream of the control valves joins together and enters in feed/effluent
exchanger 15E-1. It is a shell and tube exchanger, with the shell fluid moving in a helical
pattern guided by helical baffles from top to bottom. The feed is distributed through
4280 tubes from bottom to top. There is an expansion bellow at the bottom of the tube
side to take care of the thermal expansion. The heat duty of the exchanger is 26.965
MMKcal. Because of helical motion of shell fluid and its height, it is called as HeliTower.
Along with the feed, recycle H2 stream ex 15K-1 is mixed in the 15E-1-inlet nozzle.
Recycle H2 stream (38000 NM3/hr. at a pr. of 5.8 kg/cm2g and temp. of 123 oC) has
84% H2 (C1-2%, C2-2%, C3-2%, C4-2%, C5-1.5% and C6+ of 6.5%). Combined feed
gets preheated from about 100 oC to 430 oC by the effluent from 3rd Reactor, which gets
cooled down from about 455 oC to 105 oC. Feed ex 15E1 is in total vapour phase at a
pr. of 5.0 kg/cm2g.
CRU- 02 - 01
PART-C
2.2
REACTION SECTION:
Due to the endothermic nature of the reforming reactions, the overall reforming is
achieved in stages with inter stage heater provided to raise the temperature.
2.2.1 HEATERS:
There are three Reactors (15R-1,R-2 & R-3) each provided with reaction heater
namely 15F-1, F-2 & F-3. These heaters have been included in a simple shape
common firebox and are designed by IFP of FRANCE. For 15F-2, preheating of
1st reactor effluent is provided in the common convection section so as to have
radiant heat duty close to that of 15F-1. Crossover between the convection and
radiant section of the reforming heaters is of 30" dia pipe designed for low pr.
BURNERS:
The heaters are provided with John Zink PSFFG series burners. These
burners are floor mounted, vertical upshot flat flame style burners capable
of lower emission. Staged fuel technology with central primary gun and
staged tips is used to achieve lower NOX emission. This is achieved by
putting a small percentage of fuel gas through the staged tips, which
lowers the initial flame temperature without reducing the heat released
from the burners.
2.2.3 PILOT BURNERS :
Pilot burners of self-inspiriting type are provided which requires FG
pressure of 0.35 kg/cm2g with a heat release of 20,000 Kcal/hr.
For pilot burners lighting, portable HE (high energy) igniter are provided
which works on 2000 volts. The firing tip provided is suitable for
continuous temperature of 900 oC. Draft at burners should be 12 mmwc so
as to have draft at bridge wall around 25 mmwc. The excess air to be
controlled at 10%.
CRU- 02 02
PART-C
(1) 2 No. of New pumps 15P-101A/B (one operating + one standby pumps)
installed. Existing P/F of 14P-6A/B extended to place new pumps. New electrical
connection provided for new pumps.
(2) 14T-2 Vessel, Sulphiding vessel for NHDT used for DMDS dosing.
(3) 15FC-01 LPD Converted to Sample point.
(4) Vessel which is opened to atmosphere, connected to flare header
with N2 blanketing.
(5) For proper mixing of DMDS with Reformate N2 bubbling started.
T'put , TPH
40
45
50
60
S injection, ppm
0.35
0.31
0.31
0.31
CRU- 02 01*
15P-101A/B
Deviation
Possible Cause
Consequences
Safe Guard
Flow
Less flow of
DMDS
Pump Strainer
Chock
S Content in
CRU feed will
decrease
FI provided in
dosing line with
alarm<1 L/h
No Flow of
DMDS
Solution
Back flow of
Reformer feed
may occur
NRV provided
No Flow of
CCRU Feed
Emergency
situation
DMDS pump
will continue
pumping the
solution
More flow of
DMDS
solution
Stroke
adjustment
problem
S content in
CRU feed will
increase
Low Pressure
Pump strainer
chock
Back flow of
reformer feed
may occur
NRV provided
High Pressure
Operational
Requirement
No significant
impact
PG provided
Pressur
e
CRU- 02 01*
15F-1
15F-2
15F-3
INLET TEMP.
ATTRIBUTE
DEG. C.
UNITS
425/451*
406/443*
451/482*
OUTLET TEMP.
DUTY
INLET PR.
OUTLET PR.
TUBE PASSES
LENGTH OF TUBE
EXPOSED SURFACE AREA
TUBE SIZE
DEG. C.
MMKcal /HR
KG/CM2
KG/CM2
NUMBER's
METERS
SQ. M.
520/540*
8.98
4.8
4.6
36
20
201
3"SCH 40
520/540*
8.00 / 1.90**
4.15
3.9
36/32**
20/17**
201/155**
3"SCH 40
520/540*
6.15
3.65
3.5
36
13.7
138
3"SCH 40
DESIGN PR.
BURNERS IN CENTRALROW
DUTY OF CENTRAL BURNERS
BURNERS IN SIDE ROW
DUTY OF SIDE ROW BURNERS
FLAME DIMENSION (L X W X D)
KG/CM2 ***
NUMBER's
MMKcal /HR
NUMBER's
MMKcal /HR
METERS
8
6
1.45
12
0.73
2.5X0.8X0.45
7.4
6
1.25
12
0.63
2.5X0.8X0.45
6.8
6
1
12
0.5
2.0X0.8X0.45
**
2.2.4
REACTORS:
In the reactors 15-R-1 / R-2 / R-3 the feed contacts the reforming catalyst
which is divided approximately in the ratio 15: 30: 55. In the CCR process,
the catalyst circulates continuously:
o In reactors, in the space between the external grid and the central pipe
from the top to the bottom,
o From one reactor bottom to the top of the next one,
o From the last reactor to the regeneration unit for regeneration,
o From the regeneration unit, the regenerated catalyst returns to the 1st
reactor.
CCRU OPERATING MANUAL
CRU- 02 - 03
PART-C
flows radially over a slow moving bed of bimetallic catalyst and exits through the
O/L nozzle at the bottom. The radial flow of feed is achieved by directing the
flow through external grid to catalyst bed & exit is made to central outlet
collector pipe. Gas tight baffle is provided on the outlet pipe to avoid shortcircuiting of the feed to outlet pipe at the entrance. SCALLOP were installed
inside the reactors during July 2010 s/d.
Reactors data is furnished in the following table:
REACTORS
PR (OP. / DESIGN)
TEMP (OP. / DESIGN)
I.D (SHELL), MM
I.D (GRID), MM
O.D (CENTER PIPE)
LENGTH, TL to TL
15-R-1
15-R-2
15-R-3
4.6 / 7.6
520 / 540
1900
1550
750
4925
3.9 / 6.9
520 / 540
2250
1850
750
6317
3.5 / 6.5
520 / 540
2650
2200
750
7725
Material of construction for shell & heads is 1.25 Cr & 0.5 Mo and for internals is
SA 240 type 321. Reactor vessels are designed for full vacuum.
In the regeneration unit, the catalyst is regenerated by means of an automatic
regeneration loop system. Catalyst circulation is achieved either by gravity flow
or by gas lift system and is discussed later on.
Effluent leaving 15-R-3, after heat exchange in 15-E-1, is cooled in air cooler 15AC-1 A/B/C/D/E/F to 65 deg.C and then by trim cooler 15-E-2 A/B to 45 deg.C
before entering the separator 15-V-1.
Separator is operated at a pr. of 2.3 kg/cm2 .The separated gas is compressed
in the recycle gas compressor 15-K-1 and a part is recycled to the reactors. The
remaining gas, which constitutes the hydrogen production gas, is routed to a
recontacting section to improve hydrogen purity and recover liquid yield.
The separated liquid is pumped by 15-P-1 A/B from 15-V-1 under level control
15LIC-1501 to recontacting section.
CRU- 02 04
PART-C
2.3
RECONTACTING SECTION:
The balance hydrogen gas (27,800 NM3/hr at 5.8 kg/cm2g and 123 oC) is
recontacted with the separated liquid (67 M3/hr) from 15-P-1 A/B.
The recontacted mixture is then cooled to 10 oC (pr. 4.8 kg/cm2 g) in following
stages for a high recovery of C 3+ contained in the hydrogen and a high
concentration of hydrogen in the hydrogen rich gas product.
Then the stream is fed into recontacting drum 15-V-2, the high-pressure absorber
at - 10oC at 4.8 kg/cm2g.
Hydrogen rich gas from 15V-2 (25,000 NM3/hr, having a composition of H2-90%,
C1-2.5%, C2-3.0%, C3-2.0%, C4-1.0%, C5+ -0.5%) after heat exchange in 15E4 at a temp of 36 deg.C and pr. of 5.3 kg/cm2 is routed to either H2 unit PSA for
purification or to FG/Flare through PIC -1507.
The separated liquid in the recontacting drum 15V-2 after heat up in 15-E-5 is
pumped by 15-P-2 A/B under level control 15 LIC-1505 to the LPG recovery and
stabilisation section. A part of 015 V-2 vapour effluent after heating in 15E4 may
be used in the dryer which is detailed later on. Facility to route V2 bottom
products directly to reformate r/d line, upstream of r/d shutdown valve 15LD12 is
also available.
2.4
DEBUTANISER SECTION**:
The cooled separated liquid from 15-V-2 is contacted with stabilizer off gas
(5000 NM3/hr, which contains H2=2%, C1=4%, C2=33%, C3=45%, C4=13%,
C5=3%) and allowed to separate in LPG absorber drum 15 V-3 which is at a pr.
of 15.8 kg/cm2 g. The purpose of this step is to recover the maximum quantity of
LPG i.e. C3 and C4's from the stabiliser overhead vapour.
CRU- 02 05
PART-C
Vapour from 15V-3 (68 NM3/hr.) is routed to fuel gas under pressure control 15
PIC-1509. This stream is predominantly light ends i.e. C1 and C2' (H2-46%, C112%, C2-26%, C3-12%, C4-3%, C5-1%) and this controls the stabiliser operating
pressure. Separated liquid from 15V-3 is pumped by 15P-3 under level control
15 LIC-1506 and is preheated in stabiliser feed-bottoms exchanger 15E-7 to a
temp. of 131 deg.C. This feed enters 44 trays stabiliser 15 C-1 on its tray no.17.
The stabiliser is operated at 17 kg/cm 2g to reduces the C4 and lighter fraction in
the reformate to have a vapour pressure less than 0.4 kg/cm 2.
15-C-1 overheads, at a temp of 62-66 deg.C, are condensed and cooled to a
temp. of 45 deg.C in water coolers 15-E-8 A/B/C/D and collected in the stabiliser
reflux drum 15-V-4. The uncondensed vapours are routed back to 15-V-3 for
CRU- 02 06
PART-C
This heater is a part of Non IFP heater block which is operated in balance draft
mode with ID and FD's fan in operation. Heater has been provided with low pass
flow firing cut off as detected by FSLL-1505A/B/C/D. Stabiliser reboiler pump
auto start facility has also been provided to start the stand-by pump in case if low
flow is detected by FSLL-1514 at pump 15P-5 discharge.
Bottoms product from the stabiliser at 224 deg.C. after partial cooling in the
stabiliser Feed/Bottom exchanger 15-E-7 to 123 deg.C. is further cooled in the
reformate air cooler 15-AC-4 A/B to 65 deg. and finally in trim cooler 15-E-11 to
45 deg. for routing to storage. Reformate rundown flow is controlled by 15LIC1511 which is actuated by 15LIC-1507. In case of low-low level in stabiliser
LSLL-1508 will shut down the shut-down valve LV-1512. For chemicals batch
2.5
CATALYST REGENERATION:
It is achieved in two steps. Coke combustion is followed by an oxychlorination
and calcination step where optimum amount of chlorine level is restored. Design
capacity of the regeneration loop is 30 kg of coke burnt per hour. Accordingly
catalyst flow rate is around 500 kg/hr. In case of high level of coke on the catalyst
(>6%), the catalyst flow rate through the regenerator must be limited in order to
not exceed this maximum value of coke burnt per hour. The flexibility of the
regenerator will allow a smooth operation with only 30% of coke capacity.
The catalyst regeneration procedure includes:
1.
2.
3.
4.
5.
CRU- 02 07
PART-C
The first three steps are performed inside the Regenerator 17R-1 which is
explained below.
2.5.1 COKE BURNING:
Regenerator receives catalyst from its lock hopper 17V-2 in batches. Each batch
is equivalent of one hour of catalyst circulation. Top of the regenerator is swept
by small flow of N2 (from dedicated N2 header II) supplied by PDIC-1704 which
prevents oxygen from combustion zone to come up in the storage volume. From
this zone, catalyst enters in the 1st regeneration bed through eight legs.
During this catalyst flow, it gets preheated to a temperature of 440 deg. due to
the heat of the inlet regeneration gas (7420 NM3/hr) which enters at 470 deg C
and at a pr. of 5.4 kg/cm2. Regeneration gas is an inert gas used as heat and
reactant carrier in the catalyst regeneration loop and is supplied by Regeneration
loop compressor 17K-1 A/B.
Compressors 17K-1 A/B is reciprocating dry piston type with capacity of 8500
NM3/hr with electric driver of 250 KW rating. Compressor is operated at suction
pr. of 3.2 kg/cm2 g and delivers discharge pr. of 6.2 kg/cm2 g and temperature of
80 deg.C. Loaders for 75% capacity have been provided. While starting the
compressor ensure no pressure surge on the screen inside the regenerator.
Ensure the opening of compressor spill back C/V FC16.Also ensure there is min
flow thru the oxy-calcination zone by FC05. Permanent suction filter 17G-3 to
trap particle (possibly alumina or desiccant) size bigger than 5 microns has been
installed. Pressure drop across this filter in clean condition should be 0.05
kg/cm2 and the maximum allowable pr. drop before cleaning is 0.5 kg/cm2.
Compressor discharge flow is divided in two parts, main flow of 7420 nm3/hr
used in combustion zone and the balance 650 nm3/hr used in calcination and ox
chlorination zone. The composition of the gas is in the following range (N2= 82100%, CO2=17-0%, O2=1-0%, traces of Cl2, HCl). O2 % is limited to 0.5 - 0.7 %
for the controlled combustion in the 1st bed.
Main flow is preheated to 440 deg.C. in the feed effluent exchanger 17E-1. Final
temperature adjustment to 470 deg.C is done in electrical heater 17EH-1
(designed for a maximum temperature of 550 deg. with maximum heating
equivalent to 185 KW, minimum 50 and design 215 KW. 17EH-1 outlet
temperature is controlled by TIC-1751. This gas at a pr. of 5.4 kg/cm2 and
temperature of 470 deg.C enters the regenerator and flows through two radial
beds. All the oxygen of this regeneration gas will be consumed in the first
combustion bed and heat produced will be absorbed by the regeneration gas,
which is collected in the centre pipe.
CCRU OPERATING MANUAL
CRU- 02 08
PART-C
Catalyst which still contains some coke is collected and transferred by an other set of 8
pipes into the 2nd combustion bed at a temperature of 480 oC. For the complete
combustion of coke, Air (133 NM3/hr) is introduced under flow control FIC-1702 so as to
have 0.4 - 0.6 vol. % oxygen in the 2nd bed.
The 2nd bed produces less heat than the 1st. O2 in the regeneration outlet gas is
monitored by oxygen analyser AIC-1703 and is maintained between 0.2 - 0.3 vol. % by
adjusting FIC-1702 through cascaded loop. Catalyst, which arrives at the bottom of the
second bed, is and must be free of coke. This is essential as otherwise temperature
runaway could occurs and damage the catalyst in the oxychlorination zone. Catalyst
regeneration is checked by:
2.5.2 CALCINATION :
Calcination gas is introduced in the bottom part of the regenerator. FIC-1705,
three way valve controls the flow of 17K-1 discharge gas (650 nm3/hr) for the
calcination operation ( Rest of the 17K-1 discharge will be going to combustion
side through the same three way valve FV-1705). This is mixed with air (182
nm3/hr) supplied by FIC-1701 in order to reach O2 level of 4-6 % as measured
by O2 analyser AIC-1706 which resets FIC-1701. FI-1705 is gives total of gas to
calcination plus the air. This calcination gas is heated from 70 to 430 deg.C in
feed / effluent exchanger 17E-2. It is further heated to a controlled temperature of
540 deg.C. in electrical heater 17EH-2 by TIC-1752. This 50 KW heater supplies
34 KW of absorbed duty. Calcination gas enters at pressure of 5.7 kg/cm2,
circulates up flow in the axial bed and is collected at the outlet. On the calcination
zone new spike tray was installed for better cl- fixation during July 2010
shutdown.
2.5.3 OXYCHLORINATION :
Catalyst from combustion zone is collected by 6 pipes and sent to axial bed
where oxychlorination takes place. Gas from the calcination zone at a
temperature of 510 deg.C. flows upwards and is mixed with chlorination agent.
C2Cl4 injection is done by pump 17P-4 A/B. Dosing tank 17T-2 of 1500 litres is
made up of stainless steel. Daily estimated maximum consumption of C 2Cl4 is 62
kg. Oxygen level of 4 - 6 % is maintained in this zone.
CCRU OPERATING MANUAL
CRU- 02 09
PART-C
CRU- 02 - 10
PART-C
bottom on caustic side compartment, epoxy coating has been provided. Water injection
is done by pump 17P-2 A/B at the rate of 3 m3/hr. Liquid discharge from caustic side
approx. 200 kg/hr. will have Na2CO3 / NaOH / NaCl and NaOCl to a max. of 4 % wt and
shall be routed to drain system of Merox through LIC-1721. Water side effluent (3000
kg/hr) having traces of Na2CO3 / NaOH / NaCl and NaOCl shall go to OWS / drain of
Merox unit through LIC-1720.
Washing drum pressure is controlled by PIC-1761 A/B (split range, A is vent to
silencer and B is Nitrogen make up) which is resetted by the pressure of the 1st
reactor (PI-1727). Continuous exhaust of 150 - 350 NM3/hr is expected.
CRU- 02 10*
PART-C
Add 168 L of IPA in the vessel by observing level rise from 30% to 42.8 %.
Start dosing solution of IPA and C2CL4 with minimum rate @ 8 cm/min.
Critical parameters to be observed :
1.
2.
3.
During Regenerator
interlock(High temp. of Combustion/Oxy zone,Low
regeneration gas flow and high combustion O2 percent) C2CL4 pump to be
stopped immediately from field to save catalyst. Due to dealy in stopping C2CL4
pump overchlorination of C2CL4 in Oxy zone may lead to hydrocracking when
catalyst enters in reactor section. Also some time in Regenerator lift stop
condition if C2CL4 runs for long time then catalyst may agglomerate with each
other and it may chock the spider legs of Regenerator bottom.
Therefore its stopping interlock
provided for any of the below
parameters/interlocks:17-AU-01( High combustion zone O2 percent)
17-FD-31 (Low regeneration gas flow)
17-TU-01/2/3/4 (high temperature of combutsion /calcination /oxy-chlorination)
After normalization of Regenerator parameter C2CL4 pump again to be started
manually from field.
Auto stopping facility will increase catalyst life and Regenerator lift operation
reliability will improve.
CRU- 02 10*
PART-C
2.5.4 DRYER :
Gas coming out of the washing drum is saturated with water at a pressure of 3.6
kg/cm2. Dryer package unit includes two drums, one in operation and one in
regeneration. Dryer ensures water content in the outlet to be less than 50 ppm
vol. Dryer will have a cycle time of minimum 6 hours. Allowable pressure drop is
0.3 kg/cm2 with maximum limit of 0.5 kg/cm2.goes through a dryer 17DR-1 and
then through filter 17G-3 before to compressor 17K-1.
2.6
CATALYST CIRCULATION :
The total flow rate of the lift gas must remain as steady as possible because any
change in this flow will affect the velocity of the catalyst in the lift line. This flow
rate must be checked carefully because a too high velocity may lead to too high
catalyst attrition rate.
This nitrogen gas ex 17-K-3 A/B going to the lift pot 17-V-34 is divided into two
flows:
a. The primary gas through FIC-1711, which initiates the lift operation.
b. The secondary gas through PDV-1711, which governs the catalyst flow.
Within the proper operating range, the rate of catalyst flow is proportional to
the secondary flow rate of gas. When the secondary gas is stopped, no
catalyst can move in the lift. The pressure drop measured between the lift pot
and the next upper hopper indicates the catalyst flow. Nearly equal to zero
when there no catalyst flow, this pressure drop will increase to about 100
gr/cm2 when there is catalyst flow. This measure is used as indication of
catalyst flow in the control used for the follow-up of the operation of the lifts.
2.6.1
Catalyst surge vessels (upper hoppers) 17-V-10/12/13 are provided at the top
of each reactor in order to compensate for differences in catalyst flow between
the lifts. It is also a protection against variations of void fraction of the catalyst
in the reactors. Each upper hopper is equipped with gamma-ray level sensors.
One level sensor gives a continuous information for the control, the other gives
on-off information for catalyst lift cut-off. The level will be adjusted at 50% and
the measure will be used through a cascade to modify the set point of the
PDIC used to monitor the catalyst flow.
CRU- 02 - 11
PART-C
In case of low level, detected by a cut-off, the PDICV will be automatically closed until
the defect disappears.
Following Gama ray detection systems are provided:17-V-1 Upper Surge Drum
LSH-1702, LSL-1703
17-R-1 Regenerator
LT-1702, LSLL-1704
Catalyst circulation is carried out by means of gas lift system, which carries
the catalyst from the bottom of each reactor to the top of the following reactor.
The catalyst then flows downward through each reactor bed by gravity
hydrogen rich gas is used as carrier in the regeneration system.
Between reaction system and regeneration loop, the catalyst is carried by a
specific Nitrogen circulation loop. Catalyst batches are transferred periodically
to the regenerator for regeneration.
2.6.2
SEQUENCE TRANSFER:
Spent catalyst (at approx. 200 deg C.) is stored in the regenerator upper
surge drum 17V-1, which is at a pressure of 2.9 kg/cm2 slightly lower than the
pressure of the last reactor 15R-3 (3.3 kg/cm2). When upper surge drum is
full of catalyst, this amount of catalyst is transferred to the lock hopper 17V-2
and then from lock hopper to regenerator in batch operation. Transfer is
carried out transfer sequence UC-1701, which is explained as below. The
sequence is divided into two main operations Load and Unload.
Load operation transfers batch of catalyst from upper surge drum to lock
hopper in approximately 20 minutes and is carried out automatically as given
below:
1. Verify the conditions are good to start the load operation i.e. valves UV1701, 1702, 1703, 1704 and 1708 are close and that enough place is
available in lock hopper 17V-2 (LAL-1703 ON)
2. Open valve UV-1707 to equilibrate pressure between the upper surge
drum and lock hopper.
3. Wait for the pressure equilibrium {ABS(PI1701-PI-1702)<0.3 kg/cm2}
4. Wait for enough catalyst in the upper surge drum level.
5. Open valve UV-1702 and UV-1701. The catalyst will fill up the lock hopper.
CCRU OPERATING MANUAL
CRU- 02 12
PART-C
6. Wait for high level in lock hopper (LAH1702 ON). The lock hopper is full
now.
7. Close valve UV-1701.
8. Wait for 10 secs.
9. Close valve UV-1702 and UV-1707.
10. Go to UNLOAD.
Unload operation transfer a batch of catalyst from lock hopper to the regenerator
and will take approximately 20 minutes and is carried out automatically on the
completion of load operation as given below:
1. Wait for the conditions are good to start the unload operation i.e. valves UV1701,1702, and 1707 are close. Enough place in the regenerator top head is
ensured.
2. Open valve UV-1708 to equilibrate pressure between the lock hopper and
regenerator 17R-1.
3. Wait for the pressure equilibrium [ABS (PI1702-PI-1703)<0.3 kg/cm2]
4. Open valve UV-1704 and UV-1703. The catalyst will be unloaded from the
lock hopper into the top of the regenerator.
5. Wait for low level in lock hopper (LAL1703 ON). The batch of catalyst has
been transferred to the regenerator.
6. Close valve UV-1703.
7. Wait for 10 seconds.
8. Close valve UV-1704 and UV-1708. The lock hopper is empty and ready for
a new catalyst batch.
9. Go to LOAD.
The catalyst is achieved by means of a gas lift system. Hydrogen rich gas is used
as carrier in the reaction section, Nitrogen is used as carrier between the reaction
and the regeneration section.
The catalyst is lifted from the bottom of the regenerator to the top of the 1st
reactor by nitrogen lift, flows downward in the reactor by gravity, from bottom to
the next by hydrogen lift and from bottom of the last reactor to the regenerator by
nitrogen lift.
The catalyst is transferred periodically from the upper surge drum to the lock
hopper and from the lock hopper to the regenerator. Catalyst surge vessels are
provided at the top of each reactor in order to compensate for differences in
catalyst flow between the lifts.
CCRU OPERATING MANUAL
CRU- 02 13
PART-C
The lift gas controls catalyst flow. It is achieved by Primary gas, which initiates the lift
operation (FIC control). Secondary flow, which governs the catalyst flow (PDIC control)
When the total gas flow is constant, the rate of catalyst flow is proportional to the
secondary gas flow rate. The total gas flow is controlled by action on primary gas. When
secondary gas is stopped no catalyst can move in the lift. The pressure drop measured
between the lift pot and the next upper indicates the catalyst flow. This will be nearly
equal to zero when there is no catalyst flow and will increase to 100 gm/cm2 when there
is catalyst flow.
2.7
TRANSFER SEQUENCE:
2.7.1 DRYER
The Dryer 15-DR-1 can be used during the start-up operations. According to the
actual design, it is estimated that this dryer has to be regenerated three times
during a unit startup.
In drying service, part of the recycle gas goes down stream through 15DR1. The
regeneration of the dryer is performed in two times:
Heating by a part of the produced hydrogen gas. The gas is heated in 15-EH-1
(controlled by TIC-1558), goes through the dryer and is cooled in cooler 15-E-12
before feeding into the KO drum 15-V-6.
CRU- 02 14
PART-C
Chemical Name:
Activated alumina.
Molecular Weight:
N/A
Chemical Formula:
Chemical Family:
Al2O3
Modified Alumina
Percent
Hazardous
90-95
No
Moisture
Balance
No
Odor
Solubility
Bulk Density
Nil
Insoluble in water.
0.80 0.1 kg/L.
NA
Hazardous
Incompatibilities
CATALYST USE:
Removal of chlorides from hydrocarbons.
CRU- 02 14*
PART-C
2.8
(ASHH-1704/1705)
CRU- 02 - 15
An automatic isolation valve (HS-1715) is also installed on the seal leg under
the regenerator in order to isolate it from the reaction section in case of large
perturbation in the pressure balance of the unit, for example recycle
compressor shutdown. The interlock I-1703 closes the automatic isolation
valve in case of: the high regeneration temperature (TSHH1701/1702/1703/1704) high O 2 content in regenerator inlet (ASHH-1701), low
flow to regenerator (FSLL-1731)
Remark:
The pressure balance is made through small pipes 2" full of catalyst and so a
very small flow of gas is enough to create very large pressure drop.
If the delta P falls quickly to zero, it means that there is no more catalyst in the
pipe, and in this case the best solution is to close the valves and also the seal
gas flow to allow for a proper filling of the pipe by catalyst.
2.8.3
REGENERATION LOOP
(A) The regeneration loop unit
Inert gas is used as heat and reactant carrier in the catalyst regeneration loop.
A compressor 17K-1 A/B ensures the gas circulation. At the discharge of 017K-1, the gas is split into two flows.
The main flow, used in the two combustion zones, is preheated in the feed
effluent exchanger 017-E-1. Electrical heater 017-EH-1 will allow for a precise
adjustment of the regenerator inlet temperature 420-440 oC.
The gas, after preheating the spent catalyst in the top of the regenerator, will
flow through the two radial beds.
The Regeneration of CRU catalyst needs dry air with minimum dew point of
-40 deg C.Around 360Nm 3/hr of dry air ex air purification units is being
consumed from ccru N2 plant.
During the non availability of dry air from ccru N 2 plant due to various reasons
like Freon system failure, air compressor failure etc, a new 4 dry air line ex
New N2 plant has been laid down. This .line also improves the reliability of the
regeneration
and
was
implemented
via
process
scheme
(MR/TS/PS//CRU/2005/06). After coke burn off, the re-action heat which is at
about 400oC is recovered in the feed-effluent exchanger 017-E-1, then the gas
is cooled down by the air-cooler 017-AC-1 before it is routed to washing drum
017-V-5 along with calcination gas. The secondary flow, used successively for
calcination and oxychlorination is mixed with air from N 2 plant (FIC-1701) in
order to reach a concentration of around 4 to 6% of oxygen, (AE 1706) then
heated through feed/effluent exchanger 017-E-2 and electrical heater 017-EH2 to about 500oC.
CCRU OPERATING MANUAL
CRU- 02 - 16
PART-C
The calcination gas circulates up flow in an axial bed, is collected at the outlet, mixed
with a chlorination agent through 017-P-4 A/B then circulates down flow through the
axial oxychlorination bed. The chlorination agent is added when the calcination
temperature reaches to about 470oC.
After heat recovery in the feed effluent exchanger 017-E-2, this gas is mixed with the
main flow, and sent to the washing drum 017-V-5, where the acid gases are neutralised
with 10% caustic soda solution.(To eliminate corrosion problems due to the chlorine
compounds in the regeneration effluent, a gas washing section is provided in order to
keep constant the quality of the regeneration gas.) The regeneration effluent gas is
washed by contacting with a caustic solution pumped by 17-P-1 A/B and cooled in a trim
cooler 17-E-3 to get the lower possible temperature in the washing drum. The liquid is
injected through a spray nozzle 017-SM-2 in the line located after the air cooler.
Contacting is performed into a static mixer 017-SM-1, right after the injection point.
Final cooling is done in the washing drum 017-V-5. Final washing is done in the washing
drum 17-V-5 by contacting water on bubble cap trays. The water (Process water/DM
water) has two functions, washing of the gas and cooling. The gas coming out from the
washing drum goes through dryer 017-DR-1 then through a filter 017-G-3 where the
eventual particles are trapped and finally back to the regeneration loop compressor 017K-1. Pressure is controlled by means of gas purge from washing drum 017-V5. The
pressure of the regeneration loop is reseted by the pressure of the first reactor PI-1727.
Earlier only level switch was provided at mist eliminator. At high level swich actuates the
solenoid valve provided at drain line for removing moisture from 17DR-1 circuit.
However some time SOV malfunctions and chances of water carryover to adsorber bed.
Water carryover affect the performace of catalyst bed and moisture will slip from
adsorber bed. High moisture gas will also affect Regenerator(17R-1) catalyst. At high
moistur fixation of chloride on Pt catalyst(acidic function of catalyst) will be affected and
in combustion zone chances of hdydrothermal sintering.
By providing level indication of mist eliminator on DCS performace of adsorption has
been improved and dew point of Regeneration gas at adsorber bed outlet has been well
maintained within the limit. Hence catalyst life of 17DR-1 adsorber(Alumina based) and
17R-1(Pt based) both has been improved.
CRU- 02 - 17
By providing running indication and Heater failure alarm of 17DR-1 Heater on DCS
Adsorber bed Regeneration during Heating cycle has been improved and moisture
slippage can be avoided and we are able in maintaining moisture < 50ppm at Adsorber
outlet.
Provision of New drain line and control valve from level troll of
Moisture separator of 17DR-1
New drain line along with control valve has been provided from level troll of
moisture separator and control valve has been cascaded with level indication of mist
eliminator. New control in Auto mode very efficiently removes the moisture from
17DR-1 circuit. Also some time manually by operating this control valve moisture can
be removed.
By providing new control valve performace of 17DR-1 adsorption has been
improved and dew point of Regeneration gas at adsorber bed outlet has been well
maintained within the limit. Hence catalyst life of 17DR-1 adsorber(Alumina based) and
17R-1(Pt based) both has been improved
CCRU OPERATING MANUAL
PART-C
CRU- 02 17*
11
Specifications
Product
Particle Form
Size in mm
Water static adsorption at 60% relative humidity, %
Surface area, m2/gm
Pore Volume cc/100gm
Bulk density, gm/lit
Particle crushing strength, daN
Attrition resistance AIF 5 min, %
Chemical properties:
Al as Al2O3, %
Na as Na2O, ppm
Loss on ignition at 300-1000Deg C, %
Typical Value
AxSorb D 2-5
Spheres
2-5
20(min)
300 (min)
44
760-860
14 (min)
99 (min)
93.8(min)
5000(max)
7.0(max)
S.No Specifications
Value
1
2
3
10700
3.7
45
180 (Normal)
200 (Max)
N2
O2
CO2
Cl2
HCL
H2O
H2S
82-100%
3-8%
Balance
2 ppm *
2 ppm *
Saturated
1 ppm
CRU- 02 17*
PART-C
Second bed
Outlet temperature
530 deg C
The 3 first steps are performed in the regenerator 017-R-1, the step 4 is
performed in the first lower hopper 017-V-3, the last step is performed in the
reduction chamber 017-V-1.
CRU- 02 18
PART-C
(B)
General arrangement
The regenerator 017-R-1 works at a pressure slightly higher than the one of
the first reactor 015-R-1. Spent catalyst is stored in the upper surge drum 017V-1 at a pressure slightly lower than the pressure of the last reactor 015-R-3.
Upper surge drum 017-V-1 and the top of the regenerator are both under
nitrogen pressure, so only a pressure adjustment is needed, this will be made
in the lock hopper 017-V-2 through PI-1702.
The equivalent of one hour of catalyst circulation is stored in the upper surge
drum 017-V-1. When high level is reached, an automatic operation begins as
follows.
Check that 017-V-2 is empty and at the same pressure than 017-V-1.
Open gas tight (UV-1701) and catalyst tight valves (UV-1702) between the
two drums.
Unload the catalyst from 017-V-1 until high level is reached in 017-V2.
Then the same operation is made between the top of the regenerator and 017-V-2
Open gas tight and catalyst tight valves between the two drums
Unload the catalyst from 017-V-2 until low level is reached in 017-V-2
CRU- 02 19
PART-C
C)
Catalyst Heating
The top of the regenerator is swept by a small flow off fresh nitrogen gas
through 17 PDIC-1704, which prevents oxygen from the combustion zone to
come up in this storage volume.
In this part and in the 8 legs, which allow the catalyst to enter the first
regeneration bed, the catalyst is smoothly preheated by the regeneration gas
inlet.
(D) Coke burn off
The catalyst then flows through the first combustion bed, which is designed in
the same way as the former reactors. The combustion gas is as follow:
All the oxygen will be burnt and the heat produced will be absorbed by the
regeneration gas, which is collected in the centre pipe.
Then the catalyst, which still contains some coke is collected and transferred
by another set of 8 pipes into the second combustion bed. Air is introduced
under flow control (FIC-1702) IN ORDER TO GET AROUND 0.2% of oxygen
at regenerator outlet.
The second coke burn off produces less heat than the first one, the design is
made in such a way that there is too much oxygen introduced compared to
the coke remaining on the catalyst.
O2% is 0.2 to 0.3 vol. at the regenerator outlet, Gas outlet temperature
between 500 - 515 oC
The catalyst, which arrives in the bottom of the second bed is and must be
free of coke. This key item will be adjusted by the two air injection in the
combustion zones, and if necessary by decreasing the catalyst flow rate in the
regenerator (for example in case of upset of coke on the catalyst: more than
7%).
CRU- 02 20
PART-C
(E)
Regeneration Checking
The panel operator can always check the following information in order to
run the unit correctly
The temperature difference between the inlet and the outlet on both
combustion beds.
Low oxygen content in the gas at the outlet of the combustion zone.
(F) Oxychlorination
The catalyst is then collected by 6 pipes and sent to an axial bed where
Oxychlorination takes place.
Oxychlorination gas is the gas previously used for the calcination. This gas is
hot, and flows from top to bottom. Chlorine is injected in this zone.
Oxygen
4 to 6% vol.
Temperature
510 oC
(G) Calcination
Calcination gas is introduced in the bottom part of the regenerator. This gas
contains 4 to 6% of oxygen. It flows from bottom to top before being collected
and then sent to the Oxychlorination zone.
Oxygen
4 to 6% vol.
Temperature
520 oC
Water
CRU- 02 21
PART-C
(H)
Cooling
The catalyst is then collected by 6 pipes and flows into the lower hopper 017V-3, which is under slight over pressure of nitrogen. The pipes are not
insulated in order to allow for a natural cooling by convection.
Catalyst flows from there down to the lift pot, 17-V-34 where it's entrained by
a flow of nitrogen gas into the first upper hopper 17V-10.
This hopper 17 V-10 is only a storage under nitrogen where catalyst is
accumulated before to be introduced in the reduction chamber 17-V-11.
The gas used for the lift operation is recovered from the first upper hopper,
cooled, and filtered in a catalyst fines filter 17-G-2.
Remark:
When catalyst make up is needed in the unit, a drum is added to the hopper
017-V-4, which is pressurised at the pressure of 017-R-1, and after the valve
opening, fresh catalyst will be smoothly added into the calcination bed.
(I) Reduction
Reduction of the freshly regenerated catalyst in 17-R-1 is done in the
reduction chamber 17-V-11, which is provided above 15-R-1. The hydrogen
rich gas from 15-K-1 is heated in hydrogen rich gas exchanger 17-E-4 and
then in reduction heater, 17-EH-3 (Electric heater) before using in 17-V-11 for
reduction of the catalyst.
This operation is slightly exothermic and the inlet temperature is thus adjusted
in order to have hydrogen rich gas around 450 deg C at the 17-EH-3 outlet. In
case of high temperature, which is indicated by TSHH-1711, electric supply to
the heater will be cut-off. This operation is continuous.
The residence time in the reduction chamber is 2 hours. After reduction, the
gas is cooled down first in the feed/effluent exchanger, 017-E-4 then in the air
cooler, 017-AC2 and sent to fuel gas under PDIC-1702 control.
The heated hydrogen rich gas ex 17-E-4 is also used in 17-V-21/22 and 17-V31/32.
CRU- 02 22
PART-C
Note: while starting the reduction heater after long shutdown it is advisable to drain the
heater shell so as to ensure the no condensate is present inside the system.Drain line
via process scheme (MR/TS/PS/CRU/2007/02) has been provided for draining facility.
2.8.5 NITROGEN GAS LIFT SYSTEM
(A) Description
Nitrogen lift gas is used for the first and the last lifts.
After separation of the lift gas and the catalyst in the elutriator, the gas flows
through the fines filter 17-G-1/2 where the catalyst dust is recovered.
The gas flow enters in the middle of the drum. In the top of the drum several
cartridges off filtering elements are fixed. The gas flows through, the catalyst
dust is trapped on these cartridges, which are cleaned, when the DP
increases, by a counter flow of nitrogen.
After cooling, the gas is re-circulated by means of compressors 017-K-3 A/B
(B) Safety
The quality of the gas is controlled continuously by two analysers:
O2 analyser
H2 analyser
In case of O2 or H2 contaminates the lift gas, there are two levels of operation:
If high level is reached, the reaction section and the nitrogen lift gas are
isolated by closing the safety valve UV-1705 and 1706.
When the quality is recovered, the catalyst circulation may restart.
CRU- 02 23
Nitrogen sealing: a controlled flow of inert gas is used to keep the drums
connected with the reaction section at a slightly higher pressure than the
reaction section.
Safety valves: if the nitrogen sealing fails for any reason the valves will be
closed automatically, isolating the two sections.
These valves are actuated by air and air pressure to actuators is controlled by
solenoid valves.
In addition to the normal control system, an independent, dedicated system
comprising hardware, software interlocks prevents any mis- operation or
accidental opening of valves.
A push button in control room also allows to close of the three automatic
valves in case of problem on the unit.
2.8.6
CATALYST REPLACEMENT
On line replacement::
This operation is performed in the lock hopper. Every time this drum is full of
old spent catalyst, it is isolated and depressurized to atmosphere. Then, the
catalyst is withdrawn out from the unit by the way of the side connection
located in between the 2 valves underneath the lock hopper. The spent
catalyst goes down to the ground through a 3" temporary line and it is
collected and stored into drums, previously filled-up with nitrogen.
The fresh new catalyst is introduced in the lock hopper, then transferred as
usual down to the regenerator where it will be dried before entering the
reaction section.
Shutdown replacement:
CRU- 02 - 24
This operation is carried out after the normal procedural shutdown and cooling of the
reactor/regenerator sections. It is ensured that the catalyst bed temperature as shown
by skin indications is not more than 80 deg C. Two to three purges with Nitrogen to
remove hydrocarbon traces is done through 15PC05, each time pressurizing up to 2.0
Kg/cm2 and de-pressurising up to 0.2 Kg/cm 2(g). All vessels in the system are drained
out to CBD before purging with Nitrogen. All the necessary blinding jobs are released
after checking for LEL for <2% in CRU gas through 15PC05. The spools from the
reactor and regenerator bottoms, between pearlo valves are dropped with the first
pearlo valve in closed position. Unloading elbows 3 size, are connected and flexible
hoses are connected to the elbow ends. Empty drums are arranged at the bottom of the
reactors and regenerators. The drums are properly numbered in sequence to facilitate
re-loading. Unloading rate can be controlled by the first pearlo valve opening. One
running nitrogen hose is provided inside the catalyst drums being unloaded to avoid any
sparks due to coked catalyst attrition. The filled drums are sealed under nitrogen
atmosphere and stacked under cover.
2.8.7 PROCEDURE FOR REGENERATOR CLEANING & REPAIR:
Regeneration shutdown
CRU- 02 - 25
S.NO
1
2
3
4
5
6
7
8
9
10
LOCATION
CRU- 02 - 26
MH1 to be boxed-up
Leaks to be attended
CRU- 02 - 27
Flue gases of the reformer furnaces 15F-1, 15F-2 & 15F-3 exit at a temp of 615
Considering the immense heat recovery potential of these flue gases, a steam
generation facility has been laid. Steam is generated at M.P. level. Originally HP
steam was generated from the system to cater to the needs of the Ebara
compressor that consumes HP steam in its turbine and exhausts LP steam. Later
the steam generation system was modified to generate MP steam and the HP
steam requirement of the RGC compressor is met from the better quality HP
steam from TPS header.
The BFW is supplied to CRU from TPS .The BFW supplied & MP steam
generated shall meet following specifications:
STREAM
B.F.W.
TDS ,ppm
STEAM
<1
Not detectable
Silica as SiO2
Dissolved Oxygen
Dryness
>99.9%
Na + K
Fe
Fe + Cu
Cu
Cl ,ppm (max)
nil
Conductivity, umho/cm
pH
Oil , ppm (max)
0.2 @ 20 C
<1
7-10
>8
Not detectable
The BFW is made available the CRU B/L from TPS at 106 kg/cm 2 pr. & 125 C.
The steam will exit the desuperheater at 16 kg/cm 2 g and 2500 C.
The BFW is dosed with TSP @ 1 ppm in steam drum. Blow down rate is kept at
3% of the steam generation rate, which is 16740 kg/hr normal.
CRU- 02 28
PART-C
PROCESS DESCRIPTION:
The Steam generation system is designed for a forced type circulation for proper
distribution of flow through the steam generation coils. The BFW from TPS is fed
to the steam drum (15V-16) through 15 EE-191 (coil submerged in the steam
drum) & then BFW preheater furnace coils 15 F-8.The steam drum level control
is through a separate 2" line bypassing the above flow circuit & BFW comes
directly through LIC-1901. BFW temp at B/L is 120 0 C, at 15 EE-191 O/L is 135 0
C & at 15 F-8 O/L is 2330 C. The steam drum temp is 2820 C.
BFW circulating pump 15 P-15 A/B takes suction from steam drum (15-V-16) &
its discharge is passed through two steam generation coils 15 F-5, 15 F-7
through FIC 1902 & FIC 1903 respectively. Water vaporisation occurs in the coils
as a result of the heat pick-up by the circulating liquid, which then flashes in the
steam drum. The generated steam leaves the drum under pressure control via
PIC-1901 to the super heater coil 15 F-6.
The superheated steam temp control is done in the de-superheater 15-X-191 by
BFW injection in the steam via TIC-1909.
The BFW coil, steam generation coils & the superheater coil cannot withstand
dry run conditions. To avoid any chance of the dry running of the coils, the standby BFW circulation pump will take start in case of low flow detection (below 50 m 3
/hr) through any of the two steam generation coils. The fuel gas to the reformer
furnace will be cut-off in case the low flow condition persists for more than 30
seconds.
Trisodium Phosphate is continuously injected in the steam drum directly. TSP
solution is stored in the plant in 15-V-17 as 10 % by wt. solution .15-V-17 tank is
equipped with mixer 15-MX-1 for preparing homogeneous solutions. TSP is
dosed @ 1ppm in steam drum by reciprocating pumps 15-P-16 A/B. Normal
dosing rate is 0.2 LPH.
Steam drum blow down rate is kept at 3% of the steam generation rate. The
blow down is made to the blow down vessel 15-V-15 from which it is let out after
flashing out & cooling by mixing with service water.
CRU- 02 29
PART-C
CRU- 02 30
PART-C
reactors at a faster rate and supplies a greater heat sink for the endothermic
heat of reaction. Also the hydrogen partial pressure is linked to the H2/HC
ratio.
5) A lower H2/Hc ratio decreases the H2 partial pressure and increases coke
formation. The H2 partial pr. is mainly adjusted through recycle flow because
there is very little flexibility in varying total pressure. Within typical operating
range, the H2/HC ratio has little influence on product quality or yields. For a
given unit, it is set by design based on economic considerations.
6) Quality of feed: The quality of reformer feed, once pretreated, is mainly
expressed by its chemical analysis and its distillation range.
a) Chemical Analysis: The reformer feed consists of Paraffins, Naphthenes,
Aromatics (or PNA). As dehydrogenation of naphthenes into aromatics. An
index (A+0.85N), where N and A are the liquid volume percent of
naphthenes and Aromatics in the feed is used to characterize the feed. The
higher this index, the lower is the severity required to attain the reformate
octane. The lower this index i.e. the higher the paraffins content, the higher
the severity of operation required to meet the same product specifications.
b) Distillation Range: The reformer feed distillation range is as follows:
IBP = Between 70 100 deg C
FBP = Between 150 180 deg C
A feed with a low IBP generally contains more C6 and lighter paraffins and
has a poor naphthenic and aromatic content. Consequently it requires
higher severity to obtain the same octane number than a feed with a higher
IBP. Another consideration while selecting IBP of reformer feed is that of
eliminating benzene precursors from the feed to meet the recent benzene
content restrictions on gasoline. Feed with IBP above 82 deg C is selected
to eliminate cyclohexane, which readily forms benzene in reformer.
CRU- 02 31
PART-C
Heavier feeds (i.e. feed with higher FBP) have a high naphthenic and
aromatic content, thus they need lower severity to obtain good yields. But
the heavier fractions contain polynuclear aromatics, which are coke
precursors.
In the present system, gas path ex 15V-3(LPG Absorber) via Control valve
15PC-09 goes to FG Header or Flare Header. LPG absorber section of
CCRU is not in line as gas path ex 15-V-3 to FG header is blocked due to
mechanical problem in the seat of gate valve (2 nos). Due to this slippage
of LPG Component in FG Header takes place.
As a stop gap
arrangement, it is proposed to route gases ex LPG absorber(15-V-3) to
FG header via FG line of stabilizer reflux drum(15-V-4) as a scheme no
MR/TS/PS/CRU/2015/3.
In scheme from HPV of 15V-3 a new line hooked between two Block
valve of FG line of 15V-4 and 15PC-09 shifted in New line .Kindly note that
original system to be revived after replacing gate valves in FG line of 15-V3 in the next available opportunity and this temporary line is to be blinded.
After commissioning of this scheme, 15-V-3 taken in line and stabilizer off
gases routed to fuel gas header after LPG absorption in 15-V-3. It will
reduce the slippage of LPG component to FG header.
CRU- 02 32
PART-C
CRU- 02 32*
PART-C
CRU- 02-32*
PART-C
Restarting reactions
Reactions, which not only can lead to an octane reduction but also to a loss of
reformate yield. These reactions are obviously the ones to be avoided.
3.1
+3 H2
NaphtheneAromatic
The reaction is rapid and highly endothermic. It is promoted by the metal catalyst
function and is favored by high temperature and low pressure. Naphthenes are
obviously the most desirable feed components because in addition to being easy to
promote they produce by-product hydrogen as well as the aromatic hydrocarbon.
CRU- 03 01
PART-C
The speed of reaction increases with temperature and is not effected by the
hydrogen partial pressure.
3.1.2 Paraffin dehydrocyclisation
This is a several step process, which applies either to normal or iso paraffins. It
involves dehydrogenation with the release of one hydrogen mole followed by
naphthene
and
the
subsequent
CH2
CH2
CH
CH2
CH2
+H2
CH3
CH2
CH2
CH3
CH3
CH
C7 H16
CH
CH2
CH3
C7 H14
CH2
CH2
CH2
CH2
CH
CH3
CH
CH2
CH2
CH3
CH3
CH2
CH
CH2
CH3
CH2
CH2
CH
CH
CH
H2C
CH
CH2
CH2 CH
CH CH3
CH2
HC
CH3
CH
C
+
CH3+3H2
CH
Toluene
CCRU OPERATING MANUAL
CRU- 03 02
PART-C
temperature. Both metal and acid catalyst functions are needed to promote this
reaction.
Thermodynamics dictates the equilibrium, which could be theoretically reached
(i.e. if the time was infinite). Kinetics dictates the rate of Rx. I.e. possibilities to
reach a state close to equilibrium in a finite time.
Increase of
Kinetics
Pressure
decreases
non affected
Temperature
increases
increases
decreases
decreases
(1)
Increase of
Kinetics
Pressure
decreases
decrease
Temperature
increases
increases
H2/HC ratio
decreases
decreases
CRU- 03 03
PART-C
3.2
C7 H16
C7 H16
The reaction is slightly exothermic and does not affect the number of carbons. It
is limited by the thermodynamics i.e. the equilibrium reaction of branched to
normal paraffins decreases as the molecular weight increases. Isomerization
reactions result from carbonium ion intermediate reactions. These reactions are
promoted by the acidic functions of the catalyst. These reactions depends
mainly on temperature and pressure has no effect.
From kinetic viewpoint high temperature favours isomerization but hydrogen
partial pressure is indifferent.
3.2.2 Isomerization of napthenes
The isomerization of a cyclopentane to a cyclohexane must occur as the first
step in converting the C5 naphthene to an aromatic.
Alkylcyclopentane
Alkylcyclohexane
CRU- 03 04
PART-C
towards the desired direction. This type of reaction is also easier for higher
carbon number.
3.3
RETARDING REACTIONS
3.3.1 Hydrocracking
Due to the difficult ring formations and isomerization reactions that the alkylcyclopentanes and paraffins must undergo coupled with the acid function of the
catalyst, the possibility of acid promoted hydrocracking reactions occurring is
very strong.
+H2
Paraffin
+H2
+
+H2
or
C2+
This reaction leads to light ends plus lower molecular weight paraffins.
Paraffin hydrocracking is relatively rapid and is favoured by high temperature and
high pressure. The higher molecular weight paraffins i.e. those, which most
easily dehydrocylise tend to crack first.
These reactions are exothermic, consume hydrogen and should be avoided.
CCRU OPERATING MANUAL
CRU- 03 05
PART-C
3.3.2 Hydrodealkylation
Hydrodealkylation is the breakage of the branched radical (-CH 3 or CH2H5) of an
aromatic ring.
Xylene (two radical groups) can be dealkylated into toluene (one radical group)
which in turn can be dealkylated to benzene.
The standard representation is:
+H2
Xylene
+CH4
Toluene
+H2
Toluene
+CH4
Benzene
HC
CH3
Benzene
Propylene
CCRU OPERATING MANUAL
Isopropylbenzene
CRU- 03 06
PART-C
Dismutation
Two toluene rings (one branched CH3 radical) can dismute to produce one
benezene ring (no branched radical) and one xylene ring (two rranched radicals),
as shown:
Toluene
Toluene
Benzene
Xylene
This reaction, promoted by the catalyst metallic function, occurs only in very
severe conditions of temperature and pressure. This reaction is negligible with
the selected catalyst at the conditions of reforming.
3.3.4 Coking
Coke formation on the catalyst results from a very complex group of chemical
reactions, the detailed mechanism of which is not fully known yet.
Coke formation is linked to heavy unsaturated products such as polynuclear
aromatics (or polycyclics which can be dehydrogenated) resulting either from the
feed or from the polymerisation of aromatics involved in some of the reforming
reactions (dehydrocyclisation, dismutation ). Traces of heavy olefins or diolefins
may also result from the reforming reactions (dehydrocyclization, alkylation, for
instance) and promote coke formation.A high-end boiling point of the feed likely
means greater amount of polyaromatics and then a higher coking tendency.
Since polymerization is promoted by high temperature, poor distribution in a
reactor favors local high temperatures and coke build up.
Coke deposit on the catalyst support reduces the active contact area and greatly
reduces catalyst activity.
Low pressure unfortunately favors coke formation. This is why low pressure
reforming requires a continuous regenerated catalyst. In reforming the
continuous catalyst regeneration loop allows to maintain a controlled low level
coke content on the catalyst while operating at low pressure.
CCRU OPERATING MANUAL
CRU- 03 07
PART-C
As the naphtha feed contains a wide range of paraffins and naphthenes and as
the reaction rates vary considerably with the carbon number of the reactant, all
these reactions occur in series and parallel to each other producing a
complicated reaction scheme. However in an effort to simplify the scheme
according to the reaction rate the reactions take place in the following order;
1st REACTOR
Isomerization, Dehydrogenation
2nd REACTOR
Isomerization, Dehydrogenation,
Dehydrocyclisation, Cracking
3rd REACTOR
:
Dehydrocyclisation, Cracking
As dehydrogenation is easily promoted, highly endothermic and more
predominant in the first two reactors, the temperature drops across the reactors
diminish from reactors one through four. Dehydrocyclisation which is favored by
high temperature is therefore easier to promote in the last of the reactors which
have an overall higher weight average bed temperature.
CR-401 replaced by New Catalyst CR-601 in November 2013.
CR-601 Fresh Catalyst Properties:
Physical Properties
Surface Area, m2/gm
206.0
Chemical Analysis
Carbon, wt%
Chlorine, wt%
Sulfur, ppm
Gamma alumina, %
Alpha alumina, %
Fe, ppm
NA
1.04
0
*
*
Na, ppm
2240
Pb, ppm
<1
Cu, ppm
<1
LOI
PSD, wt%
>1.7 mm
1.7-1.4 mm
<1.4 mm
275
CATALYST
4.1.1 CR-201
99.292
0.708
0
CRU- 03 08
MANUFACTURER:
PROCATALYST
Presentation
1.8 mm
Bulk density
Pore Volume
Surface area
0.60 cm3/g
200 m2/g
Quantity:
15R-1
7.5 m3
15R-2
15.0 m3
15R-3
27.5 m3
10.72 m3
CR-201 has been developed to suit continuous regeneration reforming process. High
Selectivity offering maximum C5+ and Hydrogen yield at very low pressure. High
Mechanical strength offering minimum abrasion in catalyst transfer through lifts between
reactors. High Regenerability based on a very low surface area decrease after
numerous regenerations.
Packing:
217 litre non-returnable steel drums, 120 kg net/drum
Inert alumina balls:
This material is used in the top and the bottom of the reactor in order to avoid any
disturbance.
Type
Void fraction
0.3
Quantity
6mm diameter (1/4)
0.67M3
2.19M3
Quantity
CCRU OPERATING MANUAL
PART-C
4.2
CHEMICALS
CRU- 04 01
154
Chlorine wt %
92
1.595
Viscosity @ 200C
1.0 M Pas
Freezing point
-22.60C
Boiling point
76.80C
5.32(air=1)
Estimated consumption
300kg/year max.
C2CL4 is injection into the liquid feed when the continuous regeneration unit is
shut down. Injection rate 1PPM wt C 2CL4 injection fluid is a mixture of 1 wt %
C2CL4 in reformate.
4.2.2 Caustic soda
Estimate consumption of pure NAOH:
Daily consumption based on 100 Be solution
6.0kg/hr.
1440kg
4.2.3 Nitrogen
Sufficient nitrogen for one shutdown and one startup be kept on hand at all times.
Generally nitrogen requirement is 10x vol. of plant.
Distribution of nitrogen
The above is in addition to that required for the catalyst regeneration section.
CCRU OPERATING MANUAL
PART-C
CRU- 04 02
This section describes the procedure to be followed for starting up the unit for the
first time after erection or after a plant turnaround. Before proceeding for the start
up, the following steps should have been completed in the order shown:
1) Each section should have been leak tested (initial leak tests) and dry out
carried out for catalyst loading.
2) Catalyst has been loaded in the reactors and regenerator and the relevant
sections have been leak tested again and partially entered to residual O2
content between 2 to 5%. The residual O2 is necessary to avoid catalyst
sintering during the catalyst drying stage.
3) The unit is kept blinded at battery limits on the feed and product lines and
on fuel and flare gas headers.
4) The PSVs releasing to flare are to be kept blinded.
5) The PSV on separator drum to atmosphere is kept lined up.
6) The PSVs in regeneration section, N2 lift section are kept in normal lineup.
The sequence of first start-up (after the catalyst is loaded in the unit) is as
follows:
1) Circulation of catalyst and drying of catalyst under an atmosphere with a
residual O2 content.
2) Complete inerting of all sections with N2, to O2 content less than 0.2%
volume. This is done to prepare the unit for pressurization with hydrogen.
3) Stabiliser start-up at total reflux.
4) Pressurization with H2 of the reaction section and the absorber section.
5) Heating up and reduction of the catalyst.
6) Oil in.
7) Operation of the unit at low capacity and low severity.
CRU- 05 01
PART-C
Pressurize the reformer loop with N2 upto 3.0 kg/cm2g and inject air to
achieve 2 to 5% O2.
2.
Start the recycle gas compressor, 15-K-1 as per the standard procedure.
Start regeneration loop compressor, 17-K-1 and N2 lift gas compressor,
17-K-3.
3.
4.
Fire the reforming furnaces. Start reduction gas heater. Increase the
temperatures in the reactors and regenerator beds at the rate of 20 deg C
per hour upto 250 deg C.
5.
Again raise temperatures @ 20 deg C per hour upto 480 deg C in reactors
and 450 Deg C in the reductor and to 350 deg C in the regeneration
section. When temperature is above 300 deg C. start to drain water at all
low points of the sections and keep record of the amount drained. Keep
these conditions for about 8 hours. After 8 hours, maintain the same
conditions if the drained water stays above 0.2 liter per hour.
6.
When the total amount of water drained at all low points is lower than 0.2
liter per hour, decrease the bed temperatures to 300 deg C at a rate of 40
deg C per hour. Stop the fired heaters and electrical heaters.
7.
Stop the catalyst circulation. After elapsing one or two hours, stop 15-K-1,
17-K-1 & 17-K-3.
CRU- 05 02
FINAL INERTING: The purpose of final inerting is to reduce the O2 content in all
the sections below 0.2 % volume prior to the hydrocarbon introduction. During
the final inerting stage, the following steps are carried out:
a) All the compressors are stopped, isolated and purged with N2.
b) Remove blinds on all process lines between the sections, to/from the
battery limits (except liquid feed line).
c) Remove blinds on safety valves to flare.
d) Blind the safety valves previously to atmosphere during the drying stage.
Also blind the 15-V-1 PCV to atmosphere and line it up to flare.
For the inerting, depressurize the reaction section to 0.1 bar g, then
pressurize the reaction section with N2 introduced at 15-K-1 discharge,
upto 4 bar g. Depressurize upto 0.1 bar g, through 15-V-1 drain and also
through all low points and dead legs. Repeat this procedure till the O2
content is below 0.2% volume. Now leave residual pressure of about 0.1
bar g. Do the same for the HP absorber section and for the regeneration
section. Generally the required O2 content is achieved in about 3 to 4
cycles of pressurization and depressurization.
5.3
CRU- 05 03
Maintain the column pressure around 6 to 7 bar g. When the level in the
reflux drum reaches 50%, send reflux to the column. Operate the column
at total reflux.
Pressurization of the Unit:
After inerting, all the sections are left with some residual N2 pressure.
Pressurize N2 lift gas circuit with N2 upto 3.5 bar g at 17-V-6 (17-K-3
suction K.O. drum).
Pressurize regeneration gas circuit with N2 upto 4.5 bar g at the suction of
the regeneration loop compressor, 17-K-1).
Pressurize the reaction and absorber section with pure H2 (of the required
specifications) via the H2 pressurisation line at the recycle gas line to 15E-1. Set the pressure of the separator drum, 15-PC-1505 at around 3.5
bar g.
5.4
CRU- 05 04
Raise the reactors inlet temperatures and the reductor inlet temperature to
480 deg C at the rate of 40 deg C per hour. Maintain this temperature for at
least 12 hours or more if the total water drained at low points is more than
0.2 liter/hr.
Decrease reactor inlet temperatures and reductor inlet temperature to 360
deg C at the rate of 40 deg C per hour.
Stop catalyst circulation.
OIL IN:
After the catalyst reduction, the reaction section is ready for feed introduction.
The first start-up of the reformer should be done with desulfurised naphtha
(DSN). Prior to feed introduction, just ensure that the unit status is as follows:
a) The stabilizer is running at total reflux.
b) All the process lines are deblinded
c) 15-K-1 is running at full capacity.
d) 15-PC-1507 is lined up.
e) Catalyst circulation is stopped and UV-1715, UV-1705, UV1706 are kept
closed. Also all Pearlo valves on catalyst lines are closed.
f) Regeneration loop is stopped, electric heaters are switched Off and 17-K1 kept stopped.
g) 17-K-3 is kept running with normal discharge set pressure.
h) Reactor inlet temperatures are steady at 360 deg C i.e. the temperature at
which oil in is to be done.
i) Cooling water is in use in all water coolers/condensers and air coolers are
in service.
j) Blinds from the reformer feed filters are removed.
5.5
FEED INTRODUCTION:
The reformer feed is introduced in 10 minutes at 60% capacity i.e. 40 Ts/Hr, with
20 Ts/Hr in each of the two feed flow controllers, FC-1501/1502. Feed injection
must be done quickly enough to insure a minimum flow on the fresh catalyst.
After oil in, stop the H2 injection to the reformer loop and set the pressure
controller on15-V-2 gas (PC-1507), in Auto at design conditions.
CRU- 05 05
When liquid appears in separator drum (15-V-1) & level is 50%, start 15-P-1 and
send liquid to 15-V-2. When level in 15-V-2 reaches 50%, start 15-P-2 and send
liquid to LPG absorber drum, 15-V-3. When level in 15-V-3 reaches 50%, start
15-P-3 and feed the stabilizer as smoothly as possible. Route LPG to OffSpec(not under production due to low hydrocracking reactions)
The unit operation is continued at low severity. The low severity operation allows
to lower the water and H2S content in the recycle gas without any harm to the
catalyst.
The low severity operation is characterized by:
1) A higher than design H2/HC ratio (with feed at 60% and recycle gas
compressor at full capacity).
2) Separator drum pressure higher than normal.
3) Temperature, which is increased step by step as water content in the
recycle gas drops.
Follow the below mentioned steps for raising the severity of operation:
A) Raise the temperature to 400 deg C at the rate of 20 deg C per hour. Start
C2Cl4 injection with the reformer feed @ 5 ppm wt. Stabilise the unit
conditions at this temperature.
B) Raise the temperature to 450 deg C at the rate of 25 deg C per hour. Keep
this temperature as long as the water content in the recycle gas is higher
than 200 ppm vol. Establish normal gas flow to the reduction chamber and
bring the reduction gas heater outlet temperature to 430 deg C.
C) When the water content in the recycle gas drops below 200 ppm, increase
the reactor inlet temperatures to 460 deg C in one hour. Maintain these
conditions till the recycle gas moisture is higher than 100 ppm vol.
D) When the water content in the recycle gas drops below 100 ppm, increase
the reactor inlet temperatures to 470 deg C in one hour. Maintain these
conditions till the recycle gas moisture is higher than 50ppm vol.
CRU- 05 06
E) When the water content in the recycle gas drops below 50 ppm, increase
the reactor inlet temperatures to 480 deg C in one hour. Maintain these
conditions till the recycle gas moisture is higher than 30 ppm vol. Now also
reduce the chlorine injection with reformer feed to 2 ppm wt. Decrease the
separator drum pressure to 3.0 kg/cm2 g in two hours.
5.6
5.7
REGENERATION START-UP:
Regeneration of CRU catalyst is started when the coke content is higher than at
least 3%. Below 3% coke level on the catalyst, the regeneration is unsteady and
can be unsafe. For checking the coke content of the catalyst, catalyst sample is
taken from the lock hopper after transferring at least 3 or 4 batches of catalyst.
By this means, we can be sure that we get a true representative sample of
catalyst from the last reactor. After the coke on the catalyst is found more than
3%, catalyst regeneration can be started.
Procedure for the catalyst circulation start-up and regeneration is as:
a) Start N2 lift loop. Set the bias between the separator drum pressure,
15PC-05 and the N2 compressor K.O. drum pressure, 17PC-62 at 0.02
bar.
b) Start regeneration loop compressor with pure N2 and establish normal
flows through the burning and calcination zones in Auto mode. Pressure of
the regeneration loop, 17PC-61 is set with bias of 0.7 Kg/cm2 over the first
reactor pressure, 17PI27.
CRU- 05 07
CRU- 05 - 08
n) In case after switching over the air, temperature rise is observed in the
calcination zone, immediately switch back the air to the burning zone. This
action
o) should be very fast otherwise the temperature rise is very fast and can be
dangerous.
p) Check carefully the operation of the loop trim cooler, washing drum,
caustic solution circulation etc. The circulating caustic solution should be
analysed for total sodium concentration (to be kept higher than 3%) and
pH between 8.5 & 9.5. The operation of 17DR-1 should be ensured to be
on normal conditions.
q) The O2 content in the calcination zone should be between 4 to 6% vol.
Ensure that the temperature in oxy-chlorination zone is above 470 deg C
and then start C2Cl4 dosing to the regenerator at recommended dosing
rate. The dosing rate of C2Cl4 is adjusted in proportion to the catalyst
circulation and to the chlorine level of the spent catalyst in the upper surge
drum. Catalyst samples should be periodically taken to regeneration and
the chlorination conditions.
CRU- 05 - 09
Proposed by AXENS
CRU- 05 10
1.
Scope
This document presents detailed information regarding the activation that is to be performed
for freshly loaded reforming catalyst in its oxide state, before start-up (feed-in).
To ensure that all the catalyst in the Aromizing and CCR units is dried and reduced, catalyst is
circulated through the reactors and regenerator. Instructions and guidelines for the catalyst
circulation are provided in a separate procedure SOG - Reforming and CCR unit catalyst
circulation procedure.
2.
Safety precautions
Personal protective equipment as per Owners Standard Operating Procedures for field
operators / common field tasks.
3.
Reference document
Manpower
1 supervisor,
5.
Procedure
99.5 % vol.
0.1% vol
50 ppm vol
0.2% vol
100 ppm vol
1 ppm vol
20 ppm vol
Each section as defined in AXENS Operating Instructions has been leak tested previously.
The reaction section of Reforming and the nitrogen and regeneration sections of CCR unit
have been dried out in accordance with AXENS procedure SOG - Reforming and CCR unit
initial dry-out
procedure.
Catalyst has been loaded in Reforming reactors and in the regenerator and the catalyst
circulation vessels of CCR unit in accordance with AXENS procedure SOG - Reforming
and CCR unit catalyst loading procedure.
Compressors have been isolated; purged with N2 and left under an atmosphere of pure N2.
Blinds have been removed on all process lines between the sections (if any remain) - with the
exception of Recontacting and Stabilization sections.
Blinds have been removed on all safety valves to flare.
Hydrogen lift gas exchanger PSV and Reduction exchanger PSV are routed to flare
Swing elbows have been turned to the flare :
o
the exchanger must be depressurized only from the effluent outlet (separator drum).
Shut-off the steam and immediately pressurize the section with fuel gas or hydrogen to
prevent vacuum as steam condenses. Dedicated lines are provided for this purpose,
connected to the upper section of the stabilizer respectively for fuel gas and
hydrogen. The fuel gas/hydrogen is admitted, the system will cool down, and
condensate can be drained off. The column is now ready for charging with naphtha.
5.2. Catalyst drying out
o
The same nitrogen specification will apply during drying out step. Maximum impurities level
shall be confirmed before introducing nitrogen into the system:
N2
O2
H2O
H2 + HC
CO + CO2
Chlorine
SO2
99.5 % vol.
0.1% vol
50 ppm vol
0.2% vol
100 ppm vol
1 ppm vol
20 ppm vol
system
shutdown
and
establish
nitrogen
Load up the nitrogen compressors as required, up to 100% if necessary for obtaining the
required lift gas flow rates to lifts 2, 3 and 4 for catalyst circulation during the catalyst dry-out
see AXENS procedure SOG - Reforming and CCR unit catalyst circulation procedure.
For each of the five lifts, the total nitrogen gas flow must be set according to relevant
calculation block result, using the following calculation parameters (to be entered by the board
operator):
o
Note: The aforementioned parameter values are valid for this particular catalyst
circulation before startup only.
Capacity of the nitrogen compressors permitting, increase the nitrogen flow rate to the
reduction chamber maximum achievable.
If necessary, decrease the set point of nitrogen compressor K.O. drum pressure below 3.5 bar
g, to avoid discharging nitrogen from separator drum pressure control. While lowering the
pressure, make sure that compressor discharge temperatures remain below alarm settings.
Then, commission nitrogen compressor K.O. drum differential pressure controller with the
prevailing pressure difference as the set point. Once tuning of the controller is satisfactory it
can be left in AUTO mode.
Commission the Elutriation blower and operate it at 80% of design capacity.
Tune pressure and flow controllers for the nitrogen compressors and lifts as required
before leaving them in AUTO mode.
Stop primary gas flow for the lift pots 2, 3 and 4. Unload the nitrogen compressors as
required.
Stop firing for the Reforming heaters, then stop the recycle compressor.
Stop seal gas flows for the lower hoppers 2, 3 and 4.
The reaction section and the hydrogen and hydrogen rich gas sections can now be prepared
for the introduction of hydrogen, to perform the reduction of the Reforming catalyst.
5.3. Catalyst reduction
5.3.1. Preparation
Close double block valves on the following lines.
o
Between recycle compressor suction and nitrogen lift gas compressor suction
Between nitrogen lift gas compressors discharge and hydrogen lift gas exchanger
Electrolytic hydrogen shall be used for the reduction of the catalyst metal oxides. The quantity
of hydrogen necessary to perform the reduction step is N times the volume of the reaction and
recontacting sections, N being 1.3 times the start-up operating pressure. This quantity takes into
account maintain of the pressure in reaction section up to the oil-in. As an alternative, hydrogen
produced by a steam reforming + PSA unit (99.9 vol% of H2, H2O < 100 vol ppm and CO +
CO2 < 20 vol ppm) can also be used. Both of them being dry and hydrocarbon free will allow
reducing the metals oxides in a proper way. In several cases, as to ease the operation of recycle
gas compressor reluctant to operate with low molecular weight, it is possible to add nitrogen to
the pure hydrogen to adjust the molecular weight of the recycle gas. In such a case the hydrogen
purity must remain higher than 60 vol%. If none of the above mentioned hydrogen gas is available
it is possible to use hydrogen rich gas from a reformer unit, mixed with nitrogen. Hydrogen purity
must stay higher than 75 vol% and C2+ content shall be limited to 2 vol% maximum.
Set pressure controller of the separator drum at 3 bar g.
Increase the pressure of the separator drum up to 2.8 bar g: Nitrogen is displaced by
hydrogen from recycle gas compressor discharge to separator (compressors are isolated and
purged separately).
Perform a 2 hours leak test then start-up the recycle gas compressor.
Check again all the flanges for leaks using an explosimeter.
All interlocks related to catalyst circulation are made operational.
5.3.2. Operation
Start the recycle compressor. Increase the capacity up to the maximum and circulate
hydrogen gas in reaction section. Due to nitrogen dilution that increase molecular weight of
the circulated gas, recycle compressor transient operating conditions are closed to normal
ones. Particular precautions shall be taken to keep a minimum of 60 vol% of hydrogen in the
circulated gas.
Commission the hydrogen purity on line analyzer.
Start the H2 rich gas compressor at 50% capacity and increase the HP absorber drum pressure
recycling all the gas to the separator drum through the spill back.
Catalyst
heating-up
and
Light on the burners of the pre-heater and inter-heaters and increase the temperatures at
the inlet of reactors up to 300C at the rate of 40C/h.
Set the flow control to reduction chamber at 80% of design capacity and pressure
difference control between reduction chamber outlet and first reactor at 0.1 bar.
Switch on the reduction chamber electrical heater and increase its outlet temperature up to
300C at the rate of 40C/h.
When the temperature of 300C is reached in the reactors, start catalyst circulation. Set
the catalyst circulation flow at the maximum compatible with the P in the reaction section. If
not possible, catalyst circulation flow should be performed by batch.
Increase the temperature up to 480C at the reactors inlets and at the reduction chamber inlet
at a rate of 40C/h.
Stabilize the temperatures until the difference between inlet and outlet of the reactors is
lower than 30 C.
Maintain this temperature for a minimum of 2 hours until the total water drained at the low
points is lower than 0.05 wt% of the catalyst weight per hour.
Drained water quantity during the reduction step must be strictly recorded by field operators.
Owing to the difficulty of sustaining a steady catalyst circulation when the reaction section
is under hydrogen (low DP in reactors), this step shall be maintained long enough to ensure
that the catalyst contained in the upper and lower hoppers has been reduced.
Decrease then temperatures at reactors inlets down to oil in temperature 440C at the rate of
40C/hour.
Decrease reduction chamber inlet down to 400 C at the rate of 40C/hour.
Stop catalyst circulation: isolate the manual catalyst tight valves under the lower hoppers.
500
40C/h
Oil In
400
300
H2 PRESSURIZATION TO 2.8
BAR G
START CATALYS
T
200
40C/h
40C/h
CATALYST CIRCULATION
STARTED
CIRCULATION
500
400
300
200
Regeneration start-up
20C/h
100
2h
0
hours
Proposed by AXENS
CRU- 05 - 11
1.
Scope
The purpose of this procedure is to oil-in the Reforming unit from low severity conditions up to high
severity and start the catalyst circulation.
2.
Safety Precautions:
Personal protective equipment required
3.
Manpower:
2 board operators in the control room, 1 supervisor, 1 Axens supervisor in the control room,
4.
Prerequisites:
The status of the Reforming unit is as follows:
o Reaction section is under H2 at start-up pressure.
o Check that blinds have been removed: at separator bottom pumps (suction and discharge), and
at LPG absorber pumps (suction and discharge).
o Level with heavy hydrotreated naphtha into separator drum has been performed at 20% above
LAL.
o Separator bottom pumps are commissioned and started, circulation is performed through the
mini-flow line, strainers have been cleaned after a short cold close loop circulation,
o
H2 rich gas compressors are operating with spill back valves full opened, o
Catalyst
circulation is stopped.
o The regeneration loop is in stand-by: electrical heaters are in service (maximum 300C
outlet temperature), the regeneration loop compressor is in service, air injection being closed.
o
Outlet temperature of the reduction heater is maintained at 400C, and the flow is set to
Differential pressure between the reduction chamber and the first reactor is set at 10 kPa.
All instruments of the recontacting section are commissioned. A last check of all other
instruments in the reaction section and nitrogen section is made, including flowmeter orifice
correction.
Batch of chlorine solution (20 wt% of chloriding agent in hydrotreated naphtha) has been
prepared o Chlorine pump for injection in the feed has been commissioned
o
Note: During the oil in and until the reaction section operating conditions are stabilized, the water
content in the recycle gas must be recorded every hour.
5.
Feed specifications
A batch of desulfurized naphtha will be used as start up feed for the Reforming unit. All possible
precautions must be taken to ensure this naphtha batch is free of water. Then it is strongly
recommended to treat desulfurized Naphtha from storage through HDT Stripper Column.
When the Stripper bottom products reach water content lower than 10 wtppm switch it to the
reformer reaction section.
The specifications of the feed acceptable for the startup are: o feed with similar ASTM distillation than
design feed
o impurities according to the following:
Poisons
Source
Arsenic
5 ppb max
Cracked Naphthas
Lead
5 ppb max
Recycled slops
Copper
Corrosion
Mercury
ppb max
Naphtha - condensates
Iron Silicon
Corrosion
Nickel
Additives (foaming)
Chromium
Corrosion Corrosion
Organic nitrogen
Total sulfur
Halogens
ppm max
Water
and 1 ppm max
oxygenated products
lower
than
(start up only)
10
ppm
6.
If the stabilization section was inerted with steam it has been subsequently pressurized with fuel gas.
_ If the stabilization section was inerted with nitrogen, purge nitrogen to vent or to flare,
then pressurize with fuel gas.
Fill-up the bottom of the stabilizer with desulfurized naphtha from storage through:
_ Start-up line to the discharge of the separator bottom pumps (by-pass of the recontacting section),
_ Open valve to allow separator drum filling up. Commission and check the level
measurement instruments. Establish a level around 40%.
_ Start the separator bottom pump through the mini-flow line. Switch from one pump to the
other to check pumps operation and clean the strainer. After this checking, the level of the
vessel can be decreased to 10% and the pumps can be shutdown.
_ Route the hydrotreated naphtha from the bypass line to LPG absorber drum
_ When LPG absorber drum level is established at 40%, start LPG absorber bottom
pump, _ Then route hydrotreated Naphtha to Stabilizer.
_ Switch from one pump to the other to check pumps operation and clean the strainer.
When the stabilizer bottom level indicates 40%, route bottom of the column to HC dry slop tank
until liquid is clear. Then fill-up for dilution the sulfiding agent drum and chloriding agent drum,
then stop the naphtha make-up and:
_ Close flow control valves
_ Establish a close loop around the stabilizer reboiler through the stabilizer reboiler pump
(if any).
_ Set the flow at design conditions.
_ Start the stabilizer air cooler with the manual louvers fully opened. _ Commission cooling
water to the overhead trim condenser
_ Light the stabilizer reboiler burners and slowly warm up the column (or line up steam in
case of steam reboiler)
_ Commission Reformate trim cooler Pressure should stay around 0.6 to 0.7 MPa g.
_ When the level of the reflux drum indicates 50%, start stabilizer reflux pump and send
reflux to the column.
_ Operate stabilizer on total reflux and establish normal operating conditions.
Note: Depending on the composition of the naphtha circulated to the stabilizer, it may not be
possible to bring the column to total reflux mode nor reach stable operation. In that case the
column shall be heated up and reflux will be set up after oil in only.
7.
When liquid appears in the separator drum, and the level starts to increase, route the
product to the recontacting drum section (control valve in manual mode) by using separator
bottom pump.
_ When liquid appears in the recontacting drum and the level is above 50%, start to feed
the LPG Absorber drum via level control valve.
_ When level start to increase through the LPG absorber, start the LPG absorber pump and
feed the stabilizer column (control valve in manual mode) going through stabilizer feed
chloride adsorber (Lead-lag Position).
_ When stabilizer column bottom level start to increase, start to route Reformate to off spec
tank until it reaches specification to be routed to on spec tank / downstream units.
_ Maintain sufficient duty at reboiler to maintain reflux conditions until reaching LPG
specification at Reflux Drum.
_ Start chloriding agent with injection pump to feed, starting rate 25 wtppm of pure component
related to feed. Dilution in the chloriding agent drum must be 20 wt% during this step.
Duration of this step is difficult to estimate so operation team can prepare daily a mixture
according to the moisture of recycle gas to save chemicals. Maintain HCl content in the
Recycle gas at a minimum value of 2 volppm and possibly below 5 volppm to avoid
excessive chlorination.
Note: Chloriding agent injection rates as well as HCl content in the recycle gas provided in this
procedure are estimated values. The purpose of this injection is to avoid excessive chlorine
elution from the catalyst as long as recycle moisture content is high. The injection rates
may be adjusted based on recycle/catalyst chlorine equilibrium, measured as HCl content
in the recycle gas (using draeger tubes). In case no HCl is detected in the recycle gas,
chlorine injection rate shall be increased until HCl detection.
_ Commission the H2 rich gas chloride adsorbers.
_ As soon as the pressure control to flare on the separator drum start opening, increase the
pressure at H2 rich gas compressor discharge to close the spill back valves by increasing
pressure of recontacting drum.
_ At the beginning of the operation, send H2 rich gas (pressure controller in auto mode) to
the FG network.
After the oil-in, the LPG production will start to increase slowly. Stabilizer being
stabilized and having reflux drum level around 50%,
_ When reflux drum is full of on-spec LPG and level is adequate, route LPG to fractionation.
9.
Low severity operation at reduced capacity
The low severity operation allows to lower the water content in the recycle gas, without
damage to the catalyst. It also enables a check of the operation of the catalyst circulation and to
carry out the reduction of this fraction of the catalyst which was at the very beginning in the
regenerator, and has not been contacted by H2 gas.
The low severity operation is characterized by:
o H2/HC ratio higher than 2.5 (feed at 60% and recycle compressor at full capacity).
o
Temperatures which will be increased first to 480C and then to 495C as the water
content in the recycle gas drops.
During the different steps the water content of the recycle will be determined by lab analysis
until it falls within the range of the on line moisture analyzer. During this time, the water content
in the recycle gas must be recorded every hour.
o
To check the chlorine in the recycle gas it is necessary to foresee HCl Drger tubes or
equivalent (range 1 volppm to 10 volppm).
IMPORTANT: From the moment when feed is introduced do not stop the recycle compressor
since this would favour a quick build up of coke on the catalyst. In case of emergency shut
down of the recycle compressor, shut-off heaters and feed immediately (refer to Emergency
shutdown).
9.1. Step at 480C
_ After the unit conditions are stabilized at RITs = 440C, in 4 hours, increase the
temperature at the reactors inlet to 480C at 20C/h. Stabilize the unit and keep this
temperature as long as the water content in the recycle is higher than 200 volppm.
_ Commission the purification unit (Refer to vendor procedure),
_ Set the reduction chamber inlet temperature to 430C. Set HV at tube side outlet of hydrogen
lift gas exchanger opening and PDV at tube side outlet of reduction exchanger set point at
10 kPa. When flows are stabilized, then increase reduction chamber inlet temperature to
480C (20C/h).
_ Set differential pressure between 1st upper hopper and reduction chamber at 15 kPa.
_ The HCl content in the recycle gas will be checked with Drger tubes. According to the HCl
content, the chlorine injection shall be adjusted with a injection target of 10 to 25 wtppm
depending on the moisture content in the recycle gas and measured HCl content.
_ Set differential pressure between fourth reactor bottom and nitrogen compressor suction
at 0.105 MPa g,
_ Set differential pressure between first reactor top and calcination inlet at 70 kPa.
_ Decrease the pressure at the separator drum down to normal operating pressure over a
two hours period.
Check that differential pressure controllers are operational and that pressure in both
regeneration section and nitrogen lift loop decreases in parallel.
_ Start the catalyst circulation in order to perform the reduction of the catalyst included
in the regeneration system as soon as reduction chamber is operating steadily at design
conditions.
_ After reduction of the total inventory of catalyst contained in the regeneration system, the
catalyst circulation rate is increased to fill the lock hopper in about 3 hours.
_ Take sample of catalyst every day in order to analyse carbon and chlorine contents. The
regeneration will be started when the coke level of the circulating catalyst reaches 3 wt%.
9.2. High severity operation
High severity at 60% capacity Step 1
_
Until now the unit is operated at 60% capacity, with maximum recycle gas flow.
Reactors inlet temperatures are stabilized at 480C.
_ When the moisture content of the recycle gas falls under 200 volppm, increase RITs up to
495C at the rate of 3C/h.
_ Reduce chlorine injection to 5 wtppm related to feed, by decreasing pump flowrate. (Same
diluted product at 20 wt% or change dilution and the flowrate accordingly).
Note: Feed rate may be increased from this step, at the rate of 2% per hour. Higher feed
rate helps decreasing recycle gas moisture faster. However the temperature being still
limited to 495C, operator must bear in mind that product quality main not be sustained
while increasing feed rate. Any product quality drop shall not be compensated by
temperature increase until next step.
High severity at 60% capacity Step 2
_ When the moisture content of the recycle gas falls under 30 volppm, increase RITs
up to the required temperature to meet aromatics specifications at the rate of 3C/h.
_ Stabilize the unit under these conditions.
_ Modify the chloriding agent tank dilution to get a dilution at 1 wt%.
_ Reduce chlorine injection down to 1 wtppm related to feed, with a chloriding agent
dilution at 1 wt%.
_ Check HCl content in the recycle gas. If HCl content is higher than 2 volppm, then stop
chlorine injection.
_ Start DMDS injection to feed as to have sulfur content in feed equal to 0.3 wtppm, having a
DMDS diluted at 1 wt% in hydrotreated naphtha. Maintain the H2S in the recycle gas below
1 volppm.
_ Check H2S content in the recycle gas. Value must remain below 1 volppm.
High severity at nominal capacity
_ Increase the feed by increments of 5% per hour. After each increment of feed, raise the
RITs by 2C.
_ Allow the unit to stabilize. A flow increase must always be achieved prior to temperature
increase.
Below 30
30 to 200
(temperature = 495C)
25
(temperature = 480C)
above 200
C
RECYCLE MOISTURE < 30 VOLPPM
RECYCLE MOISTURE < 200 VOLPPM
Capacity
3C/h
500
increase
495C stabilization
480C stabilization
3C/h
stabilization
CL INJECTION 5 WTPPM
CL INJECTION 1 WTPPM
20C/h
START CATALYST CIRCULATION
400
REACTORS TEMPERATURE
REDUCTION CHAMBER TEMPERATURE
PURIFICATION UNIT COMMISSIONED
2h
CRU- 06 - 01
STAND BY STATUS
Feed pump shut down.
Catalyst circulation and regeneration partially shut down (i.e. Cat
circulation stopped, Regeneration compressor 17 K-1 A/B and N 2
compressor 17K-3 A/B still on.
Air compressor running but air injection valves FCV-1701 & 1702
closed and blocked.
Recycle compressor 15K-1 is operation.
Heaters on and reactor inlet temperature at 400 oC.
Separator drum PCV to flare.
Reaction section and HP absorber section pressure maintained by H 2
make up from storage.
Stabilizer isolated, at total reflux.
6.2
CRU- 06 - 02
6.3
ii)
Or after decoking.
c) First all the steps are to be carried out for the long duration shut
down.
d) HP absorber Section is to be depressurized. Positive isolation is to
be done as follows;
i) Hydrogen make-up.
ii.
iii.
Bottom of HP absorber.
iv.
v.
Fuel Gas
e) Section is to be pressurized up to 4Kg/ cm 2 with N2 (Recycle
compressor) was isolate & under N2 pressure) and unit is to be
depressurized to flare & low points.
The above operation is to be repeated till (Hydrogen + Hydrocarbon)
content comes down to 0.2 or less than 0.2 volume %.
f) Now positive isolation between reaction section & HP absorber
section at the separation drum bottom.
PSVs & PCV & their by pass to flare are to be blinded. Remove the
blind of the separation drum PSV to atmosphere.
g) Ejector suction line is to be de-blinded & pull the vacuum of the
reaction section down to 0.5Kg absolute. Now break the vacuum by
Injecting N2 upto 0.1Kg (Guage).
CRU- 06 - 03
Note: Nitrogen lift loop & regeneration section are already under Nitrogen.
Take care for Nitrogen sweeping or vacuum. Also care should be
taken to avoid stress corrosion for the stainless steel equipment.
h) If the catalyst is at end of life, it shall be replaced by new one. The
coked catalyst will be dumped from the bottom of reactors and
regenerator under nitrogen atmosphere into the drums.
i) If the catalyst is to be reused after unloading, the alternate procedure
(Coarse decoking) must be used prior to unloading.
NOTE:
catalyst
6.4
CRU- 06 - 04
Keep the washing drum 17-v-5, caustic recycle pump 17-P-1 A/B
water injection pump, 17-P-2-A/B in normal operation.
Remarks: if the shutdown is to last a few hours, a more efficient fines
filters 17-G-1/G-2 back flushing can be performed, by decreasing lifts
A-D gas flows to 50%.
CRU- 06 - 05
CRU- 06 - 06
INTRODUCTION
The objectives, which will govern the steps to be taken in such a situation,
are;
To protect the operating personnel.
To protect the catalyst.
To protect the equipment.
Concerning the catalyst preservation, we must avoid.
An excessive gain in temperature which can change the structure of
the Alumina (>700 oC). To keep grain temperature below 7000c,bed
temperature, must never exceed the E.O.L. operating temperature.
The presence of hydrocarbons without a sufficient pressure of
hydrogen results in a rapid coke deposit and the possible formation of
catalyst cakes, which hampers the catalyst circulation and favours
channeling.
The quick depressurization of the Alumina support induces the formation of
catalyst dust and fines.
NOTE: SHUTDOWN CAUSES ARE HANDLED BY AUTOMATIC SHUT
DOWN TRIPS. THESE TRIP DEVICES MUST ALWAYS BE
OPERATIONAL.
BUT IN CASE OF FAILURE OR BY PASS OF THESE DEVICES, THE
PROCEDURES BELOW INCLUDE ALL THE ACTIONS TO BE
UNDERTAKEN BY THE OPERATORS ASSUMING NO ACTION BY THE
AUTOMATIC DEVICES.
The general course of actions to be followed in an emergency situation is
summarized here under:
Cut fire to all reaction heaters.
At the same time shut-off the liquid feed.
Maintain the reaction section pressure.
Isolate the reaction section from the HP absorber section.
CRU- 07 - 01
7.2
LOSS OF FEED
A loss of feed may result:
Either from a feed pump failure coupled with an unexpected delay in
starting the spare pump.
Or more likely from leaks or other difficulties in the feed line which
require to interrupt momentarily the feed.
When the feed is not available any more, the following steps must be
taken:
The recycle compressor 15k-1 being kept at its maximum capacity,
decrease the reactors inlet temperature to 400 0C (500c/hr), then
maintain these conditions in order to sweep hydrocarbons from the
catalyst.
At the same time, isolate reaction section from the HP absorber
section then PCV1507 on HP absorber 15V-2 then close block valves
on the hydrogen rich gas lines to users and fuel gas.
Shutdown the catalyst circulation and the regeneration.
Increase
the
separator
drum
15V-1
pressure
to
the
value
CRU- 07 - 02
IFP furnaces will trip on low recycle flow interlock. If stabilizer furnace
is on line cut off firing and close 15FC09.
At the same time shut-off the two feed FCVs 1501/1502 and close
the corresponding block valves.
Watch the heaters tube skin temperatures. If there is a runaway trend,
open air dampers and inject snuffing steam.
Increase the separator drum pressure to the value recommended for
start up/shutdown.
Isolate the reaction section from the HP absorber section while
closing the PCV-1507 on the HP absorber 15-V-2, then close block
valves on the H2 rich gas lines to users and fuel gas.
Shutdown the reduction heater 17-EH-3 and close the H2 rich gas
FCV-1710 to reductor 17-V-11 and the outlet DPCV-1702.
Shutdown catalyst circulation and regeneration.
When the levels start to decrease in the separator drum 15-V-1, HP
absorber 15-V-2, LPG absorber 15-V-3, and stabilizer 15-C-1, Shutdown the related pumps and isolate the control valves by block
valves. Keep the stabilizer 15-C-1 at total reflux conditions.
Let the reactors cool down. This could take several days because of
the lack of hydrogen circulation.
Keep the pressure of the reaction section by injection H 2 rich gas from
the header or from H2 storage.
CCRU OPERATING MANUAL
PART-C
CRU- 07 - 03
7.2.2 ABSORBER
FAILURE
FEED
PUMPS
OR
STABILIZER
FEED
PUMP
This situation requires the same actions as for FEED LOSS to the unit.
7.2.3 REBOILER PUMPS 15-P-5A/B FAILURE
As it is impossible to send to storage or to other users un-stabilized
gasoline, this is equivalent to the loss of feed, as the feed charge must be
cut-off immediately and same action is to be taken as for FEED LOSS to the
unit.
7.3
UTILITIES FAILURE
7.3.1 Fuel Gas:
All burners (reactor preheater and heaters, reboiler heater) will shut down.
Cut off feed immediately and proceed as per FEED LOSS with however the
following difference: in order to ensure the highest possible temperature for
hydrocarbon sweeping with the recycle gas, air to reactor heater burners
(primary and secondary air) must be closed.
The recycle compressor 15-K-1 is shut down when the reactor temperatures
fall below 2500C.
7.3.2 Cooling water failure:
In case of partial cooling water failure, it should be sufficient to reduce the
severity and the fed flow rate to the reaction section as to maintain
reasonable vessels and products temperatures. Watch carefully pumps and
compressors for possible overheating.
CRU- 07 - 04
In case of total cooling water failure the unit must be shut down:
Cut-off fire to all the reactors heaters.
Feed control valve FCVs 1501/1502 to be closed and down stream
block valve is to be isolated.
Keep the recycle gas compressor 15-K-1 in service as long as it is
possible without risks for the machine, in order to cool down the
heaters tubes and the catalyst.
Simultaneously with the heaters and feed cut-off:
-
pressure
to
the
valve
CRU- 07 - 05
CRU- 07 - 06
Check that catalyst circulation is stopped and that the following safety
valves are properly closed:
CRU- 07 - 07
S No
1
2
3
Details of action
Inform S/I and alert FO about emergency
Inform Unit Incharge and RSM about
disturbance
Inform MSQ, OM&S regarding change in
Routing
Action By
PO
SI & PO
SI & PO
FO & PO
FO & PO
FO & PO
SI & PO
SI & PO
CRU- 07- 08
Feed and heaters are shut down, catalyst circulation and regeneration
sections are stopped. The reaction section is isolated from the HP
absorber section and cooled down under an atmosphere of hydrogen.
Recycle compressor is stopped and isolated under nitrogen.
The stabilization section is isolated from the HP absorber section.
Both are under an atmosphere of hydrogen or fuel gas.
CRU- 08 01
8.2
Make sure that the previous shut down sequence was correct i.e. the
circulation of catalyst has been stopped first and then air to burning
zone and calcination. If yes proceed to the next step.
Start regeneration loop compressor, if required, control flow in manual
mode through FCV-1716, switch to auto.
Adjust flows to the combustion beds and to calcination through PDV1706 A and B respectively.
Set bias between first reactor top and regeneration loop pressure at
0.7 bar-if required i.e., if compressor has to be restarted.
Start air compressor if required.
Check O2 analyzers are ready for use.
Set burning gas heater outlet TIC-1751 at 450 0C.
Set calcination heater outlet TIC-1752 at 530/535 0C.
Check that first burning zone inlet temperature is approximately
4150C.
Make sure caustic recycle pump, water injection pump and washing
system operates satisfactorily.
Open the FV 1701 and FV 1702 (air flow to 2 nd burning zone and to
calcination) and adjust set points to the previous ones.
Switch on cascades between oxygen analyzers and FCVs when the
required O2 content has been reached.
Open ON/OFF remote operated valves UV 1715 on regenerator
bottom pipe.
Start the catalyst lifts. First from last reactor to regenerator etc.
Set PDC-1715 on the lift from the last reactor to the regenerator at its
design figure.
CRU- 08 02
If at the previous shutdown, the air injection was stopped prior to stopping
the catalyst circulation, some coked catalyst has entered the calcination
zone. Special caution must be taken at restart. At the beginning air must be
directed exclusively to the burning zone and none to the calcination zone.
Only when the catalyst contained in the calciation / oxychlorination zone has
been replaced with catalyst from the burning zone air can be directed to the
calcination zone again.
8.2.2 After a total shutdown
Note:
In normal steady conditions and design feeds, the unit normally operates
with a coke content on the catalyst between 4 to 6% wt.(12.).
However the Reforming unit can be maintained on stream without the
regeneration section for some period of time.
In this case the limiting factor being the coke deposit, the lower the severity,
the longer this period. It is then recommended to reduce reactor
temperatures to approximately 4800C and flow to approximately 60% with
maximum recycle rate in order not to significantly exceed the 6% wt coke
deposit. The period without regeneration might then last up to two weeks.
However regeneration with coke deposit higher than 6% wt have been
carried out. In this case, operators must bear in mind that the coke burning
capacity (kg/hr) of the unit is limited. Consequently upon restart of the
regeneration they must adjust the catalyst circulation rate taking account of:
CCRU OPERATING MANUAL
PART-C
a)
CRU- 08 03
b)
80 Kg/hr
10%
Qcata (kg/h)
wt
CRU- 08 04
CRU- 08 04*
GENERAL
The main causes of concern related to process and utilities for the reformer
unit are:
Unexpected decrease of octane number.
Loss of reformate yield.
Unexpected delta T reduction in the first catalytic bed.
High hydrocracking rate and risk of a temperature run away.
High pressure drop in the reactor or regenerator.
Besides above, mechanical troubles or failures, which hopefully do not result
in immediate shutdown, must also be considered. The most frequent are:
Failure of regeneration.
Failure of the nitrogen lift gas system.
Failure of chlorine injection.
Failure of catalyst circulation.
Washing section default.
Difficulties in controlling the regeneration temperature.
9.2
CRU- 09 01
CRU- 09 02
9.3
CRU- 09 03
9.4
CRU- 09 04
Generally hydrocracking does not occur in the first reactor because the
average temperature is lower.
But the most worrying aspect of a decreased delta T is when it cannot be
related to one of the above reasons and results from a permanent
poisoning with metals.
Lead, arsenic and other metals are very severe catalyst poisons.
Due to the very high poisoning activity of the metals, the catalyst in the
first reactor is affected first, and the delta T through this reactor
decreases. The endothermic reactions (naphthenes dehydrogenation)
move then to the 2nd reactor, which exhibits an unexpected high delta T.
Heavy metals generally result either from the crude processed or from a
poor operation of the upstream hydrotreating Unit. Reprocessing leaded
gasoline (not a common occurrence to day) can also cause catalyst
poisoning.
Metals poisoning requires the dumping of the catalyst load.
9.5
i.
ii.
A too high severity (either a too high temperature at reactor inlet or a too
low space velocity).
iii.
i.
ii.
Not to introduce feed for the first time on a fresh catalyst, at temperature
higher than 3600C. For a subsequent restart, the temperature limit can be
increased to 4250C.
When increasing throughput, increase flow first and increase temperature
afterwards.
iii.
CRU- 09 05
iv.
v.
i.
ii.
Increase the feed rate to full capacity (to increase space velocity).
iii.
9.6
i.
Broken catalyst particles are being trapped between the vertical wires of
the central pipe and obstruct the open area. Then lines and dust also
accumulate and dust starts building a cake around the centre pipe. At this
point the pressure drop starts to increase significantly. Depending upon
the amount of dust the pressure drop increased more or less quickly.
ii.
It can take between one to six months to reach about 1 Kg/cm2. The
maximum allowable pressure drop is dependant upon the required
severity of the operation and throughput, as the recycle gas rate decrease
significantly.
CRU- 09 -06
9.6.2 Prevention
The best prevention is to record, on a periodic basis, the lift conditions
and the reactor pressure drop. The lift gas velocity must be adjusted to
the recommended velocity as calculated in 11.5.3. One must keep in
mind that when an excessive pressure drop occurs, it is already too late to
correct the cause. This is why maintaining the recommended catalyst
velocity in the pipe is so important.
9.6.3 Reactor cleaning
The only way to reduce the pressure drop when it becomes unacceptable
is to shut down the unit, unload the affected reactor and screen the
catalyst with a 1.7MM x 7MM mesh with a screening machine. The
catalyst must be stored in drums under an atmosphere of nitrogen.
Depending upon the time available for this unplanned shutdown and also
of the time to run until the next planned shutdown, the reactor may be
inspected and cleaned. Special attention must be then given to the
cleaning of the central pipe.
Then the screened catalyst will be loaded again. Generally a catalyst
make-up of 3 to 4 % is required.
9.6.4 Regenerator
An excessive pressure drop may also develop in the regenerator by the
same process as for the reactors(s).
9.6.5 Stop catalyst circulation
As soon as the pressure drop reaches 1.0kg/cm 2 Instead of normal figure
of 0.2kg/ cm2 a cleaning of regenerator is recommended. This operation
can be conducted without shutting down the feed to reforming unit.
Let the regeneration loop cool down: cut electric heaters and
continue nitrogen circulation if applicable
CRU- 09 07
Depending upon he downtime available and the time to run until the next
planned shutdown, decision may be taken to inspect the regenerator or not,
prior to reloading the catalyst.
9.7
FAILURE OF REGENERATION
Regeneration may have to be shut down if :
CRU- 09 08
Close manual special catalyst tight valves below the 1 st, 2nd reactor
as well as ON/OFF remote operated valves UV 1706 (3 rd reactor
bottom) and UV 1715, UV 1705.
9.9
For a few hours only: keep running without any change, the
chlorine loss will be compensated later.
CRU- 09 09
Increase
gas
flow
to
first
combustion
bed
(FIC
1716),
Increase gas flow through both the combustion beds (FIC 1716).
If does not work (i.e. TI-1706 still below 460 0C) then oxychlorination
step will not be satisfactory. Low coke content must be suspected.
1703/FIC-1702 on.
o Depending upon temperature excursion decrease or stop air
injection (FIC-1701).
CCRU OPERATING MANUAL
PART-C
CRU- 09 10
PDIC-1706 is set too low and part of the calcination exhaust gas
flows to the second combustion zone and by-passes the preheater.
This last cause is identified by:
An inlet gas flow to calcination (FIC-1705) greater than the outlet gas flow
(FI-1721).
CRU- 09 11
PART-C
CRU- 09 12
Proposed Modifications:
Considering the presently installed facilities (no nitrogen storage) in
Mathura and keeping in mind requirement of minimum possible line
modification to be carried out during the upcoming shutdown, AXENS
proposes following modifications to enable IOCL-Mathura to perform
emergency catalyst circulation.
Based on our discussion dated 18th Mar13, basis of modification
considers that Nitrogen is available from refinery nitrogen header in a
uninterrupted manner (Pressure Normal: 5.0
Kg/cm2g, Min: 3.5 Kg/cm2g
Proposed Modifications for Nitrogen Lifts (Lift 1 and Lift-4): Refer Drawing
No-017-02-41-1115 Rev-3
Proposed Modifications for Hydrogen Lifts (Lift 2 and Lift-3): Refer Drawing No017-02-41-1113 Rev 3
CRU- 09 13
PART-C
Lift pots below the 3rd reactor (4th lift pot) and below the regenerator (1st
lift pot) will be normally isolated by automatic safety gas tight valve
closure.
Close at least one out of the two manual valves located on each seal
legs below reactors 1 & 2.
Close the globe valves located on each seal gas inlet line (H2 injection)
to the 2nd and 3rd lower hoppers. This is to prevent gas backing during
lining-up of nitrogen to the system for emergency circulation.
Also, close FV-1710 located in the reduction gas inlet line of 4-H-017002-B5D-PR
Check that the PDV on seal gas inlet line to the 1 st lower hopper is
closed.
Check that the FV on seal gas inlet line to the 4 th lower hopper is closed.
Close the isolation valves of hydrogen lift gas supply at recycle gas
compressor discharge line (4- H-017-001-A5A-PR).
CRU- 09 14
PART-C
Open the manual valve(s) located on the seal leg below the reactor. This
operation ensures a catalyst transfer from the reactor to the related lift
pot.
Check lift pot is full by knocking the catalyst seal leg.
Close manual valve(s) on the seal leg.
Open the PDV located on secondary gas injection.
Open the bypass globe valve located on the FV of primary gas injection
to the lift pot.
Use Nitrogen to perform catalyst transfer from lift pot to upper hopper.
Check lift pot is empty by knocking the catalyst seal leg (or check level of
downstream upper hopper if available).
Close the bypass globe valve located on the FV of primary gas injection
to the lift pot.
Close the PDV located on secondary gas injection.
Repeat the above steps until related Upper Hopper level has decreased
by 3 to 5% to ensure catalyst bed release is done properly and that bed
is not packed anymore.
Each transfer step should end with empty conditions of the lift pot.
Continue till sufficient nitrogen pressure is available for catalyst lifting. In
case of Nitrogen pressure becomes lower than expected for catalyst
lifting, getting the lift pot empty allows catalyst bed release by filling the
pot by opening seal leg manual valve. If possible, cooling process must
be stopped until Nitrogen pressure can be recovered to lift the catalyst.
At the end of emergency circulation, Close Nitrogen valve at hydrogen
rich gas compressor inlet as well as at nitrogen lift gas compressor
discharge.
For safety reasons nitrogen supply to hydrogen circuit (E04 inlet) line
blind must be put back in closed position before sending hydrogen to the
catalyst circulation system.
To ensure catalyst bed release is done properly and that bed is not packed
anymore the most relevant criteria is the Upper Hopper level decrease.
Therefore it is advised to continue catalyst emergency circulation until relevant
level decrease is noticed (3 to 5 % depending of level fluctuation)
CRU- 09 - 15
PART-C
The hydrogen flow to the hydrotreatment and other users. Flow orifice
coefficient must be corrected to maintain the requested hydrogen make
up to the various users.
The flow of gas to the lifts B and C must also be recalculated and adjust if
required. This gas flow impacts on the flow of catalyst.
CRU- 09 16
PART-C
10.0
10.1
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19
20.
21.
22.
23.
24.
25.
26.
EQUIPMENT LIST
VESSELS/REACTORS/REGENERATOR/FILTERS/COLUMNS
/FURNACES
EQUIPMENT NAME
REFORMING SEPARATOR DRUM
RECONTACTING DRUM
LPG ABSORBER DRUM
STABILISER REFLUX DRUM
REGENERATION GAS K.O. DRUM FOR 15 DR-1
FLARE KO DRUM
C.B.D DRUM
FUEL GAS K.O. DRUM (EX CRU)
FG K.O. DRUM (FGEX 99 UNIT)
STEAM GENERATOR BLOW DOWN DRUM
STEAM GENERATOR DRUM
PHOSPHATE DOSING DRUM
LIQUID AMONIA RECEIVER
SUPER FEED SURGE DRUM
OIL TANK SEPERATOR OF NH3 COMPRESSOR-A
OIL TANK SEPERATOR OF NH3 COMPRESSOR-B
KNOCK OUT DRUM
OIL, AMONIA RECOVERY TANK
WATER DOSING TANK
CHLORIDING AGENT DOSING TANK
WASHING DRUM
REGENERATION LOOP DRIVE
CAUSTIC TANK
CHLORIDE AGENT TANK
UPPER SURGE DRUM
LOCK HOPPER
TAG NAME
15V-1
15V-2
15V-3
15V-4
15V-6
15V-8
15V-9
15V-10
15V-11
15V-15
15V-16
15V-17
15-V-20
15-V-21
15-V-22A
15-V-22B
15-V-23
15-V-24
15VT-1
15VT-2
17V-5
17 DR-1
17T-1
17T-2
17V-1
17V-2
CRU- 10 01
PART-C
27.
17V-4
28
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
17V-10
17V-11
17V-31
17V-34
17V-12
17V-21
17V-22
17V-32
17V-13
17V-23
17V-33
17V-6
015/R-1/2/3
17R-1
15 G 22A
15 G 22B
15 G 23A
15 G 23B
17G-1/2
17G-3
15G-1A/B
15J-1
CRU- 10 02
PART-C
50.
51.
52.
53.
10.2
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
15F-1/2/3/4
15F-5/6/7/8
15C-1
15CT-1
EXCHANGERS
EQUIPMENT NAME
REACTOR FEED, EFFLUENT (HELI TOWER)
REACTOR EFFLUENT TRIM COOLER
RECONTACTING DRUM FEED COOLER
RECONTACTING DRUM FEED/VAP EXCHANGER
RECONTACTING DRUM FEED/BOTTOM
EXCHANGER
RECONTACTING DRUM CHILLER
STABILISER FEED/BOTTOM EXCHANGER
STABILISER TRIM CONDENSER
HEAVY REFORMATE TRIM COOLER
REGENERATION GAS COOLER
AMONIA CONDENSOR
TAG NAME
15E-1
15E-2
15E-3
15E-4
15E-5
15E-6
15E-7
15E-8 A/B/C/D
15E-11
15E-12
15E-20
12.
13.
14.
15.
16.
17.
15E-21
15E-22A
15E-22B
17E-1
17E-2
17E-3
CRU- 10 03
PART-C
18.
19.
10.3
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
17E-4
17E-5
PUMPS
EQUIPMENT NAME
SEPARATOR BOTTOM PUMP
LPG ABSORBER FEED PUMP
STABILIZER FEED PUMP
STABILIZER FEFLUX PUMP
STABILIZER REBOILER CIRCULATION PUMP
WATER INJECTION PUMP
CHLORIDE INJECTION PUMP
CBD PUMP (VERTICAL)
15K-1 AUX L.O. PUMP
EMERGENCY LUBE OIL PUMP
COOLING WATER PUMP
REFRIGERATION COMPRESSOR LUBE OIL PUMP
PHOSPHATE DOSING PUMP
BFW CIRCULATION PUMP
CAUSTIC RECYCLE PUMP
WATER INJECTION PUMP
CAUSTIC INJECTION PUMP
CHLORIDE INJECTION PUMP
REGENERATION LOOP COMP MAIN LUBE OIL
TAG NAME
015PM-1A/1B
015PM-2A/2B
015PM-3A/3B
015PM-4A/4B
015PM-5A/5B
015PM-8A/8B
015PM-9A/9B
015PM-10
15K-1 M-1
15K-1 M-2
15X-M2A/B
15X-M1A/B/C/D
15PM-16A/16B
15PM-15A/B
17P-1A/B
17PM2A/B
17PM3A/B
17PM4A/B
17K-1 M1A/B
PUMP
CCRU OPERATING MANUAL
CRU- 10 04
PART-C
SL.
NO.
20.
EQUIPMENT NAME
TAG NAME
17K-3 M1A/B
21.
22.
23.
17K-1A
LO PUMP A
17K-1A
LO PUMP B
17K-1B
LO PUMP A
17K-1B
LO PUMP B
17-K-3A LO
PUMP
24.
25.
26.
17-K-3B LO
PUMP
27.
15K-1 M2
10.4
SL.
NO.
1.
TAG NAME
015AC-01A
/B/C/D/E/F
2.
3.
4.
5.
6.
15AC-4A/4B
17AC-1
17EH-1/2/3
15EH-1
17 S-1
CRU- 10 - 05
10.5
SL.
NO.
1.
2.
3.
4.
5.
6.
7.
10.6
S.
NO
.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
EQUIPMENT NAME
TAG NAME
15-X-MA/MB
15-X-M3
15KM-3
15KM-2A/2B
17KM-1A/B
17KM-3A/B
15K-1
EQUIPMENT NO.
15 PSV 1501
15 PSV 1502
15 PSV 1503
15 PSV 1504
15 PSV 1505
15 PSV 1506
15 PSV 1507
15 PSV 1508
15 PSV 1509
15 PSV 1510
15 PSV 1511
15 PSV 1514
15 PSV 1515
15 PSV 1901
15 PSV 1902
DESCRIPTION
ON 15-V-1
ON 15-V-1
ON 15-K-1
ON 15-K-1
ON 15-P-9A
ON 15-P-9B
ON 15-P-8A
ON 15-P-8B
ON 15-V-2
ON 15-V-3
ON 15-C-1
ON 15-DR-1
ON 15-V-4
ON 15-V-16
ON 15-V-16
SET
PRESSURE
Kg/cm2 g)
5.3
5.3
8.8
9.0
18.1
18.1
18.1
18.1
7.8
18.3
18.3
7.4
18.3
20.0
20.0
No. IN
LINE
BOTH
BOTH
0NE
0NE
0NE
0NE
0NE
0NE
0NE
0NE
0NE
BOTH
CRU- 10 - 06
PART-C
16.
17.
18.
19
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
15 PSV 1903
15 PSV 1904
15 PSV 1905
15 PSV 2301
15 PSV 2302
15 PSV 5001
15 PSV 5002
15 PSV 5003
15 PSV 5004
15 PSV 5005
15 PSV 5006
15 PSV 5007
15 PSV 5008
15 PSV 5009
15 PSV 5010
ON 15-P-16B
ON 15-P-16A
ON SHS HEADER OF 15-V-16
ON 15-V-10
ON 15-V-11
ON 15-V-22A
ON 15-V-22B
ON 15-E-20
ON 15-V-20
ON 15-V-21
ON 15-V-23
ON 15-V-24
LUBE OIL PUMP A
LUBE OIL PUMP B
LUBE OIL PUMP C
19.0
19.0
18.5
7.8
7.8
21.0
21.0
21.0
21.0
18.0
18.0
18.0
16.0
16.0
16.0
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
15 PSV 5011
15 TSV 1516
15 TSV 1517
15 TSV 1518
15 TSV 1519
15 TSV 1520
15 TSV 1521
15 TSV 2601
17 PSV 1701
17 PSV 1702
17 PSV 1703
17 PSV 1704
17 PSV 1705
17 PSV 1706
17 PSV 1707
17 PSV 1708
16.0
7.0
7.0
7.0
7.0
7.0
7.0
7.0
10.0
8.9
8.9
7.2
9.5
9.5
11.5
11.5
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
CRU- 10 07
PART-C
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
17 PSV 1709
17 PSV 1710
17 PSV 1711
17 PSV 1712
17 PSV 1713
17 PSV 1714
17 PSV 1715
17 PSV 1718
17 PSV 1719
17 PSV 2001
17 PSV 2002
17 PSV 2003
17 PSV 2004
17 PSV 2005
17 TSV 1720
17 TSV 1721
17 TS V 2001
ON 17-P-4A
ON 17-P-4B
ON 17-V-10
ON 17-G-1
ON 17-G-2
ON 17-K-3A
ON 17-K-3B
ON 17-V-6
ON 17-V-4
ON 17-G-405A
ON 17-G-405B
ON 17-G-400
ON 17-G-402A
ON 17-G-402B
ON CWR EX-17-E-3
ON CWR EX-17-E-5
ON CWR EX-17-E-404
11.5
11.5
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
ONE
CRU- 10 - 08
PART-C
RECYCLE
GAS
COMPRESSOR
15K-1
I - 1503/ PREHEATER 15F-1
1504
70%
I -1505/
1506
8.2 T/Hr
I-1507/
1508
I
1509 /
1510
I - 1511
8.2 T/Hr
0.4 Kg/cm2
0.4 Kg/cm2
reboiler 1) Low
circulation
rate 15.15 T/Hr
through
heater
coils
FSLL-1565/A/B/C/D.
2) Fuel
gas
low-low
0.4 Kg/cm2
pressure PSLL 1581.
Hand with HS-1541.
Stabilizer reboiler 1) Stabilizer reboiler pumps 14.0 T/Hr
pumps 15P5A/P5B
low-low flow FSLL-1514.
ACTION
To cut off fe
by
clos
valves
1501/1502
To stop 15K-1
closing LV-15
1) To close
gas
va
UV-1511
To close p
valves HV-15
1) To close
gas
va
UV-1521
To close p
valve HV-152
1)
To close
gas
va
UV-1531
2) To
cl
pilot
va
HV-1531
1) To close
gas val
UV-1541.
To close p
valve HV-154
To start
second
pu
15P5A
15P5B
I 1512 Stabilizer
15V-4
I - 1513
To close L
shut down va
LV-1510.
To
cl
reformate S
valve LV-151
CRU- 11 - 01
PART-C
11.2
(UNIT 17)
The safeties are divided in two types according to the degree of safety requested,
there are
(A)
(B)
The software safeties are configured in logic blocks in the DCS, they are
referenced as sequences 17xx or interlocks/permissive conditions.
They are sequences 1703, 1711, 1712, 1713, 1714.
The hardware safeties are hardwired using relays technology or programmed in
PLC, Programmable Logic Controllers, they are referenced as Interlocks Ixxx.
They are I-1701, I-1702, I-1703, I-1704, I-1705, I-1706 Reductor heater stop.
In addition to the software described here below, we recommend also to duplicate
by software safety the hardware interlocks I-1701 and I-1702, specially if they are
hardwired.
(A) SOFTWARE SAFETIES CONFIGURED IN THE DCS
The purpose of the safety sequences is to force control valves to close/open in
case of abnormal conditions detected by on/off alarms or interlock devices.
When an abnormal condition is detected, the safety sequence forces the control
valve to close, overriding the normal operation in cascade or automatic mode.
To be able to restart the defaults must have disappear.
Initiated by
Action:
Restart:
CRU- 11 - 02
PART-C
low differential pressure between the first lift pot and the first lower
hopper (alarm on PDAL 1725)
CRU- 11 - 03
PART-C
the pressure difference between the reductor and the upper hopper
is low (PDALL 1730 on alarm)
the pressure difference between the reactor and the lower hopper is
low (PDALL 1731 on alarm)
CRU- 11 - 04
PART-C
CRU- 11 - 05
PART-C
alarm)
Low sealing gas flow (FALL- 1733 on alarm).
Low pressure of sealing gas (PALL- 1751)
Request by operator by action on HS1701,
Pollution of nitrogen by hydrogen or oxygen (AAHH-1705,AAHH-1704 on alarm)
CRU- 11 - 06
PART-C
CRU- 11 - 07
PART-C
15FD1906
15FD1906
15FD 04
15PD58
HS1514
(H.W.)Panel
PSLL1558
(H.W.)Panel
15PD 68
HS1521
(H.W.)Panel
PB 19
(H.W.) Panel
15PD 78
HS 1531
(H.W.) Panel
6
7
8
9
10
11
TAG NAME
DESCRIPTION
12
14.
PSLL1578
(H.W.) Panel
FV1501
(H.W.) Panel
15FD 1906
15.
15PD88
16.
HS1541
CLOSE 15F4 FG + PG UV1541 + HV 1541
(H.W.)Panel
PSLL 1588
15F4 FG LOW PRESS. BYPASS SWITCH
(H.W.)Panel
15FD65,A,B,C,D ANY ONE PASS V. LOW TRIP 15F4 UV 1541
13.
17.
18.
CRU- 11 - 08
PART-C
SL.
NO
.
19.
FSLL 1514
20.
15LD 08
21.
15LD 10
TAG NAME
DESCRIPTION
17LD 04
23
17AU01
24
17AD03
25.
17FD31
26.
17PD25
27.
17TU01
28.
17TU02
29.
17TU03
30.
17TU04
31.
HS1715
32
HS1701
17LD10
CRU- 11 - 09
34.
17PDD30
35.
17FD32
36.
17PD51
37.
17ASH04
38.
17ASH05
39.
HS1705
40.
HS1725
17LD12
17LD13
43.
17FD33
44.
17ASH04
45.
17ASH05
46.
17PDD31
47.
17PD51
48.
17LU01
49.
HS1706
50.
HS1726
CRU- 11 - 10
PART-C
SL.
TAG NAME
DESCRIPTION
NO
.
15K1 EQUIPMENT SAFETY INTERLOCKS
51.
52.
53.
54.
55.
56.
57.
58.
59.
60
61.
62.
63.
64.
65.
66.
67.
68.
PSL4001
MOS6
(H.W.) Panel
TSHH 4011
MOS7
(H.W.) Panel
PSLL 4002
A,B,C
MOS8
(H.W.) Panel
PSHH4060
A/B/C
MOS 9
(H.W.) Panel
PSHH 4060
A/B/C
MOS10
(H.W.) Panel
S.T. 4101 A/B/C
MOS11
(H.W.) PANEL
MOS12
(H.W.) Panel
CRU- 11 - 11
PART-C
SL.
TAG NAME
DESCRIPTION
NO
.
69.
MOS01
(H.W.) Panel
AAHH 4101
MOS 02
(H.W.) Panel
VAHH4102 A/B
MOS 03
(H.W.) Panel
AAHH 4102
MOS 04
(H.W.) Panel
TAHH 4101A
80.
MOS 05
(H.W.)Panel
HS1502 (Ebara
Emerg trip)
PSL 4001
81.
LSL 4001
82.
Governor speed
over RPM
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
17LU23
84.
TSH1707
85.
TSH1713
(TU11)
17LU26
86.
CRU- 11 - 12
SL.
NO
.
87.
17TU17
88.
17TU18
89.
17PD002A
90.
17PD002B
91.
TSHH 301A
92.
17TU101A
93.
17TU102A
94.
17TU101B
95.
17TU102B
96.
17PD301A
97.
17PD301B
98.
17PD101A
99.
17PD101B
TAG NAME
DESCRIPTION
CRU- 11 - 13
NITROGEN UNIT
1.0 INTRODUCTION
Inert gas is required on continuous basis as well as intermittently in CRU
process and as a utility for misc. activities such as purging & pressure
testing etc. In addition it is required on continuous basis for the inert
blanketing of hydrotreated naphtha tank. To meet the above requirement,
Nitrogen plant supplied by M/S BHPV using M/s Airliquide's cryogenic
process of air liquefaction has been installed as a package unit. The plant
is capable of generating 600 NM3 /Hr gaseous nitrogen which can be
supplied at various consuming points at 7.0 Kg/cm 2g through Nitrogen
header - I. For supply at a pressure of 12.0 Kg/cm 2g (through Nitrogen
header - II) as required in CRU process, a booster compressor is provided.
Depending upon the withdrawal of gaseous nitrogen from the Nitrogen plant,
the balance nitrogen can be withdrawn in liquid form and stored in liquid
Nitrogen storage vessel. Four nos. of liquid nitrogen storage vessels each
of 50m3 capacity have been provided. One gaseous nitrogen vessel of
capacity 10 m3 is also provided, which acts as buffer for the intermittent
consumption of gaseous Nitrogen in CRU process.
Nitrogen produced by cryogenic process i.e. by distillation of air at low
temperature is of the purity of 99.99 %, whereas nitrogen produced by
Pressure Swing Adsorption is of the purity of 99.8 % max.
N2- 01 - 01
NITROGEN REQUIREMENT
For CRU normal operations, Nitrogen is required at :
- De-sulfurised Naphtha (DSN) Tank blanketing 350 NM3/HR (continuous).
- Catalyst Regeneration 100 NM3/HR (continuous).
- Lock Hopper 9 NM3 every hour @ 108 NM3/HR for 5 minutes.
As utility, Nitrogen will be required during Start up & Shut down for Purging
and Pressure testing of different equipment and lines.
2.2
AIR REQUIREMENT
Two numbers of Air compressors (one running, one standby) each of
capacity 4500 NM3/HR (with discharge pressure of 8.0 Kg/cm 2g) have
been provided to meet the following requirement.
- 1870 NM3/HR Process air for the production of GN2 and LN2.
- 360 NM3/HR Dry air for CRU (Dew Point -40 oC).
- 2220 NM3/HR compressed air as Service air.
2.3
PRODUCT QUALITY
Unit is designed to produce Nitrogen of following quality :
2.4
Nitrogen
99.99 %
Carbon dioxide
Oxygen
Dew point
PRODUCTION PATTERN
The nitrogen required is withdrawn as a gaseous Nitrogen and the remaining
is withdrawn as liquid Nitrogen. Following is the production pattern from the
plant under normal conditions of operation:
STREAM
GN2 (NM3/Hr)
LN2 (equivalent GN2
NM3/Hr)
45
50
55
65
N2- 02 - 01
3.0
PRINCIPLE OF OPERATION
Air is composed of Oxygen (20.96 % by volume) and Nitrogen (78.11 % by
volume). In addition, it has 5 rare gases, which may be found in following
proportions:
Argon 0.93%, Neon 0.0015% (approx.), Helium 0.0005% (approx.), Krypton
0.0001 % (approx.), Xenon 0.000008 % (approx.). Varying quantities of
water vapour, Carbon dioxide, Hydrocarbons (mainly acetylene) and ozone
are also present in air.
In liquid state, oxygen and nitrogen form a mixture of two liquids, which are
miscible in all proportions. The liquid mixture can be separated into Oxygen
and Nitrogen by using the property of volatility difference of oxygen &
nitrogen. Nitrogen (boiling point - 196 o C) is more volatile than Oxygen
(boiling point - 183o C).
The boiling temperatures of the air, nitrogen and oxygen rises with increase
in the pressure. By raising the pressure alone, Air can't be condensed at
ordinary temperature. The maximum temperature at which these gases can
be liquefied is called "Critical Temperature". Above critical temperature, no
gas can be liquefied. The Critical constants of air, nitrogen and oxygen are :
Parameter / Componant
Critical Temperature,
oC
AIR
OXYGEN
-140.7
-118.9
38.45
51.34
NITROGEN
-147.1
34.6
N2- 03 - 01
4.1
4.2
REFRIGERATION SECTION
Air from the compressor discharge @ 2230 NM 3/Hr is cooled to a
temperature of 10o C for the removal of moisture to the maximum possible
extent. This is achieved by passing the air through the Refrigeration
Evaporator 40-E-12. Refrigerant (Freon-22) is evaporated in 40-E-12 to cool
the air to a temperature of 10o C. The cooled air enters into a moisture
separator (40-B-1), where the condensed water gets separated from the air
and is periodically removed through an air trap.
The Refrigeration system consists of Freon Compressor with Oil separator
(one running, one standby), Condenser (water-cooled), Suction liquid heat
exchanger (double pipe type) and evaporating cooler.
N2- 04 - 01
4.3
N2- 04 - 02
4.4
N2- 04 - 03
Item
Units
Flow
Operating
Pressure
Temp. at warm
end
Temp. at cold end
Heat Load
NM3/Hr
Kg/cm2g
oC
oC
Kcal/Hr
Air
1,820
Fluid
Pure N2 WN2(LP) WN2(MP)
500
1,270
1,200
7.4
7.08
0.32
3.5
15
13
13
-150
-166.7
-171.6
-179.2
-173.6
90,636
26,418
64,218
9,585
The pure gaseous nitrogen comes out from the top of the condenser at 7.4
Kg/cm2g and at -167.2 o C. A part of liquid nitrogen is drawn off as product
through the 40LC2242 and is received in liquid Nitrogen cold converters 40-
N2- 04 - 04
LIN-1 & 2. 40LC2242 control the level of Rich liquid bath of vaporiser 40E-4.
The flow, temperature and pressure of shell and tube sides of the 40-E-4 are
as under:
Stream
Units
Shell Side
Rich Liquid
Tube side
Pure N2
NM3/Hr
NM3/Hr
1,270
1907
---
1,407
NM3/Hr
Kg/cm2g
1,270
500
3.4
7.4
oC
-173.6
-171.6
Kcal/Hr
67,467
67,467
Fluid
Flow Rate (Total)
Liquid flow
Vapour flow
Operating pressure
Operating Temp.
Heat Load
4.5
N2- 04 - 05
and 40FV2222B opens from 50-100% and is connected with the impure
nitrogen line for venting. An on-line oxygen analyser 40AI2219 monitors the
oxygen content of Nitrogen gas. When the oxygen level goes above 3.0
PPM, 40AI2219 will open 40FV2222B for venting the impure nitrogen and
close 40LC2242 for stopping liquid nitrogen withdrawal.
N2- 04 - 06
N2- 04 - 07
5.1
STEPS OF REGENERATIONS:
The steps involved and the valves status during adsorption and regeneration
of the Adsorbers is as given below in the table:
STATUS OF CYCLOMATIC VALVES DURING
STEP
1
2
3
4
5
6
7
8
9
10
11
12
13
14
N D B F H K M P
C C C
C C C
C C C
C C C
C C C
C C C
C O C
ISOLATION
ADSORPTION
C C C C C C C O
DEPRESSURISATION ADSORPTION
C C C O C C C O
BLOWING
ADSORPTION
C C O C O O C O
HEATING ( 1 hr. )
ADSORPTION
C C C C O O C O
COOLING ( 2 1/2 hrs.) ADSORPTION
C C C C O O C O
ISOLATION
ADSORPTION
C C C C C C C O
PRESSURISATION
ADSORPTION
C C C C C C O O
CYCLIC OPERATION CONTINUES AS PER STEP No. 1 TO 14.
O : OPEN
C
C
C
C
C
C
C
O
O
O
O
O
O
O
C C C
C O C
O C O
C C O
C C O
C C C
C C C
C C C
C C C
C C C
C C C
C C C
C C C
C C C
: CLOSE
N2- 05 - 01
C
C
O
O
O
C
C
C
C
C
C
C
C
C
NOTES:
1. During the adsorption, the flow of air is from bottom to top where as in
regeneration the flow of waste nitrogen is from top to bottom.
2. Depressurisation IS COMPLETE ONLY WHEN pre-set TIME HAS
ELAPSED AND pressure IN ADSORBER IS LESS THAN pre-set VALUE AS
SENSED BY PSL-2215/2216*
3. Blowing is done with waste nitrogen WN2 through E-16 and will be
complete only when pre-set time has elapsed.
4. During Heating step, heater E-16 gets switched ON when WN2 flow of
385 NM3/Hr (as sensed by FSL-2217B) and indicated by 40FI2217 is
established. WN2 temperature at E-16 outlet is maintained at 150 oC.
Heating cycle continues till heating period has completed its pre-set time
(one hour) and temperature at Adsorber outlet has reached the pre-set limit
sensed by TSH-2214 B.
5. During cooling step, heater E-16 gets switched off. Flow of WN2 is
maintained at 385 NM3/Hr. Cooling step is completed after the completion of
pre-set time (2hrs. 30 minutes) and temperature after the Adsorbers has
reached the pre-set limit sensed by TSL-2214 B.
6. Pressurisation step is complete when pre-set time has elapsed and the
differential pressure between the Adsorbers is less than the pre-set value
(0.2 Kg/cm2) as sensed by PDSL-2207/2208*.
* Tags are for Adsorber R-2
FLOW SAFETY ON THE REGENERATION GAS:
FSL2217B ensures a minimum flow of 385 NM 3/Hr of WN2 during heating
step, If the flow decreases below this set limit, it will give an alarm
FAL2217B. During the heating step, it stops the heating in a time lag of 3-5
minutes if the flow is not established.
TEMP. SAFETY ON THE REGENERATION GAS:
It is foreseen a safety minimum +100 o C and another safety maximum
+300oC on the regeneration gas in automatic/manual operation. The safety
Maximum TSHH2209B causes an alarm and makes dead the resistance of
the Heater.
N2- 05- 02
N2- 05- 03
6.1
LUBRICATION SYSTEM
The lubrication system for the compressor is completely self contained and
mounted on the base plate. Oil is drawn from the oil reservoir located in the
base plate and passes through the oil pump. Two oil pumps are provided a
pre-lube pump and a main oil pump. The pre-lube oil pump, driven by an
electric motor, serves to prime the main oil pump and flood the compressor
bearings and oil lines before the compressor starts. The prelube pump
starts when the control panel is energized (turn on the switch which will start
the panel as well as POP) and runs until the compressor is up to speed and
the main oil pump develops oil pressure. The prelube pump stops
automatically between 15 - 40 seconds of the start of the compressor as per
the timer setting. The timer setting should be long enough to keep the pump
running until the compressor has reached full operating speed. When the
unit trips on the shutdown cycle, the prelube pump will start immediately and
will continue to run until the panel is de-energised.
N2- 06 - 01
After the compressor stops, the prelube pump should be allowed to run 20 to
30 minutes to cool down the compressor bearings. Seal air pressure
transmitter interlock prevents the prelube pump from operating if seal air
pressure is not established.
The main lube oil pump is a positive displacement type pump driven by the
main shaft. The oil from prelube pump / main oil pump is cooled in the dual
oil cooler and filtered in dual oil filter. The oil temperature is controlled by
adjusting the water flow at the discharge of the cooler. Enough water has to
flow through the oil cooler to maintain a normal operating temperature of 40
oC to 45 o C to the compressor bearings. The oil filter has 10 micron treated
paper element. The main pump discharge pressure is controlled by a relief
valve down stream of the oil filter. In the event of stopping the main driver or
power failure, the main oil pump will continue to supply oil to the bearing and
gears during coast down.
The oil pumps are equipped with an inlet strainer for protection against
foreign particles. Check valves in the discharge line of the prelube pump
and on the inlet of the main pump are provided to prevent reverse flow
through the pumps.
Relief valve allows the input pressure to the compressor to be raised or
lowered by adjusting the valve setting. A stream of the oil goes to both the
bearings of the motor through RO. The remaining oil passes through the
compressor bearings and drains into the reservoir. Low oil pressure
protection is provided by a pressure-sensing device that will trip the unit and
light the alarm light. Abnormal oil temperature protection is provided by
temperature sensing device set to trip the unit and light the alarm light. The
same device acts as interlock to prevent the unit from being started if oil
temperature is below the minimum. A wet element type 4 kW (415 volts)
lube oil reservoir heater is supplied to ensure adequate oil temperature for
compressor start up. An oil temperature control device is supplied that
automatically regulates proper oil temperature to the bearings by mixing hot
and cold oil at the oil cooler.
N2- 06 - 02
The lube oil used in the compressor must meet the following specifications
Viscosity at 100 oF ( ASTM D-88 )
Flash Point, Open Cup ( ASTM D-92 )
Viscosity Index ( ASTM D-2270)
Carbon Residue ( ASTM D-524 )
Steam Emulsion Number ( ASTM D-157 )
Total Acid Number ( ASTM D-974 )
Emulsification ( ASTM D-1401)
6.2
140-170 Cst
370 oF Min.
85 Min.
0.08% Max.
120 Max.
0.15 Max.
30 Minutes
CONTROL SYSTEM
The control system includes all devices necessary for starting and stopping
the compressor, controlling system pressure, and assuring safe operation
with respect to lubrication, vibration and temperature. The basic control
system is designed for constant pressure operation. The control system also
includes a surge-sensing device that protects the compressor from
sustained operation in the unstable surge region. The control system
provided for this compressor is 'AUTO-DUAL CONTROL PANEL'. The 'autodual' control panel functions as the modulate control in the 'modulate' mode,
but has an addition "Modulate + Two Step" control mode.
N2- 06 - 03
MODULATE CONTROL
Modulate type of control maintains the system pressure at a constant value,
which is accomplished by throttling the inlet valve within the compressor
throttle range. If the system flow demand is less than the minimum throttled
capacity, constant discharge pressure will be maintained by leaving the
throttled inlet valve at the minimum throttled capacity and venting the rest
through the bypass valve also called the unloading valve.
D
I
S
C
H
A
R
G
E
P
R
E
S
S
U
R
E
SURGE
LIMIT
100%
UNLOAD
THROTTLE
RANGE
RANGE
0%
CAPACITY
100%
The compressor is at full capacity when the inlet valve (CV-2) is fully open
and the unloading valve (CV-1) is fully closed. At full capacity the
compressor is operating at point "A" on the performance curve and the
controller will send the proper 'full load' signal to CV-1 & CV-2 when at point
"A" on the curve.
As flow demand decreases, constant discharge pressure is maintained by
reducing the flow delivery to the system by throttling the inlet valve (CV-2)
and keeping the unloading valve fully closed. The compressor will follow
flow demand changes between points "A" and "B" by throttling CV-2. As flow
demand is reduced and the maximum inlet throttle range is reached, the
compressor approaches its surge point.
N2- 06 - 04
To prevent the compressor from operating within the surge region, the
control signal keeps the CV-2 at the maximum inlet throttle point and meet
the lesser demand by blowing off surplus air through CV-1. The compressor
will follow flow demand between points "B" and "C" by throttling the CV-1.
Throttling the unloading valve provides capacity control from the minimum
throttled capacity to zero capacity requirements.
DUAL CONTROL
'Two Step' type of control operates the compressor between pre-set
pressures and cycles the compressors from full capacity to zero capacity.
D
I
S
C
H
A
R
G
E
P
R
E
S
S
U
R
E
SURGE
LIMIT
B
A
100%
TWO STEP
RANGE
0%
CAPACITY
100%
Two step is a load - unload type operation and is used when system
demand is less than 50 % of compressor capacity.
When the compressor loads in two steps, it will go to point "D" on the
performance curve. The inlet valve (CV-2) will be fully open and unloading
valve (CV-1) fully closed. As system pressure increases to a value equal to
point "B" on the performance curve, the two step control pressure switch will
cause the compressor to unload (point "C").
The compressor unloads by opening CV-1 and closing CV-2 to a position as
permitted by the unload limit regulator. As system pressure drops to a value
N2- 06 - 05
equal to point "D" on the performance curve the two step control pressure
switch will load the compressor.
AUTO DUAL CONTROL
The "auto-dual'" control panel functions the same as the modulate control
panel in the 'Modulate' mode, but has an additional "Modulate + Two Step"
control mode. Selection between Modulate and Auto dual control
(modulate + two step) can be made at the control panel.
D
I
S
C
H
A
R
G
E
P
R
E
S
S
U
R
E
SURGE
LIMIT
100%
THROTTL
RANGE
0%
CAPACITY
100%
When capacity requirements are within the throttle range of the compressor,
the compressor operates efficiently by automatically throttling the inlet valve
(CV-1) to maintain constant pressure. If capacity requirement decrease
below the maximum throttle range, the compressor will unload. When
system pressure decreases to a pre-set cut-in-pressure, the compressor
goes to load condition. The compressor will follow the natural curve to the
constant pressure setting, and will respond to the demand requirements of
the system by remaining at full load or throttling and then unloading.
N2- 06 - 06
6.3
N2- 06 - 07
6.4
N2- 06 - 08
Precaution:
From CRU Air Compressor discharge air is supplied through 40PC-2203.
Pressure at control valve downstream is maintained from 7.2 to 7.4kg/cm2.
However in case if air compressor trips or pressure reduce below 6.5kg/cm2.
Following action to be taken to avoid back flow of ATF/Kerosene in CRU
Air line header:
(1) Inform Merox Unit Operator to close their air Control valve and Block Valve.
(2) Immediately in close Control valve 40PC-2203 from DCS and Merox side Air
Block Valve in pipe rack of N2 Plant.
N2- 06 08*
N2- 06 09*
With the present 6 CW header from south battery limit, pressure in the supply header at
40AC1 compressor inlet was found to be only 2.8 kg/cm2g while pressure in the return
header was 2.4 kg/cm2g. Due to this small difference in pressure between the supply and
return headers, effective flow across Air compressor package was found to be less than 15
m3/hr against the design mentioned earlier. The low pressure differential is also attributed to
the physical location of the nitrogen plant (North B/L), which is farthest from the Supply
header of CCRU (South B/L), resulting in a low supply pressure at the Nitrogen plant and
maximum back pressure in return header Pressure.
3.0 Proposal:
In view of this, a separate 10 header from the Process Cooling Tower Cooling Water
header is to be provided from south battery limit of CCRU for the Nitrogen plant. With New
PCT CW Pumps CW supply pressure in Header is approximately 5.0 Kg/cm2g while CW
return pressure of PCT header is approximately 2.5 Kg/cm2g. Further, there is a
comfortable margin for additional 300 m3/hr from PCT without affecting the supply
parameters to other units. Hook-up from the main supply header at south battery limit in
water block PCT CW pump area can be through hot tapping while the connections to
compressors can be done one after the other. However, hooking up of the new header to the
Freon refrigeration system may require a short time bottling-up of the Nitrogen plant. But
production department done hook job without bottling-up the N2 plant and without
affecting any parameter. Following is the procedure:
3.1 Procedure for Hookup job of New PCT to Interstage Cooler of Air Compressor,
Freon Condenser and Expansion Turbine Condenser.
1
2
3
4
5
6
7
40AC-2 is running with External C.W. Header. Line up 40AC-1 with Internal C.W.
Header. Start 40AC-1 in Venting for checking reliability of Compressor and C/O
40AC-2 to 40AC-1.
Stop 40AC-2 and Isolate External Header for Hookup job from new PCT.
After Hookup and Precommissioning job , C/O to 40AC-2 and Line up Interstage
Cooler of 40AC-2 with New PCT.
For Isolation of Internal Cooling Water Header
Stop 40AC-1 and Isolate C.W. Supply and Return of Interstage Cooler.
For Freon Condenser Provide Temporary C.W. Supply at Strainer B/P Line B/W
Two B/V. and Cooling water O/L will be lineup in Open Drain.
For Expansion Turbine Provide Temporary C.W. Supply at C.W.(S) Drain. And
O/L will be lineup in Open Drain.
After Temporary Connection of C.W. to Interstage Cooler of Air Compressor, Freon
Condenser and Expansion Turbine Condenser, Isolate Internal Cooling Water
Header from at SBL near IFP Furnace. Then Proceed for Hookup job with New
PCT.
N2- 06 09*
5.0Benefits:
(1)
The facility is proposed for operational reliability and stopping of avoidable loss by
stoppage of open draining of cooling water @ 80 m3/hr from the Air Compressor inter stage
coolers.
(2)
Frequent tripping of air compressor will be reduced and N2 plant operational
reliability will increase
N2- 06 09*
6.5
INTERLOCKS
The various interlocks / securities provided on the compressor are:
S.No DESCRIPTION
1
2
3
4
Vibration Stage-1
Vibration Stage-2
Vibration Stage-3
Lube oil supply
Pressure
UNITS
ALERT
TAG VALUE
MIL
VAH-1
MIL
VAH-2
MIL
VAH-3
Kg/cm PAL-2
2g
oC
TAH-1
0.85
0.8
0.8
1.26
TRIP
TAG
VALU
E
VSHH-1 1.05
VSHH-2
1
VSHH-3
1
PSLL-2 1.12
49
TSHH-1
52
TAL-1
21
TSLL-1
18
TAH-2
46
TSHH-2
49
TAH-4
46
TSHH-4
49
TAH-6
49
TSHH-6
52
PAL-1
---
PSLL-1
0.42
N2- 06 - 09
7.1
REFRIGERATION COMPRESSOR
It is a reciprocating, four cylinders, forced lubricated 'Kirloskar' make (GK-25
model) vertical compressor. The compressor is driven by NGEF make 15
kW electrical motor of 1500 rpm through V-belt drive. It has a shaft driven
lube oil pump for the lubrication. A 40-watt crankcase heater powered from
220 Volts AC supply has been provided. The main feature of the compressor
are:
: 2000 / 1080.
: 70 mm / 55 mm.
N2- 07 - 01
Displacement
: 846 cm3
: 73.65 m3/hr
The compressor has been provided with 50% capacity control valve
assembly on cylinder cover. The capacity regulator comprises an electric
solenoid valve, which can be energised, or denergised as per the
refrigeration system load requirements. It works on the principle of cutting
off suction gas to 2 out of 4 cylinders. The ports of solenoid operated valves
are open, when solenoid is not actuated. The suction gas from the
crankcase is sucked into cylinder through solenoid operated valves. When
the solenoid is actuated the ports of the solenoid operated valves are closed
and the suction gas cannot enter into the cylinder through these solenoid
operated valves. Then two pistons reciprocate without compression. Thus
compressor is unloaded to 50 % of the full load.
As the air temperature attains the TSL4417 level, the solenoid is energised
and compressor gets unloaded to 50% of the full load. The compressor will
trip if the air temperature drops to the TSLL4417 level.
The Compressor has been provided with the following interlocks, which will
trip the compressor in case of any fault:
1) Compressor suction pressure low (PSL4415/PSL4425*) at 1.0 Kg/cm 2
2) Compressor discharge pressure high (PSH4416/PSH4426*) at 17.5
Kg/cm2
3) Lube oil pressure low (PSL4414/PSL4424*), it remain bypassed for 0- 60
seconds from compressor starting through a delay timer) at 0.8 Kg/cm 2
4) Condenser cooling water flow-low (FSL4400).
5) Cooled Air temperature (Evaporator outlet) low (TSLL4417) at 3 deg C
For all above trips, annunciation windows indicating the fault are provided in
Local control panel. The ACCEPT push button to be pressed to
acknowledged the fault and silence the hooter.
After the occurrence and rectification of the fault, RESET push button to be
pressed to clear the fault displayed in annunciation window.
N2- 07 - 02
FLUID
CONDENSER
EVAPORATOR
Shell
Tube
Shell
R-22
Water
Air
Tube
R-22
FLOW, Kg/Hr
1,375
1,200
3,103
90/45
33/38
110/-
EXCHANGER*
1,150
Shell
Liquid
R-22
1,150
Tube
Gaseous
R-22
1,150
45/10
5/5
45/42
6.7/12.2
65/-
65/10
30/0
65/4
65/4
16.7/19
4/5
8/8
5/19
16.6/19
4/19
1
114 Tubes
8152
Tubes
62,645
39,860
---
The values are given as per the INGERSOLL-RAND Instrument schedule and settings drawing no. RIN
60880, REV-2 (4 Sheets).
N2- 07 - 03
7.2
STARTING PROCEDURE
- Fill the Freon till suction header pressure is 2.0 Kg/cm 2g.
- Establish CW flow through the condenser and compressor jacket.
- Check compressor oil level, oil level in idle condition is 3/4th of the sight
glass.
- Establish air flow through evaporator.
- Check the local panel for the lamp indication "Interlock OK." glowing.
- Open compressor discharge valve, condenser inlet valve.
- Open compressor suction valve partially.
- Start the compressor and observe oil pressure Compressor will build up oil
pressure in 20-40 seconds. Observe compressor running sound, motor
current and drop in suction pressure.
7.3
STOPPING PROCEDURE
- Switch off liquid line solenoid valve.
- Stop the compressor.
- Close suction and discharge valve.
N2- 07 - 04
7.4
TROUBLE SHOOTING
CONDENSER
High head pressure due to :
1) Sealed condenser tubes
2) Refrigerant overcharge
3) Non condensable
EVAPORATOR
The following symptoms show refrigerant shortage in evaporator:
1) Low suction pressure.
2) Bubbles in sight glass.
3) High expansion valve superheat.
4) Temperature drops in liquid line (due to restriction).
N2- 07 - 05
PARAMETER
UNIT
MODE-1
MODE-II
MODE-III
KG/CM2G
KG/CM2G
3.57
3.57
3.57
0.37
0.37
0.37
INLET PRESSURE
OUTLET PRESSURE
INLET TEMP.
oC
-150
-150
15
OUTLET TEMP.
oC
-179.64
-179
-44.86
FLOW RATE
1,540
1,200
950
6
7
8
9
10
EFFICIENCY
COLD PRODUCTION
SHAFT SPEED
FLOW RANGE
NOZZLE OPENING
NM3/HR
%
KW
RPM
%
MM2
81
15.34
39,700
0-100
353.78
79
11.66
36,000
0-100
275.1
71
20.34
43,000
0-100
341.85
N2- 08 - 01
8.1
N2- 08 - 02
The lube oil used in the Turbine must meet the following specifications:
Viscosity at 40 oC ( ASTM D-445 )
Viscosity at 100 oC ( ASTM D-445 )
22 cst
113
8.2
4.6 cst
202 oC Min.
-30 oC
0.864 g/cc
100 oC
40/40/0 ml, 15 mn
0/0 ml/ml
8.3
PROCEDURE'S
START UP PROCEDURE
PRELIMINARY CHECKS:
Check inlet screen on process side is installed.
Check turbine rotor for free rotation.
N2- 08 - 03
N2- 08 - 04
Check pressure drop across filter F-7, if high change the filter.
Check that bearing oil outlet temperature is about inlet temp.
Check lube oil system for leaks.
Expander Start-up
Bring seal gas and lube oil system into operation.
Open block valves to turbine inlet and outlet.
Check that no alarm lamp is on.
Check that nozzles are closed.
Depress turbine reset. Push start button to open quick shut-off valve UV2806.
Open the nozzles slowly to the point where the turbine starts to rotate.
Close drain valve on turbine casing.
Check if the turbine running is normal (no abnormal noise).
Increase turbine speed gradually by opening the nozzles.
Adjust brake load by flow variation through brake control valve FCV9.
Observe that all parameters are within the limits.
STEADY STATE OPERATION
Operate nozzles and oil brake, as cold production requires.
Do not operate the expander/oil brake under conditions, which lead to
excessive thrust load (high process pressure).
Check complete operating system for oil leaks, seal gas leaks, water leaks,
and product leakage regularly.
N2- 08 - 05
automatically.
Close block valves to turbine.
Open drain valve on turbine casing.
Shut seal gas supply only after the oil outlet temperature TI9 is above 20 o
C.
NOTE:
Oil pump OP-6 to be switched off after a minimum period of 30 minutes in
case if the turbine is going to be shut for a longer period. Prior to restart
the expander must be thawed.
CAUTION !
In case the turbine is stopped in cold condition (no seal gas, power failure
etc...) The cold creeps from turbine towards the turbine side bearing and the
expander bearing will freeze. Start up of the turbine under these conditions
will lead to a bearing failure because in addition to the above, the oil supply
holes will also get blocked by frozen oil.
N2- 08 - 06
9.1
PREPARATION OF ADSORBERS:
Preparation of adsorbers involves Blowing of the adsorbers, Catalyst
loading and regeneration. Blowing is done to remove dust and dirt from the
system using instrument air. The catalyst loading is done with care using a
funnel (chute) to prevent damage to adsorbent by free fall. The adsorbent
must imperatively be regenerated before being put into service.
9.2
Each and every circuit will be checked and dried, until air outlet temperature
at each end reaches 50-60 o C. The outlet pressure of the warm air should
not exceed 0.5 Kg/cm2g. The drying is finished when the last air outlet is
N2- 09 - 01
PART-D
warm. After completion of drying of a circuit, shut all its outlets and mark with
red marker before putting another circuit into drying.
9.3
N2- 09 - 02
Cold Box
Open start up bypass valve WAG-05 (Air to expansion turbine).
Open 1" diameter air inlet valve (VAG-03F) to cold box slowly to obtain M.P.
column pressure (40PC2243) to 2-3 Kg/cm 2g.
Start the expansion turbine as given in chapter 8.
Adjust turbine outlet pressure to 0.5 Kg/cm 2g by adjusting waste nitrogen
header pressure control valve (40PC2218).
Shut the dry air for adsorber regeneration valve (VAG-06) and open waste
nitrogen to adsorber valve (VNR-10).
Pressurize the M.P. column (40-K-1) to 7.4 Kg/cm 2g slowly by opening the
main air inlet valve (VAG-03E) to cold box.
Adjust turbine inlet pressure to 3.4 Kg/cm 2g by adjusting start up bypass
valve (WAG05). Cool the plant as much as possible and let the equipment
work while pressure of different circuits are raised to their working pressure.
Facility for quick start up with liquid nitrogen is also available. Its procedure
shall be given after clarification from M/s BHPV.
End of the Cooling Down
At certain stage, because of the waste of cold due to lack of insulation, the
temperature becomes steady and the progression is no longer possible.
N2- 09 - 03
9.4
9.5
9.6
FINAL START UP
9.6.1 FIRST STAGE
Start the section as per 9.3.1.
Wait, for the cooling down of the system.
9.6.2 SECOND STAGE
Adjust 40TI2246 at - 85 oC (Mid part temperature of the exchanger) with the
valve WNR-02, waste nitrogen gas ex 40-E-4 to expansion turbine.
It is the period of appearance of liquid.
The liquid appears first at 40LC2241. At the beginning, drain it through its
bottom drain valve PK-1A.
Drain all circuits where liquid appears for the first time, so that all impurities
are eliminated. Keep waste N2 outlet pressure (40PI2244) at 3.0 Kg/cm 2g
with WAG-05 open, kept the pressure of the MP column (40PI2243) by
adjusting valve VAG-02 & VAD-03.
The liquid is gathered in the vat of the column and its level is maintained at
about 50 % through 40LC2241.
As the rich liquid is released from 40LC2241 towards the vaporiser, the level
40LC2242 starts building up.
Due to vaporization of the rich liquid in
vaporiser start closing WAG-05 (if it is open). Maintain L.P. column pressure
at about 3.4 Kg/cm2g.
N2- 09 - 04
Set 40PC2243 on auto, as the L.P. column level (40LC2242) reaches about
40%, condensation at the top of M.P. column begins resulting of reflux. It is
visible through the indication of 40PDI2245 (around 1250 mmWC).
10.0
N2- 09 - 05
PROLONGED STOPPAGE
10.2
EMERGENCY SHUTDOWN
Follow the procedure listed at 10.1.1 if it is a short time stoppage. Follow
10.1.2 if it is a prolonged stoppage.
N2- 10 - 01
S No
Details of action
Action
By
PO
SI &
PO
SI &
PO
PO
FO
FO &
PO
FO &
PO
FO &
PO
N2- 10 - 02
N2- 11 - 01
DERIMMING PATH
AIR PATH
: INLET AD 09
OUTLET AD 06
VALVE CLOSE VAG 05 (S/U B/P)
MP COLUMN
: INLET AD 09
OUTLETPK 01, PK 1B, RLR 1, GK 1 VALVE CLOSE
LIC 2241, LT 2241, LIC 2242, PDT 2245,PT 2243
GN2 PATH
: INLETAD 09
OUTLETAD 10, RNG 01
LN2 PATH
: INLET AD 09
OUTLETCONVERTER DRAIN (THROUGH LIC 2242), WNL 03
VAPORISER
: INLET AD 08
OUTLET GE 4, RE 4C, PE 4A, LT 2242 A/B, PT 2244
WASTE N2
MID PATH
: INLET AD 08
OUTLET AD 04 (OPEN WNR 02 FOR SOME TIME)
TURBINE
OUTLET PATH
: INLET AD 05
OUTLET PV 2218 (25% OPEN)
TURBINE
: INLET AD 05
OUTLET AD 04 (OPEN QSV TURBINE DRAIN)
N2- 11 - 02
Personnel having
remained
in
an
over-oxygenated
atmosphere shall make sure that his cloths have actually been ventilated
before he approaches a flame. Otherwise they might catch fire when in
contact with a flame or a spark, that causes serious burns.
N2- 12 - 01
PART-D
N2- 13 - 01
PART-D
N2- 13 - 02
PART-D
40 C 1
40 CB 1
40 E 1
4.
5.
40 E 10
40 E 101
6.
40 E 102
7.
40 E 103
8.
40 E 104
9.
10.
40 E 11
40 E 110
SET
PRESSURE
Kg/cm2 g)
N2- 13 - 03
TYPE
11.
12.
13.
14.
15.
16.
17.
18.
19
20.
21.
40
40
40
40
40
40
40
40
40
40
40
E 111
E 112
E 113
E 12
E 17
E 20
E 21
E 4
EH 16
EH 18
G 1
22.
40 G 2
23.
40 G 3A
24.
40 G 3B
25.
40 IC 1A
26.
40 IC 1B
27.
40 IC 2A
28.
40 IC 2B
29.
40 IC 3A
30.
40 IC 3B
31.
40 IC 4A
32.
40 IC 4B
33.
40 IC 5A
EVAPORATOR
EVAPORATOR
EVAPORATOR
EVAPORATOR
DERIMING HEATER
DOUBLE TUBE EXCHANGER
FREON CONDENSER
VAPORISER OF COLD BOX-1
REGENERATION HEATER
ELECTRICAL TRIM HEATER
OIL SEPERATOR OF FREON
COMPRESSOR-1
OIL SEPERATOR OF FREON
COMPRESSOR-2
AIR FILTER OF COLD BOX
U/S
AIR FILTER OF COLD BOX
U/S
1ST STAGE INTER COOLER
OF AIR COMPRESSOR-A
1ST STAGE INTER COOLER
OF AIR COMPRESSOR-B
2ND STAGE INTER COOLER
OF AIR COMPRESSOR-A
2ND STAGE INTER COOLER
OF AIR COMPRESSOR-B
3RDSTAGE INTER COOLER
OF AIR COMPRESSOR-A
3RDSTAGE INTER COOLER
OF AIR COMPRESSOR-B
LUBE OIL COOLER OF AIR
COMPRESSOR-A
LUBE OIL COOLER OF AIR
COMPRESSOR-B
LUBE OIL COOLER OF AIR
COMPRESSOR-A
N2- 13 - 04
34.
40 IC 5B
35.
36.
37.
38.
39.
40.
41.
42.
43.
40
40
40
40
40
40
40
40
40
PSV
PSV
PSV
PSV
PSV
PSV
PSV
PSV
PSV
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
40
40
40
40
40
40
40
40
40
40
PSV 2281
PSV 3308
PSV 3309
PSV 3318
PSV 3319
PSV 3320
PSV 4410
RX 1
RX 2
V 1
54.
55.
56.
40 V 101
40 V 102
40 V 103
2203
2206
2211
2212
2230
2231
2247
2249
2257
8.8
1.0
8.0
1.29
1.29
1.29
4.0
1.0
CONV
CONV
CONV
CONV
CONV
CONV
CONV
CONV
2.0
CONV
7.70
7.70
7.70
CONV
CONV
CONV
N2- 13 - 05
57.
58.
59.
40 V 104
40 V 2
40 V 3A
60.
40 V 3B
LIN-4
GASEOUS NITROGEN TANK
DISCHARGE K.O. DRUM OF
AIR COMPRESSOR-A
DISCHARGE K.O. DRUM OF
AIR COMPRESSOR-B
N2- 13 - 06
NH3- 01 - 01
NH3- 02 - 01
To maintain constant cooling water flow through condenser and oil cooler
one package type cooling tower has been installed.
Also new Cooling water circuit has been installed directly from the refinery
Cooling Water header in case of non availability of cooling tower.
Additional Ammonia condenser installed in parallel of old Ammonia
Condenser on November 2013.
In case of Ammonia Condenser high DP in Tube side due to Chockage. One
can be isolated for cleaning and other can be taken in line without stopping
Refrigeration system.
DESCRIPTION
FLOW
KG/HR
TEMP.
oC
PRESS.
KG/CM2g
4,441
-15
2.41
822.5
-5.5
3.54
COMP. DISCHAREG
77.9
15.3
428 LPM
77.9
19
428 LPM
45
17.5
428 LPM
45
17.2
CONDENSER INLET
77.9
15.3
RECEIVER OUTLET
41
15.3
0.5
7.9
10
-5.5
2.54
11
12
13
14
CHILLER OUTLET
15
SUPERFEED FLASHING IN KO
16
65 M3/HR.
33/37
17
395M3/HR
33/37
NH3- 03 - 01
NH3- 03 01*
NH3- 04 - 01
PART-E
-15 / 77.8 Oc
Flow
4441 kg/hr,
Power required
506 kW
Speed
2950 RPM
: 15.51 / 20 Kg./cm2 g
: 77.9 / - 177 oC
OIL COOLER:
There are two oil coolers for two sets of compressors:
Kg./cm2 g
Operating Pressure
: 19
: 78/45 oC
OIL PUMPS:
Each set of compressor is equipped with two oil pumps. The pumps are
David Brown UK make with capacity of 450 liters/min. with 9.3 kW motor.
CONDENSER:
It is horizontal exchanger of Dia 812mm, Length 6000mm with 848 tubes of
3/4"OD.
Operating temp. ammonia IN/OUT
: 78 / 41OC
: 33 / 37oC
NEW CONDENSER
Operating Pressure
: 16.3 kg/cm2
Operating temperature
: 78/ 41 oC
: 33 / 37oC
NH3- 04 - 02
RECEIVER:
It is horizontal type vessel of volume 7.2m3
Operating pressure : 15.29 Kg./cm2 g
: 41oC
Operating temp.
SUPERFEED VESSEL:
It is horizontal flooded type exchanger of 457 mm OD and 3000mm length
having 200 nos. 3/4" tubes. It is designed for flow of 822 kg/hr in tube side.
Shell side operating pressure and temp. are 2.54 Kg./cm 2 g and -5.5oC.
Tube side-operating temp. is 0.5oC.
SURGE DRUM:
Volume
= 0.24 m3
Operating temp.
KNOCK OUT POT:
Operating temp.
Operating temp.
COOLING TOWER:
= 455 m3/hr,
= 45 kW (KEC make)
= 15 kW (KEC make)
NH3- 04 - 03
STARTING PROCEDURE:
Ensure cooling water flow through condenser and oil cooler.
Check and ensure that all the valves in the oil circuit are open, with one oil
filter and one oil pump in line.
Check and ensure that the following valves in the refrigerant circuit are open:
Oil Tank Separator (OTS) outlet valves.
Condenser inlet/outlet valves.
Receiver outlet valves.
All liquid line valves except hand expansion valve and liquid line
strainer.
All superfeed vessel valves feeding ammonia to tube and shell side.
Superfeed suction valve.
Vapour line valves leading to and from KO. drum.
Compressor main suction valve.
Isolation valve for superfeed stand pipe.
Check the oil level in OTS. This should be between the top most U-clamp
bolt of the level gauge glass and the glass top.
Start the oil pump. Ensure that differential oil pressure is minimum 2.1
Kg./cm2 and maximum 4 Kg./cm2. This can be controlled by adjusting the
by-pass valve on by pass line.
Diff. oil pressure = (Oil Pump Disc. pressure) - (Comp. Discharge.
pressure).
Operating Philosophy for maintaining Oil/Gas DP of Ammonia
Package:
Initially open 50% bypass valve(Oil Pump discharge to Oil separator) of Oil
Pump. After starting Compressor maintain differential pressure with
compressor load by adjusting bypass valve.
New Oil gas DP Interlock has been revised from 1.0Kg./cm 2 to 0.8 Kg./cm2.
So minimum differential oil pressure to be maintained upto 1.5Kg./cm 2.
Below this pump performance to be checked by M/M. Never allow differential
oil pressure more than 4 Kg./cm2. It may overload the pump.
NH3- 05 - 01
Check the compressor is fully unloaded and the 10% load limit switch is
actuated.
If all the safety requirement are satisfied then compressor ready to
start lamp will glow indicating that the compressor can be started.
Keep the system in manual mode by selecting the same through the
Auto/Manual selection switch.
Start the compressor. After the compressor attains full speed, check the
following:
Discharge pressure is less than 18 Kg./cm 2 g.
Suction pressure is around 3 Kg./cm2 g.
Oil differential pressure is more than 2.1 Kg./cm 2.
Once the compressor is started, its capacity can be controlled either
manually (with the help of loading/unloading push buttons) or automatically
with the help of capacity controller. Load the compressor by pressing the
"Raise" push button. Care should be taken to ensure that in each installment
the compressor is not loaded to more than 10% of the earlier loading value.
This is to ensure that the other system parameters are not disturbed due to
abrupt loading of the machine. The percentage loading of the compressor
can be seen on the indicator at the back of the compressors.
Compressor loading can also be done manually by the valves facing
opposite each other on the load side and can be unload by the valves facing
opposite to each other on unload side.
For reducing the compressor capacity the same can be accomplished by
pressing the lower push button. The same care as mentioned in previous
para should be taken while unloading the machine.
5.2
STOPPING PROCEDURE:
Stop the compressor by pressing the compressor stop push button.
Close the oil bleeder line valve.
Keep the oil pump running for some time till the compressor is fully
unloaded.
Stop the oil pump.
Isolate the CW of lube oil cooler and drain it. (This is done due to the past
experience of tube leaks)
An emergency stop push button has been placed behind the field panel to
stop the compressor in case of emergency.
NH3- 05 - 02
PART-E
NH3- 06 - 01
Sr.
no
ALARM
DESCRIPTION
COMP-1 COMP-2
TAG.NO
TAG.NO.
.
15 PSL 15 PSL
5001
5005
TRIP
SET. COMP-1 COMP-2
POINT
SET.
POINT
TAG.NO. TAG.NO.
0.0
15 PSLL
5002
15PSLL
5006
-0.2
15 PSH
5003
15 PSH
5007
17
15 PSHH 15 PSHH
5004
5008
18
15 TSH
5001
15 TSH
5003
85
15TSHH
5002
90
15LSH 5003
15LSHH
5005
15LSL
5001
15TSHH
5004
15LSL
5002
15LSH
5003
6 Receiver
7 Condenser water DP NORMAL OPERAING DP
IS 1.0 KG/CM2
( KG/CM2)
15DPSL
5001
15DPSL
5002
15DPSL
5003
0.5
DPSL
5004
DPSL
5005
1.0
NORMAL OPERAING DP
IS 1.0 KG/CM2
DPSL
DPSL
1.5
5004
5005
0.5
THE VALUES FOR ALARM AND TRIP SETTING HAVE BEEN TAKEN FROM
INSTRUMENTS TEST CERTIFICATES. ACTUAL SET POINTS TO BE
CONFIRMED. PRESSURE SETTINGS TO BE CHECKED FOR ABS. OR
GAUGE.
NH3- 07 - 01
8.0
NH3- 08 - 01
8) If any of the oil pump (main or stand by) is running, the indicating lamp
"OIL PUMP FOR COMPRESSOR RUNNING" will glow.
ii)
iii)
NH3- 09 - 01
GENERAL DESCRIPTION
Combustion air required for Naptha splitter reboiler (09 F-01) and Stabilizer
reboiler (015-F-04) is fed by the two forced draft fans 15K-02A/B, and the air
is pre heated in glass tube air preheater and then in the Cast air pre heater
combined flue gas of all four heaters (09F-01, 14F-01, 14F-02, 15F-04) after
the convection section enters Cast air preheater then glass air pre heater,
enters ID Fan 15K-03 finally leave through a stack, which is common for all
heaters. However 14F-01, 14F-02 are provided with natural draft burners.
1.1
placed in the grooves before bolting. The flanges provide the necessary gap
for the flue gas passage. The flanges also have peripheral grooves on all
four sides to accommodate asbestos rope to ensure all tightness between
adjacent tubes.
APH- 01 - 01
Flue gas enters at the top of the hot end and flows vertically down over the
outside of tubes and leaves the air preheater at the bottom of the cold end.
Air enters the air preheater at the bottom of the cold end. Air enters the air
preheater at the side of the cold end flows first through the cold end tubes.
On leaving the cold end the air is turned through 180 degrees and flows
horizontally through the hot end tubes of the air preheater. The flue gas in is
a single pass, which flows, vertically down from top to bottom and the air is
on three passes.
1.2
1.3
COMMISSIONING INSTRUCTIONS
Commissioning procedure for an air preheater has to be formulated
considering the furnace/process heater to which it is going to be hooked into
and the overall system conditions.
The instructions mentioned here for commissioning assistance are meant for
the general safety of the air preheater equipment alone.
APH- 01 - 02
PART-F
temperature at glass APH inlet is below 240 0C. Air preheater performance
has also been checked under turndown conditions.
It is to be noted that the air bypass is necessary during winter. The user
shall review the actual quantity to be bypassed considering the other
equipment in the system like dampers, furnaces etc.
However, it is recommended that under no circumstances the flue gas exit
temperatures are allowed to go below the recommended values and the air
bypass may need to be adjusted accordingly to avoid acid condensation
under all operating conditions and special care need to be taken when the
air preheater is taken on line. The Tube skin temperature on the last row of
tubes in the cast APH section should be monitored closely and should be
kept atleast 100C above the dew point of the flue gases.
1.4
APH- 01 - 03
However, for the safe operation, it is recommended to monitor the flue gas
pressure drop and when this approaches the limit of ID Fan capacity, the air
preheater should be taken out of line and washed. This could probably be
because of soot deposition due to abnormally poor combustion in the
furnace.
1.5
WASHING PROCEDURE
Washing of air preheater has to be done by taking it off line.
Vendors
instructions for carrying out the washing of the APH should be followed
thoroughly.
NOTE: Commissioning, Maintenance and Washing Instructions above
are general only and vendors instructions in the above regard
must be followed thoroughly.
APH- 01 - 04
DESIGN DATA
Note : These instructions are established on the assumption that air and flue
gas are uniformly distributed at the inlet flanges and through the air
preheater.
2.2
PROCESS PARAMETERS
Table 1 & 2 specifies the performance of the cast tube and glass tube air
preheaters respectively at design conditions:
TABLE 1 (FOR CAPH)
1.
Air temperature in 0C
119
2.
287
3.
50833
4.
310
5.
210
6.
75306
7.
2.08
8.
80/55
Air temperature in 0C
35
2.
119
3.
50833
4.
210
5.
160
6.
75306
7.
1.04
8.
60/60
APH- 02 - 01
3.1
INTERLOCK SCHEME
Following interlocks have been provided for the safe operation of the
furnaces in the event of failure of any operating equipment or any
abnormality in the process condition.
3.1.1 FD FAN FAILURE
Failure of FD fans can be sensed by
a)
b)
c)
During normal operation both the FD fans will run at 50% process load. In
the event of failure of one of the fans as sensed by XL-3101/XL-3102 or
FSL-3104/FSL-3105 the working fan will go to 100% process load and the
tripped Fan will be isolated automatically through the pneumatic actuator of
the
discharge
damper,
HV-3107/HV-3108
(As
the
case
may
APH- 03 - 01
be)
b)
APH- 03 - 02
b)
c)
3.1.7 Stack Damper HV-3105 shall not be closed unless ID Fan is running.
3.1.8 During turndown operation only one fan will operate and in the event
of failure of working fan as sensed by XL-3111/3114 or FSL3104/3105, standby fan shall start automatically.
Fan discharge
damper HV-3107/3108 of the tripped fan will close and that of standby
fan will open simultaneously. During this fan switch over operation,
fuel supply to the furnace shall attain minimum flow for a time period
of 0.30 seconds.
3.1.9 Each interlock shall have individual by pass option (except interlocks
specified in 3.1.3 & 3.1.4) available at main control panel with lamp
indication.
APH- 03 - 03
3.1.10 Emergency
Emergency stop push bottom has provided on the main control panel
on pressing which all drives will trip, dampers HV-3101, HV-3102, HV3103, HV3104 and HV-3105 will open even if interlocks are in bypass
mode and simultaneously fuel supply to all the furnaces will be cut off.
An additional local emergency push button shall be provided 15 m
away from the heater in Break Glass enclosure.
3.2
Set Point
TAG NO.
TAH 3101
TAH 3108
TAH 3115
TAH 3122
TAH 3129
TAH 3132
SERVICE/LOCATION
Fuel gas at Convection Outlet of 014-F-1
Fuel gas at Convection Outlet of 014-F-2
Fuel gas at Convection Outlet of 09-F-01
Fuel gas at Convection Outlet of 015-F-04
Fuel gas at Cast APH ( 015-FP-01) inlet
Fuel gas at duct upstream of Glass APH
SET POINT
345 0C
335 0C
230 0C
325 0C
280 0C
230 0C
TAHH 3132
(015-FP-02) inlet
Fuel gas at duct upstream of Glass APH
240 0C
TAG NO.
TAH 3133
(015-FP-02) inlet
SERVICE/LOCATION
Fuel gas at duct downstream of Glass APH
TAL3133
TAHH 3134
( 015-FP-02) inlet
Fuel gas at ID Fan suction
SET POINT
185 0C
155 0C
195 0C
TALL 3134
150 0C
Following are the indicative values of set points of alarms and trips for
different instruments. These may require tuning during actual plant operation
and assessing the performance.
APH- 03 - 04
PART-F
TAH 3136
TAH 3137
TAH 3141
PAH 3101
PAH 3102
PAH 3103
235 0C
235 0C
180 0C
+2mmWC
+2mmWC
+2mmWC
PAHH 3103
PAH 3104
PAHH 3104
PAHH 3107
+5mm WC
+2mmWC
+5mm WC
(-) 40mmWC
[Adj:0 to(-)100mmWC]
+ 20mmWC
PALL 3111
[Adj:0 to(+)50mmWC*]
+ 15mmWC
PAH 3112
PAH 3113
PAH 3114
PAH 3115
FALL 3101
04
Flue gas at Furnace Arch 09-F-01
Flue gas at Furnace Arch 015-F-04
Flue gas at Furnace Arch 014-F-01
Flue gas at Furnace Arch 14-F-02
Air to 09-F-01
[Adj:0 to(+)50mmWC*]
+ 1mmWC
+ 1mmWC
+ 2mmWC
+ 2mmWC
10800
PALL 3110
FALL 3102
FALL 3103
F-04
APH- 03 - 05
PART-F
TAG NO.
FAL 3104
SERVICE/LOCATION
FD an (15-K-02A) suction duct
SET POINT
1200
[Adj: 10000 to 30000]
FAL 3105
12000
[Adj: 10000 to 30000]
AAH 3107
6%
01
2%
#
AAH 3108
6%
04
2%
AAL 3107
AAL 3108
#
* Indicates set points are tentatively only and to be adjusted based upon
burner performance.
# Indicates marked tag nos. are not shown in the APH systemP&ID
APH- 03 06
PART-F
FOR CAPH
FOR GAPH
1.
250
175
2.
175
150
3.
Air temperature in 0C
116
35
4.
235
116
ID Fan Parameter:
1.
ID Suction temperature :
145 0C
2.
ID Suction Draft :
-170mmWC
3.
750
4.
Ampere :
120A
5.
42
6.
48
7.
Oil temperature :
65
8.
85 LPM
Parameter
Unit
deg C
deg C
deg C
deg C
deg C
deg C
mmWC
Mkcal/hr
Design
35
287
310
200
160
160
-200
3.12
Actual
with Old
CAPH
35
95-105
210-230
180
105-110
105-110
-300
0.8
Actual
with New
CAPH
35
235
250
175
150
145
-172
2.10
Calculation
Air flow
Cp of Air
Delta T of Air
235 35 = 200
Heat Duty
SRFT
1680 SRFT/Yr
1 SRFT
Total saving
/Yr
APH- 03 06*
PART-F
hydrogen header. The off gas from the PSA-140 is compressed using 06-K04 A/B and sent to fuel gas header. Facility exists for using this off gas in
reformer from upstream of compressor.
In HGUs the steam reforming of naphtha or natural gas done and reformed
gas is purified in PSAs of respective units. The pure hydrogen gas from
PSAs is having H2 purity of 99.99 % vol. The pure hydrogen is sent to fresh
hydrogen network (20 kg/cm2 g).
The fresh hydrogen is utilised in HGU/CCRU/NHTU of CCRU/ DHDT/
OHCU/ MSQ Units/TGTU.
An offsite Hydrogen facility to store hydrogen during normal operation and
supply hydrogen during start up has been provided. Facility to unload
hydrogen cylinder has also been provided to supply hydrogen for the very
first start-up of the unit. The offsite hydrogen facility section comprises of the
followings:
1. Three Hydrogen gas storage bullets each of capacity 220 m 3 (which were
installed along with CRU project) and fourth bullet identical to other three
have been installed in DHDT/MSQ Projects.
2. A three stage reciprocating Hydrogen Compressor (42-K-01) to store
Hydrogen at a pressure of 40.0 Kg/cm 2g.
3. Unloading of Hydrogen cylinders.
4. A 2" dia. line connects Hydrogen offsite facility with CRU to supply and
receive hydrogen gas from CRU.
H2- 01 - 01
H2- 01 - 02
pressure indication in field and Control room, which can give process high
and low alarms.
The 2" inlet/outlet line of the bullet is provided with a Remote Operated
Valve's (ROV's) for emergency isolation of the bullets locally (Compressor
house). The ROV can be closed from CRU control room also.
Minimum residual pressure of 2.0 kg/cm 2g should be maintained in the
bullets.
H2- 02 - 01
PART-G
3.1
8
9
4
8.8
47
119
293
215.5
330
6
9
8.6
19.4
45
122
151
215.5
4.25
9
19
41
45
124
76
215.5
LUBRICATION SYSTEM
The compressor is equipped with a self-contained, force feed lubrication
system for the bearing and running surfaces of the compressor frame and
running gear. Parts lubricated by the frame lubrication system include the
main crankshaft journal bearings, crankpin bearings, crosshead pin
bushings, and cross heads. A frame mounted oil pump is a gear type pump
with two rotating gears is driven directly off the end of the compressor
crankshaft. A motor driven auxiliary pump has been provided for the priming
of the main pump and the pre-lubrication of the compressor bearing and
running surfaces prior to starting the unit.
The oil is drawn from the frame sump through a screen type strainer and into
the crankshaft driven gear type oil pump. The pump forces the oil through a
cooler and then through a filter (with replaceable cartridge type element).
H2- 03 - 01
PART-G
The cooled and filtered oil then flows under pressure to the main crankshaft
journal bearing, located at the oil pump and of the frame and from there
through drilled passages in the crankshaft to the crankpin bearings and drive
end main bearing. A rifle-drilled hole through each connecting rod conducts
the oil from the crankpin to the crosshead pin bushing located in the small
(eye) end of the rod. The oil then enters the hollow crosshead pin from
where it is distributed to the pin surfaces and the crosshead shoes. After
passing through and lubricating the various parts, the oil drains back into the
frame sump.
Oil from the filter goes to drive end main bearing and to the oil pressure
gauge and also to the low oil pressure shut down switch. The spring loaded,
ball check type relief valve protects the lubrication system from excessive oil
pressure resulting from (i) low ambient starting temperatures, or (ii) clogging
of the oil filter.
168.4
10.2
193
0.45
0
The capacity of the frame oil sump is 26 litres. The operating level of the oil
should be maintained at the line on the gauge glass. The oil can be added
to the frame sump while the unit is running by removing the breather cap
and pouring the oil into the breather tube.
The lube oil cooler is designed for an oil inlet / outlet temperature of 71 / 65
o
C. Cooling water 11.3 lpm to be supplied at 29 oC.
3.2
H2- 03 - 02
PART-G
H2- 03 - 03
PART-G
3.3
START UP PROCEDURE
Check the oil level in the frame sump and refill as required to bring the
operating level to the line on the gauge glass.
Start the auxiliary oil pump for the lubrication at least 10-15 minutes before
the start up of the compressor.
Open the suction and discharge B/V of the compressor.
Manually turn the compressor through at least one complete revolution to be
sure all moving parts are clear.
Turn on the cooling water supply to the inter coolers, after cooler and also to
cylinders.
Drain the liquid if any from the first stage suction knock out drum
Start the driver and run the compressor with no load for a few minutes to
warm up the unit. Listen for unusual noises during the warm up period.
Check the oil pressure in the frame lubrication system; the normal operating
oil pressure should be 1.8 to 3.5 kg/cm 2g.
When the unit is warmed up and determined to be running satisfactorily, the
compressor can be loaded.
CAUTION
If the compressor was started without turning on the cooling water and the
cylinders have heated up, shut down immediately and allow the cylinder
H2- 03 - 04
PART-G
parts to cool. Do not introduce cooling water to hot parts or they may crack.
After the unit has cooled, the water can be turned on and the machine
restarted.
3.4
STOPPING PROCEDURE
Unload the unit.
Stop the driver.
Shut off the cooling water supply.
3.5
EMERGENCY STOPPAGE
If an emergency occurs requiring immediate shutdown of the compressor,
the unit can be shut down under load; however open the final stage bypass
valve to reduce the back pressure load on the compressor, permitting the
machine to coast to a stop versus stopping in several revolution under load.
In the event of an automatic shutdown, the system pressure to be relieved
immediately.
Shut off the cooling water supply, if the compressor will not be operating
again within ten minutes.
3.6
S.No
1
2
3
4
5
INTERLOCKS
DESCRIPTION
ALERT
TAG
Lube oil supply pressure Kg/cm2g PAL-1001
1st suction pressure
Kg/cm2g PAL-1003
1st stage discharge temp. oC
TAH-1001
2nd stage discharge temp. oC
TAH-1003
o
3rd stage discharge temp. C
TAH-1005
UNITS
TRIP
VALUE TAG
0.55
PALL-1002
3.8
PALL-1004
125
TAHH-1002
128
TAHH-1004
130
TAHH-1006
VALUE
0.35
3.6
130
135
136
The above data has been taken from Instrument schedule RIN-40935EW
H2- 03 - 05
PART-G
4.0
with PCV2002 and taking 42-K-1 in line. The compressor has to be stopped
when cylinder pressure reaches 4 Kg/cm2g.
Close all the valves and depressurize the cylinder rack to cold stack and
replenish the empty hydrogen cylinders.
During unloading of cylinders, Hydrogen can be supplied to CRU (i.e.
cylinder outlet is connected to Bullets as well as CRU).
The ROV on the Bullet under receipt is to be kept in open position, while
ROV's of other two Bullets to be kept in closed position.
H2- 04 - 01
PART-G
5.0
H2- 05 - 01
PART-G
6.0
6.1
PROPERTIES:
Reference Temperature
Standard pressure (1atm) psia
Density (at 68 deg F and 1 atm)
Flammability Limits
Hydrogen-air mixture
Hydrogen-oxygen mixture
Explosive limits
Hydrogen-air mixture
Hydrogen-oxygen mixture
68 deg F
14.69 KPa
0.00523 lb/ft3
Lower = 4% volume
Lower = 4% volume
The major hazards associated with hydrogen are fires and explosions, and in
the event of contact with the liquid or cold boil off vapor, frostbite and burns.
Deflagration and detonation: Hydrogen gas can burn in two modes, as a
deflagration or as a detonation.
In a deflagration, the ordinary mode of burning, the flame travels through the
mixture at
Subsonic speeds. This happens, for instance, when an unconfined cloud of
hydrogen-air
mixture is ignited by a small ignition source. Under these circumstances, the flame
will travel at a rate anywhere from ten to several hundred feet per second. The rapid
expansion of hot gases produces a pressure wave. Witnesses hear a noise, often a
very
loud noise, and may say that an explosion occurred. The pressure wave from rapid
unconfined burning may be strong enough to damage nearby structures and cause
injuries to personnel.
In a detonation, the flame and the shock wave travel through the mixture at
supersonic
speeds. The pressure ratio across a detonation wave is considerably greater than
that in a deflagration. The hazards to personnel, structures, and nearby facilities are
greater in a detonation. A detonation will often build up from an ordinary deflagration
that has been ignited in a confined or partly confined mixture.
CCRU OPERATING MANUAL
H2- 06 - 01
PART-G
This can occur even when ignition is caused by a minimal energy source. It takes a
powerful ignition source to produce detonation in an unconfined hydrogen-air
mixture. However, a confined mixture of hydrogen with air or oxygen can be
detonated by a relatively small ignition source.
Leakage, diffusion, and buoyancy: These hazards result from the difficulty in
containing hydrogen. Hydrogen diffuses extensively, and when a liquid spill or large
gas release occurs, a combustible mixture can form over a considerable distance
from the spill location
Leakage: Hydrogen, in both the liquid and gaseous states, is particularly subject to
leakage because of its low viscosity and low molecular weight (leakage is inversely
proportional to viscosity). Because of its low viscosity alone, the leakage rate of liquid
hydrogen is roughly 100 times that of JP-4 fuel, 50 times that of water, and 10 times
that
of liquid nitrogen.
Diffusion and buoyancy: The diffusion rate of hydrogen in air is approximately 3.8
times faster than air in air. In a 500-gallon ground-spill demonstration experiment,
liquid hydrogen diffused to a non-explosive mixture after about 1 minute. Air
turbulence increases the rate of hydrogen diffusion
The buoyancy of hydrogen tends to limit the spread of combustible mixtures
resulting from a hydrogen release. Although hydrogen vapor is heavier than air at the
temperatures existing after evaporation from a liquid spill, at temperatures above
418o F the hydrogen vapor becomes lighter than air, thereby making the cloud
buoyant. (See NASA STD 8719.16, Safety Standard for Hydrogen and Hydrogen
Systems, Chapter 2, for more specific related information)
6.2
H2- 06 - 02
PART-G
The flammable mixture may be diluted with either of its constituents until it is no
longer flammable. Two limits of flammability are defined: the lower limit, the minimum
amount of combustible gas that makes a mixture flammable; and the upper limit, the
maximum amount of combustible gas in a flammable mixture.
The flammability limits based on the volume percent of hydrogen in air (at 1.03
Kg/cm2) are 4.0 and 75.0. The flammability limits based on the volume percent of
hydrogen in oxygen (at 1.03 Kg/cm 2) are 4.0 and 94.0. Reducing the pressure below
1 atmosphere tends to narrow the flammability range by raising the lower limit and
lowering the upper limit. No mixture of hydrogen and air has been found to be
flammable below 0.077 Kg/cm2.
Auto ignition: Temperatures of about 565.5 oC are usually required for mixtures of
hydrogen with air or oxygen to auto ignite at 1.03 Kg/cm 2; however, at pressures from
0.21 to 0.56 Kg/cm2, autoignitions have occurred near hot hydrogen and flash fire.
The primary hazard of using hot hydrogen (565 to 3315 C) is that a large leak at
temperatures above the autoignition temperature will almost always result in a flash
fire. Other safety criteria are the same as for ambient temperature gaseous
hydrogen. System construction materialsmust be suitable for use at the elevated
temperatures
Ignition at low energy input: Hydrogen-air mixtures can ignite with very low
energyinput, 1/10th that required igniting a gasoline-air mixture. For reference, an
invisible spark or a static spark from a person can cause ignition.
Lack of flame color: Hydrogen-oxygen and hydrogen-pure air flames are colorless.
(Any visible flame is caused by impurities.) Colorless hydrogen Hydrogen diffuses
rapidly if not confined. At room temperature, hydrogen is the lightest of all gases, only
1/14th as heavy as air; consequently, it rises. Therefore, inverted pockets will trap
hydrogen gas. Avoid covers, suspended ceilings, or places where pockets may form
and trap hydrogen gas.
Fire Classifications:
CLASS A
CLASS B
: Flammable liquids
CLASS C
CLASS D
H2- 06 - 03
MISCELLANEOUS
1.0 UTILITY SYSTEM
GENERAL
Utility system consists of cooling water, DM-Water, Boiler feed water, HP system,
Fuel gas, nitrogen, LP system, service water, Plant air, Drinking water, Flare
system, HCs/CBD system.
Brief descriptions of the aforesaid facilities for each system are given below:
1.1
Instrument air:
Instrument air enters the unit through a 3 line with a spectacle blind at the
down stream of battery limit block valve. Various tapping are taken from the
main header inside the unit to supply dry, clean air to the instruments of
different sections.
1.2
Drinking Water:
Drinking water enters the unit through a 2 line with a spectacle blind at the
down steam of the battery limit block valve.
Drinking water is distributed in side the unit to two eye wash and safety
shower points hear chemical drums.
1.3
Steam:
1.3.1 Low Pressure Steam:
Low pressure steam enters into the unit at the battery limit through a
14 line with a spectacle blind at the down steam of 05BL block valve,
two block valves, one on the OSBL side and another on the ISBL side
MISC- 01- 01
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
ID Fan.
x.
9/F-1.
LP steam from 15-K T-1 (steam turbine of 15-K-1) out let joins the LP
steam header in side the unit so also the 15-K-1 lube oil turbine outlet
steam. LP steam header pressure is maintained by venting excess
steam through a PCV provided at the up steam of air atmospheric
vent. The atmospheric vent is provided with a silencer near 15-F-4.
One LP steam tapping has been taken from 15-KT-1 out let line which
joint the LP steam header for the new units out side the south side
battery limit. This take off line is provided with a block valve at the
take off point and two block valves at the battery limit.
1.3.2 Medium Pressure Steam:
MP steam enters the unit through a 8 line provided with OSBL and
ISBL block valves. OSBL block valve is provided with a spectacle
blind. This steam line is provided with local as well as DCS mounted
PI and TI. Flare indication is given in DCS.
MISC- 01 - 02
ii.
17-DR-1
iii.
iv.
HY-1402
v.
vi.
vii.
viii.
ix.
x.
MISC- 01- 03
Cooling Water:
Cooling water enters the unit through a 22 line.
A spectacle blind is
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
xiv.
xv.
xvi.
xvii.
xviii.
xix.
MISC- 01- 04
xx.
xxi.
xxii.
xxiii.
To APH system.
1.6
1.7
MISC- 01- 05
FG from the battery limit is received in FG knock out drum 15-V-11, through
pressure controller 15PC91. The drum is also provided with L.G. and high
level switch and visual alarm and level indication in CRT.
FG from 15-V-11 goes through a 8 line to the burners of the following
furnaces after passing through isolation block-valves, shut down valves and
pressure control valves.
i
ii
14-V-1
ii.
14-T-1
iii.
9-V-1
iv.
14-C-1
v.
15-C-1
gases from 15-V-2, 15-V-3 and 17-AC-2 through 10 , 1.5, 4 line join
a 12 line with two branches one goes out from the unit through a 8
line with a flow indication at the battery limit and a block-valve. There
is a spectacle blind at the upstream of the battery limit block valve.
The other branch through a block valve and a NRV joins a 10 header.
FG can flow to the 10 header through the NRV. The 10 FG header is
connected to the 8 out let line of 15-V-11 through two block
valves with a NRV and a spectacle blind in between, the HRV opens
in the direction of 10 line at the down stream of the previous NRV.
FG to the non IFP furnaces are supplied through this 10 line, 15-V-11
outlet 8 line supplies FG to the IFP furnaces.
MISC- 01- 06
One 1 line is provided from the 10 line for purging the line into flare header.
This line is provided with a block valve.
To tackle frequent chockage of fuel gas C/V, strainers, FG KOD demister
and foreign particles basket filter of 80-100 microns with bypass facility has
been installed on the u/s of 15V11.process scheme MR/TS/PS/CRU/2008/05
An electric heater 15EH1 (modified heater) has been provided on upstream
of 15V11for heating the fuel gas to get rid of salt deposition. Also on the
absence of electric heater a MP steam jacket on the upstream of 15V11 has
been provided to heat up the fuel gas.
1.8
Nitrogen System:
Nitrogen (gas) is supplied in the unit from nitrogen plant installed within CRU
battery limit.
Gaseous nitrogen is supplied through two headers (header-I and header II)
to meet the requirement of CRU.
Gaseous nitrogen from the cold box of nitrogen plant is divided into two
parts. One part goes to the off side through a battery limit block valve.
The other part taken from the upstream of battery block-valve through a 3
line, which is provided with two block valves and a spectacle blind I between,
and this line is marked as Header-I. Header-I flow is measured by a FE and
its indication is given by FI in CRT.
Gaseous nitrogen can be supplied from liquid nitrogen storage vessels via
vaporisers through header-I.
Nitrogen (gas) from Header-I is required to serve the following purposes:
i.
ii.
iii.
iv.
v.
MISC- 01- 07
vi.
vii.
viii.
ix.
x.
xi.
xii.
Header-II:
Two nos. nitrogen booster compressor are provided in the nitrogen plant.
These compressors take suction from the cold box outlet nitrogen line and
boos-up the pressure from 7Kg/cm2 to about 11.5Kg/cm2.
The discharge line of booster compressor is marked as Header-II.
This line is provided with two block valves and a spectacle blind in between
at the west side of nitrogen plant battery limit. This line is provided with a FE
to give the flow indication in CRT. Gaseous nitrogen is supplied to the
following vessels and reactors to serve different operational functions.
i.
17-V-5
ii.
17-V-6
iii.
17-G-1A/B
iv.
17-R-1
v.
17-V-1
vi.
17-V-3
vii.
17-V-10
viii.
17-V-23
Gaseous nitrogen can also be supplied from liquid N2 storage vessels (new)
through vaporiser (new) at the down stream of gaseous nitrogen battery limit
block-valve.
MISC- 01- 08
1.9
Plant Air:
Plant air enters the unit through a 6 line having a spectacle blind at the
down stream of the battery limit block-valve. One local PI is provided at the
battery limit.
One FE is installed on the line to give the flow indication through a FI in CRT.
Plant air is used in the unit for different operations as follow:
i.
ii.
iii.
Dry air from the nitrogen plant is used in 17-R-1 for catalyst regeneration.
1.10
Service Water:
Service water enters the unit through a 3 line having a spectacle blind at the
down stream of the battery limit block valve. A local PI is provided at the
battery limit. A battery limit a FE is installed in the line to give the flow
indication in the CRT.
Service water is used at the following points in side the battery limit.
i.
ii.
To 17-P-2A/B suction
iii.
To steam generator
iv.
To APH system.
MISC- 01- 09
1.11
Flare system:
Gases from, columns, vessels, compressors and reactors after passing
through PSVs join a Common 26 Flare header that runs across the unit.
FG lines for IFP and non-IFP heaters are connected to the flare line through
double block valves with a spectacle blind in between.
All compressor discharge line PSVs are connected to the flare header.
9-V-1 pressure can be controlled by venting excess gas through a pressure
control valve into the flare header.
14-V-1 pressure is also controlled by a split range control system, which
vents excess gas into the flare header 15-V-1, 15-V-2 and 15-V-3 pressures
can also be controlled by venting excess gas into the flare header.
The common flare header is connected to a flare knock out drum 15-V-8.
Pump seal pot vents are connected to the flare header 15-V-8 is having LG,
high and low level alarms in CRT. Gases from 15-V-8 finally goes to the flare
through a 26 line provided with a block valve at the battery limit.
HCs and CBD system:
Hydrocarbons from columns, vessels exchangers pumps and compressors
can be drained into CBD drum, 15-V-9.
15-V-9 is provided with high and low level alarm and a local level indicator as
well as a level indication in the CRT.
15-P-10 is a submerged pump, which is installed in the CBD drum for
pumping out liquid into the slop header.
MISC- 01- 10
A GENERAL:
A-1.
No shift personnel shall leave the plant unless properly relieved or permitted
by his supervisors. However persons completing sixteen hours shall be
released by the supervisor by making alternate arrangements.
A-2.
Fire of any nature and intensity must be immediately reported to Fire Station,
RSM and DMPN/PNM/SPNM(U).
A-3.
Whenever any accident takes place, shift PNE/SPNE shall act as follows:
MISC- 02- 01
Fill up form A-1 for accident reporting and send one copy each to Fire
Station and Medical.
If form A-1 is not available, inform Fire Station Shift In-charge on phone.
Also inform RSM.
A-4.
Absentee and Overtime Statements shall be sent to time office with in fortyfive minutes of the commencement of the shift.
A-5.
PNE/SPNE in each shift shall initial the previous shift Log-Book and also the
Instruction Book to conform that they have read it.
B-2.
For Normal operation, Planned S/D and Start-up, and Emergencies handling
follow procedures given in the Operating manual.
B-3.
Any intermitted operation done in the plant should be specifically written with
starting and completion time.
B-4.
Clearance to be issued for all maintenance jobs. On the work clearance all
column must be ticked / crossed as applicable for the clearance part.
Pollution and Environment related jobs to be given top prooity (priority no.
one).
MISC- 02- 02
B-5.
B-6.
B-7.
Copy of clearances / work orders issued and job completion certificates must
be kept for record.
B-8.
B-9.
Follow lab. Sampling schedule. Log reason if any of the sample could not
be sent along with the reason.
B-10. Follow pumps change over schedule. Record the same in the log-book.
Also record reason if any change over could not be done.
B-11. Morning shift PNE/SPNE to ensure that daily log-sheet print outs are taken
and filed. He should also check if the field and panel log books and registers
are filled and duly signed.
All employees must follow safety guidelines and safety rules as framed in
Mathura Refinery Safety manual.
C-2.
Use Safety Halmet while entering HARD HAT AREA. This is for the safety of
all of us. The usage of Safety halmet in-side the B/L is to raised to
maximum.
C-3.
SYSTEM
AUTHORITY
ACTION
PROCESS
TRIP
CPNM
MISC- 02- 03
EQUIPMENT
TRIP
GM(T)
CMNM/CITY/
SITM/CPNM
GM(T)
C-4.
All Safety valves must be kept in line with both sides isolation valves car
sealed/wire sealed in wise open condition. If any of the Safety valves is
required to be isolated due to passing or leak, take the standby safety valve
in-line and isolate the defective one. Standby PSV to be attended on priority
and kept and stand-by. For isolation of safety valve where stand-by is not
available, procedures outlined above for security system shall be used.
C-5.
While handling chemicals, use safety wears. Shift PNE / SPNE should
satisfy themselves regarding the adequacy of protection (use of PVC hand
gloves, apron, face shield, safety goggle, hand gloves or gas mask etc.)
required to carry out the job.
C-6.
All drains and vents on lines and equipments handling hydrocarbons and
dangerous chemicals are to be kept properly capped or blinded. Even
sample points from where regular samples are collected should be kept
preferably capped hand tight.
C-7.
C-8.
C-9.
LPG and Light Naphtha are not to be drained into OWS as it may create
vapour cloud at various places leading to fire and explosion.
MISC- 02- 04
C-10. Any line / equipment which has been under hydrocarbon service, should not
be exposed to atmosphere / air unless it is made free of hydrocarbons either
by streaming or by water flushing.
Similarly when any equipment is exposed to air, it is to be made free of air
before putting it into hydrocarbon service.
C-11. Rotary equipment is to handed over to Maintenance only after proper
isolation (process isolation, draining and electrical de-energisation). Confirm
the de-energisation by pressing the start button in the field.
C-12. Any excavated area or opening at higher attitude must be properly
barricaded to eliminate chances of anybody falling down.
C-13. Wooden planks, bamboos ropes, oil soaked cotton wastes or any other
combustible material must not be allowed to remain in the unit area specially
near hot equipments as it can result in fire.
C-14. First aid box must be available in PNE/SPNE office. Ensure refill of the
box as and when required. Record in the log-book for deficiency.
C-15. Constant watch to be kept on firebox conditions. Boxes must be clear and
there should be no flame impingement on the tubes.
C-16. Naphtha is not to be given to any person / section for washing or cleaning
purposes.
C-17. Scales / mucks taken out from equipments under lighter hydrocarbon service
(e.g. fuel gas, LPG and naphtha) are to be kept wet and carefully removed to
a safer place and buried. This is to prevent fire due to presence of
pyrophoric iron.
C-18. Naphtha / Reformate rundown temperature should not exceed 45-46 deg. C.
Keeping it on the lower side will be preferable. This is to reduce fugitive
emission, hydrocarbon loss and reduce the possibility of hydrocarbon
vapours coming out of receiving tank and forming vapour cloud that may
result in fire.
C-19. Utility steam points have been provided at various locations in the plant. At
all critical areas (such as furnaces, Reboiler pumps, columns bottom
platforms, Reforming reactors different platforms. LPG pumps etc.) steam
hoses should be kept connected and rolled for fire fighting purpose.
MISC- 02- 05
C-20. If any nitrogen leak is observed in the nitrogen plant, which might has made
the area oxygen deficient, use air mask or an air hose provided for this
purpose near.
C-21. Steam leak can cause steam burn while working on it. To reduce the risk of
person getting injured due to the HP steam leakage.
-
C-22. All floors to be kept clean and dry to avoid person falling due to uneven
surface or slippery area. Get the areas levelled if any sagging is observed.
To keep the area dry, minimise Hydrocarbon, Chemicals, Steam and Water
leaks by attended them as and when noticed.
D-HOUSE KEEPING:
D-1.
D-3.
Ensure that the bins provided in the area are used for the collection of
garbage. Garbage collected in the bins should be disposed off at regular
intervals by civil maintenance. Record follow up for the same in the logbook.
D-4.
Shoes are not allowed inside the DDCS Control room. Control room to be
maintained dust free to avoid frequent Electronic Cards Failure.
D-5.
D-6.
MISC- 02- 06
D-7.
Ensure that sample point and chemical / oil drum valves are closed properly
immediately after the completion of the job. This is essential as;
E-ENVIRONMENT RELATED:
E-1.
E-2.
E-3.
E-4.
E-5.
MISC- 02- 07
E-6.
E-7.
Steam, process water, process cooling water and fire water leaks should be
reported in the Log-Book and attended at the earliest.
While taking round of the unit, check open channel for any oil. No oil is to be
allowed to go to open channel. If oil is noticed, act as follow:
Block the channel to prevent the oil going further. Locate and stop the
E-8.
During normal plant round, if any Hydrocarbon leak is notices, report it in the
Log-Book and get it attended at the earliest. If required isolated the
system/equipment and get the leak attended. Gaseous hydrocarbons in
addition to fire hazards have effect on environment also.
Liquid
hydrocarbons in addition to fire hazards have affect on land and water
pollution.
E-9. To minimise risk associated with Naphtha leak in cooling water (EMS
programme) check visually on weekly basis (preferably on Mondays) cooling
water sample at B/L for any naphtha and send the sample to lab. for the
HCs content as per the schedule. This checking is highly important as
cooling water is used in the number of naphtha exchangers. (09E-1, 9E-4,
14E-2, 14E-4A/B, 14E-5, 15E-2A/B, 15E-3, 15E-8A/B/C/D & 15E-11) where
naphtha pressure is higher than the cooling water pressure and any leak in
the exchanger will lead to naphtha carry over to the cooling tower. In case of
any abnormality inform PUE(Water block), RSM and PNM/SPNM, identify
the leaking exchanger and isolate the cooler if leak is confirmed.
E-10. Service water consumption is to be minimised (EMS programme). Ensure
the following for the same;
E-11. Hydrogen leak if any should be attended on priority as the leak may increase
very soon due to high pressure.
E-12. Freon refrigeration system should be maintained leak proof. Periodically
check the system for leaks and get the same attended on top priority.
MISC- 02- 08
F- CBD SYSTEM
As the reforming unit handles light HCs , The closed blow down system
needs special attention.
F-1.
F-2.
F-3.
F-4.
F-5.
F-6.
Ensure blanketing steam to CBD vent line is always kept charged. In case
of LP steam failure, isolate the steam to CBD vent to avoid any back flow
HCs to LP steam header.
Normally CBD system is to be kept floating with flare and isolated from the
atmospheric vent. This requires CBD network to be all leak proof. However,
if due to any reason (such as leakage), the system may be floated with
atmosphere. While floating with atmosphere, ensure that blanketing steam
(LP steam) is opened prior to opening of the atmospheric vent.
Check CBD vessel level in each shift. Pump out the CBD vessel if level is
more than 30%. Level to be kept in the range of 10-30%.
Weekly (preferably on Wed. Evening shift) check CBD pump performance
(even if the level is low) with discharge valve close. This is to ensure that
pump motor is in energised condition and pump develops pressure. Record
observation in the log-book.
Before and after draining any material to CBD, check the CBD level and
record in the log-book.
CBD all the clean out points must be kept blinded. All columns, Vessels and
exchangers drains to CBD to be kept blinded.
G- OWS SYSTEM
As the reforming unit handles light HCs The OWS system needs special
attention.
G-1.
G-2.
G-3.
OWS drain lines for the system, equipments and lines under hydrocarbon
service must be kept blinded.
Unit OWS and Storm sewer system are common. The storm channel inside
the unit to be kept lined up to OWS and isolated to the open channel near
steam drum.
Oil spillage if any, must be contained and not to be allowed to spread,
Draining of Naphtha in OWS will lead to the formation of HCs vapour cloud,
which can catch fire from the unit heater. However in case of spillage, flush
out the OWS system thoroughly.
CCRU OPERATING MANUAL
PART-H
MISC- 02- 09
G-4.
G-5.
All sewage /OWS / Storm water manhole must always be kept covered.
Screens, mesh provided in the OWS funnel shall be kept cleaned to avoid
funnel chokage, which will lead to oil / chemical spillage on the floor while
draining.
H-5.
H-6.
Unit B/L Valve shall be always full open and car sealed. Under no condition
it is to be isolated without the permission of DMPN / PNM or RSM.
Keep fuel gas purge to flare header charged near Non-IFP heaters.
Keep Flare KO pot drain to CBD and OWS in de-blinded condition. However
normal draining shall be done to DBD only.
Flare KO drum pr. and level to be checked while checking the unit. Level in
the KO pot to be kept in the lowest level gauge only. Under no case the flare
header Pr. will be more than 0.5 bar.
Under normal operations, no level build up is expected in the flare KO drum,
however if level build up is experienced, then check all the safety valves for
passing and simultaneously inform PNE VBU/MEROX for him to take care of
levels at the flare KO vessels.
All safety valves, which are to be kept in line, must be with safety valve inlet
and discharge valves wide open and car-sealed. Spare / Stand-by safety
valves should be with inlet valve close and discharge valve open and carsealed.
Keep air and HCs system isolated by blind. Air to unit 17 for regeneration to
be de-blinded at the time of regeneration only.
I-2.
MISC- 02- 10
PART-H
I-3.
emergency, the system is to be kept isolated by double block and bleed. I.e.
keep both the valves isolated and bleeder open. Any minor passing of any
of the valve will vent out the leak to atmosphere.
I-4.
While charging Nitrogen in any system, ensure that nitrogen pr. is higher
than the system pressure.
I-5.
Isolate nitrogen product block valve installed at the D/S of product valve
when the nitrogen unit is under start-up.
I-6.
Lead box,
Outer MS shell
J-1.
Ensure Radiation danger boards are kept displayed near the source
location.
J-2.
While working on the source or in the very vicinity, isolate the source by
closing its shutter.
J-3.
J-4.
In case of major fire in the vicinity of the source, isolate the source and
inform RSM, and DMPN/PNM/SPNM.
MISC- 02- 11
PART-H
J-5.
K-OPERATIONAL
K-1.
Follow the procedures as given in the operating manuals for the unit and its
different sections for the normal operations, start-up/ shutdown and
emergencies handling.
K-2.
NSU lighter product to be normally kept lined up with AVU. Heavy Naphtha
product to be routed to either HTU feed or to the Naphtha tank as per the
daily instruction through production line / Stop line.
K-3
K-4
K-5
If Sulfur slippage of more than 1 ppm is observed from the hydrotreating unit
in two consecutive results with hydrotreating unit at normal operating
condition, reduce the High Sulfur feed processing in HTU to 25% of the total
feed.
K-6
Keep constant watch on Stripper / stabiliser level and ensure that level is not
lost. This is to ensure that gases / LPG do not escape through the bottom
circuit to rundown tank creating fire hazard.
K-7
Ensure that liquid hydrocarbons are not carried by the fuel gas ex 14V2&14V-4 to 20C-6.
MISC- 02- 12
PART-H
K-9
Ensure that liquid hydrocarbons are not carried by gases ex 15V-2 to the fuel
gas system. This may create a fire situation. Cross check its level indication
with level gauge.
b)
c)
Caustic, Chloride and water dosing to unit 17 shall be done during the
catalyst regeneration only.
K-11. During each shift, confirm the level indications response by varying the level
of the vessels / column by 5%. Simultaneously get the levels cross
checked in the field LGs.
K-12. While topping up DSN tank, ensure the followings:
a)
b)
c)
MISC- 02- 13
PART-H
K-17 Ensure furnace draft physically by looking at the furnace.Also cross checks
the draft readings with local gauge and that of DCS.
K-18 Ensure the box temperature, skin temperature of every furnace and make
sure to keep them within the limits.
Maximum Skin temperature limits for
K-19 Ensure the status of interlock while taking charge on every shift.
K20. Update interlock register as and when any interlock is bypassed.
K21.Ensure no flaring during normal operation. In Case so take corrective actions
immediately without any delay.
K22.whenever feed pumps of NHTU fails in OM&S survive the unit by taking hot
feed from NSU bottom. Please ensure the specification w.r.t the line foreign
materials of the feed before taking the feed.
K23.Whenever temperature in ox chlorination is found on higher side, burning in
regeneration to be converted to black burning mode.
MISC- 02- 14
PART-H
K24. All the Advance Process Control strategies to be kept on-line. In case of a
problem forcing a strategy to be taken to Auto mode, report in the shift logbook
as well as to the advance control group.
K25.Ensure the performance of all electric heaters by analyzing their trends in dcs
and mention in log book in case of any abnormalities.
MISC- 02- 15
PART-H
Introduction
The human element of the system has one of the biggest potentials for either
causing or preventing a major incident. Safe job performance by operators,
3.2
Scope
For performing any work in the refinery by any person other than the operating
personnel of that area, a duly authorised written permit shall be obtained for by the
person/agency executing the work before commencement of the work. In
exceptional cases, the operating personal may require to issue permit to other
operating personnel such as in case of entry into confined space or so. Separate
permit shall be obtained for each activity. Following jobs should be undertaken only
after obtaining work permit:
Hot job, Excavation, Road/dyke cutting, Electrical lock-out/energising, Confined
space entry, Boxing up of vessel/furnace/ column, Working at elevation, working on
fragile roof structures, Radiography, Crane Operation.
The above list of jobs is indicative and not exhaustive.
MISC- 03- 01
PART-H
3.3
Depending on the nature of the job as mentioned in 3.2, there are seven types of
permit:
Cold work permit
Hot work permit/ Vessel entry / Vessel box up/ Excavation permit
Working at height permit
Radiation permit
3.3.1
DEFINITIONS
a) Hot Work: Hot Work is an activity that may produce enough heat to ignite a
flammable air - hydrocarbon mixture or a flammable substance. This includes all
works which produces spark, running of IC engine, breaking of concrete, use of
ordinary torches etc.
b) Cold Work: Cold Work is an activity that does not produce sufficient heat to ignite
a flammable air- hydrocarbon mixture or a flammable substance.
c) Radiation Work: Any activity that is carried with a source of ionizing radiation,
which does not produce sufficient heat to ignite a flammable air- hydrocarbon
mixture or a flammable substance.
d) Working at Height: Any activity that is carried out at 2.5 meters & above on
temporary structure, scaffolds etc.
e) Excavation: Any excavation work inside refinery of depth 200mm or more.
f) Confined space: A restricted space, not meant for human occupancy and where
there is likelihood of presence of undesirable condition for human safety.
3.4
General Requirements
All jobs in the refinery shall be carried out under valid work permit only. Normally
operating personnel do not require work permit, however in exceptional cases,
work permit is require
Work permits in the refinery shall meet the requirements of OISD-STD-105 titled
'Work Permit System'.
CCRU OPERATING MANUAL
MISC- 03- 02
PART-H
Separate permit must be issued for each job. Multiple jobs in a single permit are
prohibited.
Permits should be in printed forms, in triplicate or duplicate depending on nature of
job, serially numbered and different colour code may be adopted for different types
of permits.
Depending on nature of jobs, type of permit required shall be decided.
'Working at Height Permit' shall be required for working at a height of more than 2.5
meters from where the working personnel are liable to fall.
Safety harness with lifelines secured with a fixed structure is a must for working at
height. Provision of safety net shall also be considered based on site condition.
For excavation jobs, the following is to be ensured:
A warning or protective barricade of 1 meter height with red & white band/ selfglowing caution board is provided around excavation site.
Excavated material is piled at least one meter away from the edge of the trench or
depth of the trench whichever is greater.
Provision of two entries/exits is made.
Safe angle or repose or proper shoring/strutting to prevent cave-in is provided.
Permit issuing authority shall satisfy him that permit conditions are met before
issuing permit. It is also to be ensured that permit conditions are maintained in
course of execution of the job.
Before issuing a permit, equipment is inspected to ensure that the equipment/
facility is prepared and safe to carry out the assigned work, the area is cleaned and
all safety precautions have been adopted. Wherever necessary, equipment is
isolated, drained/ depressurised, properly purged, water flushed, gas test and
oxygen deficiency test are done. All concerned are to be trained on Work Permit
System for proper implementation. Certification and documentation of the training
imparted is a must.
MISC- 03- 03
PART-H
3.5
RESPONSIBILITIES
Gas test has been carried out, if required. (Gas test is mandatory for hot work and
entry into confined space).
Avoid giving general/ vague remarks on permit, which is not specific.
For working at height, ensure that there is provision of safe access to the work site
and there is provision of ladder/ platform/ scaffold for safe execution of work. Check
those scaffolds provided are with green tag.
Ensure positive isolation of electric equipment and decide about the extent of
isolation required for the job.
Close the permit on completion of work and retain the copy for at least one month.
Keep your copy of permit always with you.
Dont sign the permit without authority.
MISC- 03- 04
PART-H
3.6
PROCEDURES
General
Refinery Management shall issue the appropriate authority limits for various types
of permits. For blanket hot work and dyke cutting, permits should be obtained from
higher authorities and the facility should be restored as quickly as possible.
Entire refinery shall be divided into various zones. For each zone, Gas Safety
Inspector (GSI) and Fire Permit Signatory (FPS) shall be authorized. Normally, 'A'
and 'B' grade officers are made GSI and officers in grade 'C' and above are
designated as FPS. In addition, SRSM/RSM shall be authorized as FPS for the
entire refinery.
Dy. General Manager/General Manager shall authorize gas Safety Inspectors and
Fire Permit Signatories. List of authorized GSI and FPS shall be updated and
issued to all concerned at least once in a year.
Hot work permits shall be normally valid for 7 days. The authorized person can
extend validity after ensuring that all permit conditions are complied. However shift
wise clearance for the job is to be obtained.
Blanket hot work permit shall be issued with the authorization of DGM (PN) for one
month or above as mentioned below:
For Laboratory and Workshop or any place where hot work is required everyday
and the same is safe.
In instances like plant turn around or an activity where work is of continuous nature
involving round the clock activity.
For project construction area in non-operating areas.
However, for cutting process lines, specific permit shall be required.
For road cutting HOD permission is required and in case of dyke cutting,
permission of DGM shall be obtained.
MISC- 03- 05
PART-H
For carrying out hot jobs beyond normal working hours (General Shift) or on
Sundays/Holidays, permission shall be obtained from HOD/DGM. In case
concerned HOD/DGM is not available on duty, SRSM/RSM may give the
permission on instruction from HOD/DGM.
Whenever required, permit shall be renewed by the authority that is competent to
issue permit after ensuring all necessary checks as required in case of fresh permit.
The renewal is to be recorded on all the three copies of the permit.
Each and every permit shall accompany a clearance certificate. Job can be
executed only after obtaining clearance certificate from operating department.
Clearance certificate shall be renewed in each shift by GSI.
Permits and clearance certificate shall be available at the job site while the job is
being executed.
Permits shall be signed and returned to the issuing authority after completion of the
job. It is to be ensured that the area has been cleared of all debris and temporary
electrical connections have been removed.
The issuer on receiving back the permit would satisfy himself regarding completion
of the job and that the area has been cleaned. Then he shall also sign the permit
and keep the records for one month. In case of hot work permit and confined space
entry permit, the same shall be forwarded to F&S Department along with the
issuer's copy.
Cold Work
Hot Work/ Vessel entry/ Vessel box up/ Excavation permit
Working at Height
Radiation permit
Hot Work Permit also covers permission for vehicle entry inside operation area.
MISC- 03- 06
PART-H
The location of the work should be specified clearly in terms of the plant, plant area,
building, vessel or equipment. Identification number of the equipment should be
mentioned.
Area in-charge/GSI shall check the permit conditions prescribed in the format.
Permit shall be issued only after satisfying all the conditions. Additional precautions
and remarks, if any, shall be clearly mentioned. All the items shall be marked
appropriately in the boxes under heading done and Not Required.
Unsafe conditions for performance of work may arise from surrounding area. It
should be cleaned-up to remove flammable material such as oil, rags, grass etc.
(iii)
MISC- 03- 07
PART-H
(iv)
Considered hazard from other routine / non-routine operations and persons
alerted
Other activities (routine / non-routine) being carried out near-by which can create
conditions unsafe for performance of the permit work, should be taken into
consideration and the concerned persons should be alerted accordingly.
(v)
Before issuing permit for mechanical / electrical work in the operating area, it
should be ensured that electrical switches are locked-out and cautionary tags duly
signed with date and time are attached. Wherever local locking arrangement is
provided in the field, the same should be used. Refer format for electrical lockout /
energizing given in OISD-STD-137 on "Inspection of Electrical Equipment".
(vi)
Running water hose and portable fire extinguisher are required respectively to flush
/ dilute in case of release of any hazardous chemical or to quench sparks and to
put out small fires immediately.
(vii)
In order to meet any contingency, it should be ensured that the fire water system
including firewater pumps, storage, network etc. is checked and kept ready for
immediate use.
(viii)
Blinding is one of the most effective ways of isolation. Blinds should be installed as
close to the vessel as possible. If lines cannot be blinded, they should be
disconnected and the open ends should be made safe by installing pipe
caps/plugs, blind flanges, mud packing etc.
MISC- 03- 08
PART-H
(ix)
such as level gauges, small nozzles / bleeders on vessels, laterals in pipe work etc.
All low point drains should be in unplugged condition.
(x)
MISC- 03- 09
PART-H
No hot work shall be permitted unless the Explosive meter reading is zero. Vessel
entry, where no hot work is to be carried out, may be permitted if combustible gases
are up-to 5% of lower explosive limit (LEL). Entry with an air supplied mask may be
permitted with LEL of upto 50%.
The oxygen level should be at least 19.5 % vol. and the concentration of toxic
gases below the threshold limits.
(xiii)
In order to protect against welding sparks which can provide ignition in operating
areas, shields are to be provided. The shield material should be non-flammable and
should be kept wet with water.
(xiv)
Where natural ventilation is not available, fans/air eductors are provided. Some
types of work like welding may generate fumes. Facilities may be required for the
speedy dispersal of these fumes. Only approved reduced voltage extension lights
(not exceeding 24 volts) are to be allowed for work inside vessels from
consideration of personal safety.
(xv)
To prevent any unwarranted entry in the work area and also to caution other
personnel taking actions which may endanger people working on the permit job,
precautionary tags/boards are to be provided like "No Entry" sign on roads or
"Caution-Men at Work Inside" on the manhole of a vessel.
CCRU OPERATING MANUAL
MISC- 03- 10
PART-H
MISC- 03- 11
PART-H
(II) Scaffolds been tagged with green card duly filled and signed by scaffold
supervisor
Scaffolding should be tagged with red tag or green tag,
Green Tag: Means scaffold is safe for use.
Red Tag: Means not for use.
(III) Scaffold erected on firm ground and sole plate & base plate have been used
A good base is essential, so that the ground or floor on which the scaffolding is
going to stand should be carefully examined. Soil or made up ground will need
consolidating. Sole plates at least 9" x 1" (230 mm x 40 mm) cross section are
required to spread the load on earth, made up ground, asphalted surface etc. Sole
plates shall extend under at least two standards and joints shall be positioned so
that they fall within one half to one third of the distance between any two adjacent
standards. At the end standard the sole plate shall project a similar distance.
(IV) Platforms been provided with Toe board, guardrail & area below is barricaded.
TOE-BOARD (Also known as a Kicking Board) - A board positioned at the edge of a
platform or place so as to prevent persons, tools and materials falling from the
platform or place.
GUARDRAIL - (Also wrongly known as a Handrail) - A tube connected at the edge
of platform and other places to prevent persons falling from platform of place.
(V) Proper means of access to the scaffold including use of standard aluminum
ladder provided
Access to a working platform is best achieved by providing a separate ladder tower
or cantilevered access platform so as not to obstruct the platform and to minimize
the possibility of persons falling through the gap in the guardrail or decking
Work permit is a document, which certifies that all practicable precautions have
been taken for carrying out the job. Hence, it is desirable that the work permit form
shall be filled up personally by the GSI. GSI shall satisfy himself that all precautions
have been taken to ensure that the work site is gas free and will remain so during
execution of the job.
In case of cold work, radiography, working at height, only GSI shall sign the work
permit. In case of hot work, both GSI and FPS shall sign the permit. FPS must
satisfy himself that the job can be carried out safely and the permit conditions will
remain valid during execution of the job. For major construction sites, the
contractor/ consultant/ shall issue permit for working at height.
CCRU OPERATING MANUAL
MISC- 03- 12
PART-H
In case, electricity is involved, GSI shall request P&U Department for electrical
isolation. No work permit shall be issued unless electrical isolation is obtained.
In case of hot job, permits signed by both GSI and FPS shall be registered in Fire
Station. Fire Safety Officer in the shift shall check that the permit is filled properly in
all respect before registering the permit. FSO shall allot a number on the permit
with validity and put his signature. The registration shall be carried out at F&S
control room after ensuring signature of authorized signatory for the zone.
For excavation permit, permittee shall obtain the clearance from the respective
discipline like Civil Maintenance, Electrical Maintenance, Telecom, MIS, Production/
P&U, Fire & Safety in prescribed form as a prerequisite condition.
The authorized original copy of the permit shall be given to the receiver. Duplicate
copy shall be retained in the book. In case of Hot Work Permit, F&S Department
shall retain one copy.
Job can commence only after getting clearance certificate. Clearance in each shift
shall be given by GSI of the area after checking permit conditions.
MISC- 03- 13
PART-H
On completion of a hot work/ Vessel entry/ Vessel box up/ Excavation, the permit
shall be signed by permittee and returned to the issuer along with clearance
certificate. The issuer will then send the permit to F&S Department along with his
copy. F&S Department shall record the completion of the job and keep the permits
(two copy) along with the F&S copy, which was submitted during registration.
Hence, after completion of the job, shift in-charge of F&S Department will keep all
the three copies of hot wok permit together and preserve these at least for one
month.
MISC- 03- 14
Yellow
Open Channel
Blue
Domestic Sewage -
MISC- 04- 01
5.1
5.1.1
ROLES
RESPONSIBLITY
RESOURCES AND RELIABILTY PLANNING
Planning for feed processing products quality,
equipment
co-ordination/participation
in:
SPNM(U)/PNM
SPNM (U)
SPNM (U)
SPNM(U)/PNM /
DMPN
PNM / DMPN
Relevant instructions
instructions.
to
shift
officers
through
5.3
CONTROL MECHANISM
PNM / DMPN
DMPN
MISC- 05- 01
Panel operator
Field operation
Field operator
Flare area
Field operator
Operator C
maintenance
group
Shift officer
Panel operator
Shift officer
MISC- 05- 02
Shift officer
Field operator
DMPN
5.6.3
For feed back on unit operations refer log book & lab
DMPN / PNM /
SPNM
register
MISC- 05- 03
6.0
STANDARDS
NAME OF STANDARD
OISD-STD-105
OISD-STD-106
OISD-STD-108
Recommendation
handling.
OISD-STD-109
OISD-RP- 110
OISD-STD-111
OISD-STD-112
OISD-STD-113
OISD-STD-116
OISD-STD-118
(Rev 1)
OISD-STD-119
(Rev 1)
Inspection of pumps.
OISD-STD-120
Inspection of compressors.
OISD-STD-121
OISD-STD-122
OISD-RP-123
practices
on
oil
hydrocarbon
storage
mixture
MISC- 06- 01
&
&
STANDARDS
NAME OF STANDARD
OISD-RP-124
OISD-RP-125
OISD-RP-126
Specific maintenance
equipments.
OISD-STD-127
OISD-STD-128
OISD-STD-129
OISD-STD-130
OISD-STD-132
OISD-STD-133
OISD-STD-134
OISD-STD-135
OISD-STD-137
OISD-STD-142
OISD-RP-147
Inspection &
installations.
OISD-RP-148
OISD-STD-152
Safety instrumentation
hydrocarbon industry.
OISD-STD-153
safe
practices
practices
for
for
during
process
rotating
electrical
system
MISC- 06- 02
in
STANDARDS
NAME OF STANDARD
OISD-STD-154
Part I
Part II
OISD-STD-163
OISD-GDN-166
MISC- 06- 03
TAG NO
DISCRIPTION
RANGE
SETTING
ACTION
09 FURNACE 1
1
09 FSLL-1201 B
09 F1 PASS FLOW P 1
0-20.66 M3/HR
19.81 M3/HR
TRIP
09 FSLL-1202 B
09 F1 PASS FLOW P 2
0-20.66 M3/HR
19.81 M3/HR
TRIP
09 FSLL-1203 B
09 F1 PASS FLOW P 3
0-20.66 M3/HR
19.81 M3/HR
TRIP
09 FSLL-1204 B
09 F1 PASS FLOW P 4
0-20.66 M3/HR
19.81 M3/HR
TRIP
09 FSLL-1210 B
09 F1 PASS FLOW P 5
0-20.66 M3/HR
19.81 M3/HR
TRIP
09 FSLL-1211 B
09 F1 PASS FLOW P 6
0-20.66 M3/HR
19.81 M3/HR
TRIP
09 PSLL 1210 B
09 FI P/G PR
-------------------
0.4 KG/CM
TRIP
PSH 3103 B
FUR;ARCH PR HI - 09 F1
+2 MMWC
TRIP
PSH 3103 C
FUR;ARCH PR HI - 09 F1
+2 MMWC
TRIP
10 PSHH 3103 B
FUR;ARCH PR HI - 09 F1
+ 5MMWC
TRIP
11 PSHH 3103 C
FUR;ARCH PR HI - 09 F1
+ 5MMWC
TRIP
12 PSH 3103 A
FUR;ARCH PR HI - 09 F1
+2 MMWC
TRIP
13 PSHH 3103 A
FUR;ARCH PR HI - 09 F1
+ 5MMWC
TRIP
14 14 FSLL 1416
0-52301.63 KG/HR
49103.4 KG/HR
15 14 FSLL 1404
0.3111.26 KG/HR
3000 KG/HR
16 14 FSLL 1411 B
0-827.34 KG/HR
767.7 KG/HR
17 14 FSLL 1419 A
0-13072.05 KG/HR
10229.90 KG/HR
18 14 FSLL 1419 B
0-13072.05 KG/HR
10229.90 KG/HR
19 14 FSLL 1419 C
0-13072.05 KG/HR
10229.90 KG/HR
20 14 FSLL 1419 D
0-13072.05 KG/HR
10229.90 KG/HR
21 14 PSH 3101
14 F1 ARCH PR V.HI
-25 TO +25MMWC
+2 MMWC
22 14 PSLL 1422
14 F1 FUEAL GAS PR
------------
0.4 KG/CM
23 14 PSLL 1422 B
14 F1 PILOT GAS PR
------------
0.4 KG/CM
24 14 PSLL1442
14 F2 FUEL GAS
------------
0.4 KG/CM
14 FURNACE 1 & 2
MISC- 07- 01
25 14 PSLL 1442 B
14 F2 PILOT GAS
26 14 TSHH 1473
----------
0.4 KG/CM
330 DEG C
-----------
0.35 KG/CM
27 14 PSLL 1474A
----------
KG/CM
28 14 TSHH 1477A
118 DEG C
29 14 PAHH 1476A
KG/CM2
30 14 PSL 2001A
-------------
0.55 Kg/Cm
31 14 PSLL 2007A
---------
2.4 Kg/Cm
--------
0.35 KG/CM
34 14 PSLL 1474B
35 14 TSHH 1477B
--------
118 DEG C
36 14 PAHH 1476B
--------
KG/CM2
37 14 PSL 2001B
--------
0.55 Kg/Cm
38 14 PSLL 2007B
--------
2.4 Kg/Cm
KG/CM2
---------
0.35 Kg/Cm
40 14 PSLL 1004A
----------
16.17 Kg/Cm
41 14 TSHH 1002A
----------
106 C
42 14 TSHH 1004A
---------
106 C
43 14 PSL 1001A
----------
0.55 Kg/Cm
44 14 PSLL 1006A
14 K1A CW IN HDR PR
----------
2.4 Kg/Cm
45 14 LSHH 1409
---------
75%
-----------
0.35 Kg/Cm
47 14 PSLL 1004B
---------
16.17 Kg/Cm
MISC- 07- 02
48 14 TSHH 1002B
----------
106 C
49 14 TSHH 1004B
-----------
106 C
50 14 PSL 1001B
----------
0.55 Kg/Cm
51 14 PSLL 1006B
14 K1B CW IN HDR PR
----------
2.4 Kg/Cm
52 15 PSLL 1558 B
15 F1 P/G PR V.LO
-----
0.4 KG/CM
53 15 PSLL 1568 B
15 F2 P/G PR V.LO
-----
0.4 KG/CM
54 15 PSLL 1578 B
15 F3 F/G PR V.LO
----
0.4 KG/CM
55 15 FSLL 1565 A
0-16133.22 KG/HR
15150.45 KG/HR
56 15 FSLL 1565 B
0-16133.22 KG/HR
15150.45 KG/HR
57 15 FSLL 1565 C
15 F4 PASS FLOW P 3
0-16133.22 KG/HR
15150.45 KG/HR
58 15 FSLL 1565 D
15 F4 PASS FLOW P 4
0-16133.22 KG/HR
15150.45 KG/HR
59 15 PSLL 1588 B
15 F4 P/G PR V.LO
60 15 FSLL 1906
0-308000 KG/HR
57000 KG/HR
61 15 FSL 3104
0-60000 NM3/HR
12000 KG/HR
62 15 TSHH 3141C
0-200 DEG C
90 C
63 15 FSLL 3142 B
50 LPM
64 15 FSL 3105
FD 2-SUCT FLOW
0-60000 NM3/HR
12000 KG/HR
65 15 FSLL 3144 B
0-200 LPM
50 LPM
66 15 TSHH 3142C
FD B (15 K02)
0-200 DEG C
90 C
67 15 PSLL 3110
--
5mmWC
68 15 PSLL 3111
--
5mmWC
38000 KG/HR
10800 KG/HR
70 15 PSHH 3107
-250 TO +25MMWC
-40 MMWC
71 15 FSLL 3102
16500 KG/HR
4500 KG/HR
72 15 TSHH 3132
0-400 DEG C
240 C
73 15 FSLL 3103
15 FURNACE 1/2/3/4
-------
0.4 KG/CM
ID/FD FANS
15000 KG/HR
MISC- 07- 03
74 15 FSLL 3140 B
0-200 LPM
50 LPM
75 15 TSHH 3140 B
0-200 DEG C
90 C
---------
115 C
77 17 PSLL 0301A/B
17K1A/B L.O.PR.LO-LO
---------
1.5 KG/CM
78 17 TSHH 0101A/B
---------
115 C
79 17 PSLL 101A/B
17K1A/B SUCN.PR.V.LOW
--------
1.5 KG/CM
80 17 PSL 301A/B
17K1A/B L.O.HDR.PR.LO.
--------
1.8 KG/CM
81 17 LSHH 1723
75%
17K3A DIS;TEMP HI
----------
155 C
83 17 PSLL 3002A
----------
1.6 Kg/Cm
84 17 PSL 3001A
---------
2.0 Kg/Cm
85 17 LSHH 1726
---------
70%
86 17 TSHH 1718
17K3B DIS;TEMP HI
----------
155 C
87 17 PSLL 3002B
----------
1.6 Kg/Cm
88 17 PSL 3001B
---------------------------
2.0 Kg/Cm
VAHH 4101
15 K 1-
90
AAHH 4101
15 K 1-
5.2 MM
91
VAHH 4102
15 K 1-
92
AAH 4102
15 K 1-
5.2 MM
93
TAHH 4101 A
COMP.TH.RRG.TEMP.HIGH
15 K 1-
138 C
94
TAH 4101 B
TIS 4102 B
15 K 1-
132 C
95
TAH 4102 A
TIS 4102 A
15 K 1-
132 C
96
TAHH 4102 B
TUR.TH.RRG.TEMP.HIGH
15 K 1-
138 C
97
PDSL 4010
15 K1 COM.BAL.PIST PR
15 K 1-
0.3 KG/CM
MISC- 07- 04
98
PSH 4204
15 K 1-
3.3 KG/CM
99
PSH 4205
15 K 1-
1.6 KG/CM
15 K 1-
25%
OIL HDR PR LO
15 K 1-
7.0 KG/CM
15 K 1-
0.5 KG/CM
15 K 1-
0.5 KG/CM
BUF.GAS.FIL.PR.DISCH
15 K 1-
0.7 KG/CM
BUF.GAS.FIL.PR.SUCT
15 K 1-
0.7 KG/CM
LO PR LO
15 K 1-
0.89 KG/CM
15 K 1-
25%
15 K 1-
170 C
L.O SUP. PR V L
15 K 1-
0.76 KG/CM
L.O SUP. PR V L
15 K 1-
0.76 KG/CM
L.O SUP. PR V L
15 K 1-
0.76 KG/CM
15 K 1-
0.75 KG/CM
15 K 1-
0.75 KG/CM
15 K 1-
0.75 KG/CM
15 K 1-
0.75 KG/CM
15 K 1-
0.75 KG/CM
15 K 1-
0.75 KG/CM
118 ST 4101 A
15 K 1-
8896 RPM
119 ST 4101 B
15 K 1-
8896 RPM
120 ST 4101 C
15 K 1-
8896 RPM
15 V1 LEVEL V.HI
15 K 1-
70%
122 SV 4001
TRIP VALVE(SOV)
15 K 1-
110 V.AC(ASCO)
COMP.AXIAL DISPLACEMENT
COMP.AXIAL DISPLACEMENT
AIS 4101
125 XE 4101 A
COMP.RAD.VIB.(DISH. SIDE)
VIS 4101 A
126 YE 4101 A
COMP.RAD.VIB.(DISH. SIDE)
VIS 4101 A
525
MICRO.M(TRIP)
525
MICRO.M(TRIP)
105 MICRO.M
(TRIP)
105 MICRO.M
(TRIP)
MISC- 07- 05
105 MICRO.M
(TRIP)
105 MICRO.M
(TRIP)
105 MICRO.M
(TRIP)
105 MICRO.M
(TRIP)
105 MICRO.M
(TRIP)
105 MICRO.M
(TRIP)
512 MICRO.M
(TRIP)
512 MICRO.M
(TRIP)
127 XE 4101 B
COMP.RAD.VIB.(SUCT.SIDE)
VIS 4101 B
128 YE 4101 B
COMP.RAD.VIB.(SUCT.SIDE)
VIS 4101 B
129 XE 4102 A
VIS 4102 A
130 YE 4102 A
VIS 4102 A
131 XE 4102 B
TURB.RAD.VIB.(INLET SIDE)
VIS 4102 B
132 YE 4102 B
TURB.RAD.VIB.(INLET SIDE)
VIS 4102 B
AIS 4102
AIS 4102
TURBINE SPEED
TURBINE SPEED
137 TI 4101 A
COM.THR.BRG (INACT) 15 K1
132 C
138 TI 4101 B
COM.THR.BRG (INACT)
132 C
139 TI 4101 C
COM.THR.BRG (ACT)
132 C
140 TI 4101 D
COM.THR.BRG (ACT)
132 C
141 TI 4101 E
COM.THR.BRG (ACT)
132 C
142 TI 4102 G
TURB.THR.BRG (INACT)
132 C
143 TI 4102 H
TURB.THR.BRG (INACT)
132 C
144 TI 4102 J
TURB.THR.BRG (INACT)
132 C
145 TI 4102 K
TURB.THR.BRG (ACT)
132 C
146 TI 4102 L
TURB.THR.BRG (ACT)
132 C
147 FT 4301
8734 RPM
SSHH 4101 A,B,C
635-3810 MMWC
8734 RPM
CAL. 2400 MM
15 X1&2 Dish.Pr.V.High
17 Kg/Cm
15 X1&2 Dish.Temp.V.High
85 C
15 X1&2 Sucn.Pr.V.Low
0.2 Kg/Cm
0.5 Kg/Cm
80%
1.5 Kg/Cm
20%
MISC- 07- 06
2.0 Kg/Cm
125 C
125 C
125 C
COM.42
1.0 Kg/Cm
0.8 Kg/Cm
1.0 Kg/Cm
17.5 Kg/Cm
0.8 Kg/Cm
1.0 Kg/Cm
17.5 Kg/Cm
40X1&X2 Com.Disch.Temp.V.Low.
3 C
1.0 Kg/Cm
1.1 Kg/Cm
40NC1/2 - Disch.Temp.V.High
90 C
1.12 Kg/Cm
171 VB 1
1.0 MIL
172 VB 2
1.0 MIL
173 VB 3
1.0 MIL
174 TE 1
52 C
175 TI 1
18 C
176 TE 2
52 C
MISC- 07- 07
177 TE 3
52 C
178 TE 4
52 C
179 PSLL1
0.42 Kg/cm
PROCESS - GENERAL
180 FSLL 1514
15 P5 A/B
0-91263 KG/HR
80802
15 E1
0-7379 KG/HR
6895
182 FSLL1731
17 E1
0-4743.8 KG/HR
4000
183 FSLL1732
N2 II TO 1 ST UH
0-10 KG/HR
184 FSLL1733
N2 II TO 4 TH LH
0-13.41 KG/HR
N2 II TO RD CH
0-0.5 KG/CM2
0-0.3 KG CM
N2 TO RR. CH
0-0.1 KG/CM2
0-0.1 KG/CM2
CL.W.LIN
0-280 LPM
74 LPM
CL.W.LIN
0-200 LPM
50 LPM
CL.W.LIN
0-280 LPM
70 LPM
CL.W.LIN
0-200 LPM
50 LPM
CL.W.LIN
0-280 LPM
70 LPM
0-600
480 DEG .C
17 R1 REGEN
0-600 DEG C
520 DEG C
17 R1 REGEN
0-600 DEG C
535 DEG C
17 R1 REGEN
0-600 DEG C
535 DEG C
196 TSHH1712
II UH 17 V-12
0-600 DEG C
300 DEG C
197 TSHH1713
III RD UH 17-V-13
0-600 DEG C
300 DEG C
N2 II TO IST UH
0.5 KG CM2
0-0.5 KG CM2
O2 % IN N2 GAS
0-1.0 %
0.90%
10000 KG/HR
5000 KG /HR
0-600 DEG C
580 DEG C
0-600 DEG C
580 DEG C
203 17 FL 18
RECYLE FLOW
0-20000 KG/HR
10000 KG/HR
H2 % VOL IN GAS
0-10 %
0.80%
MISC- 07- 08
O2 % IN N2 GAS
0-1.0
0-0.8%
206 17 PL 2001
17 DR 1 PR.
0-8.0 KG CM2
3.9 KG CM2
14 F1 ARCH PR
-25 TO +25MMWC
+2 MMWC
14 F2 ARCH PR
-25 TO +25MMWC
+2 MMWC
15 F4 ARCH PR
-25 TO +25MMWC
+15 MMWC
15 F4 ARCH PR
-25 TO +25MMWC
+20 MMWC
211 15 FSL3104
60000 KG/HR
12000 KG/HR
60000 KG/HR
12000 KG/HR
0-600 DEG C
300 DEG C
214 17FH01
0-300 KG/HR
150 KG/HR
215 17TSH2005
0-100 C
60 C
216 17TSH2006
REGEN.GAS TEMP.
0-400 C
240 C
MISC- 07- 09
PART-H
Comp.
Trip
EFFECT
14K1A/B
1 Sucn.Pr.V.Lo.
PSLL1004 [PSLL1004B]
CAUSE
Disch.Cyl-1.Temp. V.Hi. TSHH1002
2 [TSHH1002B]
Disch.Cyl-2.Temp. V.Hi. TSHH1004
3 [TSHH1004B]
4 L.O. Pr. V.Lo. PSLL1002 [PSLL1002B]
5 CW Hdr.Pr.V.Lo. PSLL1006 (Common)
6 14V3 Level V.Hi. LSHH1409
X
X
X
X
X
X
Comp
Start
Permit
AOP
Auto
Start
AOP
Auto
Stop
(Common)
1
2
3
4
5
CW Pump ON +
Capacity Control 0% +
AOP ON +
Trip Parameters OK +
14V3 Level LSHH1409 OK (Common)
X
X
MISC- 08- 01
PART-H
Comp.
Trip
EFFEC
14K2 A/B
1 Suction
CAUSEPr V.Low PSLL1474A/B
2 Disch. Temp. V.High TSHH1477A/B
3 LO Pr V.Low PSLL2002A/B
4 Disch.Pr V.High PAHH1476A/B
5 C/W Hdr.Pr V.Low PSLL2007(common)
1
2
3
4
5
6
7
8
Comp
Start
Permit
X
X
X
X
X
AOP
Auto
Start
AOP
Auto
Stop
MISC- 08- 02
PART-H
1 Capacity Control 0% +
2 AOP ON +
3 Trip Parameters OK +
Comp
Start
Permit
X
X
X
X
X
X
AOP
Auto
Start
AOP Auto
Stop
Comp
Start
Permit
AOP
Auto
Start
AOP
Auto
Stop
X
X
X
1 Capacity Control 0% +
2 AOP ON +
3 Trip Parameters OK +
MISC- 08- 03
PART-H
3 VAHH4102
4 Axial Disp V.Hi. AAHH4102
Comp Thrust Bearing temp V.Hi
5 (TAHH4101A)
6 (TAHH4102B)
7
8
X
X
X
X
X
X
LOP2 Stop
LOP2 Start
LOP1 Stop
LOP1 Start
X
X
PermitGovr Start
CAUSE
15K1
1 Axial Disp V.Hi. VAHH4101
2 Axial Disp V.Hi. AAHH4101
PermitComp Start
EFFECT
Comp Trip
9
10
11
(2/3 Logic)
Seal Vent Gas Pr. V.Hi.
PSHH4058A/B/C (2/3 Logic)
Seal Vent Gas Pr. V.Hi.
PSHH4060A/B/C (2/3 Logic)
Turbine Speed V.Hi.
ST4101A/B/C (2/3 Logic)
X
X
X
X
X
X
1 Trip Parameters OK +
2 L.O. Pr.Lo. PSL4001 - OK +
L.O.Tank Level Lo. LSL4001 -
3 OK +
4 Turbine Speed ST4101A - OK
1 Trip Parameters OK +
2 Govr Speed below RPM +
3 L.O. Pr.Lo. PSL4001 - OK +
L.O.Tank Level Lo. LSL4001 -
4 OK +
5 External Run
X
X
X
X
X
X
X
X
X
1 Comp Trip
1 Sw. in AUTO
MISC- 08- 04
2 Start
1
2
L.O.Pr.V.Lo.
PSLL4002A/B/C(2/3) + A/M Sw.
(Auto)
A/M Sw. in MAN + Emergency
LOP Start
X
X
1 in AUTO
Comp.
Trip
40X1/2
EFFECT
1 Sucn.Pr.Lo.
PSL4415 [PSLL4425]
CAUSE
2 Disch.Pr.Hi. PSH4416 [PSHH4426]
3 L.O. Pr. Lo. PSL4414 [PSL4424]
4 Disch.Temp.V.Lo. TSLL4417 (Common)
Cooling Water Flow Lo. FSL4400
5 (Common)
1 Comp OFF
2 Oil Temp.Low
3 Trip Parameters OK +
Wash Drum Level LSHH1723 OK
4 (Common)
Comp ON + L.O. Pr. Low PSL0301A
1 [PSL0301B]
Comp ON + 20 Sec Delay + L.O.Pr.
1 Healthy
Comp
AOP Auto
Start
Start
Permit
AOP
Auto
Stop
X
X
X
X
X
X
X
MISC- 08- 05
PART-H
XX
FG/FO Pr.
V.Low (09F01)
XX
X
XX
Pass Flow
V.Low
(FSLL1419A/B
/ C/D) & COT
V.High - 14F02
Pass Flow
V.Low & COT
V.High (09F01)
Pass Flow
V.Low
(FSLL1565A/B
/ C/D) & COT
V.High - 15F04
XX
X
XX
XX
XX
XX
XX
Trip ID Fan
XX
XX
Pass Flow
V.Low & COT
V.High (14F01)
XX (With
delay
30Sec)
XX (With
delay
30Sec)
XX (With
delay
30Sec)
XX (With
delay
30Sec)
XX
XX (With
delay
30Sec)
XX
XX (With
delay
30Sec)
XX
XX (With
delay
30Sec)
XX
XX
XX (With
delay
30Sec)
MISC- 08- 06
XX
XX
XX
XX
XX
MISC- 08- 07
FanTrip
ID
DamOpen
per
XX
XX
PART-H
DamOpen
per
Fuel CutO
to
ff
DamOpen
per
Fuel CutO
to
ff
DamOpen
per
SuppCutO
ly to ff FG
DamOpen
per
Dis. Clos
e
SuppCutO
ly to ff FG
FD Start
Fan other
One FD Fan
Failure
(XL3101/3102
& FSL3104/
3105)
Both FD Fan
Failure
(XL3101&3102
/ FSL3104 &
3105/
FSLL3103)
ID Fan Failure
(XL3115 &
PSHH3107 at
ID
Sucn./Speed
Sensor)
ID Fan Failure
(XL3115 &
PSHH3107 at
ID
Sucn./Speed
sensor) &
HV3101 Not
open + 20Sec
ID Fan Failure
(XL3115 &
PSHH3107 at
ID Sucn./
Speed sensor)
& HV3102 Not
open + 20Sec
ID Fan Failure
(XL3115 &
PSHH3107 at
ID Sucn./
Speed sensor)
& HV3103 Not
open + 20Sec
ID Fan Failure
(XL3115 &
PSHH3107 at
ID Sucn./
Speed sensor)
& HV3104 Not
open + 20Sec
XX (With
delay
30Sec)
High Arch
pressure
(PSH3101)
High Arch
pressure
(PSH3102)
X (If
persist
s for
20Sec
with
delay
30Sec
)
XX
XX
XX
XX
X (If
persist
s for
20Sec
with
delay
30Sec
)
High Arch
pressure (2/3of
PSH3103ABC)
X (If
persist
s for
20Sec
with
delay
30Sec
)
High Arch
pressure
(PSH3104)
X (If
persist
s for
20Sec
with
delay
30Sec
)
XX (With
delay
30Sec)
XX (With
delay
30Sec)
XX (With
delay
30Sec)
XX (With
delay
30Sec)
Trip ID Fan
UV1541)CutOff Fuel to
15F04 (Close
Open Damper
HV3103
Open Damper
HV3102
UV1411)CutOff FG Supply
to 14F02 (Close
Open Damper
HV3105
XX
Open Damper
HV3104
Open Damper
HV3101
UV1401)CutOff FG Supply
to 14F01 (Close
MISC- 08- 08
PART-H
X (If
ZSH31
01 not
closed
after
20Sec)
X
X (If
ZSH31
02 not
closed
after
20Sec)
X (If
ZSH31
03 not
closed
after
20Sec)
X
X (If
ZSH31
04 not
closed
after
20Sec)
Trip ID Fan
CutOff FG Supply to
14F02 (Close UV1411)
CutOff FG Supply to
14F01 (Close UV1401)
X (With
delay
20Sec)
XX
XX (With
delay
30Sec)
XX (With
delay
30Sec)
XX (With
delay
30Sec)
MISC- 08- 09
15F1
CAUSE
EFFECT
X
X
X
X
X
X
X
X
X
X
MISC- 08- 10
INTRODUCTION:
Recycle gas compressor is a centrifugal compressor for the catalytic reforming unit
driven by a back-pressure steam (HP) turbine and is supplied by M/S EBARA
CORPORATION of Japan (Model No. 38MB6/SBHEG4-4). Compressor takes
suction from the reformer separator drum and discharges into the reformer feed
preheater 15E1, where it mixes as recycle gas with feed.
9.2
OPERATING PRINCIPLE:
MISC- 09- 01
Normal
Rated
Case A
PLANT
BH+AM
BH+AM
BH+AM
CONDITION
+VB
+VB
+VB
REC.GAS
REC.GAS
69,648
GAS
HANDLED
FLOW, m3/Hr
WEIGHT
FLOW, Kg/Hr
SUC/DIS PR
(Kg/cm2 g)
SUC/DIS
TEMP DEG C
MOL.WT
I/L VOL,
m3/Hr (WET)
COMP. RATIO
Case B
Case C
Case D
BH
DRYING
REDUCTION
REC.GAS
REC.GAS
N2
H2
76,613
68,998
53,657
34,484
37,932
31,125
24,750
41,000
14,000
2.2/5.8
2.2/5.8
2.2/5.8
2.2/5.8
0.6/2.48
4.0/5.1
45/105
45/105
45/108
45/109
40/141
40/64
11.7
11.7
10.666
10.9
28
3.0
24,851
27,338
24,691
19,214
24,293
24,505
2.125
2.125
2.125
2.125
2.175
1.220
2140
2334
2151
1734
1221
955
7362
7446
7702
7498
5391
7702
KW REQD
(ALL LOOSES
INCL)
SPEED (RPM)
The suction pressure of the compressor can go up to 3.7 Kg/cm2 g. Speed can be
varied from 70% to 105% through steam turbine. Compressor rated speed is 7702
rpm, min 70% speed is 5391 rpm, max. 105% speed is 8087 rpm. Critical speed of
compressor is 3400-3500 rpm and torsional critical speed is 3379 rpm.
9.3
COMPRESSOR:
MISC- 09- 02
mm. The rotation of the compressor as viewed from the turbine end is clockwise. It
takes suction from reformer seperator drum 15V1 and its discharge is routed to the
feed inlet side of the exchanger 15E1. A spillback flow through an anti-surge
controller is provided from discharge to suction via a cooler for machine protection
from surging. Compressor is equipped with dry gas seals for its shaft end sealing. A
brief description of the parts of the compressor is given below:
Casing is designed with a vertically split outer casing and horizontally split inner
casing. The inner casing is completely assembled and slid into the outer casing on
assembly. The end wall attached to the outer casing completes the casing
assembly.
Inlet guide vanes located in the front of each impeller provide proper gas flow
direction as gas enters the impellers. Inlet guide vanes are an integral part of the
diaphragm casting.
Diaphragms serve as partitions between the various stages and are generally
made of cast iron. They also form passages to direct the flow from the impeller
discharge to the inlet guide vanes of the next stage. The accurately machined
surfaces form spaces in which the impellers rotate. The extension of these surfaces
form the diffuser. The diffuser effectively coverts the velocity of the gas to pressure
energy. The diaphragms also contain inter stage seals.
Interstage labyrinth seals are to minimize leakage between the stages. The
labyrinth seal at the impeller entrance is called the impeller eye labyrinth seal while
the one located behind the impeller is called the shaft labyrinth seal.
Journal bearings are located in the bearing housing at the inlet and discharge
ends of the compressor to support the rotor assembly. The journal bearings are
pressure lubricated.
Thrust bearing function is to maintain correct axial position of the compressor rotor
and to absorb any thrust produced by the rotor. Normally the thrust is towards the
inlet of the compressor. However under abnormal operating conditions, thrust may
occur in the opposite direction. It is also pressure lubricated.
The shaft is made of forged steel. The impellers are made of alloy steel. The
impellers are accurately machined and balanced, then keyed and shrunk to the
shaft. Sleeves are used between impeller wheels for spacing. The sleeves are also
shrunk on the shaft.
Balance piston: Due to pressure rise developed through the impeller, a pressure
difference exists across the hubs and covers such that the impellers have a net
thrust in the direction of the compressor inlet.
CCRU OPERATING MANUAL
PART-H
MISC- 09- 03
The majority of this thrust is counteracted by the balance piston drum located
behind the last impeller. This is accomplished by subjecting the area on the
outboard side of the balancing piston to a lower pressure (approx. inlet pressure),
thereby creating a pressure differential opposite in direction to that on the impellers.
This low pressure is achieved by connecting the area behind the balance piston to
the inlet of the machine by balance piston line. The impeller thrust not balanced by
the balance piston is absorbed by the thrust bearing. To minimize the amount of the
gas leakage past the balancing piston, a balance piston seal is fitted in the
discharge wall.
9.4
JOHN CRANE type 28 TANDEM seals have been installed on the shaft ends for
sealing process gas leak to open atmosphere. The tandem seal is a pair of
mechanical seals installed one behind the other. Primary seal seals from process to
venting pressure and the secondary seal from vent pressure to atmosphere.
Therefore only a small leakage is discharged into the atmosphere. The process gas
leak to flare is monitored.
Temperature
Operating Pressure
6.7 Kg/cm2 g
Shaft speed
8087 rpm
Expected leakage
Guaranteed leakage
The seals are designed to cover the widest range of operating parameters and
virtually require no maintenance. A supply of filtered compressor discharge gas is
injected into cavity between inboard gas seal and the inboard labyrinth. A majority
of the gas will flow by inboard labyrinth back into compressor ensuring that the seal
cavity is free from liquids or particles that can damage the seal.
MISC- 09- 04
A small quantity of the supply gas will flow past the inboard seal to the cavity
between the inboard and outboard seals. This cavity is vented and the leakage
goes to the vent. The O/B ga seal will be sealing on the gas leakage past the
inboard seal. This in conjunction with a separation labyrinth for bearing oil prevents
the gas from entering the bearing area. The O/B gas seal also functions as a safety
seal in case inboard seal starts leaking heavily. Seal performance is monitored
through leakage rates.
Basically the seal control unit consists of gas filter system which supplies seals with
filtered gas, a leakage gas control system and a buffer gas control system to supply
inert gas to the secondary seal.
9.4.2 GAS FILTER SYSTEM:
Gas supplied to the seal should be clean with max particle size of 5 microns. This is
ensured in the filter system. Filtration is accomplished by means of dual coalescing
filters. The degree of contamination of the on-line filter is monitored by the delta P
switch. Max allowable differential pressure is 2.0 Kg/cm2, the alarm is set at 0.7
Kg/cm2. Filter may be cleaned at this stage. Entrained moisture is removed from
gas and collected. It may be drained periodically.
ALARM
TRIP
FLOW, nm3/Hr
5.15
9.30
PRESSURE, Kg/cm2 g
0.1
0.5
0.75
MISC- 09- 05
Flow
Temperature
Source
Primary buffer
gas
5.8 Kg/cm2 g
312-350
nm3/Hr
105 deg C
Discharge H2
Intermediate
buffer gas
7.0 Kg/cm2 g
2.0 nm3/Hr
ambient
Nitrogen hdr-I
6.5 Kg/cm2 g
23.3 nm3/Hr
ambient
Instrument air
NOTE: Primary buffer gas header can be supplied with nitrogen gas during start-up shutdown operations.
The CleanpacTMF is a dual stage liquid knock and fine particulate filter. It
incorporates the benefits of a pre-filter liquid removal system and a final
coalescing filter into one complete package. This model of filter has two
separate chambers (lower & upper chamber) for liquid retention. In the first
stage, the gas is redirected by the vane pack which acts to disrupt the flow and
cause turbulence, this will cause liquids and heavier end hydro-carbons to be
removed from the gas stream and allow gravity to pull them into the liquid
retention area at the bottom of the vessel. Liquid drainage occurs by gravity
and collects in the bottom chamber of the vessel.
Secondly, the gas flows through a coalescing filter element, this filter element
will remove both the particles (0.3 Absolute) and coalesce fine liquid mists
that are entrained within the gas stream after the first stage filtration. As the
gas passes through the coalescing filter, the liquid aerosol in the gas stream
accumulates in the coalescing filter forming droplets. These droplets will also
accumulate in the upper chamber of the vessel.
CLEANPAC DRAINAGE
The drain can be opened and closed manually through the use of a ball valve
on the drain lines.
PDI-120 HIGH RANGE (0.7 Kg/cm2) Cleanpac Mesh Pad Differential
Reaching the high alaram value (Red Band) is an indication of high differential
across the Cleanpac mesh pad. Possible causes of this High DP are:
Dirty mesh pad
Transmitter block valves closed, partially closed
9.5
TURBINE:
2646 KW
RATED SPEED
7446 RPM
8087
OVERSPEED TRIP
8734
CRITICAL SPEED
4100
EXHAUST PRESSURE
4.0 Kg/cm2 g
MISC- 09- 06
PART-H
Stationary diaphragms containing the interstage nozzles, expand the steam and
direct it against the following rows of rotating blades. The diaphragms are located
vertically in the casing grooves by shims at the bottom of the groves and laterally
by the means of adjusting screws at the horizontal joint.
Sentinal valve mounted on the exhaust end casing serves as a warning signal In
event the back-pressure builds upto a pre determined pressure setting above the
normal operating pressure.
Steam end bearing housing houses steam end journal bearing, the thrust
bearing, overspeed trip assembly and the governor drive arrangement. A labyrinth
seal at the inboard end prevents oil leakage along the shaft to atmosphere.
Exhaust end bearing housing contains the exhaust end journal bearing. Oil
labyrinth seals prevent oil leakage along the shaft to atmosphere.
Journal bearings(2 nos.)-one located in the steam end and the other located in
the exhaust end bearing housing are contained in bearing retainers with supports
and radially position the rotor assembly.
Thrust bearing is located in the steam end bearing housing. The purpose of the
thrust bearing is to absorb the rotor thrust and to position the rotor axially within the
casing. A thrust-bearing collar on the rotor shaft assembly transmits the rotor thrust
to the thrust bearing. The thrust bearing is also pressure lubricated.
Interstage shaft seals minimize leakage between the stages. Shaft end seals
minimize leakage at point where shaft emerges out from the casing.
Overspeed trip mechanism operates entirely dependent of the main governor
system and stops the flow of steam to turbine whenever the trip speed is exceeded.
Steam chest steam flowing from the steam inlet line to the first stage nozzle ring
passes through the steam chest. A strainer is contained in the steam chest along
with governor valve, governor valve seat. The governor valve is a venturi type
valve, which is positioned through linkage by a servo-motor.
MISC- 09- 07
PART-H
system. All gland leak is sucked by the ejector and condensed by the condenser.
Condenser is a fixed tube sheet type and uses cooling water. Condenser has one
shell pass and two tube passes and it cools down from 293 deg C to 80 deg C. MP
steam driven single stage ejector is provided to create a vacuum of 0.1 Kg/cm2. Its
normal consumption is 107 Kg/Hr MP steam. The ejector condenser system is
designed to handle 402 Kg/Hr (328 Kg/Hr steam, 74 Kg/Hr air).
MISC- 09- 08
PART-H
The turbine drive of the LO pump is a single stage, MP steam driven with inlet
steam pressure of 12 Kg/cm2g (normal)/13.0 Kg/cm2g (max)/10Kg/cm2g (min) &
exhaust steam pressure is 4.0 Kg/cm2g (nor)/4.5 (max)/3.0 (min).
The turbine drive of the LO pump has a normal operating speed of 2900 rpm, min,
allowable speed of 2400 rpm, max, continuous speed of 3150 rpm, trip speed of
3630 rpm.
Two nos. of Lo coolers (LO-EE-01 A/B) have been provided to cool LO from 65 deg
C to 49 deg C. These are conventional shell and tube heat exchangers. They are
standard outside packed, floating head with removable tube bundles. LO temp
control valve is furnished to maintain the supply oil temperature at 43 49 deg C.
This control valve is pneumatic three-way control valve. It has four tube passes and
one shell pass with a duty of 60,000 Kcal/Hr.
Twin set of LO filters (K-01A/B) each of capacity 9.24 m3/Hr (at opening temp of 49
deg C) has been provided. Filters are sized for maximum pressure drop of 0.35
Kg/cm2 when clean and passing oil at design temperature. One LO filter has been
provided for emergency oil. It has a capacity of 5.1 m3/Hr (at operating temp of
64.9 deg C). It has clean pressure drop of 0.21 Kg/cm2. The filtering elements
should be replaced when pressure drop reaches approximately 1.4 Kg/cm2. The
above filters have a degree of filtration of 10 microns. Filters are supplied by
TAIYO-TECHNICO. Filters elements are of pleated paper type supplied by HILCO
cartridges.
Continuous flow transfer valves for smooth change over of running filter/ Lo cooler
to the corresponding stand-by equipment have been provided. These valves are
two-way, six ported valves of TAIYO TECHNO make.
Bladder accumulators (2 nos.) of 0.16 m3 capacity each and total usable capacity
of 0.25 m3 have been provided. The bladders are pressurized with nitrogen upto
pre-charge pressures of 3.9 Kg/cm2 g. These accumulators are located in the
controlled pressure header to maintain adequate oil pressure in the system while
the stand-by oil pump is coming to speed. An overhead tank of 0.75 m3 capacity
has been provided for run down oil supply for about 7 minutes in case of LO
circulation failure. A portable centrifuge of capacity of 0.6 m3/Hr of ALPHA-LAVAL
make is provided for console oil clarification.
MISC- 09- 09
electrodes. Neutral
contaminants are drawn and deposited by gradient force to the edge of the
collectors where the intensity of the deformed electric field is the strongest.
As the fluid flows freely through the system, the ELC removes contaminants sub
micronic particles even smaller than 1 micron, dust, dirt and products of oxidation
such as tars or sludge and varnishes. Contaminants are trapped on cellulose
collectors for easy disposal.
The ELC does not affect soluble additives.
APPLICATION
The Electrostatic Liquid Cleaner "ELC" unit can be used for cleaning hydraulic and
lubricating oils of the following general specifications.
Temperature - below 100 degrees C and Moisture - below 500 ppm
The ELC unit cannot be used for cleaning of:
a) Oils with moisture in excess of 500 ppm
b) Oils with detergent dispersant additives
c) Some synthetic oils
d) Conductive oils
9.6
TURBINE GOVERNOR:
9.7
MISC- 09- 10
PART-H
As flow velocity and angle are reduced in the radial diffuser passage, the resultant
velocity pressure drops off to the extent where static (reservoir) pressure is no
longer held in balance and flow suddenly reverses. In some cases, there is no
audible evidence of operating in this region. The principle reason for avoiding surge
is to safe guard equipment. Operation in the surge region can result in mechanical
failure depending on the energy level involved.
15K1 is equipped with anti-surge control system designed by COMPRESSOR
CONTROLS CORPORATION. For surge protection gas is recycle from discharge
to suction via reformer gas cooler through anti-surge control valve UV-4301.
The control system consists of one series 3 plus anti-surge controller UIC-4301
which monitors relative distance d between the operating point of the compressor
and its surge control line and provides for the following actions:
MISC- 09- 11
PART-H
4. Speed of compressor
5. Discharge temperature of the compressor
6. Suction temperature of the compressor
Operator can intervene in the AUTO operation of the controller by forcing open the
recycle valve UV-4301. This is achieved by providing additional analog input signal
from an AUTO-MANUAL station HIC (through I/P transformer). The controller will
select the largest of:
9.8
For general routine operation of the unit, following instructions are to be followed:
1. Check oil reservoir to see that it is filled to proper level
2. Dry out steam ahead of throttle valve by opening drain in it. Thoroughly
warm-up the steam piping ahead of the turbine.
3. Select AUTO position of selector switch of local control panel. Open the
IDLE/RATED governor external contact to the Woodward governor (select
IDLE). The IDLE/RATED governor external should be used only on a turbine
hot start situation that is when turbine has been running on load for a
considerable time & there was an emergency S/D for a short duration only.
4. Start auxiliary oil pump to circulate oil & to insure the system is working
properly. Make sure that the oil temperature is minimum 21 deg C.
5. Drain any intermediate casing drains, and drain under throttle valve seat just
before starting and exhaust line.
6. Put any pressure regulators connected to control apparatus in operative
position.
CCRU OPERATING MANUAL
MISC- 09-12
PART-H
Push RUN and open throttle valve wide, but do not jam it. To
prevent jamming, back off the throttle valve approx. half a turn.
9. Listen for any unusual noises and feel all bearing housing, oil lines, etc. for
any signs of abnormal heating or vibration. If undue heating, vibration or
noise is detected, slow down until it disappears. If it still persists, shut down
and locate and correct the cause before restarting.
10. When turbine is uniformly warmed up and operating at 1000 rpm
satisfactorily, increase speed slowly to design speed according to turbine
start-up. Bearing temperature may indicate it is time to put water through oil
cooler. Make sure the turbine is not held in critical speed range (critical
speeds are: 3400-3500 (compressor) & 4100 (turbine)).
11. Ensure that main oil pump has picked up and that auxiliary pump has been
shutdown,
12. After the turbine has been found satisfactory at the normal operating speed,
the loading of the compressor can be taken up & can be brought on line into
normal operating conditions.
13. Check oil pressures and temperatures to be sure they are at design.
14. Frequently observe oil level in reservoir, oil piping for leaks, oil pressures
and slight indicators, bearing temperatures, shaft packing, and valve stem
packing for steam leaks.
MISC- 09- 13
PART-H
9.9
5. After turbine has completely stopped, continue to operate the auxiliary oil
pump for several hours to prevent overheating of bearing from hot rotor.
Do not shut off C.W. to oil cooler until pump is stopped.
6. Shut off the compressor suction and discharge valve
7. Open compressor drains and drain off any liquid present.
MISC- 09- 14
PART-H
2. Check that the motor of the pump is properly earthen to prevent electrical
shock.
3. Ensure that protective covers are placed over exposed rotary parts of the
pump such as pump coupling etc.
4. Check that bearing housing has adequate oil level of proper grade. Change
oil if it is dirty / contaminated.
5. Confirm whether cooling water lines are connected properly and there is
sufficient flow of water and drive out air from casing through the vent.
6. Open water / steam quench to the mechanical seal as per provision.
7. Rotate the, pump shaft by hand to ensure that it, is free and coupling is
secure.
8. Ensure that all blinds have been removed from the suction and discharge
line of the pump. Proper pressure gauge should be available on the
discharge line.
9. Check whether all bleeder valves have been closed on suction and
discharge lines of the pump. Now, open suction valve. CBD valves are to be
kept closed and flange blinded.
10. Start the pump and check the direction of rotation. Rectify the direction of
rotation if it is not right.
11. If the pump is in hot oil service, it should be gradually warmed up to a
temperature close to that of handled fluid. This is absolutely essential,
otherwise the pump casing, impeller etc may get damaged due to thermal
shock. Hot pumps are normally provided with a bypass across the check
valve to keep the idle pump hot.
12. Crack open NRV bypass valve. Do not open NRV bypass valve more else
pump will rotate in reverse direction.
13. Pump is to be slowly heated to an operating temperature (not more than 2
0
C / minute).
MISC- 10- 01
PART-H
MISC- 10- 02
PART-H
5. Fill the light oil heat exchangers with water from bottom and displace product
from the top through hose to OWS.
6. Get the exchanger positively isolated by installing blinds at inlet and outlet
nozzle flanges of both shell & tube side.
10.3 VESSELS
Following steps are to be followed for takeover of a Vessel:
1. Check that the vessel is boxed up.
2. Check that inlet and outlet valves are closed.
3. Inlet and outlet flanges are in de-blinded condition.
4. PSV is de-blinded.
5. CBD is blinded.
6. All instrument tapings are connected and bleeders are capped.
MISC- 10- 03
8. Open the vent valve (when flare line is hot due to steaming).
9. Continue the steaming for 4 hours, open the bleeders of all instrument
tapings of the vessel.
10. Stop the steaming, keep the vent and drain valve open.
11. Get the vessel isolated by installing blinds at inlet and outlet nozzle flanges
of the vessel, PSV inlet isolation valve upstream flange and PSV bypass
valve upstream flange.
12. Again do the steaming for four hrs, keeping the vent and drain valve open.
13. Stop the steaming and allow it cool.
14. Blind the steam out line.
10.4 COLUMNS
Following steps are to be followed for taking over of a Column:
1. All the manholes of the column are boxed up.
2. All the inlet and outlet nozzles and vents of the column are deblinded.
3. PSV is in de-blinded condition.
4. All the instrument tapings are connected and bleeders are capped.
5. CBD is in blinded condition.
MISC- 10- 04
9. Open the bleeders of all instrument tapings of the column during steaming.
10. Stop the steaming, keep the vent and drain valve open.
11. Get the column inlet nozzles isolated, by installing blinds at the inlet flanges
of the column, PSV inlet isolation valve upstream flange and PSV bypass
valve upstream flange
12. Again start the steaming and continue it for four hrs, put water through the
top reflux line with the steaming on. Continue the hot water washing till the
hot water at the column bottom is clear. Stop the steaming and continue the
water washing till water through the column drain is at ambient temperature.
13. Allow the column to cool.
14. Blind the steam out line.
MISC-10- 05
11.0 CHECK-LISTS:
11.1
S.N
O
DESCRIPTION
STATUS
DATE/TIME
CHECKED
BY
10
MISC-11- 01
11
12
13
14
15
16
17
18
19
20
21
22
23
MISC-11- 02
24
25
26
27
28
29
30
11.2
FURNACE LIGHT-UP:
S.N
O
DESCRIPTION
STATUS
DATE/TIME
CHECKED
BY
MISC-11- 03
10
11
12
13
14
15
MISC-11- 04
16
17
18
DESCRIPTION
STATUS
DATE/TIME
CHECKED
BY
Have
the
suction
and
discharge bottles been drained
to CBD
MISC-11- 05
10
11
12
13
DESCRIPTION
Has
the
compressor
suction/discharge bottles and
casing
leak
tested
with
nitrogen
STATUS
DATE/TIME
CHECKED
BY
MISC-11- 06
Are
the
compressor
suction/discharge bottle drains
to CBD blinded and OWS
isolated
Are
the
suction/discharge
pressure and temperature
gauges and flow meters lined
up and in working condition
Have
the
suction
and
discharge lines been deblinded
Have
the
suction
and
discharge lines been lined-up
slowly
10
11
12
13
14
15
MISC-11- 07
S.N
O
DESCRIPTION
STATUS
DATE/TIME
CHECKED
BY
DATE/TIME
CHECKED
BY
DESCRIPTION
STATUS
MISC-11- 08
10
11
12
13
14
MISC-11- 09
PART-H
S.N
O
DESCRIPTION
10
11
Have
enough
lighting
arrangements been made to
facilitate man entry
STATUS
DATE/TIME
CHECKED
BY
12
Hand
over
furnace
to
maintenance department for
jobs
MISC-11- 10
PART-H
S.NO
DESCRIPTION
STATUS
permit
DATE/TIME
CHECKED
BY
Note: Please follow the furnace light up check-list in section 11.1 for further procedures
MISC-11- 11
PART-H
Time
in
Hours
0000
Description
0100
0200
0300
0400
0500
Action
By
Panel
Panel
Panel
Panel
+ field
Panel
Actual
time
Sign
0600
0630
Panel
+ field
Field
Panel
Panel
Field
field
MISC-11- 12
PART-H
Step
s
Time
in
Hour
s
0700
Description
10
0730
11
0800
12
0900
Action
By
Panel
Field
Panel
field
Field
panel
Field
Field
Field
Field
Field
field
PNE+
M/M
Panel
Actual
time
Sign
13
1300
14
1400
400 oC.
Continue sweeping of HTU reactors with
hydrogen maintaining reactor temperature at
260 oC.
Cut off 14-F-1, 15-F-1, 2 and 3. Continue
sweeping of all the reactors with hydrogen till
the reactors temperature comes down to 100
o
C.
Vent off the steam to atmosphere. Continue to
run 15-P-15 till the SG-1/2 coils get cooled
down.
Give clearance to blind the FG of 14-F-1, 15F-1, 2 and 3.
Give clearance to blind box purging steam to
IFP heaters.
+
field
Field
+
panel
field
+
panel
PNE+
M/M
MISC-11- 13
Step
s
Time
in
Hour
s
15
2300
16
0100
17
0300
Action
By
Description
Actual
time
Field
Field
Field
Field
Field
Panel
Field
PNE
Panel
+
Field
Field
+
Panel
Panel
+
field
Panel
+
field
MISC-11- 14
Sign
Step
s
Time
in
Hour
s
18
0800
19
20
21
22
23
Action
By
Description
Actual
time
field
field
Field
PNE+
M/M
Field
Field
Field
MISC-11- 15
Sign
11.4.2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Description
Action
By
Actual
time
Sign
MISC-11- 16
PART-H
Time
in
Hours
25
26
26
27
28
29
30
31
32
33
34
Actual
Time
Description
Sign.
PNE
Field
Panel
Field
Field
Field
PNE
Field
Field
Panel
Panel
MISC-11- 17
PART-H
Time
in
Hours
35
36
37
Actual
Time
Description
Sign.
Field
Panel
PNE
M/M
MISC-11- 18
12.0
CHEMICAL IDENTITY
Chemical
Name
Corrosion Inhibitor
Synonym
s
Corrosion Inhibitor
Formula
R1NHR2NHR3RH4
Regulated
Identification
Chemical
Classificatio
n
Trade
Name
C.A.S. NO.
Shipping Name
5285-60-9
Ahuralan
ESK 50
UN
NO.
Ahuralan ESK 50
Codes/Label
Hazardous waste
I.D. No.
Hazchem Code
HAZARDOUS
INGREDIENTS
C.A.S. NO.
1. Ahuralan ESK 50
5285-60-9
HAZARDOUS
INGREDIENTS
C.A.S.
NO.
150 300
Melting/
Freezing
Point oC
<10
Physical State
Vapour
pressure
@ 35 oC, mm
Hg
Liquid
Appearance Viscous,
Yellowish
brown
< 1 mmHg Odour
@ 68oF
Pungent
MISC-12- 01
Vapour
Density
(Air = 1)
Solubility in
water @ 30 oC
Specific
Gravity
(Water = 1)
0.83
pH
UEL (%V)
Insoluble
Solubility in
others
Not applicable
0.7
Flash Point
(OC) oC
5.0
Flash Point,
(CC) oC
37
66
228
Explosion Sensitivity to
Impact
Explosion Sensitivity to Static
Electricity
CO, CO2
Hazardous Combustion
products
Hazardous Polymerization
Combustible
Yes
Explosive
Liquid
Material
Flammable
Yes
Oxidiser
Material
Pyrophoric
No
Organic
Material
Peroxide
REACTIVITY DATA
Chemical Stability
No
No
Corrosive
Material
Others
No
No
Stable
None
MISC-12- 02
Routes of Entry
Effects of Exposure/
Inhalation
Symptoms
Ingestion
Contact
Emergency Treatment
Inhalation
Ingestion
Contact
LD50 (Oral-Rat),
mg/kg
Permissible
mg/kg
Exposure Limit
ppm
Odor Threshold,
ppm
TLV (ACGIH)
ppm
STEL,
ppm
mg/kg
mg/kg
NFPA Hazard
Signals
mg/kg
Health
Flammability
Reactivity/Stabilit
y
Special
MISC-12- 03
PART-H
PREVENTIVE MEASURES
Personal Protective Equipment
Antidotes/ Dosage
MISC-12- 04
SPILLS
Steps to be taken
Waste Disposal
Method
MISC-12- 05
PART-H
12.2 AMMONIA:
CHEMICAL IDENTITY
Chemical Name : AMMONIA
Chemical Classification : Inorganic Compound
C.A.S.NO: 7664-41-7
HAZARDOUS
1. Ammonia
2.
7664-41-7
MISC-12- 06
Specific Gravity
(Water = 1)
0.771
@ 0 oC
pH
No
LEL
Not Pertinent (OC)
TDG Flammability
NA
o
C
Not Pertinent (CC)
o
UEL
16.0 %
Flash
25.0 %
Flash Point
651.0
Stable
Not available
Hazardous Polymerization
Combustible Liquid
Corrosive Material
Yes
No
Explosive Material
No
Flammable Material
Others
No
Oxidiser
No
Organic Peroxide
No
Pyrophoric Material
No
REACTIVITY DATA
Chemical Stability
Stable
Incompatibility with
Strong Oxidisers, Calcium hypochlorite, Gold,
Mercury, Silver, Halogens,
Other material
Acetaldehyde, Acrolein.
Reactivity
Reacts with Silver chloride, Silver nitrate, Silver azide, chlorine,
bromine,iodine, heavy metals and their compounds,
Incandescent reaction when heated with Calcium.
Hazardous Reaction
MISC-12- 07
Routes of Entry
Inhalation, Skin or Eyes
Effects of Exposure/ 700 ppm causes eye irritation and permanent injury may
result if prompt
Symptoms medical remedial measures are not taken. 5000 ppm may cause
death from spum inflammation, or edema of the larynx. Contact of the liquid
with skin freezes the tissues and causes the caustic burns.
Emergency Treatment
and provide artificial respiration
25 ppm
18 mg/m 3
L.D50 (Oral-Rat)
350 mg/kg
TLV (ACGIH)
35 ppm
27 mg/m3
NFPA Hazard Signals
Reactivity
Special
25 ppm
Health
2
Odour Threshold
18 mg/m 3
STEL
Flammability
1
0
PREVENTIVE MEASURES
Personal Protective
Avoid contact with liquid or vapours
Equipment
Provide rubber boots, safety goggles,
self-contained breathing apparatus,
gas mask and protective clothing in case
of liquid ammonia.
Handling and Storage
Avoid storing along with oxidizing
materials and away from all possible
Precautions
sources of ignition. Store in well
ventilated flame resistant locations.
MISC-12- 08
FIRE
Fire Extinguishing Media
Stop flow of gas. Use water spray or fog.
Special Procedure Keep the containers cool by spraying water
if exposed to heat or flame.
Unusual Hazards
Gas is suffocating.
EXPOSURE
First Aid Measures
Inhalation : Remove the victim to fresh air area,
provide artificial respiration or oxygen, if needed.
Skin : Remove the contaminated clothes and wash
the affected area with plenty of water and soap.
Eyes : Flush with plenty of water for 15 mins.
Seek medical aid.
Antidotes/Dosages
Not available.
SPILLS
Steps to be taken Contain leaking liquid on sand or earth, allow to
evaporate. Dilute the vapours with plenty of water.
Waste Disposal Method Put into a large vessel containing water, neutralise
with HCl And discharge into sewer with sufficient water.
ADDITIONAL INFORMATION/REFERENCES
A human poison by an unspecified route. Difficult to ignite. NH 3 and air in a
fire, can detonate. Potentially violent or explosive reactions on contact with
interhalogens. Forms sensitive explosive mixture with air and hydrocarbons.
Those affected with eye and pulmonary diseases should avoid exposure to
Ammonia.
MANUFACTURER/SUPPLIERS DATA
Name of firm :
Mailing Address :
MISC-12- 09
Chemical Classification :
CC14
Regulated
Identification
UN. No.
Poison, Class-6
Carbon Tetrachloride
HAZARDOUS
56-23-5
o
Melting / Freezing
C -22.6
Vapour pressure
Odour: Sweet
Point
@ 35 oC 100mm Hg at 23 oC
_________________________________________
_________________________________________________________
Vapour Density
5.30
Solubility in water @ 30 oC
Others: Miscible with Alcohol, Benzene,
(Air = 1)
Not Soluble
Chloroform Ether, CS2
MISC-12- 10
PART-H
UEL
o
Not pertinent
Flash Point
Not pertinent
Flash Point oC
Not Pertinent
Stable
Stable
Hazardous Polymerization
Combustible Liquid
Corrosive Material
No
No
Explosive Material
No
Flammable Material
Others
No
Oxidiser
No
Pyrophoric Material
REACTIVITY DATA
Chemical Stability
No
Organic Peroxide
No
Stable
Incompatibility with
Chemically active metals such as Sodium,
Magnesium, Potassium, Aluminium other material.
Tri-chloride, Di-benzoyl Peroxide & Potassiumtart-butoxide.
Reactivity
Vigorous exothermic reaction with allyl alcohol,
A1 (C2H5)3, (Benzoyl Peroxide + C2H6 ), BrF3, Di-borane, Di-silane, Liquid O2,
(AgC14 + HC1).
Hazardous Reaction
Forms impact sensitive explosive mixtures with
particulates of many metals (eg.A1).
Products
Also forms explosive mixtures with ClF 3, N2O4
etc. Forms explosive mixture with
ethylene, between 25-105 C and 30 80 bar.
MISC-12- 11
Routes of Entry
Effects of Exposure/
Skin & Eyes : Causes irritation, Inhalation causes dizziness, inco-ordination,
Symptoms anesthesia may be accompanied by nausea, liver damage & kidney
damage. Often reduces or stops urinary output. Damages central nervous
system.
Emergency Treatment
Inhalation: Remove the victim to fresh air area. Keep the patient warm & quiet.
Give artificial respiration, if breathing stops.
Ingestion: Induce vomiting, give plenty of water to drink.
Eyes: Flush with plenty of water for 15 mins.
Skin: Remove the wetted clothes & flush the affected area with plenty of water.
Seek medical aid immediately.
L.D50 (Oral-Rat)
2800 mg/kg
Permissible
5 (Skin)
Threshold: > 10 ppm
Exposure Limit
TLV (ACGIH)
ppm
30 (Skin) mg/m3
5 (Skin) ppm
125 mg/m3
Odour
Health
3
STEL
20
Flammability
0
0
PREVENTIVE MEASURES
Personal Protective
Avoid contact with liquid or vapours.
Equipment.
Provide PVC or rubber hand gloves, air supplied mask,
safety goggles, organic
vapour canister with full-face masks, rubber apron and shoes.
Handling and Storage
from heat.
Precautions
MISC-12- 12
PART-H
Not Flammable.
Not available.
SPILL
Steps to be taken Shut off leaks if without risk. Absorb on sand or earth.
Waste Disposal Method Seal all the waste in vapour-tight plastic bags for
eventual disposal.
ADDITIONAL INFORMATION/REFERENCES
A suspected human carcinogen. Violent or explosive reaction on contact with
fluorine. Potentially explosive reaction on contact with boranes. Potentially
dangerous reaction with dimethylene formamide, 1,2,3,4,5,6 - hexachlorocyclohexane or dimethylacetamide, when iron is present as catalyst. This has
narcotic action similar to that of chloroform though not as strong. Concentration
of the order of 1000-1500 ppm is sufficient to cause symptoms if exposure
continues for several hours. Repeated daily exposure to such concentrations
may result in poisoning. CC14 has caused explosions when used as fire
extinguisher on a wax fires and uranium fires.
MANUFACTURER/SUPPLIERS DATA
Name of firm :
Mailing Address :
MISC-12- 13
PART-H
CHEMICAL IDENTITY
Chemical
Name
Di-methyl Di-sulphide
Synonym
s
2,3-Dithiabutane
Formula
CH3-S-S-CH3
Regulated
Identification
Chemical
Classificatio
n
Organic compound
Trade
Name
C.A.S. NO.
Shipping Name
Di-methyl DiSulphide
UN
NO.
2381
DMDS
Codes/Label
Hazardous waste
I.D. No.
Hazchem Code
HAZARDOUS
INGREDIENTS
C.A.S. NO.
HAZARDOUS
INGREDIENTS
C.A.S.
NO.
Di-Methyl di-sulphide
PHYSICAL AND CHEMICAL DATA
Boiling
Point/
Range oC
109.7
Melting/
Freezing
Point oC
Vapour
Density
(Air = 1)
3.24
Physical State
liquid
Appearance
Vapour
pressure
@ 35 oC, mm
Hg
Odour
Solubility in
water @ 30 oC
Solubility in
others
Highly
odourou
s
MISC-12- 14
Specific
1.0569
pH
Gravity
(Water = 1)
FIRE AND EXPLOSION HAZARD DATA
Flammability Moderat LEL (%V)
e
TDG
UEL (%V)
Flammability 3
Hazardous Polymerization
Combustible
Yes
Explosive
Liquid
Material
Flammable
Yes
Oxidiser
Material
Pyrophoric
No
Organic
Material
Peroxide
REACTIVITY DATA
Chemical Stability
Stable
Incompatibility with other
material
Reactivity
No
No
Corrrosive
Material
Others
No
Oxydising materials
Emergency Treatment
MISC-12- 15
LD50 (Oral-Rat),
mg/kg
LD50 ,
mg/kg
Permissible
mg/kg
Exposure Limit
ppm
Odor Threshold,
ppm
TLV (ACGIH)
ppm
STEL,
ppm
mg/kg
mg/kg
mg/kg
NFPA Hazard
Signals
Health
PREVENTIVE MEASURES
Personal Protective
Flammability
Reactivity/Stabilit
y
Special
Antidotes/ Dosage
SPILLS
Steps to be taken
Waste Disposal
Method
ADDITIONAL INFORMATION/ REFERENCES
MANUFACTURER/ SUPPLIERS DATA
Name of firm :
Mailing Address :
MISC-12- 16
CHEMICAL IDENTITY
Chemical Name: Tri Sodium Orthophosphate
Chemical Classification : Inorganic compound
Synonyms: Sodium Phosphate
Trade Name: Sodium Phosphate
Formula: Na3PO4.12H2O
UN. NO. NA9148
Regulated
Identification
C.A.S.NO.
HAZARDOUS
Vapour pressure
@ 35 oC
mm Hg
________________________________________________________________
__________________________________
Solubility in water @ 15 oC
Vapour Density
Others:
(Air = 1)
28.3 g/100 ml
MISC-12- 17
Specific Gravity
pH:
(Water = 1)
1.062
at 20oC
LEL
Flash Point
UEL
Flash Point
Explosive Material :
No
Pyrophoric Material
REACTIVITY DATA
Chemical Stability
No
Oxidiser
No
Organic Peroxide
No
No
Stable.
Incompatibility with
Other material
Reactivity
Hazardous Reaction
POx fumes.
Products
MISC-12- 18
Routes of Entry
Effects of Exposure/ Inhalation : Nose, eyes and throat irritation; sneezing,
difficulty breathing, coughing..
Symptoms
Ingestion: Burning sensation in mouth, pain
in swallowing, stomach cramps.
Contact: Skin itching, burning sensation, inflammation;
Eyes Irritation and burning.
MODERATELY TOXIC BY INGESTION AND INHALATION.
Emergency Treatment: Obtain medical assistance.
Inhalation: Remove victim to fresh air; give artificial respiration, if breathing has
stopped. Give artificial respiration. If laboured, give oxygen.
Ingestion : Give plenty of water to conscious victim to drink. Induce vomiting
immediately.
Contact : Remove contaminated clothing and flush immediately with plenty of
water
Eyes : Flush with water.
L.D50 (Oral-Rat)
7400
mg/kg
L.D 50
Permissible
ppm
mg/mg3
Exposure Limit
TLV (ACGIH)
ppm
ppm
ppm
mg/m 3
mg/m3
Odour Threshold
STEL
mg/m3
Health
Flammability
PREVENTIVE MEASURES
Personal Protective
Rubber gloves/rubber boots. Safety goggles,
face shields, dust mask. Self contained breathing Equipment
apparatus in case of fires.
Handling and Storage
Precautions
MISC-12- 19
PART-H
EXPOSURE
First Aid Measures: Obtain medical assistance. Move victim to fresh air. If
breathing has stopped, give artificial respiration. Give water to conscious
victim to drink and induce vomiting. Remove contaminated clothing and
flush immediately with plenty of water.
Flush with plenty of water for eyes.
SPILLS
Steps to be taken
Waste Disposal Method
ADDITIONAL INFORMATION/REFERENCES
MANUFACTURER/SUPPLIERS DATA
Name of firm :
Mailing Address :
DISCLAIMER
Information contained in this material safety data sheet is believed to be reliable
but no representation, guarantee or warranties of any kind are made as to its
accuracy, suitability for a particular application or results to be obtained from
them.
MISC-12- 20
PART-H
12.6 HYDROGEN
CHEMICAL IDENTITY
HYDROGEN
Chemical
Name
Synonym
s
Hydrogen
Chemical
Classificatio
n
Formula
H2
Regulated
Identification
C.A.S. NO.
Inorganic Gas
Trade
Name
1333-74-0
Hydrogen
UN
NO.
Shipping Name
Codes/Label
Hazardous waste
I.D. No.
17
1049
2 SE
Hazchem Code
HAZARDOUS
INGREDIENTS
C.A.S. NO.
1. Hydrogen
1333-74-0
HAZARDOUS
INGREDIENTS
C.A.S.
NO.
-252.8
Physical State
Gas
Appearance
-259.18
Vapour
pressure
@ 35 oC, mm
Hg
N.A
Odour
Solubility in
water @ 30 oC
Slightly
soluble
Melting/
Freezing
Point oC
Vapour
Density
(Air = 1)
0.069
Colourl
ess
Odourle
ss
Solubility in
others
MISC-12- 21
Specific
0.0899
pH
Not Pertinent
Gravity
(Water = 1)
FIRE AND EXPLOSION HAZARD DATA
Flammability Yes
LEL (%V) 4.1
Flash Point (OC) oC
NP
NP
TDG
2
UEL (%V)
Flammability
Auto ignition Temperature oC
400
Explosion Sensitivity to
Impact
74.2
Stable
Explodes
Hazardous Polymerization
Combustible
No
Explosive
Liquid
Material
Flammable
Yes
Oxidiser
Material
Pyrophoric
No
Organic
Material
Peroxide
REACTIVITY DATA
Chemical Stability
Yes
No
Corrosive
Material
Others
No
No
Stable
MISC-12- 22
Routes of Entry
Skin, Inhalation
Effects of Exposure/
Symptoms
Emergency Treatment
Inhalation
Contact
LD50 (Oral-Rat),
mg/kg
Permissible
mg/kg
Exposure Limit
ppm
Odor Threshold,
ppm
TLV (ACGIH)
ppm
STEL,
ppm
mg/kg
mg/kg
Odourle
ss
mg/kg
NFPA Hazard
Signals
Health
0
PREVENTIVE MEASURES
Personal Protective Equipment
Flammability
4
Not
listed
Reactivity/Stabilit
y
0
Special
MISC-12- 23
FIRE
EXPOSURE
Fire Extinguishing
Media
Special Procedure
Unusual Hazards
Antidotes/ Dosage
SPILLS
Steps to be taken
Waste Disposal
Method
MISC-12- 24
CHEMICAL IDENTITY
Chemical
Name
Synonyms APA
Formula
Trade
Name
KEROBIT
BPD
N1N-di-sec-butyl-p-phenylenediamine
Regulated
Identification
Shipping Name
Kerobit BPD
Codes/Label
Hazardous waste
I.D. No.
Hazchem Code
Liquid
Viscosity (20
deg C)
30.9
mm2/s
Flash point
>100 deg
C
Crystallisatio
n point
14 deg
C
Solubility in
water @ 30 oC
Pour point
<-33 deg C
pH
Insoluble
Appearance Viscous,
reddish
Odour
Pungent
Solubility in
others
Not applicable
MISC-12- 25
Moderate
LEL (%V)
0.7
TDG
Flammability
UEL (%V)
5.0
Flash Point
(OC) oC
Flash Point,
(CC) oC
37
66
No
No
Corrosive
Material
Others
No
No
REACTIVITY DATA
Chemical Stability
Stable
None
Effects of Exposure/
Inhalation
Symptoms
Ingestion
Contact
MISC-12- 26
Emergency Treatment
Inhalation
Ingestion
Contact
LD50 (Oral-Rat),
mg/kg
Permissible
mg/kg
Exposure Limit
ppm
Odor Threshold,
ppm
TLV (ACGIH)
ppm
STEL,
ppm
mg/kg
mg/kg
mg/kg
NFPA Hazard
Signals
Health
Flammability
Reactivity/Stabilit
y
Special
PREVENTIVE MEASURES
Personal Protective Equipment
MISC-12- 27
EXPOSUR
E
Fire Extinguishing
Media
Special Procedure
Unusual Hazards
First Aid Measures
Antidotes/ Dosage
SPILLS
Steps to be taken
Waste Disposal
Method
MISC-12- 28
PART-H
TAG NAME
UNIT
DESCRIPTION
LOW
LOW
LOW
HIGH
HIGH
HIGH
m3/hr
m3/hr
Deg C
Deg C
Deg C
Deg C
%
Deg C
Deg C
Deg C
Deg C
Kg/cm2
M3/hr
M3/hr
Deg C
Kg/cm2
M3/Hr
%
M3/hr
M3/hr
M3/hr
M3/hr
M3/hr
M3/hr
Deg C
mmwc
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Kg/Hr
Deg C
Deg C
Deg C
Deg C
Kg/cm2
Deg C
Deg C
Deg C
Deg C
Deg C
80
80
70
70
100
100
30
110
110
30
20
0.6
30
30
110
0.4
5
5
20
20
20
20
20
20
130
-8
100
100
100
100
100
100
100
100
200
100
100
100
100
0.2
100
100
100
100
100
100
100
80
80
110
110
40
120
120
40
25
0.7
40
40
120
0.6
10
10
25
25
25
25
25
25
150
-7
120
120
120
120
120
120
110
110
300
110
110
110
110
0.4
110
110
110
110
110
265
265
120
100
160
160
70
150
150
75
45
1.6
120
120
160
1.0
70
40
65
65
65
65
65
65
230
1.0
170
170
170
170
170
170
160
160
960
580
580
400
400
2.8
170
170
170
170
170
275
275
130
110
165
165
80
160
160
80
50
1.8
130
150
170
1.5
80
50
70
70
70
70
70
70
260
1.5
220
220
220
220
220
220
170
170
1000
600
600
420
420
2.9
180
180
180
180
180
NSU
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
9 F1 1101
9 FC 1104
9 TI 1101
9 TIC 1102
9 TC 1103A
9 TI 1103B
9 LC 1101
9 TI 1104
9 TI 1216
9 TI 1105
9 TI 1106
9 PC 1101
9 FI 1102
9 FI 1103
9 TI 1201B
9 PDI 1109
9 FC 1105
9 LI 1104A
9 FC 1211A
9 FC 1210A
9 FC 1201A
9 FC 1202A
9 FC 1203
9 FC 1204
15 TI 3115
15 PI 3112
9 TI 1206
9 TI 1205
9 TI 1204
9 TI 1203
9 TI 1217
9 TI 1218
9 TC 1103A
9 TC 1201A
9 FI 1206
15 TI 3117
15 TI 3118
15 TI 3120
15 TI 3121
9 PC 1206
15 TI 138A
15 TI 138B
15 TI 138C
15 TI 138D
15 TI 138E
MISC-13- 01
PART-H
SNO
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
TAG NAME
UNIT
DESCRIPTION
LOW
LOW
LOW
HIGH
HIGH
HIGH
15 TI 138F
9 PC 1302
9 LC 1301
9 TI 1302
9 FI 1301
9 TI 1301
9 LI 1303
15 TI 116A
15 TI 116B
15 TI 116C
15 TI 116D
15 TI 116E
15 TI 116F
15 TI 119A
15 TI 119B
15 TI 119C
15 TI 119D
15 TI 119E
15 TI 119F
15 HC 3103
15 AC 3107
15 TI 3141
15 AI 3102
15 AI 3101
15 FC 1301
15 FC 3103
Deg C
Kg/cm2
%
Deg C
M3/Hr
Deg C
%
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
%
%
Deg C
Ppm
Ppm
T/Hr
T/Hr
100
0.4
30
20
5
20
10
130
130
130
130
130
130
130
130
130
130
130
130
20
1.0
110
60
150
4.0
8.0
110
0.6
35
25
10
25
15
150
150
150
150
150
150
150
150
150
150
150
150
25
2.0
120
80
175
5.0
15.0
170
1.6
70
40
130
75
40
280
280
280
280
280
280
280
280
280
280
280
280
65
6.0
180
160
420
9.5
45
180
1.8
75
45
140
85
50
290
290
290
290
290
290
290
290
290
290
290
290
80
7.0
200
170
450
10.0
54
14 FC 33
14 FC 40
14 FC 34
14 FI 01
14 PDI 02
14 TI 60
14 TI 70
14 TI 61
14 TI 01
14 PC 01
14 LC 01
14 LI 02
14 TI 39
14 FC 02
14 PI 50
14 TI 06
14 TC 04
14 TI 03
14 PC 22
14 PDI 06
15 TI 3101
14 FI 21
Kg/Hr
Kg/Hr
Kg/Hr
T/Hr
Kg/Cm2
Deg C
Deg C
Deg C
Deg C
Kg/Cm2
%
%
Deg C
T/Hr
Kg/Cm2
Deg C
Deg C
Deg C
Kg/Cm2
Kg/Cm2
Deg C
Kg/Hr
FCCG TO UNIT
VBN EX STORAGE
VBN EX VBU
SRN EX STORAGE
DELTA P ACROSS 14G1
FCCG TEMP
VBN EX STORAGE TEMP
VBN EX VBU TEMP
SRN TO UNIT TEMP
14V1 PRESSURE
14V1 LEVEL
14V1 BOOT LEVEL
NAPHTHA EX 14V1
FEED PUMP DISCHARGE
FEED PUMP DISCHARGE
NAPHTHA TO 14E1A
NAPHTHA TO 14R1
NAPHTHA TO 14R1
FG TO 14F1
14R1 DELTA P
14F1 EX CONVECTION
FG TO 14F1
2000
2000
2000
5
0.2
20
20
20
20
0.5
40
5
20
20
15
200
240
240
0.8
0.2
180
100
2500
2200
2200
15
0.22
25
25
25
25
0.8
45
10
25
25
20
250
250
250
1.0
0.4
22.
120
11100
11500
7100
7100
65
1.5
75
75
75
75
2.0
60
40
75
65
29
325
310
310
2.5
1.0
350
380
7500
7500
69
1.8
85
85
85
85
2.5
70
50
85
70
30
330
320
320
2.9
1.5
380
400
HTU
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
MISC-13- 02
SNO
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
TAG NAME
15 TI 3104
15 PI 3114
15 AI 3103
14 TIC 34
14 FC 05
14 FI 03
14 PI 55
14 TIC 43
14 PDI 52A
14 TI 02
14 TI 45
14 PDI 07
14 TI 08
14 TI 09
14 TI 10
14 TI 11
14 FI 10
14 FI 11A
14 PC 08
14 FC 06
14 FI 08
14 LC 05
14 LC 06
14 FC 07
14 TI 51
14 TI 52
14 TI 50
14 PC 42
14 TC 31
14 TI 30
14 TIC 24
14 TI 21
14 TC 23
14 TC 31
14 LC 12
14 TI 29
14 TI 28
14 TIC 53
14 FI 20
14 FI 14
14 TI 27
14 TC 25
14 LC 14
14 LC 15
14 TI 26
14 PC 11
14 FI 13
UNIT
DESCRIPTION
LOW
LOW
LOW
HIGH
HIGH
HIGH
Deg C
mmwc
%
Deg C
Kg/Hr
Kg/Hr
Kg/Cm2
Deg C
Kg/Cm2
Deg C
Deg C
Kg/Cm2
Deg C
Deg C
Deg C
Deg C
Kg/Hr
Kg/Hr
Kg/Cm2
Kg/Hr
Kg/Hr
%
%
T/Hr
Deg C
Deg C
Deg C
Kg/Cm2
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
%
Deg C
Deg C
Deg C
T/Hr
Kg/Hr
Deg C
Deg C
%
%
Deg C
Kg/cm2
M3/Hr
350
-08
1.0
180
100
3500
15
150
0.1
15
60
0.2
20
20
20
100
1000
1000
14
5
100
25
30
20
15
30
40
0.8
190
100
110
100
200
190
40
20
90
90
5
2000
200
40
15
05
15
09
60
450
-07
2.0
200
200
4500
20
160
0.15
20
70
0.4
30
30
30
150
1100
1500
15
10
120
30
30
25
25
35
45
1.0
200
120
115
120
220
200
50
25
100
100
10
2500
220
50
20
10
20
11
80
600
1.0
6.0
260
700
650
1.5
7.0
280
800
20000
21000
28
210
0.5
70
130
0.6
120
85
50
280
4800
3000
17.5
25
300
60
40
65
50
80
95
2.5
250
280
180
250
250
250
70
40
150
150
55
8000
255
100
55
50
45
14
250
30
225
0.6
85
150
0.8
140
100
70
300
5000
3200
18.0
30
330
70
50
70
60
90
110
2.9
255
300
190
275
260
260
80
45
160
160
60
9500
260
110
60
60
60
15
350
MISC-13- 03
SNO
TAG NAME
UNIT
DESCRIPTION
LOW
LOW
LOW
HIGH
HIGH
HIGH
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
14 FI 25
14 FC 18A
14 FC 18B
14 FC 18C
14 FC 18D
15 TI 110A
15 TI 110B
15 TI 110C
15 TI 110D
14 TI 37 A
14 TI 37B
14 TI 37C
14 TI 37D
15 HC 3101
15 HC 3102
15 AI 3103
15 TI 103A
15 TI 103B
15 TI 103C
15 TI 103D
15 TI 105A
15 TI 105B
15 TI 105C
15 TI 105D
15 TI 105E
15 TI 105F
15 TI 105G
15 TI 105H
14 PI 79
14 PC 86
14 FI 36
14 FI 35
14 FC 32
14 PI 203 A/B
14 PI 205 A/B
14 TI 16
14 TI 18
15 TI 3108
15 TI 3111
14 FI 101A
14 PI 101A
14 PI 101B
14 PI 103A
14 PI 103B
14 PI 102A
14 PI 102B
14 TI 56
M3/Hr
M3/Hr
M3/Hr
M3/Hr
M3/Hr
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
%
%
%
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Kg/cm2
Kg/cm2
Kg/Hr
Kg/Hr
Kg/Hr
Kg/cm2
Kg/cm2
Deg C
Deg C
Deg C
Deg C
Kg/Hr
Kg/cm2
Kg/cm2
Kg/cm2
Kg/cm2
Kg/cm2
Kg/cm2
Deg C
FG TO 14F2
14F2 PASS FLOW
14F2 PASS FLOW
14F2 PASS FLOW
14F2 PASS FLOW
14F1 XOVER PASS TEMP
14F1 XOVER PASS TEMP
14F1 XOVER PASS TEMP
14F1 XOVER PASS TEMP
14F2 OUTLET PASS TEMP
14F2 OUTLET PASS TEMP
14F2 OUTLET PASS TEMP
14F2 OUTLET PASS TEMP
14F1 DAMPER
14F2 DAMPER
14F1 OXYGEN
14F1 PASS TEMP
14F1 PASS TEMP
14F1 PASS TEMP
14F1 PASS TEMP
14R1 SKIN TEMP
14R1 SKIN TEMP
14R1 SKIN TEMP
14R1 SKIN TEMP
14R1 SKIN TEMP
14R1 SKIN TEMP
14R1 SKIN TEMP
14R1 SKIN TEMP
H2 EX NETWORK
H2 EX BULLET
SUCTION OF 14K2A/B
MU GAS TO 14R2
MU GAS TO 14R1
14K2 A/B SUCTION
14K2 A/B LO PRESSURE
14K2A DISCHARGE
14K2B DISCHARGE
EX CONVEXTION 14F2
ARCH LEVEL OF 14F2
14K1 JCW RETURN
SUCTION PRESS K1A
SUCTION PRESS KIB
LOP 14K1A
LOP 14K1B
DISCHARGE PRESS K1A
DISCHARGE PRESS K1B
14E1C S/S INLET
100
14
14
14
14
100
100
100
100
100
100
100
100
20
20
1.0
100
100
100
100
100
100
100
100
100
100
100
100
18
18
80
80
10
12
1.5
0
0
150
150
5
14
14
1.5
1.5
15
15
100
120
15
15
15
15
120
120
120
120
120
120
120
120
25
25
2.0
150
150
150
150
150
150
150
150
150
150
150
150
19
19
100
100
30
13
2.0
0
0
240
250
8
15
15
2.0
2.0
19
19
120
300
45
45
45
45
260
260
260
260
260
260
260
260
65
65
6.0
300
300
300
300
330
330
330
330
330
330
330
330
22
22
200
200
200
16
4.5
112
112
360
700
25
17
17
4.5
4.5
23
23
150
350
50
50
50
50
300
300
300
300
300
300
300
300
80
80
7.0
350
350
350
350
340
340
340
340
340
340
340
340
25
25
250
230
220
17
6.0
115
115
400
720
30
18
18
6.0
6.0
25
25
160
MISC-13- 04
SNO
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
TAG NAME
14 PC 53
14 TI 42A
14 TI 42B
14 TI 42C
14 TI 42D
14 TI 42E
14 TI 42F
14 TI 42G
14 TI 42H
14 TI 42I
14 TI 42J
14 TI 42K
14 TI 42L
14 TI 42M
14 TI 42N
14 TI 42O
14 TI 42P
14 TI 42Q
14 TI 42R
14 TI 42S
14 TI 42T
15 TI 102A
15 TI 102B
15 TI 102C
15 TI 102D
15 TI 105A
15 TI 105B
15 TI 105C
15 TI 105D
15 TI 109A
15 TI 109B
15 TI 109C
15 TI 109D
15 TI 112A
15 TI 112B
15 TI 112C
15 TI 112D
15 TI 3106
15 TI 3113
15 TI 3129
15 TI 3137
15 TI 3131
15 TI 3130
15 TI 3133
15 PC 3112
15 PI 3107
UNIT
Kg/cm2
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
mmwc
mmwc
DESCRIPTION
LOW
LOW
LOW
HIGH
HIGH
HIGH
23.5
140
140
140
140
140
140
140
140
140
140
140
140
140
140
140
140
140
140
140
140
130
130
130
130
150
150
150
150
150
150
150
150
150
150
150
150
250
350
100
100
100
100
150
-20
-120
24.0
150
150
150
150
150
150
150
150
150
150
150
150
150
150
150
150
150
150
150
150
150
150
150
150
160
160
160
160
160
160
160
160
160
160
160
160
300
370
115
120
120
120
160
-5
-110
26.8
180
180
180
180
180
180
180
180
180
180
180
180
180
180
180
180
180
180
180
180
330
330
330
330
380
380
380
380
300
300
300
300
300
300
300
300
450
500
280
235
235
250
185
1
-40
27.2
185
185
185
185
185
185
185
185
185
185
185
185
185
185
185
185
185
185
185
185
350
350
350
350
400
400
400
400
320
320
320
320
320
320
320
320
550
520
320
250
250
260
200
5
-35
MISC-13- 05
SNO
TAG NAME
UNIT
DESCRIPTION
LOW
LOW
LOW
HIGH
HIGH
HIGH
Kg/Hr
Kg/cm2
%
Kg/Hr
Kg/cm2
Kg/cm2
Kg/cm2
Kg/Hr
Kg/Hr
Kg/Hr
%
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
FG SUPPLY TO UNIT
FG PRESSURE
FG KO DRUM LEVEL
FG EX CRU FLOW
15F1 FG PRESS
15F2 FG PRESS
15F3 FG PRESS
15F1 FG FLOW
15F2 FG FLOW
15F3 FG FLOW
IFP STACK OXYGEN
15F1 INLET PASS SKIN
15F1 INLET PASS SKIN
15F1 INLET PASS SKIN
15F1 INLET PASS SKIN
15F1 INLET PASS SKIN
15F1 INLET PASS SKIN
15F1 OUTLET PASS SKIN
15F1 OUTLET PASS SKIN
15F1 OUTLET PASS SKIN
15F1 OUTLET PASS SKIN
15F1 OUTLET PASS SKIN
15F1 OUTLET PASS SKIN
15F1 INLET
15F1 OUTLET
15R1 ILET TEMP
15F1 ARCH LEVEL
15F2 ARCH LEVEL
15F3 ARCH LEVEL
15F2 INLET PASS SKIN
15F2 INLET PASS SKIN
15F2 INLET PASS SKIN
15F2 INLET PASS SKIN
15F2 INLET PASS SKIN
15F2 INLET PASS SKIN
15F2 OUTLET PASS SKIN
15F2 OUTLET PASS SKIN
15F2 OUTLET PASS SKIN
15F2 OUTLET PASS SKIN
15F2 OUTLET PASS SKIN
15F2 OUTLET PASS SKIN
15F1 BURNER LEVEL
15F2 BURNER LEVEL
15F2 CROSS OVER
15F2 OUTLET
15R2 INLET TEMP
15R2 OUTLET
300
2.5
5
300
0.8
0.8
0.8
100
100
100
1.0
150
150
150
150
150
150
150
150
150
150
150
150
100
200
435
00
0
0
150
150
150
150
150
150
150
150
150
150
150
150
0
0
200
200
435
200
500
2.6
10
600
1.0
1.0
1.0
150
150
150
2.0
160
160
160
160
160
160
160
160
160
160
160
160
120
250
440
00
0
0
160
160
160
160
160
160
160
160
160
160
160
160
0
0
250
250
440
380
4000
3.2
30
6000
2.8
2.8
2.8
1000
1000
1000
6.0
590
590
590
590
590
590
590
590
590
590
590
590
450
550
525
750
750
750
590
590
590
590
590
590
630
630
630
630
630
630
650
650
550
550
530
500
4300
3.5
50
6500
2.9
2.9
2.9
1200
1200
1200
7.0
600
600
600
600
600
600
600
600
600
600
600
600
500
600
530
780
780
780
600
600
600
600
600
600
640
640
640
640
640
640
700
700
600
600
535
650
CRU
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
15 FI 2301
15 PC 91
15 LI 302B
15 FI 2304
15 PC 51
15 PC 61
15 PC 71
15 FI 31
15 FI 41
15 FI 51
15 AI 1506
15 TI 167 A
15 TI 167 B
15 TI 167 C
15 TI 167 D
15 TI 167 E
15 TI 167 F
15 TI 67 A
15 TI 67 B
15 TI 67 C
15 TI 67 D
15 TI 67 E
15 TI 67 F
15 TI 02
15 TI 03
15 TC 05
15 TI 66A
15 TI 66B
15 TI 66C
15 TI 169 A
15 TI 169 B
15 TI 169 C
15 TI 169 D
15 TI 169 E
15 TI 169 F
15 TI 69 A
15 TI 69 B
15 TI 69 C
15 TI 69 D
15 TI 69 E
15 TI 69 F
15 TI 65
15 TI 68
15 TI 73
15 TI 13
15 TC 15
15 TI 16
MISC-13- 06
SNO
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
TAG NAME
15 TI 17
15 TI 19
15 TI 172 A
15 TI 172 B
15 TI 172 C
15 TI 172 D
15 TI 172 E
15 TI 172 F
15 TI 72 A
15 TI 72 B
15 TI 72 C
15 TI 72 D
15 TI 72 E
15 TI 72 F
15 TI 70
15 PDI 02
15 PDI 03
15 PDI 04
17 PI 27
15 TI 06
15 TI 07
15 TI 08
15 TI 09
15 TI 10
15 TI 11
15 TI 20
15 TI 21
15 TI 02
15 TI 01
15 PDI 01
15 FC 01
15 FC 02
15 PDI 15
15 PDI 16
15 FI 03
15 PDI 22
15 AI 02
15 PI 06
15 TI 22
15 TI 23
15 FI 05
15 PC 05
15 LC 01
15 FC 01A
15 TI 25
15 TI 26
UNIT
DESCRIPTION
LOW
LOW
LOW
HIGH
HIGH
HIGH
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Kg/cm2
Kg/cm2
Kg/cm2
Kg/cm2
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Kg/cm2
T/Hr
T/Hr
Kg/cm2
Kg/cm2
T/Hr
Kg/cm2
%
Kg/cm2
Deg C
Deg C
Kg/Hr
Kg/cm2
%
M3/Hr
Deg C
Deg C
15F3 OUTLET
15R3 INLET
15F3 INLET PASS SKIN
15F3 INLET PASS SKIN
15F3 INLET PASS SKIN
15F3 INLET PASS SKIN
15F3 INLET PASS SKIN
15F3 INLET PASS SKIN
15F3 OUTLET PASS SKIN
15F3 OUTLET PASS SKIN
15F3 OUTLET PASS SKIN
15F3 OUTLET PASS SKIN
15F3 OUTLET PASS SKIN
15F3 OUTLET PASS SKIN
15F3 OUTLET PASS SKIN
15R1 DELTA P
15R2 DELTA P
15R3 DELTA P
15R1 PRESSURE
15R1 SKIN TEMP
15R1 SKIN TEMP
15R1 SKIN TEMP
15R1 SKIN TEMP
15R1 SKIN TEMP
15R1 SKIN TEMP
15R3 OUTLET TEMP
EFFLUENT TO 15AC1
15F1 INLET
FEED FROM 14E3B
DELTA P ACROSS 15G1
FEED TO 15E1
FEED TO 15E1
FEED SIDE DELTA P
EFFLUENT SIDE DELTA P
R/G TO 15E1
DELTA P ACROSS HC
R/G PURITY
R/G TO 15E1
EFFLUENT TO 15E2
EFFLUENT TO 15V1
FG TO FLARE
15V1 PRESSURE
15V1 LEVEL
15PIA/B DISCHARGE
15V1 BOTTOM TO E3
EFFLUENT TO 15E4
200
435
150
150
150
150
150
150
150
150
150
150
150
150
150
0.01
0.01
0.01
3.0
460
460
460
460
460
460
200
70
100
80
0
12
12
0.2
0.2
8.0
0
60
2.0
25
25
0
2.2
20
10
25
20
350
440
160
160
160
160
160
160
160
160
160
160
160
160
160
0.02
0.02
0.02
3.5
470
470
470
470
470
470
250
80
120
100
0
15
15
0.3
0.3
10.5
0.08
65
2.5
30
30
0
2.6
30
15
30
25
550
530
590
590
590
590
590
590
650
650
650
650
650
650
650
0.1
0.1
0.1
5.0
510
510
510
510
510
510
500
120
450
140
1.2
32
32
1.0
1.0
14
0.9
95
5.5
65
50
1000
3.5
50
50
65
50
650
535
600
600
600
600
600
600
700
700
700
700
700
700
700
0.2
0.2
0.2
5.2
520
520
520
520
520
520
550
125
600
150
1.5
35
35
1.1
1.1
16
1.0
99
6.0
85
70
1100
4.0
65
60
70
60
MISC-13- 07
SNO
TAG NAME
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
15 PC 07
15 TI 31
15 PC 78
15 PI 08
15 FI 07
15 TI 30
15 TI 32
15 LC 05
15 PC 09
15 FI 08
15 LC 06
15 FC 09
15 PC 14
15 PC 81
15 TC 41
15 TI 42
15 LC 11
15 FI 18
XI 4101 A/B
XI 4102 A/B
YI 4101 A/B
YI 4102 A/B
AI 4101 A/B
AI 4102 A/B
TI 4101 A/B
TI 4102 A/B
15 PC 4209
15 PI 4003
15 TI 4011
15 FI 4301 A
15 TI 4012
15 PI 4004
15 PI 4005
15 TI 4013
15 FI 06
15 TI 4007
15 TI 4008
15 PI 4006
15 TI 4009
15 TI 4010
135
136
137
138
139
140
15 TI 4014
15 PI 4007
15 PC 2406
SI 4101
15 FI 1904
15 LC 1901
15 PI 4008
UNIT
DESCRIPTION
Kg/cm2
Deg C
Kg/cm2
Kg/cm2
Kg/Hr
Deg C
Deg C
%
Kg/cm2
Kg/Hr
%
Kg/Hr
Kg/cm2
Kg/cm2
Deg C
Deg C
%
T/Hr
Micro m
Micro m
Micro m
Micro m
Mm
mm
Deg C
Deg C
Kg/cm2
Kg/cm2
Deg C
T/Hr
Deg C
Kg/cm2
Kg/cm2
Deg C
Kg/Hr
Deg C
Deg C
Kg/cm2
Deg C
Deg C
Kg/cm2
15V2 PRESSURE
15C1 VAPOUR TEMP
H2 TO HGU
15E4 TO FG
15E4 TO FG
15V2 INLET
15P2 DISCHARGE
15V2 L2V2L
15V3 PRESSURE
15V3 TO FG
15V3 LEVEL
NAPHTHA TO E7
15V4 PRESSURE
FG TO 15F4
15F4 COIL OUTLET
15C1 BOTTOM
15C1 LEVEL
REFORMATE RUNDOWN
COMP RADIAL VIB SUCT
TURBINE RAD VIB EX
COMP RADIAL VIB DISCH
TURBIE RAD VIB INLET
COMP AXIAL DISP
TURBINE AXIAL DISP
COMP THRUST BNG
TURBINE JRNL BNG
OIL BACK PRESSURE
COMP DISCH PRESSURE
COMP DIS TEMP
15K1 DISCH FLOW
COMP SUCTION TEMP
COMP SUCTION PRESS
TURBINE I/L STEAM
TURBINE I/L STEAM
HP STEAM FLOW TO K1
BEARING OUTLET TEMP
BEARING OUTLET TEMP
CHEST PRESSURE
TURBINE OUTLET BNG
TURBINE O/L BNG TEMP
TURBINE
EXH
PRESSURE
TURBINE EXH TEMP
TURBINE IST STAGE
LP EXHAUST PRESSURE
15K1 RPM
WATER TO B/L
15V16 LEVEL
Deg C
Kg/cm2
Kg/cm2
Rpm
Kg/Hr
%
LOW
LOW
LOW
HIGH
HIGH
HIGH
3.9
20
2.0
4.1
1000
-15
10
25
1.0
0
25
15
2.0
0.8
50
100
30
15
0
0
0
0
-1.0
-1.0
50
50
8.0
4.0
40
11.5
20
1.0
48
300
2800
30
30
15
30
30
4.0
25
2.3
4.2
1600
-12
15
30
3.0
0
30
25
3.0
1.0
100
120
35
20
0
0
0
0
-0.5
-0.5
60
60
8.5
4.5
45
12.0
30
1.5
50
350
3200
35
35
20
35
35
4.9
50
4.0
4.8
3500
10
45
60
5.0
210
60
80
8.5
2.8
250
260
60
65
80
80
80
80
0.5
0.5
110
110
10.5
6.0
110
23
80
4.0
65
440
6.0
60
4.5
5.5
3600
12
50
70
6.0
230
70
90
9.5
2.9
300
300
70
70
100
100
100
100
1.0
1.0
130
130
11.0
6.5
120
25
90
5.0
68
460
15500
16500
60
60
30
60
60
65
65
35
65
65
1.0
1.5
4.4
5.0
160
5
2.5
5800
2500
30
180
10
3.2
6000
3000
35
220
20
4.5
7800
250
25
5.0
8200
15000
18000
60
65
MISC-13- 08
SNO
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
TAG NAME
15 FC 1901
15 TC 1908
15 LI 1901
15 AI 1902
15 FC 1902
15 AI 1903
15 FC 1903
15 TI 1903
15 TI 1904
15 TI 1905
15 TI 1906
15 TI 1907
15 TI 1921
15 TI 1922
15 TI 1923
15 PI 2208
15 FI 2201
15 TI 2204
15 PI 2209
15 FI 202A
15 TI 2205
15 FI 2403
UNIT
DESCRIPTION
LOW
LOW
LOW
HIGH
Kg/Hr
Deg C
%
Ppm
T/Hr
Ppm
T/Hr
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Kg/cm2
T/Hr
Deg C
Kg/cm2
T/Hr
Deg C
Kg/Hr
4500
100
32
40
40
40
40
100
100
150
180
250
150
150
150
20
8000
200
12
5000
180
200
5000
150
35
50
45
50
45
120
150
180
200
300
200
200
200
30
9000
250
13
6000
200
240
16000
HIGH
HIGH
18000
450
60
150
150
150
150
220
300
450
500
550
450
450
450
65
480
65
200
170
200
170
250
350
500
550
650
480
480
480
68
16000
17000
440
15
460
16
18000
19000
300
600
320
700
Deg C
Kg/cm2
Kg/cm2
Nm3/Hr
Nm3/Hr
Kg/cm2
Deg C
Kg/cm2
Kg/cm2
Nm3/Hr
Deg C
Kg/cm2
%
Kg/cm2
%
Kg/cm2
Kg/cm2
Kg/cm2
Deg C
Rpm
%
Kg/cm2
Nm3/Hr
Deg C
10
3
3
1800
1500
3.0
3
3.0
6.9
1000
-150
1200
20
2.5
17
6.5
0.12
3.0
-190
1500
0
0
100
10
15
5
5
2000
2000
3.5
4
3.5
7.1
1500
-140
1300
25
3.1
20
6.9
0.15
3.1
-180
2000
0
0.05
200
20
48
8.5
8.5
4500
4500
7.0
15
7.0
7.8
2800
-90
2000
60
3.9
45
7.6
0.5
4.0
-90
4400
15
0.5
540
175
52
10
10
4800
4800
7.2
25
7.2
8.5
3300
-80
2200
80
4.0
55
7.8
0.6
4.1
-80
4600
25
0.6
550
195
NITROGEN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
40 TI 201 A/B
40 PI 2201
40 PI 2202
40 FI 2201
40 FI 2202
40 PC 2203
40 TI 2202
40 PC 2230
40 PI 2227
40 FI 2229
40 TI 2248
40 PDI 245
40 LC 2241
40 PIC 2244
40 LIC 242A
40 PC 2243
40 PI 2256
40 PI 2251
40 TI 2255
40 SI 2251
40 AI 2219
40 PC 2218
40 FI 2217
40 TI 212A
MISC-13- 09
SNO
25
26
27
28
29
30
31
TAG NAME
40 PI 2220
40 TI 2223
40 FC 2222
40 PC 3313
40 FI 3315
40 PC 3303
40 FI 3305
DESCRIPTION
LOW
LOW
LOW
HIGH
HIGH
HIGH
2
10
150
4.0
250
5
20
3
20
250
4.5
350
6.5
35
10
40
650
6.5
1500
11
160
12
50
700
7.0
1600
12
165
BULLET A PRESSURE
BULLET B PRESSURE
BULLET C PRESSURE
BULLET D PRESSURE
COMP STAGE 1 DIS PRES
COMP STAGE 2 DIS PRES
COMP STAGE 3 DIS PRES
STAGE I DIS TEMP
STAGE 2 DIS TEMP
STAGE 3 DIS TEMP
H2 TO CRU PRESS
26
26
26
26
3
8
15
15
15
15
3
28
28
28
28
5
10
20
25
25
25
3.5
41
41
41
41
10
20
45
90
90
90
5.0
42
42
42
42
12
24
48
100
100
100
6.0
3.5
10
10
2.0
100
700
5000
25
2000
90
500
2.0
10
4.0
40
0
0
0
0
0
0
0
0
0.05
0.05
350
4.0
15
15
3.0
150
1000
7000
35
3000
110
1000
3.0
20
4.5
50
0
0
0
0
0
0
0
0
0.08
0.08
400
5.8
75
75
6.0
350
4000
6.3
80
80
7.0
400
4500
15000
17000
70
8500
200
9000
6.0
60
6.0
100
200
540
518
520
450
450
500
500
0.3
0.3
500
80
UNIT
Kg/cm2
Deg C
Nm3/Hr
Kg/cm2
Nm3/Hr
Kg/cm2
Nm3/Hr
HYDROGEN BULLET
1
2
3
4
5
6
7
8
9
10
11
42 PI 2002
42 PI 2003
42 PI 2004
42 PI 0103
42 PI 1002
42 PI 1003
42 PI 1004
42 TI 1001
42 TI 1002
42 TI 1003
42 PC 2001
Kg/cm2
Kg/cm2
Kg/cm2
Kg/cm2
Kg/cm2
Kg/cm2
Kg/cm2
Deg C
Deg C
Deg C
Kg/cm2
REGENERATION SECTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
17 PC 61
17 LC 20
17 LC 21
17 PI 16
17 FC 19
17 FI 17
17 FI 18
17 LI 22
17 FC 16
17 TC 2003
17 FC 2001
17 PI 2001
17 TI 2005
17 PI 03
17 LI 02
17 TI 03
17 TI 04
17 TI 05
17 TI 06
17 TI 07
17 TI 08
17 TI 09
17 TI 10
17 PDI 20
17 PDI 21
17 TC 51
Kg/cm2
%
%
Kg/cm2
Kg/Hr
Kg/Hr
Kg/Hr
%
Kg/Hr
Deg C
Kg/cm2
Kg/cm2
Deg C
Kg/cm2
%
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Kg/cm2
Kg/cm2
Deg C
REGEN PRESSURE
17V5 WATER SIDE LEVEL
17V5 CAUSTIC LEVEL
17V5 PRESSURE
DM WATER FLOW
PROCESS WATER
CASUTIC RECYCLE
CASUTIC TANL LEVEL
17K1 SPILL BACK
17DR1 D/S HEATER
REGEN GAS FLOW
DR1 PRE FILTER PRES.
DR1 D/S COOLER
17R1 PRESSURE
REGENERATOR LEVEL
REGEN TEMP
COMB ZONE TEMP
COMB ZONE TEMP
COMB ZONE TEMP
OXY CHLORINATION TEM
OXY CHLORINATION TEM
CALCINATION TEMP
CALCINATION TEMP
COMBUSTION DELTA P
OXY CHLORI DELTA P
COMBUSTION HEATER
MISC-13- 10
10000
230
9500
8.0
80
6.5
100
250
550
520
525
470
490
510
515
0.5
0.5
600
SNO
TAG NAME
27
28
29
30
31
32
33
34
35
36
17 TC 52
17 PI 10
17 AC 01
17 AC 03
17 AC 06
17 FI 20
17 FC 05
17 FC 01
17 FC 02
37
38
39
40
41
42
43
44
45
46
47
48
49
50
17 TI 12
17 TI 11
17 LI 01
17 LC 10
17 LC 12
17 LC 13
17 PI 02
17 PI 03
17 TC 53
17 TI 20
17 PDC 02
17 PDC 01
17 PDC 03
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
UNIT
DESCRIPTION
LOW
LOW
HIGH
HIGH
HIGH
400
8
0.4
0.15
3.0
5500
300
100
30
0.01
0
0
2.0
28
30
15
3.3
4.9
350
0
0.08
0.08
0.08
520
15
0.95
0.5
6.5
8500
800
280
200
650
18
1.0
0.6
7.0
9000
900
300
220
0.02
0.03
350
480
60
45
70
55
6.0
6.0
450
350
0.4
0.3
0.3
450
500
62
50
75
65
6.5
6.5
475
400
0.45
0.4
0.4
Deg C
Kg/cm2
%
%
%
Kg/Hr
Kg/Hr
Kg/Hr
Kg/Hr
Kg/cm2
CALCINATION HEATER
17P4 DISCHARGE
REGEN GAS OXYGEN
COMB OUTLET OXYGEN
CALCINATION OXYGEN
REGEN GAS TO 17R1
CALCINATION GAS
AIR TO REGEN
AIR TO REGEN
COMB/OX DELTA P
EFFLUENT 17E2 O/L
17EH1 INLET TEMP
17V1 LEVEL
17V10 LEVEL
17V12 LEVEL
17V13 LEVEL
17V2 PRESSURE
IN 17R1
REDN HEATER TEMP
H2 TO REDN HEATER
17G1 DELTA P
17G2 DELTA P
N2 TO 4TH HOPPER DEL P
DELTA P-15R1/V21
0
0
0.5
20
20
10
3.0
4.5
260
0
0.06
0.05
0.05
17 PDI 16
Deg C
Deg C
%
%
%
%
Kg/cm2
Kg/cm2
Deg C
Deg C
Kg/cm2
Kg/cm2
Kg/cm2
Kg/cm2
0.00
2
0.08
0.1
17 PDI 17
17 FC 10
17 FC 11
17 PDC 11
17 FC 12
17 PDC 12
17 FC 13
17 PDC 13
17 PDC 18
17 PC 62
17 FI 23
17 PC 63
17 PI 04 A/B
17 PI 03 A/B
17 TI 33
17 TI 34
17 PDC 14
17 FC 14
17PI 101A/B
17PI 301A/B
17PI 102A/B
17TI 101A/B
17TI 102A/B
Kg/cm2
Kg/Hr
Kg/Hr
Kg/cm2
Kg/Hr
Kg/cm2
Kg/Hr
Kg/cm2
Kg/cm2
Kg/cm2
Kg/Hr
Kg/cm2
Kg/cm2
Kg/cm2
Deg C
Deg C
Kg/cm2
Kg/Hr
Kg/cm2
Kg/cm2
Kg/cm2
Kg/cm2
Kg/cm2
DELTA P-15R2/V22
H2 FLOW TO EH3
N2 TO 1ST HOPPER
1ST LIFT DELTA P
H2 TO 2ND LOW HOPPER
2ND LIFT DELTA P
H2 TO 3RD LOW HOPPER
3RD LIFT DELTA P
15R3/V23 DELTA P
N2 TO KOD
N2 TO KOD
K3 SPILL BACK
K3 DISCH PRESSURE
K3 SUCTION PRESSURE
K3A OUTLET
K3B OUTLET
4TH LOW HOPPER
4TH LOW HOPPER
SUCTION K1 A/B
LO PRESS K1 A/B
OUTLET K1 A/B PRESS
O/L CYCLE1 A/B
O/L CYCLE2 A/B
0.03
180
100
0.03
60
0.03
60
0.03
0.03
2
15
3
1.5
1.0
0
0
0.06
100
1.0
1.0
3.0
0
0
0.05
200
110
0.05
80
0.05
80
0.05
0.05
2.5
25
3.5
2.0
1.5
0
0
0.08
130
2.5
2.0
4.5
0
0
0.25
600
180
0.25
130
0.35
135
0.4
0.08
4
160
7
7.5
3.5
100
100
0.4
350
5.5
5.0
8.0
120
120
0.35
650
200
0.35
150
0.45
150
0.45
0.1
4.3
180
7.5
8.5
4.0
120
120
0.5
380
6.0
6.0
9.0
125
125
17 PDC 06
350
5
0.3
0.1
1.0
5000
250
50
10
LOW
-0.02
MISC-13- 11
INTRODUCTION:
A documented procedure to investigate accidents/incidents in order to meet
the legal requirement and to find out the fact & analyze in systematic way to
identify the route cause of incident is necessary as part of safety
management system. The recommendations to avoid recurrence shall be
followed to improve the safety & health standards at work place.
All incidents including accidents in the Refinery are required to be reported,
investigated and analyzed in systematic way.
The corrective actions need to be taken to avoid reoccurrence of similar
incidents in future. While analyzing the incidents, the prioritization has to be
done for High-potential incidents, which needs more attention to reduce the
losses in terms of PEME.
14.2
SCOPE:
All accidents / incidents within the Mathura Refinery premises.
14.3
RESPONSIBILITY:
Accident / Incident reporting system shall be applicable to all accidents /
incidents occurring within Mathura Refinery and records shall be maintained
in Fire & Safety Dept. The responsibility in details is as follows:
a.
Responsibility of Worker: Any employee, who meets with an accident during his duty hours,
however small it may be, shall immediately report the same to the
Engineer In charge/ his supervisor.
If the injured is not in position to report by self, any employees, who
are present at site, shall do reporting.
If any employee takes first aid by himself or with the help of co-worker
from first aid boxes, the same shall be recorded in Register kept with
first aid boxes. {Line Supervisor responsibility - In case of personnel
injury}
b.
Responsibility of Supervisor
I.
MISC-14- 01
PART-H
In case of fatal injury, the statutory obligation requires that the location
where the accident has occurred should remain undisturbed as far as
c.
MISC-14- 02
PART-H
d.
Responsibility of CM (F&S)
Informing DGM (PN) / ED (T) / ED immediately in case of Hi-Po
incident.
Responsibility of CHRM
To intimate Police, relative & Director of factories in case of fatal injury
immediately by telephone / Fax followed by letter & messenger.
Factory Directorate shall be intimated for reportable accident as
defined in U.P. factory rule 1950.
f.
Responsibility of CM (S&EP)
To intimate OISD, CCE, Pollution Control Board immediately over
telephone / fax/ followed by letter for accident / incident required to be
reported as per rules / regulation, as defined in register of Legislative & other
requirements.
g.
Contractor Responsibility
If any contractor personnel meet with injury, he shall immediately
report to concerned supervisor / engineer of IOCL supervising the job.
HOD (F&S) shall be responsible for compliance of this procedure. HOD
(F&S) & concerned HODs shall be responsible for corrective and preventive
actions.
All accidents and Incidents shall be reported by the Line Supervisor using
the approved Accident /Incident Report format A1.
Centralized records of accidents /Incidents reports will be maintained by
HOD (F&S) and analysis of records shall be presented to the Senior
Management every quarter through Management Safety Committee
Meetings (MSCM) and every month through LMC.
14.4
DEFINITION
ACCIDENT: Accident is an undesirable, unwanted, unplanned event, which
results in injury to persons or damage of property or equipment or damage
to Environment or any of the these combination.
INCIDENT (NEARMISS): An event that, under slightly different
circumstances, may
have resulted in harm to People or Damage of
equipment, Material and Environment or any of these combination.
PERSONAL INJURY: Any bodily harm to any person
MISC-14- 03
PART-H
LOSS TIME ACCIDENT: Any Injury to a person during course of his official
duty, causing disablement for a period of 48 hrs or more immediately after
Accident or later as a effect of accident
FATALITY: Any event causing a loss of life immediately on the spot or
subsequently arising out of that accident.
OCCUPATIONAL ILLNESS: Any illness, which results from exposure to the
working Environment.
PROPERTY DAMAGE: An unplanned or undesired event, which does not
result in any injury but
has caused damage to property in terms of
equipment & material.
PROCESS LOSS: An unplanned or undesired event, which does not result
in any injury but results in substandard or decreased production.
POLUTION/ UNDESIRED ENVIRONMENTAL EVENTS: An event causing
damage to land, water or air beyond the permissible limits as specified in EP
Act or stipulated in Environment clearance of the refinery.
INSIGNIFICANT FIRE: Any Fire causing no direct loss. That fire would be
considered as insignificant fire such as grass fire/ Cotton fire/ jute fire / small
insulation fire / Electrical short circuit etc.
MINOR FIRE A fire not falling in any of the criteria of Major Fire but having
direct losses due to that fire would be deemed to be minor fire.
MAJOR FIRE: A fire would be considered as Major Fire if it meets at least
one of the following criteria:
o If the duration of the fire is more than 15 minutes and or
o if there is a plant shutdown because of fire.
o If the fire causes fatality.
o If the cost of loss of property exceeds 5 Lakhs.
COMPLAINT FROM EXTERNAL SOURCES: Any Accident / incident
complaint received from neighboring areas arising out of activities of
Mathura Refinery.
DANGEROUS OCCURANCES:
A. Bursting of plant used for containing or supplying steam under pressure
greater than atmospheric pressure.
B. Collapse or failure of a crane, derrick, winch, hoist or other appliances
used in raising or lowering persons or goods, any part thereof, or the
overturning of a crane.
CCRU OPERATING MANUAL
MISC-14- 04
PART-H
C. Explosion , fire , bursting out ,leakage ,or escape of any molten metal , or
hot liquor or gas causing bodily injury to any person or damage to any room
or place in which persons are employed or fire in rooms of cotton pressing
factories, where a cotton opener is in use.
C
D
B1
C1
D1
1
A2
B2
C2
D2
2
A3
B3
C3
D3
3
A4
B4
C4
D4
4
X
Consequence (Y-AXIS)
Code
A
B
C
D
1
2
3
4
Near-Miss incidents
Environment Loss
Breach of Law
No breach of Law / but
media attention
No breach of Law / No
media attention But
Neighbour s Complain
Loss /Complain within
battery limit
Probability: - (X-AXIS)
: Incredible (no record of such accident)
: Unlikely (one can not rule out)
: Likely but not frequently (expected)
: Frequent (certain to happen no. of times)
MISC-14- 05
Any Accident / Incidents which has potential to convert Hi-Po Accidents under
slightly different circumstances shall be termed as Hi-Po Accident / Incident
(Including Near-miss).
As per risk analysis Matrix, all losses having potential to fall under RED &
ORANGE (black in Xerox copies) boxes ie: A1,A2,A3,A4, B1, B2,B3,B4, C3, C4
and D4 shall be treated as Hi-Po Accident / Incident ( Including near-miss)
A
B
C
D
A1
B1
14.5
A2
B2
A3
B3
C3
3
A4
B4
C4
D4
4
REPORTING PROCEDURES:
MISC-14- 06
PART-H
In case of loss time accident concerned medical officer shall fill-up form no.
A-II and sent to the Fire & Safety Department with section-I completed by
the Medical officer. Officer from Fire & Safety dept. will then complete
Section-II, send a copy to Personal & administration Officer for informing the
same to Directorate of factories. In form no. 18, one copy shall be sent to
Time Office & other copies to the Department concerned. The Department
concerned will then fill in Section-III, dispatch the copies to F&S Department.
The F&S Department will keep one copy with them & one copy to concerned
department / section for implementation of preventive measures.
14.5.1.2
In case the injured person is fit to resume duty immediately after first aid or
after taking rest for some time (before the end of the shift) he shall be
allowed to resume duty accordingly.
In case the injured person is likely to become disabled for 24 hours or more
he shall be marked as on accident leave and shall be allowed to join duty
only on production of Fit for duty certificate on Form A-III from the Medical
Officer authorized for this purpose. The Medical Officer concerned shall send
the copies of Form A-III to the Fire & Safety Department, P&A Department
and the concerned department
14.5.1.3
MISC-14- 07
PART-H
FIRE REPORTING
All Fire incident shall be reported by concerned supervisor to F&S through
telephone / email / Wireless / A-I report / messenger / immediately.
Concerned Line Supervisor from Operation / maintenance/ Service dept.
shall fill the report Form No. B-I (including the analysis part of the form)
within 24 hrs and he shall identify High Potential Incident (Hi-Po) through
matrix in Form No. B1.
For Minor fires, recommendations and follow-up to be done locally by
concerned dept. and records to be maintained in form no. B-I.
The investigation shall be done for all Major/ Minor fires by Dy. Manager or
above & safety officer or category B1, B2, C3, C4 & D4 of analysis matrix
and by representative nominated by GM/ED for category B3, B4, A1, A2, A3
& A4 of analysis matrix in FIRE REPORTING FORM A-V and attach
Accident cost form no. FS-A-C. The original copy shall be sent to F&S and
retaining other copy for record and for taking corrective action by concerned
Dept. / Section.
MISC-14- 08
PART-H
14.6.0
14.6.1
14.6.2
Gathering Information
It is always a good idea to talk over the scene and the environment around
it. This gives a mental picture of actual accident. Following Source of
evidence may be looked into:-
a).
MISC-14- 09
Position Evidence
Drawing & Sketches help other people visualise what happened.
For major accident, a scale map is must, accurate drawing are
required for legal purpose.
Photo & video tape of accident scene can reveal much about an
accident & some hours of not making & drawing.
Three tips for most useful photograph
Photograph the scene from all sides. This helps orient people to the
incident.
Use a long / medium / close up sequence:- General Scene.
- Equipment / work Station
-Put a pencil to show the actual damage.
Take assistance of professional photographer.
c).
Part Evidences
Following shall be looked into:Proper item for talks - tool / equipment.
Damage.
Previous damage.
Wear.
Safe guards.
Label, signs & marking.
d).
Paper Evidences
Following shall be looked into:Log Book.
Training record.
Job request.
MISC-14- 10
Work Permit.
Tasks procedures.
MOM.
Statement.
Analyzing Causes
Once all the facts are gathered, the team is faced with a large
quantity of information by classifying information into five stages of
loss caution, the tasks may become simple
Losses
Contacts
Immediate Causes
Basic Causes
Lack of control areas.
Lack of
Control
Inadequate
Basic
Causes
Personal
Factors
System
Standard
Complianc
e
Substandar
d
Acts
Job
Factors
Immediate
Cause
Substandar
d
Conditions
Incident
Events
Losses
Unintende
d
Harm
or
Damage
MISC-14- 11
PART-H
Personal facts.
Job factors
System deficiencies.
Avoid the Satisfaction of Search syndrome, i.e, don't stop the analysis
when you first find some evidence to support your favorite hypothesis.
Explore alternatives.
Process should include all contributing factor. Apply principle of
critical few.
The investigation team decide which critical few
immediate & basis causes contributed to the accident or Near-miss.
14.6.3
14.7
COST ANALYSES:
The cost involved with accidents, fire, High Potential Near Miss Incidents
(Hi-Po), process Loss, Occupational illness and Undesired Environmental
events shall be analyzed and evaluated as per form no. FS-A-C.
MISC-14- 12
PART-H
14.8.0
14.8.1 The report shall be jointly signed by the investigating officers and forwarded
to the respective departmental HODs for their comments and
implementation of the recommendations for appropriate corrective and
preventive actions.
14.8.2 Investigation Report duly filled shall be forwarded to Fire Safety Department
for purpose of record.
b)
14.10.0
MISC-14- 13
PART-H
b)
LOCATION
First Aid Center
First Aid Box
Emergency response
Maint record / accidental damage
Customer Complaint
Personnel record
Waste disposal
RESPONSIBILITY
Medical Officer
Area Incharge
F&SM (TS)
CMNM / CMNCL / CITM / CPUM
CTSM
CHRM
CPNM
All concerned responsible shall prepare a Quarterly report & submit to DMFS.
DMFS shall prepare a report on Accident /Incident reports with investigation.
14.11 CO-ORDINATION WITH EXTERNAL AGENCY
If External Auditor turn up for investigation of any accident, CM(S&EP) will coordinate with them.
14.12 CIRCULATION OF LESSON LEARNED REPORT
CM (F&S) shall issue the lesson learned report to all concerned on form no.
FS-A-L
14.13 MAJOR ACCIDENT/ INCIDENT ANNOUNCEMENT:
Concerned HOD shall announce Major accident/ Incident (Including Hi-Po) in
format no. FS-A-M (A).
14.14 MAJOR ACCIDENT/ INCIDENT REVIEW:
Concerned HOD shall review Major accident/ Incident (Including Hi-Po) in
format no. FS-A-M (R).
14.15 TRAINING ON ACCIDENT / INCIDENT INVESTIGATION
Regular training shall be arranged for Dy. Manager or above / section head on
accident reporting and investigation for effective reporting and investigation
by all concerned. Following topics shall be covered:-
MISC-14- 14
PART-H
Consequence Measurement
B).
Minor
Lost time
Major injury
Fatalities
Disabling Injury
Property damage
Major Property damage
Process Loss
Major Process Loss
Near Miss
Occupation illness.
CCRU OPERATING MANUAL
MISC-14- 15
PART-H
D).
E).
MISC-14- 16
(For any Fatal accident, 6000 man days loss shall be taken into consideration)
Severity Rate (Based on Occupational illness)
=Man days Lost x 106
Man hours Worked
Severity rate (Major Property Damage)
=Cost of Major property damage x 106
Man hours worked
Severity rate (Major process Loss)
=Cost of Major process Loss x 106
Man hours worked
14.16.2
Cause & control Analysis
Refinery, Deptt,. Section & Occupation wise injury illness shall be analysis
for various factor as listed below:Location
Time of Accident
Activity at the time of accident.
Age of injured
Experience
Occupation
Type of injury
Location of injury
Cost of Accident
Sub-standard conditions
Substandard act
Personal Factor
Job Factor
Type of Contact
Management of control
Others
CCRU OPERATING MANUAL
MISC-14- 17
PART-H
Property damage, fires, process loss and undesired environmental event shall
be analyzed for immediate causes, basic causes & lack of control.
The result of such analysis shall be distributed to all concerned on monthly /
quarterly basis.
ORIGINATOR
A-1
A-V
A-II
A-1
A-III/ A-IV
A-III/A-IV
MEDICAL
A-II
A-II
A-I
A-III/ A--IV
P&A
A-I
MISC-14- 18
Review of A-V by
HOD
Analysis/ Wide
Circulation
Records compiled
MISC-14- 19
A regular schedule for sampling is followed in CRU. Hydrocarbon samples are sent
everyday in the morning shift at 7:00 am and water samples are collected both in
the morning and evening shifts. Samples are collected in corked sample bottles
after proper flushing. Gas samples are collected in fresh bladders, after purging
well and are clamped tight. Samples Collected are stored in the sampling point and
are taken to the laboratory by samplers by 8:00 am. The lab results are reported
over SAP and the same is noted down in the lab register. The schedule for the
same is as below;
SNO
STREAM
DEN.
1
2
3
4
5
6
SNO
1
NSU FEED
HY. NAPHTHA
LT. NAPHTHA
HTU FEED
CRU FEED
REFORMATE
SUL
H2S
RVP
RON
BEN
94
<1%
1.0
0.75
0.75
0.79
<0.5
<4
<0.5
2
SH STEAM
** Give blow down if silica is higher
8.8-9.2
SILICA
<5
<10
<0.2
STREAM
15K1 GAS
15V2 GAS
14V2 GAS
14V4 GAS
MON
MOIST
TUE
WED
DAY
THU
THU
THU
THU
MOIST
FRI
SAT
ANALYSIS FOR
O2,N2,CO,CO2
O2,N2,CO,CO2
O2,N2,CO,CO2
DENSITY, pH
Cl
< 500 ppm
MISC-15- 01
PART-H
DAY
ANALYSIS FOR
15K1 LO
40AC1 LO
TUE + FRI
TUE + FRI
BS & W
BS & W, DEN, VIS, FLASH, ACIDITY
MISC-15- 02
PART-H
The following is the list of hazardous chemicals used in CCRU with their normal
inventories maintained in field:
S.NO
PCE (C2CL4)
APA
(KEROBIT)
CI
(AHRULAN)
DMDS
STOCK,
DRUMS
Note:
PCE -APA -CI
-DMDS--
Perchloro ethylene
Anti-polymerization agent
Corrosion inhibitor
Di-methyl di sulfide
MISC-16- 01
PART-H
SYSTEM
DESCRIPTION/LOCATION
SIZE
(Inch)
NO
S
TYPE
14
SP
LIMIT
SP
NORTH
SP
SP
SP
SP
TAIL
BATTERY
8
9
SP
10
SP
11
SP
12
FO SUPPLY TO UNIT
TAIL
13
TAIL
14
1.5
SP
1.5
SP
15
16
SP
17
SP
18
SP
19
TAIL
20
SP
21
SP
SP
SP
SP
22
23
24
25
SP
26
11
SP
SIZE
(Inch)
NO
S
TYPE
SP
MISC-17- 01
PART-H
SL
NO
27
SYSTEM
DESCRIPTION/LOCATION
C5-90 TO AVU-BETWEEN TWO B/VS
28
29
SP
TAIL
TAIL
NSU
NSU
10
TAIL
NSU
12
TAIL
NSU
12
TAIL
NSU
TAIL
NSU
TAIL
NSU
1.5
TAIL
NSU
TAIL
NSU
TAIL
NSU
TAIL
10
NSU
SP
11
NSU
TAIL
12
NSU
SP
13
NSU
SP
14
NSU
SP
15
NSU
SP
16
NSU
TAIL
17
NSU
TAIL
18
NSU
10
TAIL
19
NSU
18
TAIL
9V1
9V5
9F1
9C1
MISC-17- 02
PART-H
SL
N
O
SYS
TEM
DESCRIPTION/LOCATION
SIZ
E
(Inc
h)
NO
S
TYPE
20
NSU
TAIL
21
NSU
14
TAIL
22
NSU
23
NSU
HTU
TAIL
TAIL
TAIL
HTU
TAIL
HTU
TAIL
HTU
SP
HTU
TAIL
HTU
TAIL
HTU
TAIL
HTU
1.5
SP
HTU
TAIL
10
HTU
TAIL
11
HTU
TAIL
12
HTU
1.5
SP
13
HTU
TAIL
14
HTU
1.5
SP
15
HTU
HTU
ING TO BE DONE)
TAIL
1.5
SP
16
HTU
17
HTU
14V1
14V2
14V4
14V3
14V5
MISC-17- 03
PART-H
SL
NO
18
SYSTEM
HTU
DESCRIPTION/LOCATION
SIZE
(Inch)
NO
S
TYPE
12
SP
19
HTU
14R1
20
HTU
SP
21
HTU
TAIL
22
HTU
12
SP
23
HTU
16
SP
24
HTU
SP
25
HTU
SP
26
HTU
TAIL
27
HTU
TAIL
28
HTU
TAIL
SP
16
SP
14F1
HTU
30
HTU
31
HTU
32
HTU
SP
33
HTU
12
SP
34
HTU
16
SP
35
HTU
SP
36
HTU
TAIL
37
HTU
TAIL
38
HTU
TAIL
14R1
14F2
MISC-17- 04
PART-H
SL
NO
SYSTEM
SIZE
(Inch)
NO
S
TYPE
TAIL
DESCRIPTION/LOCATION
39
HTU
40
HTU
TAIL
41
HTU
TAIL
14C1
42
HTU
TAIL
43
HTU
TAIL
44
HTU
12
TAIL
45
HTU
12
TAIL
46
HTU
SP
47
HTU
SP
SP
SP
SP
SP
26
TAIL
22
TAIL
14
TAIL
24
TAIL
HC INLET NOZZLE
24
20
SP
TAIL
SP
18
TAIL
10
TAIL
TAIL
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
IFP HTR
15 E-1
15V1
15V2
MISC-17- 05
PART-H
SL NO
CR
17 U
CR
18 U
CR
19 U
SYSTEM
15V3
DESCRIPTI
ON/LOCATI
ON
SIZE
(Inch)
NOS
TYPE
1
SP
TAIL
1
TAIL
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
15V4
1.5
TAIL
TAIL
SP
TAIL
TAIL
10
TAIL
TAIL
TAIL
SP
10
TAIL
MISC
10
TAIL
MISC
1.5
TAIL
MISC
SP
MISC
SP
MISC
20
TAIL
MISC
18
TAIL
MISC
N2 TO EBARA SUCTION
SP
SP
SP
16
SP
16
TAIL
TAIL
TAIL
15DR1
15V16
MISC-17- 06
PART-H
SL
NO
SYSTEM
DESCRIPTION/LOCATION
SIZE
(Inch)
NO
S
TYPE
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
CR
U
15C01
TAIL
TAIL
14
TAIL
10
TAIL
1.5
TAIL
1.5
TAIL
16
TAIL
TAIL
TAIL
TAIL
TAIL
10
TAIL
12
TAIL
TAIL
TAIL
MISC-17- 07
SYSTEM
15R-1
4"
15R-1
4"
15R-1
3"
15R-1
4"
15R-1
1"
15R-1
3"
15R-1
2"
15R-1
26"
15R-1
3"
10
15R-1
2"
11
15R-1
20"
12
15R-1
2"
14
15R-2
3"
15
15R-2
2"
16
15R-2
17
15R-2
18
15R-2
26
19
15R-2
2"
20
15R-2
20"
21
15R-2
26
22
15R-2
20
DESCRIPTION / LOCATION
SIZE
MISC-17- 08
23
15R-3
24
15R-3
25
15R-3
26
15R-3
27
15R-3
28
15R-3
26
29
15R-3
26
30
15R-3
31
15R-3
20
32
15R-3
33
15R-3
2"
SYSTEM
DESCRIPTION / LOCATION
17R1
17R1
17R1
17R1
17R1
10
17R1
10
17R1
17R1
17R1
10
17R1
SIZE
MISC-17- 09
11
17R1
12
17R1
13
17R1
MISC-17- 10
FROM
TO
00 hrs
04 hrs
04 hrs
28 hrs
(24hrs)
28 hrs
44 hrs
(16 hrs)
44 hrs
60 hrs
(16 hrs)
e)
60 hrs
76 hrs
(16 hrs)
f)
76 hrs
84 hrs
(8 hrs)
g)
Cooling
84hrs
88 hrs
(4 hrs)
h)
88 hrs
100 hrs
(12 hrs)
I)
100
hrs
108hrs
(8 hrs)
N
a)
b)
c)
DESCRIPTION
TIME
START
(Sign
TIME
END
(Sign)
MISC-18- 01
18.2 VESSEL:
S.
N
FROM
TO
00 hrs
04 hrs
b)
04 hrs
c)
28 hrs
d)
Final Steaming.
36 hrs
28 hrs
(24hrs)
36 hrs
(8hrs)
60 hrs
(24 hrs)
e)
60 hrs
76 hrs
(16 hrs)
f)
Cooling
76 hrs
92 hrs
(16 hrs)
g)
92 hrs
108 hrs
(16 hrs)
h)
108 hrs
116 hrs
(8 hrs)
a)
DESCRIPTION
TIME
START
(Sign)
TIME
END
(Sign)
MISC-18-02
MISC-19- 01
PART-H
ACTION
BY
Panel
Shift I/C
Field
Shift I/C
Panel
Panel
Panel
Field
Panel
Field
Pane
Panel
Field
Shift I/C
Field
Field
Field
Field
Panel
Field
Field
Field
Field
Field
Field
Field
Panel
Panel
Field
Field
Panel
Shift I/C
Panel
Field
Field
Field
Field
Field
Field
Panel
Field
MISC-20-01
S.NO
ACTION
BY
Panel
Panel
Panel
Shift I/C
Field
Panel
Field
Panel
Field
Field
Field
Field
Panel
Panel
Panel
Field
Field
Field
Field
Field
ACTION
BY
Panel
Panel
Panel
Field
Field
Panel
Shift I/C
Field
Field
Field
Field
Field
Field
Field
Field
Field
Field
Field
MISC-20- 02
S.NO
ACTION
BY
Field
Field
Field
Field
Field
Field
Field
Field
Field
Field
Field
Field
Field
ACTION
BY
Cut-off feed.
Isolate individual burner AUDCO valves
Close FG PC of all the three furnaces
Try to find and eliminate reasons for tripping.
Change rundown to off-spec.
Establish circulation of HTU with feed tank through start-up line
Light up as per procedure
Panel
Field
Panel
Shift I/C
Field
Field
Field
ACTION
BY
Panel
Panel
Panel
Panel
Field
Field
Field
MISC-20- 03
8. Check for LEL in the Recycle gas. Purge till LEL is within limits
9. Isolate reaction section and stripper section
10. Isolate reaction section and regenerator section
11. Catalyst unloading procedure is to be followed
12. Screen inspection and repair to be done as per recommendations
Field
Field
Field
M/M
ACTION
BY
Panel
Panel
Panel
Panel
Panel
Field
Field
Field
Shift I/C
Field
Field
Field
Field
Field
Field
Field
ACTION
BY
Stop lifts
Close all UV valves
Cut-off air to regenerator
Cut-off heaters
Purge with fresh nitrogen
Vent gas through DR1 pre filter drain
Restart after temperature reduces to limits
Panel
Panel
Panel
Panel
Field
Field
Panel
ACTION
BY
Panel
Panel
Panel
Panel
Panel
Field
Field
Panel
MISC-20- 04
ACTION
BY
Shift I/Cl
Shift I/C
Field
Field
Field
Field
Panel
ACTION
Isolate source
Open emergency air hose
Wear BA set
Cordon off area
Check O2 content
BY
Field
Field
Field
Field
Field
ACTION
Wear BA set
Isolate source
Start water curtain
Cordon off area
Inform F&S
BY
Field
Field
Field
Field
Shift I/C
ACTION
Wear BA set
Cordon off area
Isolate source
Inform F&S.
BY
Field
Field
Field
Shift I/C
ACTION
BY
Field
Shift I/C
Field
Field
Field
Field
PS: If any of the above leaks are heavy and out of control plant is to be shutdown as per
procedure.
MISC-20- 05
ACTION
BY
Panel
Panel
Field
Field
Field
Field
ACTION
BY
Field
Field
Field
Field
ACTION
BY
Isolate VBN
Increase purge from stripper
Detect reasons for tripping, rectify and light up again.
If not detected within few minutes, cut-off feed to CRU, HTU
Light-up furnace and stabilize plant
Field
Panel
Field
Panel
Field
ACTION
BY
Panel
Panel
Panel
Field
Field
Panel
Field
MISC-20- 06
ACTION
BY
Panel
Field
Field
Field
Field
Field
MISC-20- 07
14P4 A/B
14K1 A/B
15P1 A/B
15P2 A/B
15P15 A/B
CCRU:
N2 PLANT:
40X1/X2
MISC-21- 01
12/28/2015 03:03:03
230
160
90
20
** #1 (R) mra.dtr1.pv
** #2 (R) mra.dtr2.pv
** #3 (R) mra.dtr3.pv
** #4 (R) mra.dtrtot.pv
12/25/2015 01:37:05
12/25/2015 01:37:05
12/25/2015 01:37:05
12/25/2015 01:37:05
RON
95.5
95.0
94.5
RON
94.0
93.5
93.0
92.5
42356 42357 42359 42360 42361 42362 42364 42365 42366
Stripper inlet temperature or 14E-103A/B shell side O/L temperature came down to 127
degC.
Stripper Bottom temperature came down to 232 deg C.
Stripper parameter during exchanger changeov er @ 8h0m0s
220.00
245.00
250.00
12/28/2015 14:23:26***
110.00
225.00
230.00
** #1 (R) mra.14ti21.pv
** #2 (R) mra.14ti27.pv
** #3 (R) mra.14tc31.pv
12/28/2015 22:23:26***
over.
Change in parameter of reformer recator:
Reformer reactor(15R-1/2/3) delta T came down to 75/53/25 degC and total deltaT= 153
degC.
12/31/2015 15:03:16
230
160
90
20
** #1
** #2
** #3
** #4
(R) mra.dtr1.pv
(R) mra.dtr2.pv
(R) mra.dtr3.pv
(R) mra.dtrtot.pv
12/28/2015 17:08:12
12/28/2015 17:08:12
12/28/2015 17:08:12
12/28/2015 17:08:12
1. This may be due to ingress of sulphur and moisture from tubeside of 14E-3A/B to
CRU feed. Sulphur and moisture may be present in naphtha holdup in tube side due
to B/V passing.
2. During change over leak in 14E-103A/B may increased due to pressure difference
which causes more Sulphur and moisture leak.
Analysis: Recycle Gas checked with dragger tube H2S and HCL found out of range.
Above analysis confirmed sulphur and moisture slippage to CRU feed during exchanger
change over.
Action taken for removing temporary poision i.e. sulphur from reactor
catalyst and restoring chloride on catalyst:
For reducing sulphur from Reformer reactor catalyst Hydrogen sweeping started by
opening control valve 15PC-87 at Ebara discharge and purged gas removed from
15V-2(Recontacting separator drum)
C2CL4 (Perchloroethylene) dosing in CRU feed at 90% stroke started.
Purging from stripper reflux drum increased.
RIT reduced to 490 degC and T Put reduced to 55T/Hr.
CRU feed Sulphur checked by Lab
Result
(1) 0.36 ppm at 09:30 pm
(2) 0.32 ppm at 11:30pm
Doctor Test of CRU feed done found negative.
H2S and HCL Checked by dragger tube.
Result of dated
Recovery in delta
sweeping and
CCRU feed:
TIME
05:30pm
06:30pm
07:30pm
08:30pm
09:30pm
12:30pm
H2S(ppm)
>6
4.5
3
1
Traces
Traces
HCL(ppm)
>10
>10
9
6.5
4.5
4
28/12/2015.
T after H2
C2CL4 dosing in
12/31/2015 15:03:16
230
160
90
20
** #1
** #2
** #3
** #4
(R) mra.dtr1.pv
(R) mra.dtr2.pv
(R) mra.dtr3.pv
(R) mra.dtrtot.pv
12/29/2015 07:56:08
12/29/2015 07:56:08
12/29/2015 07:56:08
12/29/2015 07:56:08
Axis Title
150
100
50
0
42366
42367
42368
42369
42370
42371
42373
Coarse of Action:
In future to avoid moisture and sulphur slippage while changeover of exchanger 14E-3A/B
and 14E-103A/B following precaution to be kept in mind:
Initially Nitrogen will be taken in tube and shell side via stub of hydro testing and
dryness will be ensured from HPV.
DSN from U/S or D/S of 15G-1A/B can be taken in Tube side or Shell side of 14E103A/B for removing moisture and when Naphtha shall start coming from HPV
close the DSN valve. Drain all accumulated DSN from tube and shell side to CBD.
Again take fresh DSN in tube and shell side and after filling isolate B/V of DSN.
In changeover from 14E-3A/B to 14E-103A/B we can follow above procedure to
avoid moisture and sulphur slippage.
Currently in 14E-3A/B we are not having HPV in tube side and shell side will be
provided in coming S/D.
MISC-21- 02
0.00
-0.60
-0.50
-5.00
4/14/2016 02:03:35
** #1
** #2
** #3
** #4
4/14/2016 04:03:35
Job by M/M and I/M: After tripping Ebara Turbine pin clip job of actuator done by M/M and
Thrust bearing checked by I/M.
Tripping of Ebara at 08:41AM: Again decision takenfor Ebara start-up. Starting command
given from woodword panel for achieving Idle speed. But it tripped immediately on high axial
displacement ( increased from -0.32mm to -0.98mm) .
29.00
-1.10
-1.10
0.01
4/14/2016 08:04:32
** #1
** #2
** #3
** #4
4/14/2016 10:04:32
14) HP steam CRU side b/v isolation tried however due to its heavy body it could not be
isolated. Then, HP steam was isolated from B/V near Anti-surge C/V
15) 15-PC-14 B/V flare side
16) 15-V-4 to 15-V-3 vapor line B/V isolated
17) Reactor side pressure is maintained by 15-PC-87. Opening of B/V to be done slowly
Microsoft Office
Word Document
3) Level of steam drum to be monitored during start-up. Line-up NBL B/L and control
flow to steam drum thru B/V near steam drum platform.
4) 15-P-15 were kept running during this time. Phosphate dosing stopped
Lining-up of Regeneration Section during the temperature raising time :
1) Status of regeneration section : All perlo isolated, 17-K-1 & 17-K-3 stopped, 40-NC
stopped, H2 to Lift (17-E-4) isolated,
2) During the time, RIT is being raised to 440 C, regeneration circuit is lined-up.
3) To-Fro perlo lined-up & 17-K-3 started
4) Pre and post filter lined-up and 17-K-1 started
5) 40-NC started.
6) Perlo at R-1,2,3 and V10-V11 bottom remained isolated till lift is started
7) H2 to Lift (17-E-4) lined-up
Lining-up Stablizer
1) Status of 15-C-1 : R/D isolated, 15-V-4 to 15-V-3 vapor line isolated, 15-F-4 tripped,
Bottom pump running, 15-P-4 stopped, Column in pressurized condition
2) 15-F-4 light-up done before feed cut-in and minimum firing is maintained
3) 15-P-4 reflux pump also started
4) 15-C-1 was taken in circulation, top and bottom temp is maintained
Feed Cut-in
1) Line-up 15G-1 and take feed upto FC01/02
2) Before feed cut-in ensure draining of from U/S & D/S of FC01 & 02
3) Slowly FC01 and FC02 is opened and 40 T/hr feed is taken in equal ratio
4) Remaining Burners of 15-F-1, 2 and 3 are taken in line one-by-one during feed cutin to sustain COT
5) During feed cut-in recycle gas to be monitored and HC01 opening to be tuned to
overcome the backpressure from the feed and forbid the opening of anti surge
6) 15-V-1, 15-V-2 and 15-V-3 level are to be closely monitored
7) 15-P-1 to be operated as level starts increasing beyond 40% and to be maintained at
30%
8) As level starts increasing in 15-V-2 and 15-V-3, respective pumps to be operated to
empty out and maintain the level
9) Ammonia Comp to be taken in line as 15-V-2 pressure starts building-up, H2 rich
gas C/V is to be in closed condition, gas is to be routed in FG/Flare
10) 15-PC-87 isolated after feed cut-in
11) After feed cut-in, temperature raised @ 10 C/hr upto 480 C. (Rate of increase in
temperature to be re-confirmed by TS)
12) DMDS dosing in feed to be started (when dosing to be started to be ascertained)
13) Recycle gas moisture to be checked at 480 C, it should be < 200 ppm if not,
maintain RIT 480 C till moisture is reduced to < 200 ppm
14) Subsequently, increase RIT @ 3 C / hr upto 495 C, Recycle gas moisture to be
checked at 495 C, it should be < 30 ppm if not, maintain RIT 495 C till moisture is
reduced to < 30 ppm
15) After moisture reduces below 30 ppm, increase thru put @ 1 T/hr and RIT @ 1 C/hr
and normalized the plant
16) C2Cl4 dosing in feed to be started (when and rate of dosing to be started to be
ascertained)
Regeneration Section Start-up :
1) After feed cut-in and reaction section is stabilized, regeneration section is prepared
2) H2 to Lift (17-E-4) lined-up
3) 17-EH-1 and 17-EH-2 temp raised @ 30 C/hr
4) 17-PDC-02 lined-up
5) 17-EH-3 first drained to flare to avoid any liquid carryover for 20 min-30 min
6) 17-EH-3 temperature to be arise @ 35 C/hr upto 445 C
7) At 300 C, caustic and water established in 17-V-5
8) pH at caustic and water side to be checked and monitored to start caustic dosing if
pH reduces below 7 (pH value to start caustic to be ascertained)
9) 17-EH-1 and 17-EH-2 temp further raised to 450 C and 500 C @ 30 C/hr
10) All perlo to be lined-up
11) All UV air to be lined-up
12) Air diverted in black burning mode
13) Regeneration started in black burning mode
Steam generation Section :
1) Stream drum venting to be pinched
2) Drum level to be maintained using BFW B/V near steam drum
3) As the RIT approached to designed value, steam pressure increases
4) After steam pressure reaches 18 Kg and temperature 200 C+, steam to be diverted to
stream header
MISC-21- 02
LEDGER OF EXPERIENCE
FAILURE
ANALYSIS
REPORT
COMPILED BY
SUBMITTED BY
Mathura
Refinery
UNI
T
NO.
DATE
REFINERY
MR/PN/2015
/01
1/1/2015
Mathura
CCRU
PRESENT FAILURE/ABNORMALITY
DATE
: 1/1/2015
NATURE
: UV MALFUNCTIONING
ACTIONS TAKEN
AS UV WAS NOT RESETING SO WE JUST HOLD OR TIGHT THE UV RESET SWITCH
THROUGH A WIRE TO KEEP IT IN OPEN CONDITION TO SAVE THE PLANT AFTER
THAT INSTRUMENT TEAM ATTENDED THE SAME UV BY REPLACING SUPPLY BOX
FAILURE
ANALYSIS
REPORT
Mathura
Refinery
UNI
T
COMPILED BY
SUBMITTED BY
NO.
DATE
REFINERY
MR/PN/2015/02
5/1/2015
Mathura
CCRU
PRESENT FAILURE/ABNORMALITY
DATE
NATURE
: 5/1/2015
: KV-2201A MALFUNCTIONING
Sudden down of Cold box inlet air flow and all the N2 plant parameters after a period of
particular time
PRINCIPAL CAUSE OF FAILURE:
Time delay in One of the KV-2201A (Inlet valve of the Adsorber R-1)
FAILURE ANALYSIS
Since air compressor was running normal and there was no abnormality in air compressor
so sudden down of air discharge because of air compressor was ruled out then we do the
analysis of cyclomatic cycles and since in parallel cycle all the four KVs
2201A/2201E/2201B/2201F should be in open condition but it was observed that during
parallel sequence KV-2201A alarm is generating but it is not becoming normal like other
KVs .KV-2201A normal alarm coming after a time delay. Due to this time gap and during
the line up of R-1, KV 2201A remains in close condition, which is affecting the cold box
flow or N2 plant.
ACTIONS TAKEN
Since the parallel sequence time was only 60 sec so this time of period I/M was not able to
attend the same Kv so we increased the parallel time period up to 2000 sec to kept the Kv2201 in open position or to maintain the parallel sequence in line. After attending the KV
we again reduced the time period up to 60 sec.
FAILURE
ANALYSIS
REPORT
COMPILED BY
SUBMITTED BY
Mathura
Refinery
UNI
T
NO.
DATE
REFINERY
MR/PN/2015/03
Mathura
CCRU
PRESENT FAILURE/ABNORMALITY
DATE
NATURE
: Pump Jamming
Due to plant shut down both caustic pump was in stop mode from a long time, as we started
the pump there was no flow from the either pump, after cleaning of both pump suction
strainer cleaning still problem was not resolved finally pump was open by mechanical and it
was found that both pump impeller was chocked because of the deposition of the caustic in
pump impellers.
ACTIONS TAKEN
Due to caustic deposition problem it was decided to take pump change over frequently to
avoid the caustic deposition of caustic in pump impeller. After this decision problem is
observed again.
FAILURE ANALYSIS
REPORT
COMPILED BY
SUBMITTED BY
Mathura
Refinery
UNI
T
NO.
DATE
REFINERY
MR/PN/2015/0
4
Mathura
CCR
U
PRESENT FAILURE/ABNORMALITY
DATE
NATURE
During field visit it was observed that there was drop wise liquid was coming from 17-DR-1
Post filter drain point
PRINCIPAL CAUSE OF FAILURE:
During heating mode of 17 DR-1 there is a provision of water draining through a solenoid
valve which activate on level switch. Due to mal-operation of this solenoid valve water
could not be drained out through this valve and water carried over to the post filter of 17
DR-1.
ACTIONS TAKEN
With the alarm history it was found that alarm is coming but solenoid in not being activated
immediately solenoid attended and water carryover to post filter and reactor ruled out.
Ledger of
Experience
COMPILED BY
SUBMITTED BY
Mathura
Refinery
UNI
T
NO.
DATE
REFINERY
MR/PN/2015/05
Mathura
CCRU
PRESENT FAILURE/ABNORMALITY
DATE
: xxxxxxx
NATURE
ACTIONS TAKEN
As we have a stand by stripper bottom feed effluent exchanger so immediately
we took another exchanger in line and isolated the leaked exchanger without
any delay and done extra sampling of stripper bottom to rule out the other
sources of RON fluctuation.
Ledger of Experience
COMPILED BY
SUBMITTED BY
Mathura
Refinery
UNI
T
NO.
MR/PN/2014/1
DATE
REFINER
Y
Mathura
CCRU
PRESENT FAILURE/ABNORMALITY
DATE
: xxxxxxx
NATURE
: Compressor abnormality
ACTIONS TAKEN
After founding the Block valve sheet problem it was replaced with new one and
compressor again started .
Ledger of Experience
COMPILED BY
SUBMITTED BY
Mathura
Refinery
UNI
T
NO.
DATE
REFINERY
MR/PN/2014/2
Mathura
CCRU
PRESENT FAILURE/ABNORMALITY
DATE
: xxxxxxx
NATURE
Chokage of REGENERATOR
CHLORINATION PCE
nozzle
OBSERVATIONS/ ABNORMALITY OF PRESENT FAILURE
Frequent Chokage of REGENERATOR CHLORINATION PCE nozzle REGENERATOR
CHLORINATION
ACTIONS TAKEN
In PCE injection line N2 injection was started through RO to avoid this
problem
Oxychlorination bed temperature low due to N2 stream in the PCE
steam jacketting was done to preheat the combined stream
tapping taken from Burning gas outlet for atomising PCE
Ledger of Experience
Mathura
Refinery
UNI
T
COMPILED BY
SUBMITTED BY
NO.
DATE
REFINER
Y
CCRU
PRESENT FAILURE/ABNORMALITY
DATE
: xxxxxxx
NATURE
FAILURE ANALYSIS
Outlet collectors were suspected for chokage ,but found to be clean
MR/PN/2014/3
Mathura
Ledger of
Experience
COMPILED BY
SUBMITTED BY
Mathura
Refinery
UNI
T
NO.
DATE
REFINERY
MR/PN/2014/4
Mathura
CCRU
PRESENT FAILURE/ABNORMALITY
DATE
: xxxxxxx
NATURE
: TUBE FAILURE
FAILURE ANALYSIS
METAL DUSTING IS CALLED CATASTROPHIC CARBURISATION
UNSTABLE Fe3C DISINTEGRATES INTO Fe AND CARBON.
Fe & C PARTICLES IN DUST FORM IS SWEPT AWAY LEAVING BEHIND A SMOOTH
PIT
ACTIONS TAKEN
Reformer Shutdown was taken and leaky portion was cut and replaced
DMDS dosing started to maintain S level between 0.2 and 0.5wppm
Ledger of
Experience
COMPILED BY
SUBMITTED BY
Mathura
Refinery
UNI
T
NO.
DATE
REFINERY
MR/PN/2014/
5
Mathura
CCRU
PRESENT FAILURE/ABNORMALITY
DATE
NATURE
: xxxxxxx
: Faulty level indication
Ledger of Experience
COMPILED BY
SUBMITTED BY
Mathura
Refinery
UNI
T
NO.
DATE
REFINERY
MR/PN/2014/6
Mathura
CCRU
PRESENT FAILURE/ABNORMALITY
DATE
NATURE
: xxxxxxx
: Pump seizing
ACTIONS TAKEN
One extra water line to CBD connected in the CBD to prevent the seizing of CBD pump
RECOMMENDATIONS
Ledger of
Experience
COMPILED BY
SUBMITTED BY
Mathura
Refinery
UNI
T
NO.
DATE
REFINERY
MR/PN/2014/
7
Mathura
CCRU
PRESENT FAILURE/ABNORMALITY
DATE
NATURE
: xxxxxxx
: lift pot chocking
ACTIONS TAKEN
Regeneration stopped and lift pot opened and catalyst lumps removed and seal
atteneded.
Ledger of
Experience
COMPILED BY
SUBMITTED BY
Mathura
Refinery
UNI
T
NO.
DATE
REFINERY
MR/PN/2014/
8
Mathura
CCRU
PRESENT FAILURE/ABNORMALITY
DATE
NATURE
: xxxxxxx
: Faulty TEV (Thermal expansion valve)
ACTIONS TAKEN
TEV bypass opened and icing started at the downstream of TEVbypass results drop in
air temperature.
Ledger of
Experience
COMPILED
BY
SUBMITTED
BY
Mathura
Refinery
UNI
T
NO.
MR/PN/2014/9
DATE
REFINERY
Mathura
CCRU
PRESENT FAILURE/ABNORMALITY
DATE
NATURE
: xxxxxxx
: loading problem of 17-K-1A/B
RECOMMENDATIONS
it was recommended that during such tripping kept close 17-FV-05 and 17-PDV-06B
C/Vs manually during start up