8474L-011-Manual (1-48)

VIETNAM OIL AND GAS CORPORATION
(PETROVIETNAM)
DUNG QUAT REFINERY
OPERATING MANUAL
VOLUME 1
CRUDE DISTILLATION UNIT

UNIT 011
BOOK 1/1
Rev. 1
VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
November 2008
Rev.
:1
Chapter : 1
Page
: 1/34
1. BASIS OF DESIGN
1.1. DUTY OF PLANT
The objective of the CDU is to provide primary separation of crude oils to produce straight
run blendstocks of distillate products (after suitable downstream treatment processes) and
feedstocks for other downstream process units.
Crude oil feedstock is preheated against product and pumparound streams before being
routed to a fired heater. Primary fractionation is carried out in the main crude column
fractionator and associated side stream strippers. Overhead naphtha is further processed in
the naphtha stabiliser column. Products are cooled and rundown to intermediate storage or
further processing as appropriate. Light gas oil and heavy gas oil streams are vacuum dried
prior to rundown.
The unit is designed to operate on two crude oils:
6.5 Million Tonnes per Annum of Bach Ho crude oil (sweet case).
6.5 Million Tonnes per Annum of Dubai crude oil (sour case).
Furthermore, one operating case is based on a blend of 84.6 wt% of Bach Ho crude oil and
15.4 wt% of Dubai crude oil, such that the Jet A-1 specification for freeze point and density
can be achieve when processing the crude blend.
1.2. FEED CHARACTERISTICS
1.2.1.
Bach Ho crude
This crude oil is a light sweet crude oil with an API 39.2 and sulphur content of 0.03 %. It has
a K value of 12.3, which gives it paraffin classification. Bach Ho has a medium yield of
naphtha and good yields of middle distillates and vacuum gas oil.
Bach Ho is a high quality refining crude; low in contaminants which is well suited to cracking
refineries.
1.2.1.1.
Distillation curve
The following table shows the distillation and density curve for Bach Ho crude.
Table 1: Distillation and density curve for Bach Ho crude.
Component properties
Fraction C
Wt %
Wt % Cumm.
Density
Lights End
2.86
2.86
68-93
1.53
4.39
0.6816
93-157
8.43
12.82
0.7460
157-204
7.24
20.06
0.7734
204-260
8.38
28.44
0.7972
260-315
10.21
38.65
0.8160
315-371
12.11
50.76
0.8285
371-427
12.58
63.34
0.8437
427-482
12.84
76.18
0.8539
482-566
9.74
85.92
0.8904

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
November 2008
Rev.
:1
Chapter : 1
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Fraction C
Wt %
Wt % Cumm.
Density
>566
13.81
99.73
0.9313
Loss
1.2.1.2.
0.27
Lights Ends
The Bach Ho crude light ends content is summarized in the following table:
Table 2: Bach Ho Light end content.
1.2.2.
Component
Wt %
Methane
0.0002
Ethane
0.0031
Propane
0.0327
Isobutane
0.0488
n-butane
0.2122
Isopentane
0.3741
n-pentane
0.6270
Cyclopentane
0.0300
2,2-dimethylbutane
0.0243
2,3-dimethylbutane
0.0530
2-methyl-pentane
0.3885
3-methyl-pentane
0.2099
n-hexane
0.8528
Dubai crude
Dubai crude is a sour crude oil with an API 31.2 and a total sulphur content of 2.1 % wt. It
has a K value of 11.78, which gives it intermediate classification.
1.2.2.1.
Distillation curve
The distillation and density curves for this crude oil are shown in the table below.
Table 3: Distillation and density curve for Dubai crude.
Temperature (C)
Wt % Cumm
Density
89
0.702
120.4
10
0.741
259.8
30
0.830
372.0
50
0.890
482.2
70
0.946
678.9
90
1.033

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
1.2.2.2.
November 2008
Rev.
:1
Chapter : 1
Page
: 3/34
Light Ends
The Dubai crude light ends content is summarized in the following table:
Table 4: Dubai Light end content.
1.2.2.3.
Component
Wt %
Ethane
0.01
Propane
0.16
Isobutane
0.15
n-butane
0.59
Isopentane
0.62
n-pentane
0.93
Cyclopentane
0.09
Sulphur content
The total sulphur content in Dubai crude is 2.1 %wt with a hydrogen sulphide content less
than 0.0001 % wt.
The sulphur distillation curve for Dubai crude oil is shown in the table below.
Table 5: Total Sulphur distillation curve.
Mid Vol (%)
Total Sulfur (Wt %)
15
0.0004
20
0.0012
25
0.0024
30
0.0048
35
0.0092
40
0.0136
45
0.0184
50
0.0224
55
0.0244
60
0.0252
65
0.0264
70
0.0276
75
0.0296
80
0.0320
85
0.0356
90
0.0392

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
November 2008
Rev.
:1
Chapter : 1
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1.3. PRODUCT SPECIFICATIONS

The following products specifications shall be meet, while unit is operating on 100% Bach Ho
feed.
Table 6: Product specifications.
Specification
Value
Test Method
C5 content in LPG rich stream
1.5 mol% max.
ASTM D2163
C4 content in Full Range Naphtha
0.3 wt% max.
G.C.
Gap between the 5%vol of Kerosene

and 95% vol. of Full Range Naphtha
0C min.
ASTM D86
Gap between the 5%vol of Light Gas

Oil and 95% vol. of Kerosene
0C min.
ASTM D86
Overlap between the 95%vol of Light

Gas Oil and 5% vol. of Heavy Gas Oil
20C max.
ASTM D86
Heavy Gas Oil flash point
65 C min. (note 2)
ASTM D93
Kerosene flash point
40 C min.
ASTM D93
Kerosene smoke point
20 mm min.
ASTM D1322
Kerosene density @ 15C
0.83 kg/l max.
ASTM D1298
Light Gas Oil cetane index
45 min.
ASTM D4737
Light Gas Oil flash point
65 C min.
ASTM D93
Light Gas Oil pour point
0 C max.
ASTM D97
Residue vaporizing below 360 C
10% vol. max.
ASTM D1116 (note 1)
Note 1: Result from ASTM D1160 test converted to standard atmospheric pressure of 760
mm Hg.
Note 2: Actual HGO target flash point shall not be less than 130C to allow HGO to be
sent to Refinery Fuel Oil System
1.3.1.
Product Properties Bach Ho case
Product properties for the different flexibility Bach Ho cases are shown in the below
chapters.

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
1.3.1.1.
November 2008
Rev.
:1
Chapter : 1
Page
: 5/34
Design Case
Naphtha
C5-165
0.7105
0.001
Boiling Range
S.G 60/60F
Total Sulfur
Kinematic viscosity
37.8 C
50.0 C
70.0 C
98.9 C
cSt
cSt
cSt
cSt
0.84
0.73
RVP
kPa
27.65
Flash Point
Pour Point
Freeze Point
Cloud Point
C
C
C
C
ASTM D86
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
ASTM D1160
(760 mmHg)
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
Wt %
0.47
Kerosene
165-205
0.7757
0.009
1.21
1.03
2.64
2.15
HGO
330-370
0.8418
0.033
Residue
370+
0.8788
0.043
6.44
4.84
0.62
1.16
2.02
20.44
9.12
50.6
89.6
-23.0
-6.0
2.7
136.0
17.6
151.6
60.4
167.8
213.6
231.5
248.7
267.0
287.1
313.2
320.3
333.6
237.7
304.5
330.6
346.0
355.9
368.7
393.9
402.9
419.9
-42.7
42.2
70.6
81.7
95.2
118.9
132.3
145.9
152.0
163.5
LGO
205-330
0.8135
0.023
154.3
166.3
171.0
177.8
183.1
189.5
198.8
204.6
215.6
27.8
279.2
348.3
379.6
433.7
470.1
547.1
685.1
730.5
770.3

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
1.3.1.2.
November 2008
Rev.
:1
Chapter : 1
Page
: 6/34
Maximum Naphtha
Naphtha
C5-170
0.7143
0.001
Boiling Range
S.G 60/60F
Total Sulfur
Kinematic viscosity
37.8 C
50.0 C
70.0 C
98.9 C
cSt
cSt
cSt
cSt
0.84
0.73
RVP
kPa
26.27
Flash Point
Pour Point
Freeze Point
Cloud Point
C
C
C
C
ASTM D86
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
ASTM D1160
(760 mmHg)
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
Wt %
0.47
Kerosene
170-205
0.7786
0.010
1.26
1.08
2.70
2.19
HGO
330-370
0.8428
0.033
Residue
370+
0.8791
0.043
6.44
4.84
0.65
1.17
2.02
20.44
9.12
54.8
90.6
-22.2
-5.5
3.3
136.7
18.9
151.9
60.9
168.1
214.9
233.2
250.6
268.8
289.0
315.4
322.5
335.9
238.3
306.2
332.6
348.6
358.8
372.2
398.7
407.4
423.8
-40.2
56.1
75.8
83.5
100.1
123.1
136.1
152.0
158.2
169.8
LGO
205-330
0.8143
0.023
159.8
172.2
177.0
183.0
187.8
193.6
202.1
207.9
218.7
28.4
280.0
349.1
380.4
435.0
471.7
549.1
686.2
731.1
770.4

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
1.3.1.3.
November 2008
Rev.
:1
Chapter : 1
Page
: 7/34
Minimum Naphtha
Naphtha
C5-160
0.7093
0.001
Boiling Range
S.G 60/60F
Total Sulfur
Kinematic viscosity
37.8 C
50.0 C
70.0 C
98.9 C
cSt
cSt
cSt
cSt
0.84
0.73
RVP
kPa
28.20
Flash Point
Pour Point
Freeze Point
Cloud Point
C
C
C
C
ASTM D86
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
ASTM D1160
(760 mmHg)
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
Wt %
0.47
Kerosene
160-205
0.7751
0.009
1.20
1.03
2.70
2.19
HGO
330-370
0.8428
0.033
Residue
370+
0.8791
0.043
6.44
4.84
0.62
1.17
2.02
20.44
9.12
49.5
90.6
-22.2
-5.5
3.3
136.7
18.9
151.9
60.9
168.0
214.9
233.2
250.6
268.8
289.0
315.4
322.5
335.9
238.2
306.2
332.6
348.6
358.8
372.2
398.7
407.4
423.8
-43.0
41.8
70.0
81.0
93.6
117.3
131.0
144.0
150.1
161.7
LGO
205-330
0.8143
0.023
152.0
164.5
169.3
176.7
182.5
189.4
199.3
205.2
216.2
28.4
280.0
349.1
380.4
435.0
471.7
549.1
686.2
731.1
770.4

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
1.3.1.4.
November 2008
Rev.
:1
Chapter : 1
Page
: 8/34
Maximum Kerosene
Naphtha
C5-160
0.7093
0.001
Boiling Range
S.G 60/60F
Total Sulfur
Kinematic viscosity
37.8 C
50.0 C
70.0 C
98.9 C
cSt
cSt
cSt
cSt
0.83
0.73
RVP
kPa
28.20
Flash Point
Pour Point
Freeze Point
Cloud Point
C
C
C
C
ASTM D86
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
ASTM D1160
(760 mmHg)
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
Wt %
0.47
Kerosene
160-210
0.7762
0.010
1.22
1.04
2.78
2.25
HGO
330-370
0.8428
0.033
Residue
370+
0.8791
0.043
6.44
4.84
0.63
1.20
2.02
20.44
9.12
50.1
92.8
-21.1
-4.6
4.1
136.7
18.9
151.9
60.9
168.7
217.9
237.0
253.9
271.1
290.5
315.9
323.0
336.3
238.2
306.2
332.6
348.6
358.8
372.2
398.7
407.4
423.8
-41.7
41.8
70.0
81.0
93.5
117.3
131.2
144.4
150.5
162.1
LGO
210-330
0.8152
0.024
150.9
164.8
170.2
178.2
184.6
192.2
203.1
209.1
220.3
28.4
280.0
349.1
380.4
435.0
471.7
549.1
686.2
731.1
770.4

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
1.3.1.5.
November 2008
Rev.
:1
Chapter : 1
Page
: 9/34
Minimum Kerosene
Naphtha
C5-170
0.7143
0.001
Kerosene
170-200
0.7776
0.010
1.24
1.06
Boiling Range
S.G 60/60F
Total Sulfur
Kinematic viscosity
37.8 C
50.0 C
70.0 C
98.9 C
cSt
cSt
cSt
cSt
0.84
0.73
RVP
kPa
26.27
Flash Point
Pour Point
Freeze Point
Cloud Point
C
C
C
C
ASTM D86
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
ASTM D1160
(760 mmHg)
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
Wt %
0.47
2.61
2.13
6.44
4.84
0.64
1.15
2.02
20.44
9.12
54.3
88.3
-23.4
-6.4
2.6
136.7
18.9
151.9
60.9
167.5
211.9
229.2
247.2
266.5
287.5
314.9
322.0
335.5
238.2
306.2
332.6
348.6
358.8
372.2
398.7
407.4
423.8
-41.4
56.1
75.8
83.5
100.1
123.1
136.0
151.7
157.8
169.2
LGO
HGO
Residue
200-330 330-370
370+
0.8132
0.8473
0.8791
0.023
0.033
0.043
160.9
172.0
176.3
181.5
185.8
191.0
198.8
204.4
215.1
28.4
280.0
349.1
380.4
435.0
471.7
549.1
686.2
731.1
770.4

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
1.3.1.6.
November 2008
Rev.
:1
Chapter : 1
Page
: 10/34
Maximum LGO
Naphtha
C5-165
0.7117
0.001
Boiling Range
S.G 60/60F
Total Sulfur
Kinematic viscosity
37.8 C
50.0 C
70.0 C
98.9 C
cSt
cSt
cSt
cSt
0.84
0.73
RVP
kPa
27.17
Flash Point
Pour Point
Freeze Point
Cloud Point
C
C
C
C
ASTM D86
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
ASTM D1160
(760 mmHg)
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
Wt %
0.47
Kerosene
165-200
0.7759
0.009
1.21
1.03
2.78
2.26
HGO
340-370
0.8449
0.034
Residue
370+
0.8791
0.043
6.44
4.84
0.62
1.20
2.02
20.44
9.12
51.7
89.6
-21.1
-5.3
4.3
139.8
22.5
151.9
60.9
168.5
213.8
231.5
251.1
271.9
294.9
324.8
332.1
345.9
253.6
316.8
341.4
357.9
368.0
380.2
404.2
412.5
428.0
-42.9
42.6
71.2
82.3
96.8
120.3
133.5
147.5
153.6
165.1
LGO
200-340
0.8151
0.024
157.0
168.2
172.5
178.4
183.1
188.8
197.2
202.9
213.7
30.1
280.0
349.2
380.6
435.1
471.7
549.1
686.2
731.1
770.4

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
1.3.1.7.
November 2008
Rev.
:1
Chapter : 1
Page
: 11/34
Minimum LGO
Naphtha
C5-165
0.7119
0.001
Boiling Range
S.G 60/60F
Total Sulfur
Kinematic viscosity
37.8 C
50.0 C
70.0 C
98.9 C
cSt
cSt
cSt
cSt
0.84
0.73
RVP
kPa
27.23
Flash Point
Pour Point
Freeze Point
Cloud Point
C
C
C
C
ASTM D86
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
ASTM D1160
(760 mmHg)
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
Wt %
0.47
Kerosene
165-210
0.7777
0.010
1.25
1.07
2.58
2.11
HGO
320-370
0.8406
0.033
Residue
370+
0.8791
0.043
6.44
4.84
0.64
1.14
2.02
20.44
9.12
52.5
91.1
-23.8
-5.9
2.0
133.6
15.2
151.8
60.8
167.8
215.5
234.1
249.3
264.8
282.0
304.7
311.6
324.6
222.2
295.4
324.0
338.9
349.6
364.2
393.3
402.6
420.0
-40.5
42.6
71.2
82.3
96.8
120.3
133.7
148.4
154.6
166.3
LGO
210-320
0.813
0.023
154.3
168.3
173.7
181.2
187.1
194.1
204.3
210.2
221.3
26.7
279.9
349.0
380.3
435.0
471.7
549.1
686.2
731.1
770.4

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
1.3.1.8.
November 2008
Rev.
:1
Chapter : 1
Page
: 12/34
Maximum HGO
Naphtha
C5-165
0.7118
0.001
Boiling Range
S.G 60/60F
Total Sulfur
Kinematic viscosity
37.8 C
50.0 C
70.0 C
98.9 C
cSt
cSt
cSt
cSt
0.84
0.73
RVP
kPa
27.17
Flash Point
Pour Point
Freeze Point
Cloud Point
C
C
C
C
ASTM D86
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
ASTM D1160
(760 mmHg)
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
Wt %
0.47
Kerosene
165-205
0.7767
0.010
1.23
1.05
2.51
2.05
HGO
320-370
0.8406
0.033
Residue
370+
0.8791
0.043
6.44
4.84
0.63
1.12
2.02
20.44
9.12
52.0
88.9
-24.9
-6.8
1.2
133.6
15.2
151.8
60.8
167.1
212.6
230.3
246.0
262.4
280.5
304.1
311.1
324.2
222.2
295.5
324.0
338.9
349.6
364.2
393.3
402.6
420.0
-41.7
42.6
71.2
82.3
96.8
120.3
133.6
148.0
154.1
165.8
LGO
205-320
0.812
0.023
155.5
168.1
172.9
179.7
185.0
191.3
200.6
206.4
217.4
26.7
279.9
349.0
380.3
435.0
471.7
549.1
686.2
731.1
770.4

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
1.3.2.
November 2008
Rev.
:1
Chapter : 1
Page
: 13/34
Product Properties Dubai case
Product properties for the different flexibility Dubai cases are shown in the below chapters.
1.3.2.1.
Design Case
Naphtha
C5-165
0.718
0.053
Kerosene
165-205
0.7861
0.230
LGO
205-330
0.8364
1.127
HGO
330-370
0.8867
2.164
Residue
370+
0.9657
2.999
Boiling Range
S.G 60/60F
Total Sulfur
Kinematic viscosity
37.8 C
50.0 C
70.0 C
98.9 C
cSt
cSt
cSt
cSt
0.84
0.73
1.25
1.07
2.74
2.22
7.11
0.46
0.64
1.18
2.01
35.00
RVP
kPa
30.27
Flash Point
Pour Point
Freeze Point
Cloud Point
C
C
C
C
53.0
89.6
-25.3
-24.4
-24.8
137.1
8.7
154.0
53.7
ASTM D86
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
174.4
215.6
231.7
251.5
269.3
287.7
313.4
320.9
334.8
249.0
310.0
333.8
349.6
359.8
373.0
396.9
406.1
423.5
ASTM D1160
(760 mmHg)
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
Wt %
-50.1
44.0
62.0
69.0
98.5
110.4
126.0
144.5
150.9
163.0
153.5
168.5
174.4
181.7
187.7
193.8
201.4
206.9
217.3
305.00
43.7
146.3
206.5
234.6
288.0
336.4
409.3
586.6
651.7
723.2

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
1.3.2.2.
November 2008
Rev.
:1
Chapter : 1
Page
: 14/34
Maximum Naphtha
Naphtha
C5-170
0.7201
0.059
Kerosene
170-205
0.7877
0.239
LGO
205-330
0.836
1.120
HGO
330-370
0.8863
2.161
Residue
370+
0.9644
2.985
Boiling Range
S.G 60/60F
Total Sulfur
Kinematic viscosity
37.8 C
50.0 C
70.0 C
98.9 C
cSt
cSt
cSt
cSt
0.83
0.73
1.28
1.09
2.71
2.20
7.11
0.46
0.66
1.17
2.01
35.00
RVP
kPa
29.44
Flash Point
Pour Point
Freeze Point
Cloud Point
C
C
C
C
55.7
88.9
-25.5
-24.6
-25.2
137.0
8.5
153.2
53.0
ASTM D86
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
172.3
214.1
230.4
250.2
268.7
287.3
313.8
321.3
335.5
250.9
310.3
333.5
349.5
359.5
372.1
394.9
404.0
421.2
ASTM D1160
(760 mmHg)
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
Wt %
-49.4
44.2
63.3
70.7
100.0
112.6
128.8
148.3
154.9
167.3
159.3
173.0
178.3
184.9
190.0
195.3
202.2
207.6
217.9
305.00
42.8
143.8
203.6
231.6
285.4
334.2
406.7
585.0
650.3
723.2

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
1.3.2.3.
November 2008
Rev.
:1
Chapter : 1
Page
: 15/34
Minimum Naphtha
Naphtha
C5-160
0.7161
0.048
Kerosene
160-205
0.7839
0.216
LGO
205-330
0.836
1.120
HGO
330-370
0.8863
2.161
Residue
370+
0.9644
2.985
Boiling Range
S.G 60/60F
Total Sulfur
Kinematic viscosity
37.8 C
50.0 C
70.0 C
98.9 C
cSt
cSt
cSt
cSt
0.84
0.73
1.22
1.04
2.71
2.20
7.11
0.46
0.63
1.17
2.01
35.00
RVP
kPa
31.10
Flash Point
Pour Point
Freeze Point
Cloud Point
C
C
C
C
50.1
88.9
-25.5
-24.6
-25.2
137.0
8.5
153.2
53.0
ASTM D86
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
172.2
214.1
230.4
250.2
268.7
287.3
313.8
321.3
335.5
250.9
310.3
333.5
349.5
359.5
372.1
394.9
404.0
421.2
ASTM D1160
(760 mmHg)
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
Wt %
-50.9
43.8
60.6
67.2
97.1
108.3
123.4
141.2
147.5
159.4
148.3
164.0
170.2
177.9
184.4
191.4
199.5
205.0
215.4
305.00
42.8
143.8
203.6
231.6
285.4
334.2
406.7
585.0
650.3
723.2

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
1.3.2.4.
November 2008
Rev.
:1
Chapter : 1
Page
: 16/34
Maximum Kerosene
Naphtha
C5-160
0.7162
0.049
Kerosene
160-210
0.7855
0.232
LGO
210-330
0.8378
1.156
HGO
330-370
0.8863
2.161
Residue
370+
0.9644
2.985
Boiling Range
S.G 60/60F
Total Sulfur
Kinematic viscosity
37.8 C
50.0 C
70.0 C
98.9 C
cSt
cSt
cSt
cSt
0.84
0.73
1.24
1.06
2.82
2.28
7.11
0.46
0.64
1.20
2.01
35.00
RVP
kPa
31.10
Flash Point
Pour Point
Freeze Point
Cloud Point
C
C
C
C
50.7
91.4
-24.5
-23.7
-23.4
137.0
8.5
153.2
53.0
ASTM D86
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
174.5
217.9
234.9
255.1
271.3
289.2
314.6
322.0
336.0
250.9
310.3
333.5
349.5
359.5
372.1
394.9
404.0
421.2
ASTM D1160
(760 mmHg)
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
Wt %
-50.3
43.8
60.6
67.2
97.1
108.3
123.6
141.7
148.1
160.1
145.2
163.8
171.1
179.9
187.2
194.5
203.2
209.0
219.8
305.00
42.8
143.8
203.6
231.6
285.4
334.2
406.7
585.0
650.3
723.2

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
1.3.2.5.
November 2008
Rev.
:1
Chapter : 1
Page
: 17/34
Minimum Kerosene
Naphtha
C5-170
0.7201
0.058
Kerosene
170-200
0.7864
0.225
LGO
200-330
0.8342
1.086
HGO
330-370
0.8863
2.161
Residue
370+
0.9644
2.985
Boiling Range
S.G 60/60F
Total Sulfur
Kinematic viscosity
37.8 C
50.0 C
70.0 C
98.9 C
cSt
cSt
cSt
cSt
0.83
0.73
1.26
1.08
2.61
2.12
7.11
0.46
0.65
1.14
2.01
35.00
RVP
kPa
29.44
Flash Point
Pour Point
Freeze Point
Cloud Point
C
C
C
C
55.2
86.5
-26.6
-25.5
-27.1
137.0
8.5
153.2
53.0
ASTM D86
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
169.7
210.5
226.4
245.1
266.1
285.5
313.1
320.7
334.9
250.9
310.3
333.5
349.5
359.5
372.1
394.9
404.0
421.2
ASTM D1160
(760 mmHg)
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
Wt %
-50.0
44.2
63.3
70.7
100.0
112.6
128.8
148.0
154.4
166.6
161.8
173.1
177.5
183.1
187.6
192.5
199.0
204.2
214.1
305.00
42.8
143.8
203.6
231.6
285.4
334.2
406.7
585.0
650.3
723.2

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
1.3.2.6.
November 2008
Rev.
:1
Chapter : 1
Page
: 18/34
Maximum LGO
Naphtha
C5-165
0.7181
0.053
Kerosene
165-200
0.7845
0.213
LGO
200-340
0.8372
1.158
HGO
340-370
0.8904
2.213
Residue
370+
0.9644
2.986
Boiling Range
S.G 60/60F
Total Sulfur
Kinematic viscosity
37.8 C
50.0 C
70.0 C
98.9 C
cSt
cSt
cSt
cSt
0.84
0.73
1.23
1.05
2.77
2.24
7.11
0.46
0.63
1.19
2.01
35.00
RVP
kPa
30.20
Flash Point
Pour Point
Freeze Point
Cloud Point
C
C
C
C
52.4
87.6
-24.6
-23.4
-23.5
140.1
11.6
153.2
53.0
ASTM D86
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
170.6
212.0
228.2
249.3
270.5
292.2
323.3
331.2
346.0
267.5
321.6
342.7
359.2
368.6
379.8
400.3
409.2
425.9
ASTM D1160
(760 mmHg)
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
Wt %
-50.8
44.0
62.1
69.1
98.6
110.5
126.1
144.4
150.7
162.6
156.7
168.8
173.5
179.6
184.8
190.5
197.5
202.8
212.8
305.00
50.5
143.8
203.7
231.8
285.4
334.2
406.7
585.0
650.3
723.2

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
1.3.2.7.
November 2008
Rev.
:1
Chapter : 1
Page
: 19/34
Minimum LGO
Naphtha
C5-165
0.7183
0.054
Kerosene
165-210
0.7872
0.243
LGO
210-320
0.8346
1.075
HGO
320-370
0.8824
2.102
Residue
370+
0.9644
2.985
Boiling Range
S.G 60/60F
Total Sulfur
Kinematic viscosity
37.8 C
50.0 C
70.0 C
98.9 C
cSt
cSt
cSt
cSt
0.83
0.73
1.27
1.09
2.65
2.15
7.11
0.46
0.65
1.15
2.01
35.00
RVP
kPa
30.20
Flash Point
Pour Point
Freeze Point
Cloud Point
C
C
C
C
53.4
90.1
-26.5
-25.8
-27.0
133.8
5.5
153.2
53.0
ASTM D86
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
174.1
216.2
232.6
250.9
266.6
282.2
304.4
311.5
324.9
233.4
299.2
324.8
339.9
350.6
364.7
390.3
399.7
417.4
ASTM D1160
(760 mmHg)
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
Wt %
-49.6
44.0
62.0
69.1
98.6
110.5
126.3
145.3
151.9
164.2
150.4
168.0
174.9
183.4
189.8
196.2
204.3
210.0
220.8
305.00
36.0
143.7
203.5
231.4
285.4
334.2
406.7
585.0
650.3
723.2

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
1.3.2.8.
November 2008
Rev.
:1
Chapter : 1
Page
: 20/34
Maximum HGO
Naphtha
C5-165
0.7182
0.054
Kerosene
165-205
0.7858
0.227
LGO
205-320
0.8327
1.039
HGO
320-370
0.8824
2.102
Residue
370+
0.9644
2.985
Boiling Range
S.G 60/60F
Total Sulfur
Kinematic viscosity
37.8 C
50.0 C
70.0 C
98.9 C
cSt
cSt
cSt
cSt
0.84
0.73
1.25
1.07
2.54
2.08
7.11
0.46
0.64
1.12
2.01
35.00
RVP
kPa
30.20
Flash Point
Pour Point
Freeze Point
Cloud Point
C
C
C
C
52.8
87.6
-27.6
-26.8
-28.9
133.8
5.5
153.2
53.0
ASTM D86
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
171.5
212.4
228.3
245.8
263.9
280.3
303.6
310.8
324.4
233.4
299.2
324.8
339.9
350.6
364.7
390.3
399.7
417.4
ASTM D1160
(760 mmHg)
0%Vol
5%Vol
10%Vol
30%Vol
50%Vol
70%Vol
90%Vol
95%Vol
100%Vol
C
C
C
C
C
C
C
C
C
Wt %
-50.2
44.0
62.0
69.1
98.6
110.5
126.2
144.8
151.3
163.4
153.5
168.3
174.1
181.4
187.2
193.3
200.8
206.2
216.5
305.00
36.0
143.7
203.5
231.4
285.4
334.2
406.7
585.0
650.3
723.2

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
November 2008
Rev.
:1
Chapter : 1
Page
: 21/34
1.4. MATERIAL BALANCES

The design of the crude distillation unit is based on the following cut points.
Table 7: Design TBP cut points.
Products
TBP cut point (C)
Full Range Naphtha / Kerosene
165
Kerosene / Light Gas Oil
205
Light Gas Oil / Heavy Gas Oil
330
Heavy Gas Oil / Atmospheric residue
370
The resulting flows of these TBP cut points correspond with the normal unit operating case
(see chapters 1.4.1 and 1.4.2). Other operating cases are shown in 1.4.3 Flexibility cases.
1.4.1.
Bach Ho crude
According to the TBP cut points defined in Table 7: Design TBP cut points, the resulting
flows for Bach Ho crude oil are:
Table 8: Bach Ho case's product distribution.
1.4.2.
Product
Flow (kg/h)
% Wt of feed (water included)
LPG
2181
0.27
Naphtha
108314
13.30
Kerosene
51188
6.28
Light Gas Oil
170716
20.96
Heavy Gas Oil
69822
8.57
Residue
407324
50.01
Dubai crude
The design TBP cut points lead to the following flows for Dubai crude oil:
Table 9: Dubai case's product distribution.
1.4.3.
Product
Flow (Kg/h)
% Wt of feed (water included)
LPG
7000
0.86
Naphtha
130072
16.01
Kerosene
48747
6.00
Light Gas Oil
154839
19.06
Heavy Gas Oil
64933
7.99
Residue
403303
49.64
Flexibility cases
As stated in 1.1, the plant is designed to operate with 100 % Bach Ho case or 100 % Dubai
case. Furthermore, the unit is design to operate with different TBP cut point (see the
following sections on this point). In order to change from one case to another, the flow set

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
November 2008
Rev.
:1
Chapter : 1
Page
: 22/34
points should be changed to the values shown in this section, in order to achieve the
required product quality.
All elements of the CDU have sufficient sizing margins incorporated into the design to
achieve the flexibility requirements described below. For affected equipment, this flexibility is
considered as an alternative (i.e. not additional) to the design margins.
The pumparound flows and duties vary from Bach Ho to Dubai operation case, but inside
the same feed from one flexibility case to another the same value should be used. The flows
and duties are represented in the following table
Table 10: Pumparound flows' and duties' for Bach Ho and Dubai cases
Bach Ho Case
Dubai Case
Flow /
(kg/h)
Duty /
(kW)
Flow /
(kg/h)
Duty /
(kW)
Kerosene
pumparound
211124
9000
211110
9000
LGO pumparound
758719
29065
758676
31000
HGO pumparound
134995
4925
134963
4925
Top P/A duty is controlled by T-1101 overhead temperature (011-TIC-076), in order to adjust
the overhead flowrate to the values required to each flexibility case.
As a guideline the next table shows estimated overhead temperatures for each flexibility
cases. These values must be adjusted in field.
Table 11: Expected overhead temperatures for flexibility cases.
Bach Ho
Dubai
Design
123.6
123.7
Maximum Naphtha
129.6
127.5
Minimum Naphtha
126.2
123.3
Maximum Kerosene
126.1
123.6
Minimum Kerosene
129.3
127.2
Maximum LGO
125.4
123.7
Minimum LGO
125.7
124.2
Maximum HGO
125.7
123.9
It must be noted that if the plant is operating with a mix of Bach Ho and Dubai case, the
process water from P-1121 can not be used to feed D-1109 as it will contain H2S traces.
The stream numbers shown in the following chapters refer to PFDs stream numbers.

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
1.4.3.1.
November 2008
Rev.
:1
Chapter : 1
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Naphtha flexibility cut point
In order to maximize or minimize kerosene production, naphtha TBP cut point can be
modified in the range of 160 C to 170 C. These TBP cut points correspond with minimum
and maximum naphtha production cases, respectively.
1.4.3.1.1.
Maximum naphtha production
This flexibility cases flows, for both crude oils, are summarized in the table below.
Table 12: Maximum naphtha production flexibility cases.

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Minimum naphtha production
When the plant is operating with the minimum naphtha flexibility case for both crude oils, a
Naphtha recirculation from P-1110 to T-1101 head via line PL-110080 is required, in order to
avoid water condensation in T-1101 top trays. The amount of naphtha recirculated varies
from one case to another.
Table 13: Recirculated flow for minimum naphtha cases.
Case
Flow / (kg/h)
Bach Ho
28000
Dubai
23000
The resulting flows for this operating case are shown in the following table:

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Table 14: Minimum naphtha production flexibility case.
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Kerosene flexibility cut point
Kerosene normal cut point range of 165 C to 205 C can be varied to achieve product
requirements. In order to maximise scope for producing kerosene of acceptable quality; the
CDU is designed to produce a minimum TBP cut range of 170 C to 200 C. Additionally, in
order to maximise kerosene production, and if permitted by product quality considerations,
the CDU is designed to produce a maximum TBP cut range of 160 C to 210 C.
1.4.3.2.1.
Maximum kerosene production
Kerosene flows for this flexibility case (TBP cut range of 160 C to 210 C) are summarized
in the table below:

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Table 15: Maximum kerosene production flexibility case.
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1.4.3.2.2.
Minimum kerosene production
The resulting flows for this flexibility case are shown in the following table.
Table 16: Minimum kerosene production flexibility case.
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Diesel flexibility cut point
In order to potentially improve diesel blending flexibility, the CDU is designed to achieve a
TBP cut point of 340 C between the light gas oil and the heavy gas oil products. Also, in
order to provide additional flexibility for the campaign production of military diesel, the CDU
is designed to achieve a TBP cut point of 320 C between the light gas oil and heavy gas oil
products.
Based on the above, three operating cases have been considered: Maximum light gas oil
production (TBP cut range of 200 C to 340 C), minimum light gas oil production (TBP cut
range of 210 C to 320 C) and maximum heavy gas oil production (TBP cut range of 320 C
to 370 C).
These flexibility cases flowrates are shown in chapters 1.4.3.3.1, 1.4.3.3.2 and 1.4.3.3.3.
1.4.3.3.1.
Maximum light gas oil production
Maximum light gas oil production is summarized in the table below.

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Table 17: Maximum light gas oil production.
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1.4.3.3.2.
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Minimum light gas oil production
This flexibility cases flows for both crude oils are shown in the table below.
Table 18: Minimum light gas oil production.

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1.4.3.3.3.
Maximum heavy gas oil production
This case can be seen in the following table.

Table 19: Maximum heavy gas oil production.
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1.5. BATTERY LIMIT CONDITIONS

The battery limits conditions for Crude Distillation Unit are summarised in the following table:
Table 20: Battery limit conditions.
Battery Limit Conditions
Operating
Pressure
2
(Kg/cm g)
Operating
Temperature (C)
Crude oil from storage
20.0
50
Wild Naphtha inlet from LCO/HDT
5.5
45
Stripped water from SWS
2.5
50
Wild Naphtha from NHT
5.5
40
LGO to storage TK-5115
6.0
55
LGO to LCO / HDT
7.3
55
Desalter effluent to ETP
3.5
50
Sour Water to SWS
3.5
50
Atmospheric residue to RFCC
5.5
111/127 (note 1)
Atmospheric residue to storage (TK-5103)
4.5
85
HGO to storage (TK-5109)
5.5
55
HGO to LCO / HDT
6.5
55
Off gas to RFCC
0.7
50
Kerosene to storage (TK-5114)
6.5 / 7.5
(note 2)
40
LPG to gas recovery on RFCC
20.5
50
LPG to off-spec LPG storage (TK-5102)
20.5
50
Full range naphtha to NHT
4.0
50
Full range naphtha to storage (TK-5112)
3.5
40
Recirculation from CDU to crude tank
4.3
70
Inlet Streams
Outlet Streams

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Operating
Pressure
2
(Kg/cm g)
Operating
Temperature (C)
Light Slops from CDU
3.1
55
Heavy Slops from CDU
4.0
55
Note 1: Bach Ho crude case / Dubai crude case.

Note 2: Kerosene to blending from U-011 (CDU) / Off spec kerosene from U-014 (KTU).
1.6. GAS AND LIQUID EFFLUENTS
Refer to document Effluent Summary 8474L-011-NM-0005-001.

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2. DESCRIPTION OF PROCESS
2.1. PROCESS FLOW DESCRIPTION
The Crude Distillation Unit consists principally of a Distillation Section which separates the
different products from the Crude Oil, and a Crude Oil Preheat and Heater section that raise
the temperature of the crude oil up to the necessary condition to carry out the distillation.
In addition, there are others sections that assist the process, such as the Desalter, the
Stabilizer, or the Vacuum system.
A detailed description of each section is shown bellow, sorted from upstream to downstream
of crude.
2.1.1.
Crude Preheat
P&IDs: 8474L-011-PID-0021-101/102/103/106/107/108/109
Crude Oil is pumped from storage to the Crude Distillation Unit by the Feed Pumps P-6001
A/B/C. At the inlet of the unit, two trains of heat exchangers, (each train has two parallel
branches) separated by the Desalters (described in 2.1.2), utilize the energy available in the
system to raise the crude oil temperature.
The first train, (cold crude preheat) raises the crude temperature from 50C up to 138-133C,
corresponding to Bach-Ho and Dubai cases respectively. In order to maintain the same
crude temperature difference between the parallel branches, the entering flow to each one is
controlled by control valves, 011-TV-007A and 011-TV-007B, placed at E-1101 and E-1102
inlet, respectively.
Downstream the Desalters, the crude is pumped by the Crude Booster Pump (P-1101 A/B)
to the hot preheat train (second train), which raises the crude oil temperature from 136-131
C up to 283-277C, corresponding to Bach-Ho and Dubai cases respectively. In order to
maintain the same crude discharge temperature in each parallel branch, the entering flow is
controlled by two control valves, 011-TV-015A and 011-TV-015B, placed at E-1105 A-J and
E-1106 A-F inlets, respectively.
Table 21 summarizes the equipment involved in the preheat train and the hot fluid used in
each heat exchanger:
Table 21: Preheat Train

Train A
Train B
Cold crude preheat train
E-1101 A-H*
Residue from E-1105
E-1102
Kerosene Pump around from P-1103
E-1103 A/B
Light Gas Oil from T-1103
E-1104**
Heavy Gas Oil from E-1107
Hot crude preheat train

E-1105 A-J*
Residue from E-1108
E-1107**
HGO from T-1104
E-1106 A-F
Light Gas Oil Pump around from P1104

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E-1108 A-D*
Residue from E-1134
E-1134 A/B*
Residue from P-1106
* Heat exchangers in series (E-1101, E-1105, E-1108, E-1134)
** Heat exchangers in series (E-1104, E-1107)
Note: To see a schematic of the Preheat System, refer to 8474L-011-PFD-0010-007/015
2.1.2.
Desalters
P&IDs: 8474L-011-PID-0021-104/105/119/120
Inorganic salts are removed by emulsifying crude oil with water and separating them in a
desalter. The desalting system consists of one train of double desalters (A-1101-D-01/02),
which reduces the water extractable soluble salt content to 2.0 ppm wt (max.) and the free
water to 0.2% volume (max.) at Desalter operating temperature.
The crude oil containing sediments comes from the cold crude preheat (E-1101 A/H, E-1102,
E-1103 A/B and E-1104). The recycled water from the Second Stage Desalter (A-1101-D-02)
is injected in this crude inlet. This fluid enters in the first stage static mixer (A-1101-M-01)
which is a crude/water disperser, maximising the interfacial surface area for optimal contact
between both liquids. Downstream the mixer, the oil/water mix is homogenously emulsified in
the Emulsifying Device 011-PDV-503, upstream the First Stage Desalter (A-1101-D01). This
emulsion enters the first stage desalter where it is separated into two phases (crude oil and
water) by electrostatic coalescence. The desalted crude oil floats on the top of the vessel
and the salty water decants to the bottom where it is discharged to the ETP (Effluent
Treatment Plant).
The crude oil from the first stage (A-1101-D-01) is mixed with the dilution water coming from
E-1128 (optionally the water recycled from second stage, pumped by the Desalter Water
Recycle Pump P-1118 A/B, may be used for desalting improvement) in the second static
mixer (A-1101-M-02) followed by the second stage Emulsifying Device (011-PDV-506).
The degree of emulsion in each stage is adjusted and controlled by differential pressure
control loop across each emulsifying device (011-PDIC-503 / 011-PDIC-506).
This emulsion enters the second stage desalter (A-1101-D-02) where the separation is
produced by electrostatic coalescence again. The crude oil flows on the top of the vessel
while the water leaves from bottom and is recycled upstream the first stage desalter (A-1101D-01) by P-1118 A/B.
The desalter system is capable of treating the crude with only one stage in operation (any
desalter can by bypassed). However, the bypass of the complete system (two desalters
bypassed) is not allowed, shutting down the suction valves of P-1101 A/B (Interlock 011-SP815) if both desalter bypass valves are open.
To help the desalter dehydration and salt removal efficiency, and minimize oil content in the
water effluent, a demulsifier chemical compound is pumped from Demulsifier Storage Drum
(A-1104-D-12) by the Demulsifier Injection Pump (A-1104-P-23 A/B), and injected into both
the unit crude feed and upstream the second stage desalter.
Solids present in the crude are accumulated in the desalters bottom, so a "mud washing"
system is periodically used to remove these solids. Mud washing consists of recycling a
portion of the desalter water from E-1128 A/E to agitate the accumulated solids so that they
are washed out into the effluent water.
Desalter effluent is a combination of the periodically mud wash, produced water that came
with the crude, and the wash water resulting from the dilution and salts and other

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contaminants removal. This desalter effluent is cooled down, first with fresh make-up water
in the Desalter Water Exchanger (E-1128 A-E), and afterwards in the Desalter Effluent Air
Cooler (E-1129). Finally, it is discharged to ETP (Effluent Treatment Plant).
Desalter Water Charge Pump (P-1119 A/B) pumps the fresh make-up water, from Desalter
Water Surge Drum (D-1109) to E-1128 A-E, where is heated up to 120C, before being
injected to the crude outlet from the first stage desalter (A-1101-D-01).
The source of the D-1109 fresh make-up water could be the Stripped Water System, Service
Water or Process Water from P-1121A/B. However, the use of Process water is restricted to
sweet crude oil processing.
2.1.3.
Crude Heater
P&IDs: 8474L-011-PID-0021-110/111/133/134/135/138/143
In order to raise the temperature of the crude up to the necessary temperature for its
distillation (358-364 C, for Bach-Ho and Dubai case respectively) and vaporise part of
crude, a Crude Heater H-1101 is placed after the Hot Crude Preheat trains.
Heater H-1101 is a crude heater designed for 83740 kW duty. It consists of a double cell
cylindrical radiation heater and a single convection section. Process flow is divided at
entrance to convection section in eight symmetrical passes. After leaving convection section
flow is divided such that four passes are directed to cell 1 and the other four are directed to
cell 2. Each pass outlet is located at top of radiation section.
Additionally, remaining heat from flue gases is used to superheat low pressure steam in the
top three rows of convection section.
Radiation section is based on two identical cells of vertical tubes. There are 72 tubes per
cell, each of 17.9 m straight length spaced two tube nominal diameters. These tubes are
supported on the top and guided at their intermediate part and bottom. Crossovers from
convection to radiation section are external and welded.
Convection section located on top of the two radiation cells consists of eighteen rows of eight
tubes per row of process coil and three rows of steam superheating coil. The three bottom
rows of process coil (shock rows) are bare tubes while the fifteen rows left and the three
superheating coil rows are finned tubes of fin height which increases the installed area
while the fin height is acceptable to burn Fuel Gas and Fuel Oil.
Each burner includes a self inspirating pilot provided with an ignition rod for automatic
ignition and a detection rod for ionisation flame detection. The air intake to the pilot is
controlled by means of a venturi that consists of an air door that may be adjusted at field.
The amount of air allowed to the pilot shall be adjusted depending on the molecular weight of
the fuel burnt. When LPG is burnt in the pilot the venturi shall be partially open and adjusted
by looking at the flame. Only when very low molecular weight fuels are used should the
setting of this venturi be adjusted. If low molecular weight fuels are burnt in the pilot with
excessive air intake, the noise will alert the operator that he must close the venturi.
Three dampers are located above the convection section to enable draft control at the
heater. In order to control draft, operator shall check draft at top of radiation section
(adequate value is -2.5 mm w.g.) by means of 011-PG-511. The operator can actuate on this
value by means of the three locally installed hand controllers (011-HIC-510A/B/C) that may
also correct any flue gases maldistribution occurring at the heater. Dampers have been
designed with a maximum stop in order to leave always some free area for flue gas pass.
Dampers position in case of air or electrical failure is fully open.
This heater has been designed to operate in forced draft mode. For this operation the heater
has been provided with two blowers (B-1101 A/B) located in parallel (one in operation and
one in spare). Both have been designed for 120% of design air flow. The air flow is
controlled with the inlet guide vane of each blower. A diverter (011-XV-500) has been
installed to isolate the spare blower whilst allowing passage of air from the blower in

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operation. The diverter is positioned by means of a local handle and limit switches (011-XZL500) have been installed to give information of diverter position.
Heater duty is controlled by crude outlet temperature. The Furnace outlet temperature is
controlled by the 011-TIC-070. This controller sets the heat demand actuating on the set
point of the fuel gas and oil flow controllers and air flow controller by means of a crosslimited arrangement. This way, when an increase in duty is required, the air flowrate is
increased before the fuel gas flowrate is increased. In addition, when a decrease in heater
duty is required the fuel gas is reduced prior to the air flowrate being reduced (cross-limited
arrangement). That way a sufficient amount of combustion air is guaranteed at all times
during operation.
This control scheme shall be followed at all times during normal operation. Only in start up,
may this control scheme be passed to manual mode under strict supervision of the operator.
The correct excess air shall be maintained at all times. This may require some adjustment
during operation of the air/fuel ratio by means of 011-HIC-077.
LP steam flow to superheater coil is controlled in order to obtain the desired LP steam outlet
temperature. Following elements are involved in this loop 011-TT/TIC/TV-063. Refer to
section 3.1.1.1 for superheated LP steam control description.
2.1.4.
Crude Distillation
P&IDs: 8474L-011-PID-0021-103/109/112/113/114/115/116/125/126128/129/
Partially vaporized crude feed enters the Main Fractionator T-1101, in the flash zone where
liquid and vapour are separated. Liquid leaving the flash zone is steam stripped to recover
light components and discharged from the column as long residue. Vapours leaving the flash
zone are fractionated into lighter products and three side streams, Heavy Gas Oil (HGO),
Light Gas oil (LGO) and Kerosene.
The lighter products (Gas, LPG and Naphtha) from overhead section are totally condensed
and route to the accumulator where naphtha is separate from water and gas, then the
naphtha is stabilized in a separate column where LPG is separated (See Section 2.1.5).
The three side streams are obtained by withdrawing portion of the main fractionators internal
reflux and are steam stripped in dedicated side columns (T-1102, T-1103 and T-1104).
The properties of each fraction can be varied as required, but only at the expense of
adjacent fraction. The basis for most product specification for crude column are derived from
ASTM method. This method reports the temperature at which certain portion of the material
is vaporized. A way for settling product specification is to state the maximum allowable
ASTM End Point for the fraction.
The endpoint of sidecut will depend on the quantity withdrawn. Changing the drawoff rate is
the way in which sidecuts are kept on endpoint specifications. Temperature of the drawoff
trays is a fair indication of the endpoint and experienced operator may vary the drawoff rate
to maintain a constant tray temperature if he wishes to maintain the same product endpoint.
To reduce vapour and liquid traffic through the entire column and improve heat recovery and
separation efficiency, four intermediate cold reflux or pump around are provided, Top pump
around, kerosene pump around, LGO pump around and HGO pump around
This tower has 48 trays divided in two diameter sections: the first one from tray 1 to 42 with
an internal diameter of 6700 mm, and the second one from tray 43 to 48 with a diameter of
4000 mm. The length between tangent lines is 42850 mm.
2
The tower operates in a pressure range of 1.5 (top) to 1.9 (bottom) kg/cm g, and in a
temperature range of 130 - 124 (top) to 349 - 354 C (bottom).

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The T-1101 can be divided into 6 sections, described bellow:
Overhead Section.
Kerosene Section.
Light Gas Oil Section.
Heavy Gas Oil Section.
Overflash section
Residue Section.
2.1.4.1.
Overhead Section
A top pump-around in the Main Fractionator T-1101 provides reflux to the top section of T1101 and maintains the overhead temperature at the required level. The Top Pump-around
Pump (P-1102 A/B) takes suction of the liquid from the tray 4 and pumps it via E-1112,
where the liquid is air cooled, and then routed to the tray 1. The heat removed in Top Pumparound Air Cooler (E-1112) is adjusted to control the overhead temperature by the control
valves UV-079 and UV-080.
The overhead vapour (124 C), after receiving injection of both corrosion inhibitor and
neutralizer chemical, condenses totally through the Main Fractionator Condenser E-1111 at
50 C. The outlet from this exchanger gravity flows to the Main Fractionator Accumulator
Drum (D-1103).
In D-1103, the water is separated from the unstabilised naphtha and drained to D-1106 by
the level control valve 011-LV-040. The unstabilised naphtha is pumped to the Stabilizer
column (T-1107) by the Stabilizer Feed Pump (P-1110 A/B) via the Stabilizer Feed/Bottom
Exchanger (E-1118 A/B).
2
The controller 011-PIC-064 maintains a constant pressure of 1.3 kg/cm g in D-1103 by

means of valves PV-064 A/B/C. In case of low pressure, 011-PV-064A opens to allow fuel
gas into the accumulator drum in order to increase the pressure. In case of high pressure, off
gas from the drum is routed to the RFCC unit (Residue Fluid Catalytic Reformer unit) by
means of 011-PV-064B. However, if 011-PV-064B is overload, off gas is routed to flare by
means of 011-PV-064C.
2.1.4.2.
Kerosene Section
Kerosene is drawn off at tray 15 and part is circulated in the preheat train (E-1102) via
kerosene Pump-around Pump (P-1103 A/B). In order to ensure that separation efficiency in
the main fractionator (T-1101) is good enough to obtain the required cut point between
naphtha and kerosene, the amount of heat removed in this exchanger is adjusted by the duty
control 011-UIC-029, using 011-UV-083/084 control valves which adjust the flow through the
heat exchanger and its by-pass. Then, the kerosene is routed back to the T-1101, at Tray
12.
The other part of the Kerosene, controlled by 011-LV-011 is taken to the Kerosene Stripper
(T-1102). This stripper consists of 10 trays and a Kerosene Stripper Reboiler (E-1110), which
uses the Heavy Gas Oil (HGO) pump-around as heat source. A facility for stripping steam
injection in the bottom of the tower is also available, but it is not necessary in normal
conditions.
The top vapour of T-1102 is returned to tray 12 of T-1101. The kerosene product in the
bottom is pumped by the Kerosene Product Pump (P-1107 A/B) to the Kerosene Air Cooler
(E-1114) and then further cooled in the Kerosene Water Cooler (E-1115) to required
rundown temperature of 40C (controlled by 011-TIC-122) for the KTU.

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Light Gas Oil Section
Light Gas Oil (LGO) is drawn off at tray 26 and part flows to LGO pump around pumps (P1104 A/B) and part diverted to LGO stripper.
LGO Pump-around Pump (P-1104 A/B) routes part of the LGO to the preheat train,
specifically to E-1106 A-F. In order to ensure that the separation efficiency in the main
fractionator is good enough to obtain the required cut point between LGO and HGO, the
amount of heat removed in this exchanger is adjusted by the duty control 011-UIC-032 using
011-UV-087/088 control valves which adjust the flow through the heat exchanger and its bypass. Then the LGO is routed back to the T-1101 at tray 23.
The other part of LGO, controlled by 011-LV-013, is taken to the LGO Stripper (T-1103). This
stripper consists of 6 trays and an injection of stripping steam in the bottom, which is
controlled by 011-FV-017.
The top vapour of T-1103 is returned to T-1101 at tray 23. The LGO product in the bottom
gravity flows to E-1103 (preheat train) and afterwards to the LGO Dryer (T-1105).
2.1.4.4.
Heavy Gas Oil Section
Heavy Gas Oil (HGO) is drawn off at tray 38 and part flows to HGO pump around pumps P1105 A/B and part diverted to the HGO stripper.
HGO Pump-around Pump (P-1105 A/B) routes part of the HGO to the preheat train,
specifically to E-1109. Then, this HGO is used as the hot fluid in the Kerosene Stripper
Reboiler (E-1110). In order to ensure that the separation efficiency in the main fractionator is
good enough to obtain the required cut point between HGO and residue , the amount of heat
removed in these exchangers is adjusted by the duty control 011-UIC-031 (controls the
amount of heat exchanged in the E-1106) and 011-UIC-033 (control the overall duty
removed from the HGO) using control valves 011-UV-085/086/089/090 which adjust the flow
through each heat exchanger and their bypasses. Then, the HGO is routed back to the T1101 at Tray 35. The other part of HGO leaving tray 38 , controlled by 011-LV-016, is taken
to the HGO Stripper (T-1104). This stripper consists of 6 trays and an injection of stripping
steam in the bottom adjusted by FV-019.
The T-1104 top vapour is returned to T-1101 at tray 35. The HGO product in the bottom
gravity flows to E-1107 and E-1104 (preheat train) and afterward to the HGO Dryer (T-1106).
2.1.4.5.
Overflash Section
The flash zone is the feed entry point, coming from the heater, located between trays 42 and
43. The heater effluent is fed to the main fractionator column via a tangential nozzle to
ensure a good vapour and liquid distribution into the flash zone.
The hot vapour flows up through the tower where it contacts with colder liquid flowing down
through the tower.
Liquid from the flash zone flows down over the stripping vapour section where the light
components are stripped out.
2.1.4.6.
Residue Section
To strip off any light component that would be otherwise taken out in the residue stream,
striping steam is injected continuously in the bottom of the tower. This steam flow is
controlled by the flow control valve 011-FV-012.
The liquid level control in the bottom of T-1101 is controlled by 011-LC-007, through valves
011-FV-026/027/029 downstream of the preheat train. This control fulfils the required flow to
RFCC by means of 011-FV-029 (upstream of E-1120 A-D); the remainder of the residue is
routed to Storage by 011-FV-026/027 (split range control), after having been cooled to 85C
in E-1120 A-D.

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T-1101 bottom Residue (at 349-354 C) is pumped to the preheat train by the Residue Pump
(P-1106 A/B). In particular, fractionator residue is pumped to the heat exchangers and
following this order: E-1134 A/B, E-1108 A-D, E-1105 A-J, E-1101 A-H (See 2.1.1 Crude
Preheat).
Heat is removed from the residue with water in the Residue / Tempered Water Cooler (E1120 A-D). After that, this water is air cooled in the Tempered Water Air Cooler (E-1133).
Tempered Water Pump (P-1122 A/B) recycles the water from E-1133, along with any
necessary make-up water from the Tempered Water Drum (D-1115), to use it again as the
cooling fluid of E-1120 A-B.
2.1.5.
Stabilizer Section
P&IDs: 8474L-011-PID-0021-130/131/132
The unstabilised naphtha from D-1103 is preheated in E-1118, before entering the Stabilizer
column (T-1107), where the LPG is separated from the stabilized naphtha. This tower is a
two diameter column (1500 mm in the top and 2600 mm in the bottom), with 32 trays, a
Stabilizer Reboiler (E-1121) at the bottom and a top reflux system.
The top vapour flow is partially condensed in the Stabilizer Condenser E-1122 and then, it
gravity flows to the Stabilizer Reflux Drum (D-1104), where off gas, LPG and water are
separated.
The pressure in the Stabilizer is controlled by means of PV-068B, which allows the off gas
discharge to RFCC. In case of overload, 011-PV-068C opens to discharge the excess to the
flare system. Water level in D-1104 boot is controlled by 011-LV-050, which sends the water
to D-1103.
Part of the LPG is taken by the Stabilizer Reflux Pump (P-1114 A/B) and discharged to the
top of T-1107 as reflux. This reflux flow is controlled by 011-FV-036.
The other part of the LPG is pumped by the Stabilizer LPG Pump (P-1115 A/B) to Gas
Recovery in RFCC and its specification is controlled with a calculation set point as a ratio of
the flow to the stabilizer 011-FIC-032, with a correction for the pentane content in the LPG
stream as measured by 011-AIC-004. A separate line to LPG off-spec storage is also
available.
The liquid in the bottom of T-1107 flows continuously to the Stabilizer Reboiler (E-1121).
This heat exchanger uses High Pressure Steam (HP) as hot fluid, which has been previously
desuperheated in the Desuperheater (DS-1101) with high pressure Boiling Feed Water
(BFW).
The Full Range Naphtha discharged in the bottom is used to preheat the stabilizer feed in
the E-1118 A/B. The liquid level in the bottom of T-1107 is controlled by 011-UC-042 through
the valves FV-040 and FV-041.The Naphtha is further cooled in the Full Range Naphtha Air
Cooler (E-1126), and then, in the Full Range Naphtha Water Cooler (E-1127) before being
routed to storage.
2.1.6.
Dryers
P&IDs: 8474L-011-PID-0021-117/118/127
The LGO and HGO produced by crude distillation are routed to the LGO Drier T-1105 and
HGO Drier T-1106 respectively. Each column has 4 trays.
The LGO produced in the bottom of T-1105 is pumped to the LGO Product Cooler (E-1116)
by the LGO Product Pump (P-1112 A/B). This air cooler reduces the temperature of the LGO
to 55C before being sent to storage (TK-5115).
The HGO produced in the bottom of T-1106 is pumped to HGO Product Air Cooler (E-1117)
by the HGO Product Pump (P-1113 A/B). This exchanger along with the HGO Product Water

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Cooler (E-1119) reduces the temperature of the HGO to 55C before being sent to storage
(TK-5109).
Each tower has a level control, performed by the level control valves 011-LV-019 and 011LV-022 in the feed lines of T-1105 and T-1106, respectively.
2
A reduced operating pressure of -0.9 kg/cm g is maintained in these towers (T-1105/06) by

the Vacuum Package A-1102.
2.1.7.
Vacuum Section
P&IDs: 8474L-011-PID-0021-121/122/123/124
Vacuum system maintains a reduced pressure in the Dryers by Venturi effect. This system
consists of a Pre-Condenser (A-1102-E-30), and two stage After-Condenser (A-1102-E-31
and E-1102-E-32). Each After Condenser has a train of three parallel ejectors: A-1102-J-01
A/B/C for the first stage and A-1102-J-02 A/B/C for the second stage.
The purpose of the ejectors is to entrain tower overhead vapours and noncondensibles, by
means of medium pressure motive steam. The purpose of the condensers is to condense as
much steam and hydrocarbons as possible. Cooling water is used as cold fluid in the
condensers.
Condensate from all condensers is drained to the Drier Oil / Water Separator D-1106, where
the water is separated from the hydrocarbon phase. The hydrocarbon phase is pumped to
Slop by the Drier Slop Oil Pump (P-1120 A/B), and the water is pumped by the Ejector
Condensate Pump (P-1121 A/B) to the Stripped Water System (SWS).
The off-gas is routed to the Drier Off-gas Seal Pot D-1107 before being sent to the burners
of H-1101 along with any gas separated in D-1106.
2.1.8.
Chemical Package
P&IDs: 8474L-011-PID-0021-136/137
Four chemical compounds are continuously used in Crude Distillation Unit. Points of injection
and a brief description are included below:
2.1.8.1.
Neutralizer:
The neutralizer maximizes corrosion protection, by means of chlorides neutralization and

controlling pH in the naphtha as it condenses in vapour line and overhead condenser.
3
In this case, a continuous dosage of 5 ppm (0.002 m /h) of neutralizer is injected to the
Fractionator (T-1101) overhead vapour line, upstream of E-1111 (8474L-011-PID-0021112).The flow will be adjusted manually by operator.
The chemical is pumped from the Neutralizer Storage Drum (A-1104-D-10) to the injection
point by the Neutralizer Injection Pump (A-1104-P-26 A/B).
2.1.8.2.
Corrosion Inhibitor
The corrosion inhibitor provides excellent carbon steel resistance to acid attack from H2S,
HCl, CO2, organic acid, SOx acids and HCN.
In this case there are two injection points:
Fractionator overhead vapours line (8474L-011-PID-0021-112).
Suction of Top Pump-around P-1102 A/B (8474L-011-PID-0021-113).
The chemical is pumped from the Corrosion Inhibitor Storage Drum (A-1104-D-11) to each
injection point by the Corrosion Inhibitor Injection Pump (A-1104-P-25 A/B). A flow meter and
a valve are used to regulate the flow injected in each point.

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The total corrosion inhibitor dosage to be injected is 2 ppm (0.002 m /h).

2.1.8.3.
Demulsifier
The demulsifier increases desalter dehydration and salt removal efficiency in order to reduce
crude unit corrosion. It helps to maximize crude rates by controlling emulsion build up at the
desalter interface.
In this case, there are two injection points:
In the crude feed upstream of Cold Preheat Crude Train (8474L-011-PID-0021-101).
Upstream of second stage desalter, (8474L-011-PID-0021-104).This injection is only

required during start-up.
The chemical is pumped from the Demulsifier Storage Drum (A-1104-D-12) to each injection
point by the Demulsifier Injection Pump (A-1104-P-23 A/B). A flow meter and a valve are
used to regulate the flow injected in each point.
3
The total demulsifier dosage to be injected is 1.5 ppm (0.002 m /h).

2.1.8.4.
Antifoulant
The antifoulant reduces process side fouling caused by coke, polymers, sludge, corrosion
products, tar, and other particulate matter.
The antifoulant is injected in two places:
Feed of Cold Preheat Train (8474L-011-PID-0021-101).
Feed of Hot Preheat Train in the suction of P-1101 A/B (8474L-011-PID-0021-105).
The chemical is pumped from the Antifoulant Storage Drums (A-1104-D-13A/B) to each
injection point by the Antifoulant Injection Pumps (A-1104-P-24 A/B). A flow meter and a
valve are used to regulate the flow injected in each point.
3
The total Antifoulant dosage to be injected is 5 ppm (0.005 m /h).

2.2. THEORY OF THE PROCESS
2.2.1.
Desalter package
The desalter is provided with grids and electrodes that create an electric field inside the
vessel. This electric field makes the water droplet coalesce to create larger droplets. Water
droplets, which are not submitted to external force, have a spherical shape, and are in the
lowest energy form. When submitted to a high voltage electroctatic field, the droplets are
distorted and form a dipole, positive charges in the droplet are attracted by the negative
electrode, and negative charges are attracted by the positive one. Two adjacent droplets
have an attraction for one another. The attractive force between them tends to draw them
together if the force is sufficient to break the emulsifying stabilizer film.
The coalescence between droplets in the electrostatic field is a very rapid process. After less
than one tenth of a second, the major part of the droplets are coalesced together.
An adequate electrostatic field means:
A correct water droplets population (minimum 3% volume of emulsified water in oil).
A correct size and a good repartition of water droplets in the oil (by action of the
emulsifying device)
An efficient electrostatic field
If one of these parameters is missing or incorrect the coalescence will be incomplete.

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Vacuum package
Ejectors are dynamic fluid pumps which use the energy of a primary steam (M.P. steam for
this unit) to maintain the flow of a secondary fluid by means of a jump in pressure. They
show the following advantages:
They have no moving parts.
Little maintenance is necessary.
They have the capacity for working over periods of year.
The ejector consists of three basic parts: nozzle, mixing chamber and diffuser. The
operating principle of a steam jet ejector stage is that the pressure energy in the motive
steam is converted into velocity energy in the nozzle, and this high velocity jet of steam
entrains the hydrocarbon and non-condensable from LGO and HGO dryers. The resulting
mixture, at the resulting temperature, enters the diffuser where this velocity energy is
converted to pressure energy, so that the pressure of the mixture at the ejector discharge is
substantially higher than the pressure in the suction chamber.
2.3. ALTERNATIVES OPERATIONS
2.3.1.
Steam stripped kerosene operation
Normally the Kerosene stripper, T-1102, is operated with the reboiler E-1110. However, it
may be necessary to take E-1110 out of service while the unit is on stream. Low pressure
steam is provided as an alternative stripping medium to permit continued operation of the
stripper with E-1110 out of service. Under these conditions the kerosene product will be
routed to crude recirculation header.
To take E-1110 out or service, please refer to section 7.6
2.3.2.
One Desalter operation
Normal operation is to process the crude oil feed through both desalters in series to minimise
the amount of salt carried forward to the hot downstream heat exchangers, furnace and the
downstream equipment, and to meet the sodium specification in the RFCC feed. Wash water
normally flows counter current to the oil through both desalters in series, before being routed
to the refinery Effluent Treatment Plant.
The desalters are designed for on-line desludging. However, it may become necessary for
operational and / or maintenance reasons to shutdown one or other of the desalters. Both
the oil and the wash water pipework are configured so that either desalter may be operated
on its own while the other can be drained, valve isolated and blinded.
Refer to Normal Shutdown section 7.7 for desalter isolation procedure.
2.3.3.
LGO dryer bypass
It could be necessary to isolate the LGO drier for maintenance or other causes. The actions
needed to isolate this item are the following:
Turn to minimum LGO flexibility case
Ensure line LGO-110227 is empty by opening the drain of this line.
Close the drain and change the spectacle blind position in line LGO-110227.
Close the locked open valve on line LGO-110224 in order to stop the vacuum on the
drier.
Open drier bypass line (LGO-110227) by opening first the valve close to the line LGO110216 and next, the valve close to the line LGO-110218.

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Switch the 011-UX-012 initiator from 011-LXA-020 to 011-LXA-080, in order to ensure

the pump stops with a low low level trip in T-1103.
Set the LIC-019 controller to manual and output zero.
Close the T-1105 outlet by closing the valve on line LGO-110218.
Sent LGO product to storage tank TK-5115. This tank has a capacity of 4 days of
production without sending to the blending. Wet diesel is not really a problem because
free water will be decanted in the storage plants of blended products.
Drain the remaining hydrocarbon in the column by line CD-118548.
Blind the drier from all process lines.
Ensure vent is open, and steam out routing oily condensate to the closed drain.
Continue steaming, checking drier atmosphere regularly for hydrocarbons.
When checks are satisfactory, stop steaming, open manways, allow vessel to cool,
recheck atmosphere for oxygen and hydrocarbon and hand over to maintenance.
2.3.4.
HGO dryer bypass
The procedure is similar to the described in 2.3.3:
Turn to maximum LGO flexibility case.
Ensure line HGO-110191 is empty by opening the drain of this line.
Close the drain and change the spectacle blind position in line HGO-110191.
Close the locked open valve on line HGO-110195 in order to stop the vacuum on the
drier.
Open drier bypass line (HGO-110191) by opening first the gate valve close to the line
HGO-110182 and next, the valve close to the line HGO-110186.
Switch the 011-UX-010 initiator from 011-LXA-023 to 011-LXA-081, in order to ensure

the pump stops with a low low level trip in T-1104.
Set the LIC-022 controller to manual and output zero.
Close the T-1106 outlet by closing the valve on line HGO-110186.
Sent HGO product to storage tank TK-5109. This tank has a capacity of 4 days of
production without sending to the blending. Wet diesel is not really a problem because
free water will be decanted in the storage plants of blended products.
Drain the remaining hydrocarbon in the column by line CD-118543.
Blind the drier from all process lines.
When checks are satisfactory, stop steaming, open manways, allow vessel to cool,
recheck atmosphere for oxygen and hydrocarbon and hand over to maintenance.
2.3.5.
E-1102 and E-1104 isolation.
It could be necessary to clean E-1102 and E-1104 while unit remains online. The actions
required to be done are as follows:
Put the unit at turndown (50% of normal flow rate).

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Stop Pumparound pump P-1102 A/B. Top pumparound duty is capable of handle the
excess of duty due to the fact that unit is at turndown.
Isolate E-1102 by gate valve placed at lines K-110257 and K-110258.
Open E-1104 HGO bypass line (HGO-110185).
Close HGO circulation through E-1104 by gate valves placed on lines HGO-110181 and
HGO-110198.
Reduce then crude circulation to both heat exchangers by closing control valve 011-TV007B.
Isolate crude charge of both heat exchangers.
Drain both sides of the Heat Exchangers and to Close Drain.
Blind the heat exchangers.
When checks are satisfactory, stop steaming, allow heat exchanger to cool, recheck
atmosphere for oxygen and hydrocarbon and hand over to maintenance.

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UNIT CDU (011)
3.
DESCRIPTION OF UNIT CONTROL
3.1.
DESCRIPTION OF FLOW UNIT CONTROL

3.1.1.
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Description of main control
3.1.1.1.
Superheated low pressure steam temperature
The superheated steam temperature used to feed the strippers is controlled by 011-TIC-063
controller. The objective of this controller is to keep a constant temperature in the
superheated steam at steam coil outlet in the convection bank, by acting on two control
valves (011-TV-063A, and 011-TV-063B).
The controller signal is routed to 011-TY-063A or 011-TY-063B, which modifies the opening
percentage on 011-TV-063A and 011-TV-063B respectively, depending on its value. If the
temperature measure is lower than its set point, the controller will tend to close 011-TV-063A
and will open 011-TV-063B, in order to increase the steam flow through the steam coil in the
convection bank.
3.1.1.2.
Kerosene / LGO / HGO strippers (T-1102 / T-1103 / T-1104) and LGO / HGO
driers ( T-1105 / T-1106) level control.
The control loop is the same for all the towers mentioned. The level controller acts over the
control valve placed on the hydrocarbon stream feed, so if the level value rises above its set
point the controller will close the valve. In the table below the controllers and control valves
for each tower are shown.
Table 22: Level controller and control valves associated for strippers and driers
columns.
3.1.1.3.
Level controller
Control Valve
T-1102
011-LIC-011
011-LV-011
T-1103
011-LIC-013
011-LV-013
T-1104
011-LIC-016
011-LV-016
T-1105
011-LIC-019
011-LV-019
T-1106
011-LIC-022
011-LV-022
D-1109 level control
The objective of this controller is to maintain a constant level in the desalter water surge
drum (D-1109) by controlling the water flow inlet, by a three way split range level controller
011-LIC-025.
Each way of the split range refers to a water source:
Process water.
Stripped water from SWS.
Service water.
If the level is near its high limit the controller will close the three sources by closing the
valves 011-FV-025, 011-LV-025A and 011-LV-025B. When the level begins to decrease, the

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controller will start opening the process water (this water only can be used when the plant is
operating with 100% Bach Ho case).
If the level continues decreasing, the split range will try to open the stripped water control
valve (011-LV-025A) by 011-LY-025A. This control is routed to the minimum selector 011LY-025D, which selects the minimum signal (less opening in the control valve) between the
column level control from SWS unit and the D-1109 signal.
If the level still decreases the service water will be used by opening 011-LV-025B control
valve.
3.1.1.4.
D-1106 level controls
The objective of water level control is to keep constant the water level inside the vessel. This
control is a cascade loop in which the 011-LIC-029 output signal is used as 011-FIC-025 set
point. The 011-FIC-025 is routed to 011-FY-025 minimum selector which acts on 011-FV025 control valve.
The hydrocarbon level is an on/off control, which starts the P-1120 A/B pumps when 011LIC-028 detects high level and stops when low level is reached.
3.1.1.5.
D-1115 level control
The purpose of this control is to maintain the level inside the vessel. The level controller 011LIC-070 output is routed to 011-LV-070, which regulate the inlet of low pressure boiler feed
water to enter into the vessel.
3.1.1.6.
D-1103 water level control
This control loop is used to maintain constant the water level on D-1103. This controller 011LIC-040 is routed to 011-LV-040 that is placed on the water outlet line, so if level increases
inside the vessel the valve will open.
3.1.1.7.
D-1104 water level control
This control is similar to the explained in 3.1.1.6 D-1103 water level control, the controller
011-LIC-050 output is routed to 011-LV-050, which is placed on the water outlet line.
3.1.1.8.
T-1107 Stabilizer feed temperature control
The purpose of this controller is to keep constant the stabiliser feed temperature. The
controller 011-TIC-121 output is routed to bypass control valve 011-TV-121. If the feed to
stabiliser temperature decreases, the controller will close the control valve, in order to
increase the flow through the heat exchanger E-1118 A/B.
3.1.1.9.
T-1107 Stabilizer bottom temperature control
The objective of this control is to maintain constant the bottom temperature of the stabiliser.
This is a cascade control loop in which the temperature controller 011-TIC-113 output is
used as 011-FIC-034 set point.
If the bottom temperature decreases the controller will increases the 011-FIC-034 set point,
in order to increase the steam flow to the stabiliser reboiler E-1121.
3.1.1.10.
DS-1101 Desuperheater outlet temperature control
The purpose of this controller is to keep constant the temperature at desuperheater outlet.
This is a cascade loop in which the controller 011-PIC-201 output is routed to the 011-TIC301 set point. The temperature controller acts over 011-TV-301 control valve, in order to
ensure the steam is saturated at desuperheater outlet.

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P-1120 A/B outlet pressure controller
This control loop ensures that the control valve 011-PV-143 is closed before the pump P1120 A/B starts. As the pressure increases, due to the fact that the pump P-1120 A/B has
started, the controller 011-PIC-143 starts to open the control valve 011-PV-143. When the
pump is stopped the controller 011-PIC-143 closes the valve 011-PV-143.
3.1.1.12.
Fuel oil / atomising steam differential pressure controller
The objective of this controller is to ensure that the atomising steam pressure at burner inlet
2
is 2.1 kg/cm higher than the fuel oil pressure at burner inlet. If the pressure difference
2
measured by the controller 011-PDIC-121 is lower than 2.1 kg/cm the controller will open
the steam control valve 011-PV-121, in order to increase the steam pressure at heater inlet.
3.1.1.13.
Desalters interface level control
Both desalters, A-1101-D-01 and A-1101-D-02, are provided with level controls, 011-LIC-503
and 011-LIC-506 respectively. The output signal of 011-LIC-503 is used to regulate the
effluent water control valve 011-LV-003. The other controller, 011-LIC-506 is used to
regulate the water recirculation control valves 011-FV-005 and 011-FV-004 or, in case the
first desalter is by passed, to regulate the effluent water control valve 011-LV-003 by the
selector 011-HS-001.
The control valves for both desalters are placed in the discharge line, so an increase in the
vessel level will open the control valves.
3.1.1.14.
Ejectors inlet pressure control
The pressure inlet at the vacuum package A-1102 is adjusted by the controller 011-PIC-049
which signal is routed to 011-PV-546 control valve. If the pressure at the package inlet is
lower than its set point, the control valve will increase the recirculation flow between A-1102J-01 A/B/C outlet and A-1102-E-30 outlet, via PV-110147.
3.1.2.
Shutdown philosophy
The Emergency Shutdown System (ESD) provides trips and interlocks for preventing or
controlling emergency situations which could give rise to hazardous situations leading to
injuries to personnel, significant economic loss and/or undue environmental pollution.
Uncontrolled loss of containment is prevented by the provision of pressure safety relief
valves and by the ESD system which automatically bring the relevant part of the plant to a
safe condition.
A trip or interlock is composed of one or more initiators and one or more actions for
preventing hazards. Each trip or interlock shall be provided with a reset and where
necessary an operational override for start-up.
In general if an interlock is invoked, the interlock action shall be held on until all initiators
have returned to the safe state and the interlock reset has been pressed.
In some cases part of the trip action is to set a flow or level controller to manual with its
output set to 0% (closed) via the serial link to the DCS from the ESD System. This is strictly
not part of the trip action but is done to prevent the operator restarting with the control valve
fully open with maximum integral action. In these cases, the operation on the controller is not
included in the description of the purpose of the trip but is included in the list of actions.
The following descriptions should be read in conjunction with the CDU P&IDs (8474L-011PID-0021-001 / 138).

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CDU Emergency Shutdown (011-UX-007)
Purpose: When the ESD button in the Main Control Room (MCR) is pressed, this trip will
cause actions and other trips as detailed and ADP alarm is activated.
Initiators:
Initiator
Time
P&ID
Tag No.
Delay
No.
011-UXHS-007
0.5
seconds
101
Cause
CDU
(ESD)
Emergency
Shutdown
Actions:
Action Tag No.
P&ID No.
Service
011-UX-001
104
Desalters Protection tripped
011-UX-002
112
T-1101 Inventory Isolation tripped
011-UX-020
113
P-1102 A/B Pump Protection tripped
011-UX-023
103
011-UX-021
115
011-UX-022
116
011-UX-003
115
T-1103 Protection tripped
011-UX-004
116
011-UX-005A
134
H-1101 heater shutdown tripped
011-UX-026
131
D-1104 Inventory Isolation tripped
011-UX-017
112
011-FV-034
130
Steam to E-1121A/B closed
011-TV-301
130
Boiled feed water to E-1121 closed
011-UXA-007B
101
CDU ESD Auxiliary console (ADP)
This trip is manually reset by 011-UHSR-007

3.1.2.2.
A-1101-D-01/02 Desalter Protection (11-UX-001)
Purpose: In the event of any of High high pressure in a Desalter or inventory isolation XV015 is closed or an ESD, the following actions result:
-The following pumps are tripped:
Crude charge pumps - P-6001 A/B/C,
Crude booster pumps P-1101A/B,

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Desalter water recycle pumps P-1118 A/B, and

Desalter water charge pumps P-1119 A/B
- The following trips will be also activated:
The Fuel gas trip (UX-005B),
Fuel oil trip (UX-005C)
Pilot gas trip (UX-005E)
ADP alarm is activated
Initiators:
Initiator
Time
P&ID
Cause
Tag No.
Delay
No.
011-PXAHH-501
/504
104
High high pressure in a Desalter.
011-XZSC-015
0.5
seconds
105
Inventory isolation valve closed
011-UX-007
101
CDU Emergency Shutdown
Actions:
Action Tag No.
P&ID No.
Service
P-6001 A/B/C
060-010
060-UX-06 Crude charge pumps tripped
011-UX-008
119
011-UX-011
105
011-UX-018
104
011-UX-005B
134
H-1101 Fuel gas tripped
011-UX-005C
134
H-1101 Fuel oil tripped
011-UX-005E
134
H-1101 Pilot gas tripped

Valve 011-XV-015 reset is done via local push button 011-XHSR-015
3.1.2.3.
A-1101-D-01 Transformer TR01B Protection (011-UX-027)
Purpose: In the event of any of the following:

Low low operating level in the Desalter
Low low oil operating level in the transformer TR-01B
High-high oil operating pressure in the transformer TR-01B

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UNIT CDU (011)
November 2008
Rev.
:1
Chapter : 3
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Then the transformer TR-01B is stopped.

Initiators:
Initiator
Time
P&ID
Cause
Tag No.
Delay
No.
011-LXALL-502
0.5
seconds
104
Low low operating level

Desalter A-1101-D-01.
011-LXALL-519
0.5
seconds
104
Low low oil operating level in

transformer TR-01B
011-PXAHH-582
0.5
seconds
104
High-high
oil
pressure
transformer TR-01B
in
in
Actions:
Action Tag No.
P&ID No.
Service
011-MXS-027
104
TR-01B transformed tripped
This trip is manually reset by 11-UHSR-027.

3.1.2.4.
A-1101-D-01 Transformer TR01A Protection (011-UX-133)

Low low oil operating level in the transformer TR-01A
High-high oil operating pressure in the transformer TR-01A
Then the transformer TR-01A is stopped.
Initiators:
Initiator
Time
P&ID
Cause
Tag No.
Delay
No.
011-LXALL-502
0.5
seconds
104

011-LXALL-517
0.5
seconds
104

transformer TR-01A
011-PXAHH-580
0.5
seconds
104
High-high
oil
pressure
transformer TR-01A
in
in

DUNG QUAT REFINERY
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UNIT CDU (011)
November 2008
Rev.
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Chapter : 3
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Actions:
Action Tag No.
P&ID No.
Service
011-MXS-133
104
TR-01A transformed tripped

3.1.2.5.
A-1101-D-02 Transformer TR02B Protection (011-UX-028)

Low low oil operating level in the transformer TR-02B
High high oil operating pressure in the transformer TR-02B
Then the transformer TR-02B is stopped.
Initiators:
Initiator
Time
P&ID
Cause
Tag No.
Delay
No.
011-LXALL-505
0.5
seconds
105

011-LXALL-520
0.5
seconds
105

transformer TR-02B
011-PXAHH-583
0.5
seconds
105
High-high
oil
pressure
transformer TR-02B
Actions
Action Tag No.
P&ID No
Service
011-MXS-132
105
TR-02B transformed tripped

3.1.2.6.
A-1101-D-02 Transformer TR-02A Protection (011-UX-134)

Low low oil operating level in the transformer TR-02A
High-high oil operating pressure in the transformer TR-02A
Then the transformer TR-02A is stopped.
in
in

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
November 2008
Rev.
:1
Chapter : 3
Page
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Initiators:
Initiator
Time
P&ID
Cause
Tag No.
Delay
No.
011-LXALL-505
0.5
seconds
105

011-LXALL-518
0.5
seconds
105

transformer TR-02A
011-PXAHH-581
0.5
seconds
105
High-high
oil
pressure
transformer TR-02A
in
in
Actions
Action Tag No.
P&ID No.
Service
011-MXS-134
105
TR-02A transformed stopped

3.1.2.7.
D-1104 Inventory Isolation (011-UX-026)

manual initiation of the hand switches in the field
Initiation from CDU ESD
Low-low level in D-1104
XV-002 Inventory isolation close push button remote and local
XV-002 ESD from local panel
Then, D-1104 bottoms outlet valve XV-002 is closed, isolation valve trip alarm is activated
and the discharges pumps are tripped.
Initiators:
Initiator
Time
P&ID
Tag No.
Delay
No.
Cause
011-UXHS-026
131
Local initiation
shutdown
011-UX-007
131
CDU emergency shutdown
131
Low-low level in D-1104
131
Inventory
isolation
pushbutton (remote)
011-LXALL-032
011-XHSC-002A
0.5
seconds
push
button
close

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
Initiator
Time
P&ID
Tag No.
Delay
No.
011-XHSC-002B
011-XHSC-002B
November 2008
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:1
Chapter : 3
Page
: 9/38
Cause
131
Inventory
isolation
pushbutton (local)
close
131
XV-002 ESD from local panel
Actions
Action Tag No.
P&ID No.
Service
011-XV-002
131
Close D-1104 inventory isolation valve
011-UX-006
131
P-1114 A/B & P-1115A/B tripped
011-XXA-002
131
XV-002 trip alarm in local panel
011-MXS-134
105
TR-02A transformed stopped

XV-002 reset is done via local push button 011-XHSR-002
3.1.2.8.
H-1101 Heater Protection (011-UX-005)
This section specifies the following trips:

011-UX-005A Heater Trip, which shuts down the heater completely
011-UX-005B Fuel Gas Trip, which shuts down gas firing
011-UX-005C Fuel Oil Trip, which shuts down fuel oil firing
011-UX-005D Offgas Trip, which stops offgas firing
011-UX-005E Pilot gas Trip, which shuts down pilot gas
3.1.2.8.1.
Heater Trip (11UX-005A)
Purpose: A heater trip is used to shut the heater down on an unsafe condition.
Initiators:
Initiator Tag No.
Time
Delay
P&ID No.
Cause
011-PXAHH-017
0.5
seconds
111
High high
heater
011-LXAHH-079
0.5
seconds
134
High high level in Fuel gas K.O

Drum D-1114
134
CDU ESD
011-UX-007
on
crude
charge

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
Initiator Tag No.
Time
Delay
November 2008
Rev.
:1
Chapter : 3
Page
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P&ID No.
Cause
011-UXHS-005A
134
Local emergency shutdown
011-UXHS-005AA
134
Remote emergency shutdown
Actions:
Action Tag No.
P&ID
No.
Service
011-UX-005B
134
Fuel Gas trip initiated
011-UX-005C
134
Fuel Oil trip initiated
011-UX-005E
134
Pilot Gas trip initiated
011-B-1101A/B
133
Heater Forced Draft Fans A/B stopped
011-UXA-005B
134
H-1101 ESD Auxiliary console (ADP)
This trip is manually reset by 011-UHSR-005A. After the trip has been reset, a timer (1.5
minutes) is initiated to override the relevant trip inputs to enable the heater to be brought online.
3.1.2.8.2.
Fuel Gas Trip (011-UX-005B)
Purpose: To shut down the main fuel gas burners and route off gas to atmosphere in the
event of the following:
Low pass feed flow to crude charge heater
Low-low pressure fuel gas to burner
011-UX-005A Heater trip
011-UX-005 E Pilot gas trip
011-UX-001 Desalter protection trip
Initiators:
Initiator Tag No.
Time
Delay
P&ID
No.
Cause
011-FXALL-010
A/B/C
0.5
seconds
110
Low pass feed flow to crude

charge heater
011-PXALL-094
0.5
seconds
134
Low low pressure fuel gas to

burner
011-UX-005A
134
H-1101 Heater Trip
011-UX-005E
134
Pilot gas trip

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UNIT CDU (011)
November 2008
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Chapter : 3
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Initiator Tag No.
Time
Delay
P&ID
No.
Cause
011-UX-001
134
Desalter Protection trip
Action Tag No.
P&ID
No.
Service
011-XV-006
134
Burner fuel gas isolation valve closed
011-XV-010
134
Burner fuel gas isolation valve closed
011-XV-014
134
Emergency depressuring valve opened
011-UX-005D
134
Offgas Trip initiated
011-PIC-092
134
Fuel gas controller set to manual and output

0%
Actions:
This trip is manually reset by 011-UHSR-005B. After the trip has been reset, a timer (1.5
min) is initiated to override the relevant trip inputs and the fuel gas low low pressure, to
enable the heater to be brought on line.
011-XV-006 reset is done via local push button 011-XHSR-006
An alarm shall be provided if 011-XV-006 and 011-XV-010 are not closed 5 seconds after
the trip is initiated.
3.1.2.8.3.
Fuel Oil Trip (011-UX-005C)
Purpose: To shut down the fuel oil burners and route off gas to atmosphere in the event in
of the following:
Low pass feed flow to crude charge heater
Low-low pressure fuel oil to burner
Low differential pressure on fuel oil steam to burners
011-UX-005 E Pilot gas trip
011-UX-001 Desalter protection trip
Initiators:
Initiator Tag No.
011-FXALL-010A/B/C
Time
Delay
P&ID
No.
0.5
seconds
110
Cause
Low pass feed flow to crude

charge heater

DUNG QUAT REFINERY
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UNIT CDU (011)
November 2008
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011-PXALL-122
0.5
seconds
135
Low low pressure on Fuel oil to

burners
011-PDXALL-082
0.5
seconds
135
Low differential pressure on fuel

oil steam to burners
011-UX-005A
134
Heater Trip
011-UX-005E
134
Pilot gas trip
011-UX-001
101
Actions:
Action Tag No.
P&ID
No.
Service
011-XV-008
135
Fuel oil supply isolation valve closed
011-XV-009
135
Fuel oil return isolation valve closed
011-UX-005D
134
Offgas Trip initiated
011-PIC-118
135
Fuel oil controller set to manual and output 0%
This trip is manually reset by 011-UHSR-005C. After resetting the trip a timer (1.5 min) is
initiated to override the fuel oil low low pressure to enable the heater to be brought on-line.
An alarm shall be provided if 011-XV-008 and 011-XV-009 are not closed 5 sec after the trip
is initiated.
3.1.2.8.4.
Heater off gas (011-UX-005D)
Purpose: To route Vacuum Package offgas to atmosphere in the event in the event of the
following:
011-UX-005B Heater Fuel gas protection
011-UX-005C Heater Fuel oil protection
High-high level on off gas special piping item
011-UX-005E Heater Pilot gas trip
011-XV-004 Close pushbutton from local panel
011-XV-005 Open pushbutton from local panel
Initiators:
Initiator Tag No.
Time
Delay
P&ID No.
Cause
011-UX-005B
134
Heater Fuel gas Trip

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OPERATING MANUAL
UNIT CDU (011)
November 2008
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Chapter : 3
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Initiator Tag No.
Time
Delay
P&ID No.
Cause
011-UX-005C
134
Heater Fuel oil Trip
011-LXAHH-056
0.5
seconds
134
High-high level on SP-004 off

gas special item
011-UX-005E
134
Heater Pilot gas trip
011-XV-004
134
Open
panel
pushbutton
from
local
011-XV-005
134
Close
panel
pushbutton
from
local
Actions:
Action
No.
Tag
P&ID No.
Service
011-XV-005
134
Off gas supply valve to burners closed
011-XV-004
134
Offgas vent valve to atmosphere opened
This trip is manually reset by 011-UHSR-005D. The trip can not be reset if both the fuel gas
and fuel oil trips are active.
3.1.2.8.5.
Heater Pilot Gas Trip (011-UX-005E)
Purpose: To shut down the pilot gas and route off gas to atmosphere in the event of the
following:
Low low pressure on pilot gas to H-1101
High-high level on pilot gas special piping item
Lose of flame in more than 4 burners per cell
011-XV-007 open pushbutton from local panel
011-XV-011 open pushbutton from local panel
011-XV-012 close pushbutton from local panel
Low low air/fuel ratio to crude charge heater
Low low air flow to heater forced draft fan
011-UX-001 Desalters protection trip

DUNG QUAT REFINERY
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UNIT CDU (011)
November 2008
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Chapter : 3
Page
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Initiators:
Initiator Tag No.
Time
Delay
P&ID No.
Cause
011-PXALL-112
0.5
seconds
134
Low low pressure on pilot gas to

H-1101
011-UX-005A
134
Heater trip
0.5
seconds
138
Lose of flame in more than 4

burners per cell
011-XV-007
134
open pushbutton
panel
from
local
011-XV-011
134
open pushbutton
panel
from
local
011-XV-012
134
close
panel
from
local
011-XXALL-502
0.5
seconds
134
Low-low air/fuel ratio to crude

charge heater
011-FXALL-067
0.5
seconds
133
Low-low air flow to heater forced

draft fan
011-UX-001
134
Desalters protection trip
011-BE-501
516
to
pushbutton
Actions:
Action Tag No.
P&ID No.
Service
011-XV-007
134
Pilot gas supply closed
011-XV-011
134
Pilot gas supply closed
011-XV-012
134
Pilot vent valve opened
011-UX-005D
134
Heater off gas trip
011-UX-005C
134
Main fuel oil shutdown
011-UX-005B
134
Main fuel gas shutdown
011-UXA-005B
134
Heater ESD auxiliary console (ADP)
This trip is manually reset by 011-UHSR-005E. The trip can not be reset if both the fuel gas
and fuel oil trips are active.

DUNG QUAT REFINERY
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UNIT CDU (011)
November 2008
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Chapter : 3
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An alarm shall be provided if 011-XV-007 & 011-XV-011 are not closed 5 sec after the trip is
initiated.
3.1.2.9.
P-1101 A/B Pump Protection (011-UX-011)
Purpose: In the event of one of the following:

Low low crude flow to E-1105 A-J
Low low crude flow to E-1106 A-F
Trip of P-1101A protection from MMS
Trip of P-1101B protection from MMS
Desalters Inventory isolation valve closed
Then, the Crude Booster Pumps P-1101A/B are shutdown.
Initiators:
Initiator
Time
P&ID
Tag No.
Delay
No.
011-UX-001
105
011-FXALL058
0.5
seconds
105
Low low flow to E-1105A-J
011-FXALL059
0.5
seconds
105
0041602
Trip of P-1101A protection from MMS
0041602
Trip of P-1101B protection from MMS
0.5
seconds
105
011-UXS-091
011-UXS-092
011-XV-015
Cause
Low low flow to E-1106 A-F
Desalters Inventory isolation valve

opened less than 70%
Actions:
Action Tag No.
P&ID No.
Service
P-1101A
105
Crude Booster pump A tripped
P-1101B
105
Crude Booster puma B tripped
Notes:
This trip is manually reset by 011-UHSR-011. Motor of Pump shall be automatically stopped
when XV is less that 70% open and cannot be restarted until XV is fully opened.
3.1.2.10.
P-1102 A/B Top P/A Pumps Protection (011-UX-020)
Purpose: In the event of one of the CDU ESD or a low low flow in P-1102 A/B P/A Pumps
the pumps are stopped.

DUNG QUAT REFINERY
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UNIT CDU (011)
November 2008
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:1
Chapter : 3
Page
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Initiators:
Initiator Tag No.
Time
Delay
P&ID
No.
Cause
011-UX-007
101
CDU ESD
011-FXALL-060
0.5
seconds
113
low low flow in P-1102 A/B P/A

Pumps
Actions:
Action Tag No.
P&ID
No.
Service
P-1102A
113
Top P/A Pump stopped
P-1102B
113
Top P/A Pump stopped
011-FIC-011
113
Discharge flow controller set to manual and

output 0%
011-UXA-020B
113
Top P/A P-1102 A/B auxiliary console

3.1.2.11.
P-1104 A/B Pump Protection (011-UX-021)

a) CDU ESD or
b) a low low flow in the P-1104A/B discharge line
c) trip protection from MMS
Then, the pumps are stopped and auxiliary console ADP is activated.
Initiators:
Initiator Tag No.
Time
Delay
P&ID No.
011-UX-007
101
CDU ESD
011-FXALL-061
0.5
seconds
115
Low low flow in the discharge line

from the LGO P/A Pumps
011-UXS-093
0041-602
P-1104A trip protection from MMS
011-UXS-094
0041-602
P-1104B trip protection from MMS
Cause

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
November 2008
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:1
Chapter : 3
Page
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Actions:
Action Tag No.
P&ID No.
Service
P-1104A
115
LGO P/A Pump stopped
P-1104B
115
LGO P/A Pump stopped
011-FIC-016
115
LGO flow controller set to manual and output

0%
011-UXA-021B
115
P-1104A/B trip auxiliary console ADP

3.1.2.12.
P-1106 A/B Residue Pump Protection (011-UX-025)

Low-low level in the main fractionator
011-XV-001 P-1106 A/B suction valve closed less then 70%
011-UX-002 main fractionator inventory isolation trip
Trip pump protection from MMS
Then, the Residue Pumps P-1106 A/B are shutdown and auxiliary console ADP is activated.
Initiators:
Initiator Tag No.
Time
Delay
P&ID No.
Cause
011-LXALL-008
0.5
seconds
112
Low low level in T-1101 main

fractinator
011-XZSC-001
0.5
seconds
112
XV-001 P-1106 A/B suction valve

opened less than 70%
011-UX-002
109
T-1101
main
fractionator
inventory isolation trip
011-UXS-095
0041-602
P-1106A trip pump protection

from MMS
011-UXS-096
0041-602
P-1106B trip pump protection

from MMS

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
November 2008
Rev.
:1
Chapter : 3
Page
: 18/38
Actions:
Action Tag No.
P&ID No.
Service
P-1106 A
109
Residue Pumparound Pump Trip
P-1106 B
109
Residue Pumparound Pump Trip
UXA-025B
109
P-1106A/B trip auxiliary console ADP
011-FIC-064
125
Atmospheric residue to P-1101A/B flow

controller set to manual and output 0%
011-FQIC-029
125
Atmospheric residue to RFCC flow

011-FQIC-026
125
Atmospheric residue to storage flow

011-FQIC-027
125
Atmospheric residue to storage flow


3.1.2.13.
P-1107 A/B Kerosene product pump protection (011-UX-009)
Purpose: In the event of low-low level in the kerosene stripper T-1102, the kerosene product
pumps P-1107A/B are shutdown.
Initiators:
Initiator Tag No.
011-LXALL-010
Time
Delay
0.5
seconds
P&ID No.
Cause
114
Low-low level in the kerosene

stripper T-1102
Actions:
Action Tag No.
P&ID No.
Service
P-1107A
114
kerosene product pumps P-1107A tripped
P-1107B
114
kerosene product pumps P-1107B tripped
011-FQIC-033
129
Kerosene from P-1107A/B flow controller

set to manual and output 0%

3.1.2.14.
T-1101 Main fractionator inventory isolation (011-UX-002)

CDU emergency shutdown

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UNIT CDU (011)
November 2008
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Local inventory isolation pushbutton pressed.

011-XV-001 inventory isolation close pushbutton local pressed.
Low-low level in the main fractionator T-1101
011-XV-001 Close pushbutton local
011-XV-001 ESD from local panel.
Then, the shut off valve in the suction line is closed, the Atmospheric Residue product
pumps are stopped (via P-1106A/B Protection), the steam injection to T-1101 is stopped (via
T-1101 Protection) and the local panel trip alarm and T-1101 isolated auxiliary console
alarms are activated.
Initiators:
Initiator Tag No.
Time
Delay
P&ID No.
Cause
011-UX-007
101
CDU ESD
011-UXHS-002
112
Local
inventory
pushbutton
011-XHSC-001A
112
XV-001 inventory isolation close

pushbutton local
011-LXALL-008
0.5
seconds
112
Low-low level in main fractionator

column
011-XHSC-001B
112
XV-001 close pushbutton local
011-XHS-001B
112
ESD from local panel
isolation
Actions:
Action Tag No.
P&ID No.
Service
011-UX-025
109
P-1106A/B Protection tripped
011-XV-001
112
Atmospheric residue valve closed
011-UX-017
112
011-XXA-001
112
011-XV-001 Local panel trip alarm activated
011-UXA-002B
112
T-1101 isolated
activated
auxiliary

console
ADP

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
3.1.2.15.
November 2008
Rev.
:1
Chapter : 3
Page
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T-1101 Main fractionator Protection (11UX-017)
Purpose: In the event of any of the following

High High level in the Main fractionator T-1101 or
ESD trip signal or
T-1101 Inventory Isolation trip
Then, the superheated steam injection is stopped by closing the control valve.
Initiators:
Initiator Tag No.
Time
Delay
P&ID No.
Cause
011-UX-007
101
CDU ESD trip
011-LXAHH-078
0.5
seconds
112
High High level in T-1101.
112
T-1101 Inventory Isolation trip
011-UX-002
Actions:
Action
No.
Tag
P&ID No.
Service
011-FV-012
112
Steam flow control valve to T-1101
011-UXA017B
112
T-1101 steam closed auxiliary console ADP
Notes:
a) Trip is manually reset by 011-UHSR-017
3.1.2.16.
T-1103 LGO Stripper protection (011-UX-003)

High High level in the LGO Stripper T-1103 or
ESD trip signal
Initiators:
Initiator
Time
P&ID
Cause
Tag No.
Delay
No.
011-LXAHH-014
0.5
seconds
115
High High level in T-1103.
011-UX-007
101
CDU ESD trip

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November 2008
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Actions:
Action
No.
Tag
P&ID No.
Service
011-FV-017
115
Steam flow control valve to T-1103
011-UXA003B
115
T-1103 steam closed auxiliary console ADP

3.1.2.17.
T-1104 HGO Stripper protection (011-UX-004)

High High level in the HGO Stripper T-1103 or
ESD trip signal
Then, the superheated steam injection is stopped by closing the control valve.
Initiators:
Initiator
Time
P&ID
Cause
Tag No.
Delay
No.
011-LXAHH-017
0.5
seconds
116
High high level in T-1104.
011-UX-007
101
CDU ESD trip
Actions:
Action
P&ID No.
Service
FV-019
116
Superheated steam flow control valve closed
UXA-004B
116
T-1104 auxiliary console ADP
Tag No.

3.1.2.18.
T-1106 inlet valve closed (011-UX-040)
Purpose: In the event of low-low level in the HGO stripper T-1104 the inlet valve to T-1106
HGO Dryer is closed.

DUNG QUAT REFINERY
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UNIT CDU (011)
November 2008
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Initiators:
Initiator
Time
P&ID
Tag No.
Delay
No.
011-LXALL-052
0.5
seconds
116
Cause
Low low level in T-1104.
Actions:
Action
P&ID No.
Service
118
T-1106 HGO inlet valve closed
Tag No.
LV-022

3.1.2.19.
T-1105 inlet valve closed (011-UX-041)
Purpose: In the event of low-low level in the LGO stripper T-1103 the inlet valve to T-1105
LGO Dryer is closed.
Initiators:
Initiator
Time
P&ID
Tag No.
Delay
No.
011-LXALL-053
0.5
seconds
115
Cause
Actions:
Action
P&ID No.
Service
117
T-1105 LGO inlet valve closed
Tag No.
LV-019
3.1.2.20.
FV-040/041 full range naphtha outlet close valves (011-UX-042).
Purpose: In the event of low-low level in the stabilizer T-1107 the Full range naphtha outlet
valves to NHT and storage are closed.

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
November 2008
Rev.
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Initiators:
Initiator
Time
P&ID
Tag No.
Delay
No.
011-LXALL-054
0.5
seconds
130
Cause
Actions:
Action
P&ID No.
Service
FV-040
132
Full range naphtha

closed
FV-041
132
Full range naphtha flow control valve to Storage

closed
Tag No.
flow control valve to NHT

3.1.2.21.
P-1103A/B Kerosene P/A pump protection (011-UX-023)

CDU ESD trip signal or
Low-low flow in P-1103A/B discharge
Then, the Kerosene P/A pumps are shutdown.
Initiators:
Initiator
Time
P&ID
Cause
Tag No.
Delay
No.
011-UX-007
101
CDU ESD trip
011-FXALL-063
0.5
seconds
103
Low-low flow
discharge
Actions:
Action Tag
No.
P&ID No.
Service
P-1103 A
103
Kerosene P/A P-1103A tripped
P-1103 B
103
Kerosene P/A P-1103B tripped
in
P-1103A/B

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UNIT CDU (011)
November 2008
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Action Tag
No.
P&ID No.
Service
FIC-013
103
Kerosene P/A flow control set to manual and

output 0%
3.1.2.22.
P-1105A/B HGO P/A pump protection (011-UX-022)

CDU ESD trip signal or
Low-low flow in P-1105A/B HGO P/A discharge
Then, the HGO P/A is shutdown
Initiators:
Initiator
Time
P&ID
Cause
Tag No.
Delay
No.
011-UX-007
101
CDU ESD trip
011-FXALL-062
0.5
seconds
116
Low-low flow
discharge.
in
P-1105A/B
Actions:
Action
P&ID No.
Service
P-1105 A
116
HGO P/A P-1105A tripped
P-1105 B
116
HGO P/A P-1105B tripped
FIC-018
116
HGO flow controller set to manual and output

0%
Tag No.
3.1.2.23.
P-1119 A/B Desalter charge pumps protection (011-UX-008)
Purpose: When there is a low low level in the Desalter water surge drum D-1109 or on a
trip signal from the Desalter Protection, the desalter water pumps are stopped.

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
November 2008
Rev.
:1
Chapter : 3
Page
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Initiators:
Initiator Tag No.
Time
Delay
P&ID No.
Cause
011-LXALL-026
0.5
seconds
119
Low low level in D-1109.
011-UX-001
104
Desalter protection trip
Actions:
Action
No.
Tag
P&ID No.
Service
P-1119A
119
Desalter Water pump P-1119 A tripped
P-1119B
119
Desalter Water pump P-1119 B tripped
011-FIC-021
104
Desalter water flow controller set to manual

and output 0%

3.1.2.24.
P-1118 A/B Desalter water recycle pumps protection (011-UX-018)
Purpose: In the event of:

UX-001 Desalter Protection trip or
Low low outlet flow from P-1118A/B to FIC-004 and FIC-005.
Then, the Desalter Water Recycle Pumps P-1118A/B are shutdown.
Initiators:
Initiator
Time
P&ID
Cause
Tag No.
Delay
No.
011-UX-001
104
011-FXALL056
0.5
seconds
104
Low low flow to A-1101-D-01 and Low

low flow to E-1101/E-1102
011-FXALL057
Actions:
Action Tag No.
P&ID
No.
Service
P-1118A
104
Desalter Water Recycle Pump tripped
P-1118B
104
Desalter Water Recycle Pump tripped

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OPERATING MANUAL
UNIT CDU (011)
November 2008
Rev.
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Chapter : 3
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Action Tag No.
P&ID
No.
Service
011-FIC-004
104
Flow controller on line to A-1101-D-01 set to

Manual with 0% output
011-FIC-005
104
Flow controller on line to E-1101 and E-1102

set to Manual with 0% output

3.1.2.25.
P-1114 A/B stabilizer reflux and P-1115A/B stabilizer LPG pumps protection
(011-UX-006)
D-1104 Inventory Isolation (UX-026)
Low low level in the stabiliser accumulator drum D-1104
Pump suction isolation valve not open
Then, all running pumps are stopped.
Initiators
Initiator Tag No.
Time
Delay
P&ID
No.
Cause
011-UX-026
131
D-1104 Inventory Isolation trip
011-LXALL-048
0.5
seconds
131
011-XZSC-002
131
Valve 011-XV-002 open less than

70%
Actions:
Action Tag No.
P&ID No.
Service
P-1114A
130
Stabiliser Reflux Pump stopped
P-1114B
130
Stabiliser Reflux Pump stopped
P-1115A
131
Stabiliser LPG Pump stopped
P-1115B
131
Stabiliser LPG Pump stopped
011-FIC-036
130
Satabilizer Reflux flow controller set to manual

and output of 0%
011-FQIC-037
131
LPG product to RFCC flow controller set to

manual and output of 0%

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UNIT CDU (011)
November 2008
Rev.
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Action Tag No.
P&ID No.
Service
011-LIC-050
131
Sour water level controller set to manual and

output of 0%

3.1.2.26. Main Fractionator accumulator drum water outlet valve LV-040 close
(011 -UX-014)
Purpose: When there is a low low level in the Overheads accumulator D-1103, the LV-040
valve is closed.
Initiators:
Initiator Tag No.
Time
Delay
P&ID No.
Cause
011-LXALL-033
5
seconds
128
Actions:
Action
No.
LV-040
Tag
P&ID No.
Service
128
Water D-1103 outlet valve close

3.1.2.27.
P-1113A/B HGO product pumps protection (011-UX-010)
Purpose: When there is a low low level in the HGO Drier T-1106(or if T-1106 is by-passed,
there is a low low level in the HGO Stripper T-1104), the HGO product pumps are stopped.
Initiators:
Initiator Tag No.
011-LXALL-023
OR 011-LXALL081 as selected
by 011-UHS-010
Time
Delay
0.5
seconds
P&ID No.
Cause
118
116
Low low level in T-1104

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UNIT CDU (011)
November 2008
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Actions:
Action Tag No.
P&ID No.
Service
P-1113A
118
HGO product pump stopped
P-1113B
118
HGO product pump stopped
011-FQIC-028
127
HGO flow controller set to manual and output

0%

3.1.2.28.
P-1112A/B LGO product pumps protection (011-UX-012)
Purpose: When there is a low low level in the LGO Drier T-1105 (or if T-1105 is by-passed,
there is a low low level in the LGO Stripper), then the LGO product pumps are stopped
Initiators:
Time
Delay
Initiator Tag No.

011-LXALL-020
or
011-LXALL080 as selected
by 011-UHS-112
0.5
seconds
P&ID No.
Cause
117
115
Low low level in T-1103
Actions:
Action Tag No.
P&ID No.
Service
P-1112A
117
LGO product pump stopped
P-1112B
117
LGO product pump stopped
011-FQIC-020
117
LGO flow controller set to manual and output

of 0%

3.1.2.29.
P-1113A/B Stabilizer feed pumps protection (011-UX-013)
Purpose: When there is a low low level in the main fractionator accumulator drum D-1103,
the stabilizer feed pumps are stopped.
Initiators:
Initiator
Time
P&ID
Tag No.
Delay
No.
011-LXALL-039
5
seconds
128
Cause

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UNIT CDU (011)
November 2008
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Actions:
Action
No.
Tag
P&ID No.
Service
P-1110A
128
Stabilizer feed pump stopped
P-1110B
128
Stabilizer feed pump stopped
011-FIC-032
128
Stabilizer feed flow controller set to manual

and output 0%
Notes:
a) Trip is manually reset by 011-UHSR-013.
3.1.2.30.
P-1120A/B Drier slop pumps protection (011-UX-015)
Purpose: When there is a low low level in the drier accumulator drum D-1106 Slop oil
partition, the slop pumps are stopped.
Initiators:
Initiator Tag No.
Time
Delay
P&ID No.
Cause
011-LXALL-030
0.5
seconds
123
Low low level in D-1106 (Slop)
Actions:
Action
No.
Tag
P&ID No.
Service
P-1120A
124
Slop pump stopped
P-1120B
124
Slop pump stopped

3.1.2.31.
P-1121A/B Ejector condensate pumps protection (011-UX-016)
Purpose: When there is a low low level in the drier accumulator drum D-1106 water
partition, the water pumps are stopped.
Initiators:
Initiator Tag No.
Time
Delay
P&ID No.
Cause
011-LXALL-031
0.5
seconds
123
Low low level in D-1106 (Water).

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UNIT CDU (011)
November 2008
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Actions:
Action
No.
Tag
P&ID No.
Service
P-1121A
124
Water pump stopped
P-1121B
124
Water pump stopped
011-FIC-025
124
Condensate flow controller set to manual and

output 0%

3.1.2.32.
P-1122A/B Tempered water pumps protection (011-UX-024)
Purpose: When there is a low low level in the Tempered Water Drum D-1115, the
Tempered Water Pumps are stopped.
Initiators:
Initiator Tag No.
Time
Delay
P&ID No.
Cause
011-LXALL-069
0.5
seconds
126
Low low level in D-1115 (Water)
Actions:
Action
No.
Tag
P&ID No.
Service
P-1122A
126
Tempered Water pump stopped
P-1122B
126
Tempered Water pump stopped
011-FIC-030
126
Tempered Water flow controller set to

manual and output 0%

3.1.2.33.
H-1101 Purge and Start-up sequence (011-UX-047 to 051)
For detail description of Heater purge, pilot gas, fuel gas, fuel oil and off gas ignition
sequences refer to the following drawing 8474L-011-A3501-0110-001-003, which has been
included in attachment 2.
3.2.
OPERATING CONDITIONS
Refer to Process Flow Diagrams, which have been listed in 14.2 Process Flow Diagrams and
Material Selection Diagrams, included in attachment 6.
3.3.
PROCESS VARIABLES
This purpose of this chapter is to explain the main variables in Unit control.
The variables described are: CDU feed rate, fired heater outlet temperature, main
fractionator overhead temperature, pumparounds duty and stabilizer bottom temperature.

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UNIT CDU (011)
3.3.1.
November 2008
Rev.
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Chapter : 3
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CDU feed rate
The unit is fed by the crude charge pumps in unit 60. The crude oil flows through the cold
preheat train and enters into the desalter. In order to keep constant the desalter pressure,
the crude oil flow at the crude charge pumps is set to the same flow as the measure at the
fired heaters (011-FIC-069), by the controllers 011-FY-092 and 011-HY-002.
If the pressure in the desalter increases the inlet flow from crude charge pumps will be
reduced.
3.3.2.
Fired heater outlet temperature
This variable is very important, due to the fact that the column overflash is highly dependent
of this temperature. If an increase in duty is required, the air flow is increased before the fuel
rate is increased. On the other hand, if a decrease in heater duty is required, fuel flow rate is
firstly reduced and secondly air flow rate is reduced. This control scheme ensures that the
fired heater is always operating with an air excess, to ensure a good combustion and avoid
risk of after burning in the stack.
3.3.3.
Main fractionator overhead temperature
The overhead vapour temperature is controlled by the amount of heat removed from the top
pumparound circuit. This temperature is important because the overhead product naphtha
end point can be adjusted by changing the set point. If the temperature is higher than the set
point, the top reflux duty will increase. As a result the overhead product end point and
quantity will be reduced. On the other hand, if the temperature is lower than its set point, the
overhead product end point is lower than it should be and the control system will decrease
the top pumparound duty. So, if an increase in the overhead vapour product end point and
quantity is desired, the top pumparound temperature set point will be increased.
3.3.4.
Main fractionator pressure.
The column operating pressure depends on the pressure controlled at the main fractionator
accumulator drum D-1103. The operating pressure of a distillation column is related with the
relative volatility of the components to be separated in the different streams. Relative
volatility is a measure of the differences in volatility between 2 components, and hence their
boiling points. It indicates how easy or difficult a particular separation will be. As pressure
increases the relative volatility approaches to one. This means that the vapour pressure
characteristics of the components are more similar, and therefore they are more difficult to
be separated.
In addition, if the remaining variables keep constant, an increase in the column pressure will
decrease the overflash and therefore the internal column flow and the separation achieve will
be lower.
3.3.5.
Pumparounds.
Pumparounds must be well controlled to obtain specific products. Pumparound duty control
is essential to keep internal liquid and vapour flow inside the column. The control is acting on
the recycled product flow to the column, and on the total pumparound duty (through duty
controller).
Pumparounds are critical to maintain the optimum vapour/liquid rates in the fractionation of
the column. Inadequate pumparound heat removal and poor pumparound distribution will
result in higher column pressure, poorer fractionation and an increase in the flash zone
pressure. Excessive pumparound heat removal may result in difficulties in maintaining some
end point and may cause internal flooding.

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UNIT CDU (011)
3.3.6.
November 2008
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Specification Adjustement.
The principal specifications to which the products from the fractionator can be adjusted are
the boiling point ranges and the flash point. In general, if the fractionation is good, the end
boiling point of a side-cut equals the initial-point of the next heavier product plus a gap. A
gap is the result of a good fractionation; however overlap is more normal and will increase as
fractionation efficiency decrease. Product withdrawal flow rate are adjusted to provide the
required end points for the products and are generally set up from the top of the column
working down.
As a general rule, increasing the drawoff rate will raise the end point of the side stream cut
whilst decreasing the drawoff rate will lower its end point. An indication of the end point is the
draw off temperature of the stream leaving the column. Increasing the product withdrawn,
increases the draw off temperature and the product end point
The flash point of LGO, and HGO products can be modified by adjusting the flow of stripping
steam via, FIC-017 and FIC-019 respectively (to increase the flashpoint the stripping steam
has to be increased). However, the stripping steam can only be increased to the point where
it starts to interfere with the end point of the next higher product. If a further increase in the
flashpoint is required, other changes must be made, allowing an increase of the end point of
the next higher product.
Kerosene flash point can be adjusted by the kerosene stripper reboiler E-1110 duty via 011UIC-031 or, in case reboiler E-1110 is out of service, with steam flow via 011-FIC-015.
The specific gravity is directly related to initial and final product boiling point, so changing the
products yields is required to achieve this specification.
The freeze point is related to chemical composition of the product. As final boiling point
increases, the paraffin content in the product increases too, so the freeze point obtained will
be higher.
If residue entrainment occurs HGO can get black colour. This means that the washing
section (between HGO draw off tray and flash zone) doesnt have enough liquid flow. It is
necessary to increase the overflash or reducing the HGO draw off rate.
3.3.7.
Stripping Steam in the Main fractionator column.
Increasing this flow rate, it is possible to decrease the content of lighter fractions still present
in the residue, increasing flash point and the initial boiling point of the residue. The stripping
steam flow, controlled by 011-FV-012 will affect temperature of the flash zone and amount of
overflash.
3.3.8.
Overflash
Overflash is that portion of the feed which is vaporized in addition to the overhead and
sidestream products. The overflash condenses on the wash section plates and returns to the
flash zone and bottoms stripping section. Its purpose is to prevent coke deposition in the
wash section plates and preventing entrainment of residue up into HGO section, which
would result in off spec HGO.
The CDU is designed for a minimum of 5% overflash.
3.3.9.
Stabilizer temperature
-
The stabilizer bottom temperature has to be controlled in order to maintain the C4

specification in this stream. This control is a cascade loop in which the stabilizer bottom
temperature is controlled by the high pressure steam flow through the desuperheater (DS1101). If the bottom temperature decreases, the amount of high pressure steam will
increase, and therefore the reboiler duty, in order to raise the temperature again.

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UNIT CDU (011)
November 2008
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The temperature in the top section at constant pressure defines the quality of the LPG
product; this temperature is controlled on E-1122 (auto variable pitch controller). Settling this
control at a lower temperature will decrease LPG C5 content and will increase the tower
reflux. Increasing this temperature will increase quantity and C5 content in the LPG and will
reduce the reflux rate.
3.4.
INTER-UNIT CONTROL SCHEME

3.4.1.
Atmospheric Residue from the CDU to the RFCC
3.4.1.1.
Objective
The objective of this system is to control the level in the bottom of the Main Fractionator
column and route as much of the outgoing atmospheric residue to the RFCC as is required
3.4.1.2.
Description
This description should be read in conjunction with the following:
CDU P&IDs:
-
8474L-011-PID-0021-112
8474L-011-PID-0021-125
RFCC P&IDs:
-
8474L-015-PID-0021-301
Schematic 1: Atmospheric residue from CDU to RFCC
The level in the Main Fractionator, T-1101 is controlled by a typical Xxx40 three way split
range level controller 011-LIC-007 (direct acting). In the low range (0-33%) the signal from
011-LIC-007 goes to low selector 011-LY-007B, which selects between 011-LIC-007 and the
feed requirement of the RFCC to control the flow to the RFCC. In the mid range (33-67%)
011-LIC-007 resets the set point of 011-FQIC-026 and in the high range (67-100%) 011-LIC007 resets the set point of 011-FQIC-027.
011-FQIC-026 and 011-FQIC-027 are parallel controllers used to regulate the flow of residue
to storage. 011-FV-026 is a smaller valve than 011-FV-027 and will normally be sufficient to
control the amount of residue to storage whilst the RFCC is on-line. In the event that the
RFCC is off-line then 011-FQIC-026 will be fully open and 011-FQIC-027 will control the flow
to storage.
The RFCC feed is controlled by a split range level controller, which takes flow preferentially
from the CDU by cascading onto 011-FQIC-029 via 011-LY-007B. If there is not enough
flow coming from the CDU then flow is taken from storage by acting on a flow controller FIC402 in the line from storage.

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UNIT CDU (011)
November 2008
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BL
33-67%
LY
007A
0-100%
67-100%
LY
007C
0-100%
SP
TK-5103
FQIC
026
E-1120 A-D
SP
FQIC
027
P-1503 A/B
T-1101
LIC
007
<
0-33 %
LY
0-100%
082
LY
007B
FIC
402
SP
FQIC
029
B.L
0-100 %
FQI
401
LY
402A
LY
402B
50-100%
0-50 %
SPLIT
RANGE
LIC
402
E-1101 A-H
CDU (U-011)
D-1513
RFCC (U-015)
Schematic 1: Atmospheric residue from CDU to RFCC

3.4.2.
Full Range Naphtha from the CDU to the NHT
3.4.2.1.
Objective
To control the level of the Stabilizer T-1107, and route as much of the outgoing full range
naphtha to the NHT as is required.
3.4.2.2.
Description
CDU P&IDs:
-
8474L-011-PID-0021-130
8474L-011-PID-0021-132
NHT P&ID:
-
8474L-012-PID-0021-011
Schematic 2: Full range Naphtha from CDU to NHT
Control of level in T-1107 is by split range controller 011-LIC-042 (direct acting). In the low
range, 011-LIC-042 acts on 011-FQIC-040 through low selector 011-LY-045 to control the
flowrate to the NHT. In the high range, 011-LIC-042 acts on the rundown of full range
naphtha to storage. Low selector 011-LY-045 is used to select between T-1107 level
controller output and the full range naphtha requirement of the NHT from 012-PIC-001. The
output from 012-PIC-001 (reverse acting) is split range. In the low range naphtha is taken
from the CDU via 011-LY-045 and in the high range naphtha is taken from storage by acting
on 012-FIC-001.

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UNIT CDU (011)
November 2008
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BL
50-100%
LIC
042
0-100%
LY
046
TK-5112
FQIC
041
SPLIT
RANGE
T-1107
0-50 %
LY
044
P-1512 A/B
FIC
001
<
LY
0-100%
045
B.L
0-100 %
FQIC
040
LY
004A
LY
004B
SPLIT RANGE
0-50 %
50-100%
PIC
001
D-1201
E-1127
CDU (U-011)
NHT (U-012)
Schematic 2: Full range Naphtha from CDU to NHT

3.4.3.
LCO HDT feed control
3.4.3.1.
Objective
The objective of this system is control the level of the Feed Surge Drum, D-2401, in case of
RFCC Max Gasoline Operation, i.e. when feed to LCO HDT Unit, as defined by the Licensor,
shall consist of LCO from RFCC Unit (and potentially LCO Storage), HGO and potentially
LGO from CDU Unit
3.4.3.2.
Description
CDU P&IDs:
-
8474L-011-PID-0021-117
8474L-011-PID-0021-127
LCO HDT P&ID:

-
RFCC P&ID:
-
8474L-024-PID-0021-111
8474L-015-PID-0021-328
Schematic 3: LGO / HGO from CDU to LCO HDT and storage
In case of RFCC Max Gasoline Operation, feed to LCO HDT shall consist of:
LCO from RFCC Unit (flow-controlled within RFCC)
HGO from CDU Unit, under flow control 024-FIC-002
Potentially LGO from CDU Unit, under flow control 024-FIC-003
Potentially LCO from storage tank TK-5111, under flow control 024-FIC-001 which
controls the flow rate of LCO from storage that shall be limited to 25% of unit throughput
Selector 024-HS-003 is switched to enable the reverse action of the D-2401 level controller
024-LIC-002 onto controllers 024-FIC-002 and 024-FIC-003, through the calculation module

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UNIT CDU (011)
November 2008
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024-FY-007, therefore adjusting the flow of feeds from CDU Units (HGO and LGO) in the
target ratio.
Total LGO flow, from the CDU to both the LCO HDT and Refinery storage, is controlled at a
constant value by the action of a flow calculator that resets the set point of 011-FQIC-020 by
subtracting the flow of LGO to the LCO HDT (024-FIC-003) from the operator input.
Similarly, total HGO flow, from the CDU to both the LCO HDT and Refinery storage, is
controlled at a constant value by the action of a flow calculator that resets the set point of
011-FQIC-028 by subtracting the flow of HGO to the LCO HDT (024-FIC-002) from the
operator input.
BL
TK-5111
FIC
472
FQIC
LCO
FROM
T-1503
P-5111 A/B
B.L
FIC
001
RFCC (UNIT 015)

FY
007
HIC
115
FY
FIC
003
038
LGO
FROM
E-1116
D-2401
HS
003
LIC
002
FQIC
020
FIC
005
LGO
TO TK-5115
HIC
007
FY
GASOIL TO
E-2402A
FIC
002
039
P-2401 A/B
HGO
FROM
E-1119
FQIC
028
HGO
TO TK-5109
CDU
(U-011)
LGO HDT
(U-024)
Schematic 3: LGO / HGO from CDU to LCO HDT and storage

3.4.4.
Stripped water from the SWS to the CDU
3.4.4.1.
Objective
To control the level of the Sour Water Stripper, T-1801, and route as much of the outgoing
stripped water to the CDU as it requires.
3.4.4.2.
Description
CDU P&IDs:
-
8474L-011-PID-0021-119
8474L-011-PID-0021-123
8474L-011-PID-0021-124
SWS P&IDs:

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8474L-018-PID-0021-113
Schematic 4: Stripped water from SWS to CDU
Control of level in T-1801 is by split range controller 018-LIC-009 (direct acting). In the low
range, 018-LIC-009 acts on 011-LV-025A through 018-LY-009A and low selector
011-LY-025D to control the flowrate to the CDU. Low selector 011-LY-025D is used to select
between T-1801 level controller output and the requirement for water from the level
controller, 011-LIC-025, on the Desalter Water Surge Drum D-1109. In the high range,
018-LIC-009 acts on the control valve through LY-009B in the rundown to effluent treatment.
Control of level in D-1109 is by split range controller 011-LIC-025 (reverse acting). In the low
range 011-LIC-025 acts on the control valve in the line from the Drier Oil/Water Separator
Drum D-1106, via low select 011-FY-025, which restricts the maximum flow to that set by
011-FIC-025. In the middle range 011-LIC-025 controls the flow from the SWS as described
in the paragraph above. In the high range, 011-LIC-025 opens the control valve on the
service water supply trough 011-LY-025B.
B.L
LIC
029
<
D-1106
FIC
FY
025
025
HIC
025
0-100 %
P-1121 A/B
LY
025C
0-100 %
LY
009A
<
LY
025D
0-50 %
T-1801
D-1109
0-33%
LIC
SPLIT
RANGE
SPLIT
RANGE
33-67%
LY
009
025A
67-100%
50-100%
LY
025B
SERVICE
WATER
SUPPLY
LY
009B
TO EFFLUENT
TREATMENT
SWS
(UNIT 018)
CDU
(UNIT 011)
Schematic 4: Stripped water from SWS to CDU
LIC
025

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UNINTERRUPTIBLE POWER SUPPLY

The 230VAC UPS Power supply required for Instrumentation / Telecom equipment is
distributed from separate Power Distributed Boards (PDB) located in nearby Instrument
Technical building /Control Room. Two different UPS supplies are distributed depending on
the requirements: hour for normal process requirement or 4 hours battery back-up for
Safety and Emergency Telecommunication devices.
These Instrument Power distribution cabinets (PDB) include the distribution for 230VAC UPS
( hour and 4 hours back-up), 230VAC Non-UPS and 230VAC Emergency supply for both
Instrument /Telecom equipment in the technical building and field devices, as required.
The following vendor drawing provides a detailed distribution and list of all consumers, UPS
and non UPS:
8474L-500-A3404-1521-004-024
The Power distribution cabinets shall not be powered with all the loads in on position. This
means that the power to each consumer shall be switched on individually.
The following sequence shall be followed before startup of these Power Distribution
cabinets:
-
Ensure that all incoming and outgoing feeders are isolated, i.e switch off all MCBs
/Isolators.
Switch on the main outgoing feeders one by one at Electrical distribution panel in
Substation or from other Instrument PDB from which these Power distribution
cabinets receive the incomers.
At the Instrument PDB cabinet, switch on the main incomers Power distribution
cabinets one by one and check on the Voltmeters on the front of the cabinet.
The individual feeders/MCBs to each Instrument / Telecom consumer shall be

switched on one by one as required.
Alarm to DCS (Fuse Blown alarm):

To facilitate maintenance, Each Power distribution cabinet is provided with one common
alarm to DCS, which is activated when any of the Main Incoming feeder Fuses are blown.
3.6.
COMPLEX CONTROL DESCRIPTION

For further information refer to the following project document, 8474L-011-SP-1511-101
Control Narrative.

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UTILITY, CHEMICAL AND CATALYST REQUIREMENTS
4.1. FUEL
Refer to Estimated Utility Consumption 8474L-011-CN-0003-001 / 002 included in
attachment 1.
4.2. STEAM
attachment 1.
4.3. ELECTRICAL POWER
attachment 1.
4.4. COOLING WATER
attachment 1.
4.5. WATER
attachment 1.
4.6. NITROGEN
attachment 1.
4.7. PLANT AND INSTRUMENT AIR
attachment 1.
4.8. CHEMICALS
Refer to point 2.1.8 Chemical Package for chemical consumption.
4.9. CHEMICAL HANDLING
Refer to Chemicals MSDS.

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PREPARATION FOR INITIAL START-UP

All operations required for initial Start-up (except for heater dry-out), included bellow, have
been described on the general Precommissioning Manual: 8474L-000-PP-903. Document
number to be confirmed later.
5.1. PLANT CHECK-OUT

5.2. LINE FLUSHING
5.3. WATER CIRCULATION
2
5.4. LEAK TEST (AT 8 KG/CM )

5.5. H-1101 HEATER DRY-OUT
For heater dry-out procedure refers to the following project document: 8474L-011-B11030110-001-001.
5.6. CHEMICAL CLEANING

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6.
NORMAL START-UP
6.1.
SUMMARY OF START-UP
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The following highlights the usual steps to follow during a normal start-up of the
Crude Distillation Unit.
6.2.
Inform all concerned of the proposed time of start-up.
Purge and inert the unit as is indicated in the section 6.3 Purging and Inerting.
By pass the desalters by means of opening locked closed valves in lines PL110104 and PL-110105, and the crude booster pumps (P-1101 A/B) by means
of opening the line PL-110111. Key Interlock 011-SP-815 prevents of mistakes
on this operation since pump suction will be blocked whenever both desalters
are by-passed.
Charge the unit with straight run (SR) flushing oil as far as the Main
Fractionator bottoms, T-1101, until normal column base level is established.
With the Residue Pump P-1106 A/B, charge the Main Fractionator draw off
trays and pumparounds with flushing oil (through the line PL-110073).
With the residue pump, P-1106 A or B, circulate the SR flushing oil from the T1101 bottoms back to the crude tankage (by means of the crude recirculation
header). Allow the unit to stand with flushing oil for about three hours while
draining water from low points.
Heating up of the Unit as in indicated in the Section 6.5
When all main fractionator T-1101, and stabilizer T-1107 products, are on
specification, route them to the designated units or their appropriated tankage.
When all the products are correctly routed, gradually increase the crude charge
rate to the required rate.
FINAL PREPARATIONS
The final preparations described here are to be carried out from the point where
the plant is cold, air is in the plant equipment and piping and all the battery limit of
the unit remains blinded and also at the in plant refinery fuel oil and fuel gas
locations
Prior to the final preparations, all preliminary checks will have been carried out for
commissioning or a start-up following turnaround. Other start-ups from cold will
incorporate preliminary checks as applicable.
The preliminary checks for a production start-up are:
1. All concerned have been informed of the proposed time of start-up.
2. All vessels internals are installed, gasketed, and any internal tests carried out
properly.
3. All lines and equipment have been cleaned out and all flanges and manways
are bolted up with the correct gaskets, and equipment blinds removed or swung
open.
4. Strainers are installed where required and orientated correctly. Temporary fine
mesh strainers are installed for initial operation.
5. Orifice plates; tab diameters checked against data sheets and oriented properly
6. All control valves have correct flow orientations and have been stroked and left
closed on manual. Their by-passes checked as tightly shut-off.

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7. All checked valve orientations are signed off as correct

8. All instruments and analyzers have been calibrated and are ready for use
9. All rotating machine has been run, has correct lubrication inventories
established, has been aligned, has had rotation direction checked and guards
securely installed
10. Relief valves (systems) shop certified and installed with seals, chained
open/close valves, and interlocking open/close devices checked for correctness
per check list. Blinds and restrainers removed per check list.
11. Unit drains and vents not required for start-up purging or draining have been
checked as capped, plugged or blinded.
12. Dampers, air registers, etc. have been checked for easy movement.
13. All utility services are available at the battery limit. All relief, slops and drainage
systems are ready for use, and the main flare has been commissioned.
14. The unit has been checked free of all debris, scaffolding, planking, etc.
especially at the upper levels and on air cooler tubes.
15. All alarm circuits have been checked and are ready for use
16. Emergency shut-off valves have been tripped and reset twice.
17. Fire fighting, safety equipment and gas detectors checked for operability and
completeness.
18. Note refractory will be cured and dried out as necessary during initial heat up of
the furnace
Once these points have been checked, final preparations can be accomplished:
Remove or swing blinds to normal operating positions at battery limit lines
Make a final check to remove or swing out of use any isolation blinds at unit
equipment or in lines, except for heater fuel gas and fuel oil lines. Check
distance spools are made up or disconnected per check list. Recheck all
relief systems are in an operable position, any upstream and downstream
isolation blinds removed, and where double relief valve arrangement exists that
the installed valve in the system has its isolation valves in the locked open
position.
Commission all utilities.
Establish start-up steam flow to the steam superheated coil in the convection
bank, and vent to atmosphere through the heater steam silencer SL-1101.
Steam inlet to T-1101 and lateral strippers (T-1102, T-1103 and T-1104)
remains blocked and vents located downstream check valves will be opened
on each tower.
Charge the tempered water circulation system by filling first D-1115 (which has
to be previously filled with nitrogen) with BFW (up to an appropriate level) and
then initiate circulation via starting P-1122 A or B when pressure in vessel is
checked correct. Prior to start the pump, ensure that Pressure controller has
been put on automatic.
Charge the desalter water charge drum, D-1109, with service water via the
supply line: SW-116605.
Establish steam tracing.

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PURGING AND INERTING

The plant must be purged of air until the oxygen content is below 0.5 % in volume
before hydrocarbons may be safely introduced.
For the CDU unit, the procedure to achieve this objective is as follows:
6.4.
Open the Battery Limit Nitrogen valve and sweep or pressure/depressure

sections of the unit which will be purged with nitrogen.
Withdraw the fuses and lock off the power supply to the Desalter.
Displace air from the Desalters, A-1101-D-01 and D-02, by filling them with
water or nitrogen according to vendors operating manual (8474L-011-A50160814-001-002).
Steam purge the remaining oil pipework, exchangers, passes through the
Crude Charge Heater, H-1101, and the main Fractionator, T-1101, until all air
is displaced, draining regularly condensate from low points.
Close all low point condensate drains, close all steam vents, open up nitrogen
and then isolate steam injection points in quick succession. Nitrogen will
replace the condensing steam.
Maintain positive pressure at all times and periodically drain condensate.
HEATER START-UP
For crude charge heater H-1101 Start-up, follow the procedure developed by
vendor (8474L-011-A3501-0110-001-003).This procedure, describes the steps for
a safe heater purge, pilots and burners ignition. It has to be used together with the
Start-up P&ID: 8474L-011-A0103-001-002. These documents have been included
in attachment 2.
6.5.
HEATING UP
In this section some references are made to short, intermediate and long path on
the unit. For better comprehension of the start-up procedures, a marked copy of
the affected P&IDs is attached showing the sections referred as short,
intermediate and long path. These drawings have been included in attachment 2.
The following steps must be followed in order to increase the temperature within
the unit:
1.- Start the flow of LP steam through the superheater coil . The stream
inlets to the main fractionator, T-1101, and to the strippers, T1102/1103/1104, shall be closed and steam vent to the atmosphere (via
heater steam silencer SL-1101) shall be opened.
2.- With the residue pump P-1106 A/B, establish the circulation at minimum
pump rate of SR flushing oil from the T-1101 bottoms to the heater inlet,
and back to the T-1101, via short path (through the recirculation line 6-PL110072-B1AP-PP). Light all the H-1101 pilots, and some furnace burners
to gradually increase the circulating oil temperature to about 100C (before
starting H1101, override BSL 501-508 and BSL 509-516, reset the ESD
level). This temperature to be monitored by simultaneous reading on DCS
screen of the 011-TI-224 to 011-TI-231 and by 011-TIC-070. For details
refer to the charge heater start-up procedure (8474L-011-A3501-0110-001003).
3.- While maintaining the same circulation rate, divert the SR flushing oil
gradually to the battery limit and from unit battery limit to upstream of E1101 A-H and E-1102 via long path, (through the recirculation line 6-PL-

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110066-B1AP-ST2) maintaining 100C maximum at the heater outlet.

Continue bypassing the desalters and the crude booster pumps, P-1101
A/B.
4.- Introduce crude oil at the minimum rate into the preheat train (with the
desalters and crude booster pump bypassed) displacing the SR flushing oil
back to the crude tankage through the lines PL-110063 and PL-110122
(crude recirculation header).
5.- Continue long path circulation with the crude oil.
6.- When the crude preheat train is at about 100C, revert to short path
circulation and gradually raise the heater outlet temperature up to 270C
maximum. Then, switch to intermediate path, maintaining heater outlet
temperature at 270 C. All burners will require to be lighted prior to
increase the temperature to 270C.
7.- Start pumparounds: P-1102 A or B (top p/a) and air-cooler E-1112, P1103 A or B (kerosene p/a), P-1104 A or B (LGO p/a), P-1105 A or B
(HGO p/a) as levels build up on the draw off trays.
8.- If the heater refractory has not been dried out (see point 5.5 for heater
refractory dry-out procedure) during the initial start-up while circulating with
crude oil, gradually rise the heater temperature and dry out and cure the
refractory as necessary. Heater manufacturers instructions are described
in the 8474L-011-B1103-0110-001-001, included in attachment 2. Cool
down the heater for refractory inspection. Stop the crude oil recirculation by
stopping the reside pumps P-1106 A or B. Cut the steam to the H-1101
heater coil.
9.- Reduce, then stop the intermediate path circulation and restart the fresh
crude oil circulation.
10.- Start top Air-cooler E-1111.
11.- As levels increase:

o
Route the fractionator overhead naphtha to upstream E-1127

through start-up line PL-110640, by means of P-1110 A (or B),
and route stabilizer bottom product to the tankage via
recirculation crude header
As level increases on lateral strippers, initially route the LGO

and HGO to the pumps P-1112 A / B and P-1113 A / B,
respectively, through dryer bypass lines LGO-110227 and
HGO-110191. Then, route the drier off gas to flare and start
Medium pressure steam to vacuum package in order to initiate
the LGO and HGO dryers, T-1105 and T-1106.
Route the fractionator overhead vapour to flare initially. 011PIC-064 shall be put into manual mode and by-pass valve of
011-PV-064C shall be fully opened.
All other fractionator liquid products to combined slops and

then to crude tankage via crude recirculation header.
12.- Start injection of corrosion inhibitor into the top pumparound return
and into the fractionator overhead.
13.- Commission the first desalter, A-1101-D-01 and proceed to fill it with
crude, following the instructions given by the desalter vendor on its

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operations and maintenance manual: 8474L-011-A5016-0814-001-001

included in attachment 2.
14.- Then commission both crude booster pumps, P-1101 A and B.

following the below steps:
o
Ensure Spill back line PL-110504 is opened.
Ensure desalter pressure controller is commissioned
Ensure that by-pass around the crude booster pump is lined up.
Open at 25% gate valve placed at P-1101 discharge line.
Start pump.
Open completely the discharge valve.
15.- Start injection of superheated steam into the T-1101. In order to

prevent the entrance of wet steam to the T-1101, prior to open the inlet
valve, low point drain and 4 vent valve will remains opened until all the
steam condensate have been removed from the line and line work is at
superheated steam temperature.
16.- Raise the heater outlet temperature gradually to the operating

temperature.
17.- Establish liquid levels in the kerosene (T-1102), LGO (T-1103) and
HGO (T-1104) strippers.
18.- Start injection of superheated steam to the strippers, T-1102/1103 and

T-1104. Prior to opening the steam inlet valve, open the low point
drainages and vents to ensure that no wet steam will be introduced on the
strippers, once lines work is at superheated steam temperature
19.- Commission the respective LGO (T-1105) and HGO (T-1106) dryers
and line up with the LGO and HGO strippers, respectively.
20.- Commission the second stage desalter: A-1101-D-02 and fill it with
crude (for details refer to Desalter Operation and Maintenance Manual
8474L-011-A5016-0814-001-001).
21.- Start the stabilizer overhead condenser: E-1122.
22.- Fill the stabilizer sump and start steam to the stabiliser reboiler E1121. Thermosiphon action should begin.
23.- After establishing a level in the Stabiliser Reflux Drum, D-1104, start
total reflux back to the stabiliser T-1107 while pressure built up. The
Stabiliser overhead vapour must be routed to flare.
24.- When the stabilizer is up on temperature and pressure, close the

bypass line PL-110640, send the LPG to off specification tankage and
reduce the reflux to T-1107 to required rate.
25.- Maintain the stabilizer bottoms circulating to the Crude slop tanks until
the Naphtha reaches the required specifications. Then, naphtha will be
routed to the specific storage and LPG will be routed to RFCC Unit.
26.- Finally, when all products are on specification, they will be routed to
the designed units or appropriate tankage, as is indicated in the 6.6
streaming products.

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STREAMING PRODUCTS
As each process section of the unit is brought on line and up to normal operating
conditions, route off-spec products as follows:
6.7.
T-1101, main fractionator, off gas to flare, through 011-PV-064C. Since Off
Gas to RFCC Battery Limit is closed, 011-PIC-064 will send off gases directly
to flare.
Residue and all other liquid streams to crude tankage via crude recirculation
header: PL-110122.
Naphtha Stabiliser, T-1107, Off gas to flare. As in the case of the T-1101
gases, since the Off Gas Battery Limit is closed, 011-PIC-068 will actuate on
011-PV-068C to send off gas to the Flare.
When the kerosene is on specification, route it to kerosene tankage or to KTU

(Unit 014) as required.
When the LGO is on specification, route it to LGO tankage.
When the HGO is on specification, route it to HGO tankage.
When the LPG is on specification, route it to Gas Recovery on RFCC Unit.
When Naphtha from T-1107 bottoms is on specification, route it to Naphtha

storage.
When all main fractionator (T-1101) and stabiliser (T-1107) products are on
specification and correctly routed, gradually increase the crude charge rate to
the required level.
NORMAL OPERATION
For further details refer to operating conditions section, 3.2 Operating Conditions
and to the process flow diagrams.

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7. NORMAL SHUTDOWN
7.1. SUMMARY OF SHUTDOWN
In order to proceed to a proper and safe shut down of the crude distillation unit, the
next steps and recommendations shall be followed:
Inform all concerned of the time of the shutdown.
Reduce the crude rate as indicated in Section 7.2 Automatically, firing on

heater will be also reduced.
Product streams will be routed back to crude tankage, via crude recirculation
header, or to appropriate off-spec storage in case of LPG. Then, the heater H1101 can be shutdown, as described in Section 7.3, and the stripping steam to
the main fractionator, T-1101, and to T-1103 and T-1104 (LGO and HGO
strippers respectively) also shutdown.
Drainage philosophy during unit shut down shall be as follows:
Once the Unit is in turndown mode, all off-spec products are diverted
to crude recirculation header, except LPG which has to be routed to
LPG off-spec storage.
The crude recirculation line can be used for rundown of the

atmospheric residue back to the crude storage area. This practice is
covered in Refinery Shutdown Philosophy Document. So, slopping of
huge quantities of residue to slops system shall not be considered. In
fact, crude recirculation line can be considered the preferred way to
slop off-spec residue.
In case of, for any reason, one product is off spec, the drainage
philosophy is as follows:
For HGO and LGO, will be divert to HSO header ( as maximum

60% of the design flow)
For Kerosene and Naphtha, will be divert to LSO header ( as

maximum 60% of the design flow)
During normal operation, products should be sent to the LSO/HSO

header after cooling in the heat exchangers upstream battery limit.
Rundown temperature should not exceed 70 C. The connections to
slops placed before final rundown coolers are provided to push the full
line inventory to Slops, after the operator ensures that product has
been cooled down, and uses flushing oil to dilute it (in case HGO,
Crude and Residue).
Note that only one product at a time shall be routed to the same slop
header (light or heavy). In the case that two products must be routed to
the same slop system, the unit shall be rather put under recirculation
back to the storage tank, as hydraulic will not allow sending the two
products to the same header.
As a reminder, off spec products can be rundown to storage or

downstream Units provided that they are not to far from the
specification and provided that the normal situation can be recovered
in a reasonable timeframe. Also, the first instruction to the operator, in
case of a product is really off-spec, with no hope to recover soon,
should be to decrease unit capacity.
Reduce T-1102, T-1103 and T-1104 bottom level controller Set Point to 20%

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Stop desalter wash water.
Reduce the crude preheat train inventory by displacing the crude oil from one
of the desalters, A-1101-D-01 or D-02, by means of level controller 011-LIC506 and 011-LIC-503 Remember to isolate electricity FIRST. Refer to chapter
2.3 alternatives operations for one desalter operation mode and also to the
chapter 8 of Desalters operations and maintenance manual: 8474L-011A5016-0814-001-001.
Maintain unit pressures with fuel gas or nitrogen during cool down.
Cut crude oil feed by stopping the crude charge pumps P-6001A/B/C and
crude booster pumps, P-1101 A or B, and close the feed and product battery
limit valves.
Stop pump arounds on the main fractionator, by stopping the pump around
pumps: P-1102 A/B, P-1103 A/B, P-1104 A/B, P-1105 A/B.
Stop reflux to the naphtha stabiliser, T-1107 by stopping the P-1114 A/B.
Pump out liquid inventories to crude tankage, by means of reducing level

controller Set Point of T-1105, T-1106, D-1103 and D-1104, via crude
recirculation header and off-spec tankage for LPG.
Stop the corrosion inhibitor injection pumps
Vent T-1107 overhead system to the flare.
Flushing the Unit as indicated in Section 7.4.
Steaming out the Unit as indicated in Section 7.5.
7.2. REDUCTION OF FLOWRATES

In order to achieve a proper reduction of unit flow rates, the following steps must
be followed:
Confirm that all concerned have been informed of the time of the shutdown.
Over approximately one shift (8 hours) reduce the feedstock flow rate to 50%
of the design by reducing FIC-069 Set Point 5% by step.
When the crude rate is lower than 650 m /h,
Reduce FQIC020 (LGO to storage) Set Point to 160 m /h and then to

3
108 m /h.
Reduce FQIC033 (Kerosene to Storage) Set Point to 33 m /h.
Reduce FQIC028 (HGO to Storage) Set Point to 42 m /h.
In the same time reduce the UIC031 Set Point from 2.8 to 1.4 MW and
reduce the stripping steam flowrate.
Reduce the number of operating burners in the H-1101 to maintain the T-1101
bottoms temperature but maintain all the pilots lit. During the cool down of unit
a maximum of three burners in each cell can be taken off-line, in order to avoid
a furnace trip.
7.3. SHUTDOWN OF HEATERS AND HEAT OFF.
Stop product transfer having first advised all receiving units of imminent
shutdown. Route product streams back to tankage.
Shutdown the crude

recommendations:
charge
heater
H-1101,
following
the
next

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Put heater firing control onto manual mode.
Reduce fuel gas flow until closure of 011-PV-092, minimum fuel gas
flow will be maintained by the 011-PCV-072.
In case of H-1101 is operating with fuel oil, change 011-FIC-504 set

point to cero. Minimum fuel oil stop will ensure enough flow to burners.
In case of H-1101 is operating with fuel oil, the atomizing steam will be
reduce automatically to the oil burners.
Isolate each burner
Maintain the pilots lit for a short time in order to burn any flammable
substance could remains in the heater.
Turn light off the pilots by closing each isolating valve. It is strongly
recommended to light off one or two pilots on one cell and then one, or
two, pilot on the other cell to compensate the loss of heat on the
chambers.
Keep the blowers B-1101 A or B running in order to cool down the

heater.
Stop flow of High pressure Steam to the E-1121, naphtha stabiliser reboiler.
Cut the flow of Medium Pressure Steam to the vacuum package, A-1102.
Cut the electricity of the desalter, transformer, which remains in operation and
drain it to slops.
7.4. FLUSHING OF UNIT
The atmospheric residue, coming from the main fractionator bottoms, will have
been partially diluted by unheated crude coming forward. This product shall be
pumped away to crude tankage (see drainage philosophy described in Section
7.1).
Open up S.R. flushing oil to the fractionator, T-1101, and establish a normal
level in the bottom part (via 2 flushing connection). Reopen the crude unit
battery limit valve and pump SR flushing oil with the feed pumps from the tank
farm through the crude feed line to the CDU. Flush the crude feed line to the
desalters and fill them.
With the P-1101 A / B, pump the flushing oil from the desalters through to the
T-1101 bottoms and out to crude tankage or to heavy slops, via P-1106 A /B.
Continue with this circulation until displace the remaining oil, which will be
detected via operator monitoring sampling. Shutdown then the crude feed
pumps and close the CDU battery limit valves.
Re-establish SR flushing oil flow to the T-1101 bottoms. Circulate through short
path to the heater, and through long path to the start of the preheat train,
bypassing the crude booster pumps, P-1101 A and B. Pump this away to
heavy slops. Repeat as required over 4 or 8 hours. For short and long path
refer to marked-up P&IDs included in attachment 2.
7.5. STEAMING OUT AND PREPARATION FOR MAINTENANCE

Any section of pipe, equipment item such as a vessel, heat exchanger or pump
which needs to be accessed or opened up for maintenance must be thoroughly
cleaned and prepared before work commences.
In order to ensure a proper and safe operation proceed to follow the next steps:

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Using block valves, isolate the smallest practical volume of oil bearing pipe and
/ or equipment containing the item to be maintained. Drain as much oil as
possible to the light or heavy slops system.
The black oil section of the plant must first be thoroughly flushed to heavy
slops. Drain the flushing oil. Black section of the plant covers Crude Oil,
Residue and Heavy Gas oil.
Open vents on tower and drums and start steaming out the flushed item to
remove traces of flushing oil. Periodically drain condensate while steaming,
and run the contaminated condensate to the oily water sewer.
The white oil section of the plant must be drained thoroughly to light slops.
Open vents on tower and drums and start steaming out the item. Drain the
condensate periodically to the oily water sewer. White section covers: Light
Gas Oil, Kerosene and Naphtha sections.
In order to prevent the cooling of steam in air fin exchangers and heaters,
damper should be closed and fan stopped.
Steam out shall be maintained for more than one hour.
Pumps in LPG service, P-1114 A and B and P-1115 A and B, should be

isolated, vented to the flare and nitrogen purged.
Swing the spectacle blinds or replace the ring spacer with spades.
If the closed valves were passing, re-steam or re-purge the blinded section or
equipment.
Check the residual hydrocarbon vapours.
Release the plant for maintenance under a Permit-to-Work.
7.6. KEROSENE STRIPPER REBOILER FOR MAINTENANCE

To take E-1110 out of service, proceed as follows:
Route stripped kerosene to crude recirculation header by line K-110259.
Introduce stripping steam into the column by opening valve 011-FV-015. Prior
to open the inlet valve, low point drain and 1.5 vent valve will remains opened
until all the steam condensate have been removed from the line and line work
is at superheated steam temperature.
Close the inlet and outlet valves on the circulating HGO (lines HGO-110175
and HGO-110176), heating medium. Leave some time for the exchanger to
cool down.
Close the inlet and outlet valves on the kerosene to and from reboiler (lines K110241 and K-110242).
Drain the kerosene to the closed drain by CD-118550.
Drain the HGO to the closed drain by lines CD-118551 and CD-118552.
Blind the reboiler tubeside and shellside from all process lines.
Open the vents on the tubeside and shellside, and steam both sides of the
reboiler, routing oily condensate to the OW.
Continue steaming, checking the tubeside and shellside regularly for

hydrocarbons.
When checks are satisfactory, stop steaming, allow vessel to cool, recheck
atmosphere for hydrocarbons and hand over to maintenance.

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7.7. DESALTERS ISOLATION FOR MAINTENANCE

7.7.1.1.
First desalter isolation
To take the first stage desalter out of service, the following steps have to be
followed:
Switch the desalters level control by 011-HS-001 (at this moment the level
control 011-LIC-506 in the second stage desalter is controlled by 011-LV-003,
instead of 011-HY-003).
Close the water outlet from A-1101-D-01 to ETP (line DEW-110265).
Stop pump P-1118.
Open water outlet from A-1101-D-02 to ETP (DEW-110271).
Open the interlock valve 011-SP-815 on line PL-110104.
Close the crude inlet valve to the desalter (line PL-110003).
7.7.1.2.
Second desalter isolation
To by-pass the second stage desalter, the following steps have to be followed:
Set FIC-004 and FIC-005 in manual mode.
Open water inlet line upstream 011-FV-021 (line SW-116614).
Stop pump P-1118.
Set FIC-021 controller to manual and output zero.
Open the interlock valve 011-SP-815 on line PL-110105.
Close the crude inlet valve to the desalter (line PL-110012).
7.7.1.3.
Desalter maintenance
To remove the oil from the desalter being taken out of service, proceed as follows:
Isolate and pull the fuses from the electrostatic precipitators (refer to vendors
manual).
Adjust the oil / water interface upwards beyond the LIA high alarm by mud
wash water lines (SW-116618 and SW-116619 depending which desalter is
going to be taken out of service).The crude will be displaced by the mud wash
water to the second desalter, if the fist one is bypassing and to the crude
booster pump, if the second desalter is bypassing.
Sample the try cocks (SCC-5B-013 or SCC-5B-014) until the desalter contains
water only.
Close the valve on the crude outlet line (PL110012 or PL110015) from the
desalter. Close the water inlet valve to the desalter.
Vent the desalter and dispose of as much of the water as possible to the
desalter effluent (lines DEW-110265 and DEW-110271). Drain the remaining
water to the closed drain.
Remove any sludge, using service water.
Blind the desalter from all process lines.
Ensure vent is open, and steam out routing oily condensate to the oily water
system.

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Continue steaming, checking desalter atmosphere regularly for hydrocarbons.
When checks are satisfactory, stop steaming, open manways, allow vessel to
cool, recheck atmosphere for oxygen and hydrocarbon and hand over to
maintenance.

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8. EMERGENCY SHUTDOWN PROCEDURES

A complete description of the CDU trip systems, via Emergency Shut-down system
(ESD) is given on chapters 9.4 Trip System Chart and 9.5 Cause and Effect
diagram of this operating manual. For further clarification refer also to the Cause
and Effect Chart 8474L-011-DW-1514-201 included in attachment 3.
8.1. GENERAL EMERGENCY SHUTDOWN
The CDU unit can be completely shut-down by an operator via the emergency
push button 011-UXHS-007 which trips the 011-UX-007 CDU ESD. The actions
trigged by this Interlock are fully described on the Cause and Effect Chart, but in
general, this interlock initiates the following actions:
A-1101-D-01 and 02 Desalters protection, UX-001
T-1101 main fractionator inventory isolation, UX-002
T-1103 LGO stripper protection, UX-003
T-1104 HGO stripper protection, UX-004
H-1101 crude charge heater protection, UX-005A
T-1101 main fractionator isolation, UX-017
P-1102 A/B top p/a pumps protection, UX-020
P-1104 A/B LGO p/a pumps protection, UX-021
P-1105 A/B HGO p/a pumps protection, UX-022
P-1103 A/B kerosene p/a pumps protection, UX-023
D-1104 inventory isolation, UX-026
Additionally, operator will cut electricity to desalters transformers and will stop the
M.P. steam to Vacuum package (A-1102),
Operator at field shall verify that all the ESD actions have been executed.
8.2. POWER FAILURE
8.2.1
Total Power Failure:
In case of complete electrical power failure, all motor driven equipment will stop.
Only emergency diesel generator will remain as power source after 30 sec. of
starting. This will mainly ensure to put in safe shutdown plant.
8.2.2
Local Power Failure
In case of total loos of power in Substation 8B, Emergency Diesel Generator will
allow safe shut down of the unit. All controls in Substation, as well as DCS, are
supplied by UPS.
8.2.3
Load Power Failure:
Supplies to motors are evenly distributed across Bus bar A and B, feed from
switchgear Substation 8B. Refer to single line diagram 8474L-001-DW-1652-118
and 8474L-011-NM-1601-001.
In case of power failure on one load, the motors connected to the other Bar that
are not online can be started within an acceptable period of time without upsetting
operation. Pump start-up will be automatic with control system set for auto-start-up.

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One Board Failure
Loss of a board is equivalent to total power failure. The only valid case is lost of
HALF bus bar due to earth fault in the bus-bar which is very seldom. Consequence
will be disruption of power to consumers directly connected to this half bus-bar (not
to 400V downstream switchboard when it happens to 6.6 kV because of double
radial feeding via 6.6 / 0.4kV TRF). Again, consequence will depend whether or not
motors / consumers are spared or not connected to the other bar.
8.3. STEAM FAILURE
8.3.1.
L.P. Steam Failure
A failure on the refinery low pressure steam network implies the loss of stripping
steam. As first consequence, products will go out of specification. First action shall
be estimate the duration of the steam failure. In case of a long duration failure is
expected, unit rate shall be reduced and then the products shall be diverted to
recirculation header and LPG to off-spec storage. If failure is prolonged, a full unit
controlled shut-down have to be done. This failure also implies the loss of steam
flow through the furnace convection section, which does not implies any serious
consequence, due to superheated coil is designed for no flow conditions.
Steam tracing will also be lost, so in case of a controlled shutdown, lines should be
drained and flushed as soon as possible, in order to avoid plugging.
If the loss of steam occurs during start-up steaming/purging, open up nitrogen and
box-in the plant.
8.3.2.
M.P. Steam Failure
The loss of the medium pressure steam implies the loss of motive flow on the
steam ejectors of the vacuum package, A-1102. Therefore, vacuum is lost and
both LGO and HGO drier bypass lines must be opened. If the steam failure is
expected to be prolonged unit feed rate must be reduced and then the products will
be routed to crude recirculation header.
M.P. Steam is also used to atomize the fuel oil. In the case that H-1101 is working
with both Fuel Oil and Fuel Gas, oil connection to burners will be closed, and since
unit rate has been reduced, Fuel Gas will compensate the loss of duty. If H-1101 is
working only with Fuel Oil, the loss of MP steam implies a Fuel oil trip due to low
differential pressure between MP steam and fuel oil, and the firing control system
will try to compensate the loss of duty by opening the fuel gas. If it is not possible
(no fuel gas availability), then H-1101 must be shutdown due to loss of
combustible.
8.3.3.
H.P. Steam Failure
The loss of high pressure steam failure implies the loss heat source on the
Stabiliser (T-1107) reboiler, E-1121, and therefore, no vapour generation occurs in
the stabilizer column, so pressure will decrease inside the column and there will be
not enough pressure to send the naphtha to the battery limit.
First measure is to open the stabilizer bypass line (PL-110640) and then divert the
outlet streams to the following destinations:
Full Range Naphtha (T-1107 bottoms) to light slops.
Stabiliser overhead gases shall be routed to the flare.
LPG off spec from the Stabiliser reflux drum, D-1104, to LPG off spec.

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If it is possible, turn to minimum naphtha operation mode, in order to send as

less naphtha as possible to light slops header.
Complete Steam Failure
A similar procedure will be followed: unit feed rate will be reduced and then
products shall be diverted to slops, and if failure is expected to be prolonged a
normal shut-down of the unit must be done.
8.4. INSTRUMENT AIR FAILURE
In the event of an instrument air failure, all control and on-off valves will fail to their
safe position.
If a failure occurs that affects one or a group of instruments, then the magnitude of
the upset will dictate whether to shutdown the affected section or continue to
operate via by passes.
If a total instrument air failure occurs, the unit must be shut-down.
8.5. COOLING WATER FAILURE
Under cooling water failure scenario, CDU products (Naphtha, Kerosene and
Residue) will be too hot for storage tanks, resulting in a dangerous increase of
vapour within the tanks. LGO and HGO will run out of spec since without cooling
water, vacuum package A-1102 will stop working and vacuum will be lost.
Therefore LGO and HGO will be routed to recirculation crude header.
In order to minimise the impact on storage, unit throughput will be reduced to allow
air coolers to reduce the products outlet temperature. Additionally oil movement
operators shall be advised that rundown temperatures could be higher than
normal, depending on the Air cooler capacity. If products cannot be cooled down
enough, the unit will be shut down.
In the case that the loss of cooling water is expected to last more than a few hours,
the lack of cooling on the rotating equipment may cause a mechanical damage.
Therefore, the unit shall be put under controlled shut down.
8.6. FUEL GAS SYSTEM FAILURE
The main consequence of a failure on the Fuel gas system is the reduction on the
H-1101 duty. Fuel gas failure is detected by the 011-PXALL-094 that activates the
Fuel gas Trip, 011-UX-005 B. Closing the ESD valves that isolate the Fuel Gas to
the Crude Charge Heater, H-1101, burners.
Once the fuel gas is lost, the subsequent actions will depend on the H-1101
operating case:
If H-1101 is working with a mixture of Fuel Oil Fuel Gas, the firing control
system will try to compensate the loss of duty by opening the Fuel Oil control
valve: 011-PV-118. If the fuel oil available is not enough to compensate, the
crude charge rate will be reduced.
If H-1101 is working with 100% Fuel Gas, the operator has to reduce the crude
feed rate and products will be routed to recirculation crude header. If the fuel
gas cannot be restored within a short period and/or fuel oil cannot be made
available the unit will have to be shutdown.
8.7. FUEL OIL SYSTEM FAILURE

The failure on the Fuel oil system causes the reduction on the H-1101 duty, if fuel
oil is being used as part of fuel. Fuel oil failure is detected by the 011-PXALL-122

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that activates the Fuel Oil Trip, 011-UX-005 C. Closing the ESD valves that
isolate the Fuel oil to the Crude Charge Heater, H-1101, and burners.
Once the fuel oil is lost, the subsequent actions will depend on the H-1101
operating case:
If H-1101 is working with a mixture of Fuel Oil Fuel Gas, the firing control
system will try to compensate the loss of duty by opening the Fuel gas control
valve: 011-PV-092. If the fuel gas available is not enough to compensate, the
crude charge rate will be reduced.
If H-1101 is working with 100% Fuel Oil, the crude feed rate will be reduced
and products will be routed to recirculation crude header. If this fuel cannot be
restored within a short period of time, the unit will be shut-down.
8.8. PILOT GAS SYSTEM FAILURE

The failure of the pilot gas causes the loss of pilot flames. Pilot gas loss is detected
by both the 011-PXALL-112 and pilot flame detectors 011-BAL-501 to 516, which
activates Pilot Gas Trip 011-UX-005 E, closing the emergency valves 011-XV007 and 011 and opening the depressurizing valve 011-XV-012.
As described on the C&E Chart, 8474L-011-DW-1514-201, Pilot Gas Trip also
activates the Fuel Gas Trip, the Fuel Oil Trip and heater off gas trip. Heater
blower, B-1101 A or B, will continue running to purge the Heater chambers.
Pilot gas system failure requires a complete unit shut down.
8.9. NITROGEN FAILURE
Nitrogen is used as blanketing for D-1109 in order to avoid water discharge to flare
in case of overpressure in the vessel .This will happen in case of D-1109 level
control failure causing more water supply to D-1109, the loss of nitrogen in this
case is very unlikely scenario, so the loss of nitrogen has not any impact.
Nitrogen is also used to pressurize D-1115. Nitrogen failure could cause the
pressure to decrease inside the vessel in case level decreases. The vessel is
designed for full vacuum so no impact on this circuit is expected.
In addition, Nitrogen is used on the following sampling systems SC-3B-001, SC5B-001 to 004, SC-5B-006, SC-5B-008, SC-5B-012 to 016. In the case of a
nitrogen failure, the sampling on these services will not be performed until Nitrogen
flow is restored.
Unit general or partial shut down is not required in this scenario.
8.10.
MECHANICAL FAILURE
If a spared item fails, first start the standby equipment. Then secure and isolate the
failed item and prepare it for maintenance.
If the failed item is not spared, whenever possible, by-pass and isolate the
equipment while continuing to operate safely. Throughput will be reduced if
necessary, and the equipment will be prepared for maintenance.
The following pumps: P-1101 A/B, P-1104 A/B and P-1106 A/B are protected by a
preventive Machine Monitoring System, which control certain parameters (vibration
and bearing temperature) and allows the system to warn in advance about a bad
performance of the machine.

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9. SAFETY EQUIPMENT AND PROCEDURES

9.1. PRESSURE SAFETY DEVICES
Refer to the following documents:
Flare Discharge Summary: 8474L-011-NM-0006-001
Data sheets of Safety Relief Valves: 8474L-011-SP-1545-001
9.2. ALARM SETTINGS

Refer to the process alarm table, included in attachment 3, these values are also
available in the following project document:
System I/O list Unit 011 (8474L-011-NM-1611-001)
9.3. TRIP SETTINGS

Refer to the process trip table, included in attachment 3, these values are also
available in the following project document:
System I/O list Unit 011 (8474L-011-NM-1611-001)
9.4. TRIP SYSTEM CHART

Refer to Cause and Effect chart included in point 9.5.
9.5. CAUSE AND EFFECT DIAGRAM
Refer to the following documents included in attachment 2 and 3:
Cause and Effect Chart, 8474L-011-DW-1514-201.
H-1101 safeguarding narratives, 8474L-011-A3501-0110-001-002, issued by

Heater Vendor.
A-1101 desalter package operation and maintenance manual, chapter 4,

8474L-011-A5016-0814-001-001 issued by desalter vendor.
9.6. MATERIAL HAZARD DATA SHEETS

Material Hazard Data Sheets (MSDS) for all products involved in the unit 011, such
hydrocarbons chemicals are included in attachment 3.
9.7. SAFEGUARDING MEMORANDUM
This section describes a series of scenarios where operator intervention is required
to solve, or reduce, the contingency which may result in an undesired plant
performance, or, if prolonged, to a more severe problem.
9.7.1.
Heat exchanger tube rupture
Although this is a very unlikely scenario, operator monitoring and routine sampling
allows an early detection and therefore to minimize the impact downstream the
affected heat exchanger. Once the leak has been detected, the flow rates should
be reduced (when required) and the Heat exchanger should be by-passed, put
under maintenance in order to repair or isolate the tube or tubes.
On the CDU unit, the rupture of a tube affects mainly to the products, therefore, the
performance of the specified analysis for each stream will allow detecting any
major leak. For further details refer to section 12.1 Sampling and testing schedule.

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Chemical injection packages, A-1104.
A failure on the antifoulant or demulsifying packages will lead to a bad performance

of the unit. Loss or reduction of demulsifier can result in foam formation within the
desalters and excessive water carryover to exchanger bank and column.
Prolonged reduction or loss of antifoulant leads to a fouling of the heat exchanger
train, temperature loss on crude feed to desalters and to increasing temperature on
product rundowns.
Impact on desalters performance may be detected via the following level alarms:
011-LAH/LAL-503, 506, 501 and 504.
Operator will therefore supervise both chemical injection packages: pumps
performance and settings, level on reservoirs, etc. in order to ensure the proper
operation.
Although a failure on corrosion inhibitor package only result in risk of corrosion
system at long term, the monitoring routine have to be executed by operator.
9.7.3.
Desalter Package A-1101
Level within desalter vessels is maintained via level control 011-LIC-503 and LIC506, which controls the interface between the crude and the water phases. In the
case of failure of this controller (for instance: wrong level reading), 011-LV-003,
water to ETP control valve will move to full opened or closed position.
In case of valve full closed, 011-LAH-501 and 011-LAH-504 and 011-FQAL051 will warn the operator about this scenario. If this situation is not soon
restored, water will go through the crude outlet into the system causing salt
deposition on the pre-heat train and tray damage in the T-1101. Therefore,
operator action is required: 011-LIC-503 shall be put into manual mode and the
correct set point to keep the valve on the required position will be given by the
operator, or, if there is not a satisfying reply from the system, by-pass valve
shall be opened to re-establish the level on the desalters.
In the case of valve full opened, 011-LAL-501 and 011-LAL-504 will warn the
operator. If this situation is not soon restored, crude will not be properly
desalted and crude will flow to the ETP.
Due to the size of the desalter vessels, A-1101-D-01and D-02, the available time,
from the moment on any (high or low) level alarms are activated on the DCS
screen to the moment when crude (or water) leaks, is enough to allow an operator
to confirm the situation at field and then to proceed with the corrective actions
(estimated time: 20 mins). If failure can not be avoided between this estimated
time, operator shall decide between waiting until the problem is solved or closing
isolation valve 011-XV-015 via 011-XHS-015A.
Additionally, a full trouble shooting guide is included on the desalter package
Operating and Maintenance manual 8474L-011-A5016-0814-001-001, which
have been included in attachment 2.
9.7.4.
Kerosene pump around and rundown systems
On section 7.3 of the process control narrative, 8474L-011-SP-1511-101, the

kerosene pump around control is described. Its purpose is to remove a certain
amount of heat from the T-1101. This system is controlled via 011-UIC-029.
A failure on this controller, which is very unlikely, implies that the kerosene and
naphtha products may run out off spec.
011-AE/AT-003/005 and 006 on-line analyzers have been foreseen to warn the
operator about any deviation from the product specifications: specific gravity,

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freeze point and flash points (flash point alarms in case low kerosene flash point is
being produced) are monitored.
Additionally, the continuous supervision of the system parameters and the
performance of the tests described on the Sampling and testing schedule
(chapter 12.1 of this operating manual.) will allow the operator to detect and correct
any deviation from the product specifications.
In the case of a big deviation from the expected values, the first recommendation is
to reduce the unit feed rate in order to minimize the off-spec products flow and
then divert to LSO Header.
See point 3.3.6 for possible actions to be taken if products go out of specification.
9.7.5.
LGO pump-around and rundown systems
LGO pump-around control loop is described on the section 7.4 of the process
control narrative. The amount of heat removed from the LGO stream and the flow
of run down product in controlled via the 011-UIC-032.
A failure of this logic leads to an off-spec LGO and kerosene production.
The continuous monitoring of the system parameters and the performance of the
tests foreseen on the Sampling and testing schedule (chapter 12.1 of this
operating manual.) will allow the operator to detect and correct any deviation from
the product specifications.
If required, in case of a big deviation from the product spec, the unit feed rate shall
be reduced and the product diverted to the Heavy Slops in order to allow the
operator solving the causes of the deviation.See point 3.3.6 for possible actions to
be taken if products go out of specification.
9.7.6.
HGO pump around and rundown systems
As explained on process control narrative, 8474L-011-SP-1511-101 section 7.5,

the pump around flow and the amount of duty removed on both the HGO pump
around and on the Kerosene reboiler, E-1110, is controlled by the 011-UIC-031
and 033.
Although this is a very unlikely scenario, the failure on any of these logic controllers
leads to wrong operation of the unit, where naphtha, kerosene and HGO will run off
spec.
The continuous monitoring of the system parameters and the performance of the
tests foreseen on the Sampling and testing schedule (chapter 12.1 of this
operating manual.) will allow the operator to detect and correct any deviation from
the product specifications.
As explained on the previous points, in case of a big deviation from the expected
values, the unit feed rate should be reduced in order to minimize the off-spec
products flow and then the production diverted to the Heavy Slops.
9.7.7.
T-1101 accumulator drum, D-1103, Interphase controller (011-LIC-040) failure
Level control philosophy is described on the section 3.1.1.6 of this operating

manual.
A failure on the 011-LIC-040 drives to full open or closed the 011-LV-040, which
maintain the Water/crude interphase level on the D-1103. In both cases, system
warns the operator who has to react in order to correct the situation.

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In case of 011-LV-040 drives open. This scenario implies that the interphase
level is lost with a risk of Hydrocarbon carryover to the D-1106. In this case,
011-LXALL-033 will first alarm about the loss of level and then close the 011LV-040 via solenoid valve. This solenoid valve is activated by the ESD
Interlock UX-014. The field operator has to verify that 011-LV-040 is closed.
Once the interphase level is re-established on the vessel, operator will
maintain it on the expected values by means of the globe by-pass valve and
the 011-LG-037 until the problem on 011-LIC-040 is solved.
In case of 011-LV-040 drives closed. This scenario implies the risk of water
carryover to the stabilizer, T-1107. In this case, 011-LZL/LZAL-040 will warn
the operator about the failure of the controller and the closure of the control
valve. Field operator, by means of the by-pass control valve will restore the
interphase level until the problem on 011-LIC-040 is solved.
9.7.8.
T-1107 reflux drum, D-1104, Water boot level controller (011-LIC-050) failure.
For level control description refer to section 3.1.1.7 of this operating manual.
In case of 011-LIC-050 failure, 011-LV-050 may go to full open position with the
risk of water level loss and LPG carryover from the D-1104 to the D-1103. An open
position alarm, 011-LZASO-050 will warn the operator about this scenario.
Although pressure control system on D-1103 (011-PIC-064) can manage the
pressure rise, field operator should isolate control valve to cut the LPG leak to the
flare system, and then maintain the required level on the water boot by means of
the by-pass globe valve. This valve is accessible from the local level indicator: 011LG-051.
9.7.9.
T-1107 closed drain connection
Corrosion problems may occur in T-1107 closed drain connection (2-CD-118606A2AQ-NI).

In order to ensure that no water is keep inside this pipe, it must be drained
periodically. In addition, closed drain pipe thickness shall be checked and, in order
to avoid a mayor leakage, pipe must be replaced in case it is corroded.
9.7.10. D-1106 oil level, 011-LIC-028 fails on P-1120 A/B starting
Purpose of 011-LIC-028 is to start the Oil drain pump P-1120 A (or B) when oil
reaches a high level. This loop is described in the section 10.10 of the control
narrative 8474L-011-SP-1511-101.
If 011-LIC-028 fails, oil level continues to rise lasting around 25 minutes to fill
completely the vessel from the High liquid level. In any case, 011-LIAHH-030 will
warn to the operator that high liquid level has been passed. Once it has been
confirmed that the P-1120 A (or B) is not running, operator will proceed to put the
pump into manual mode, via 011-MHS-043A (or 011-MHS-044A for the P-1120B).
Following, Oil drain pump must be started by local push button.
9.7.11. Interlocking devices
As a protective measure, mechanical interlocking devices have been foreseen in
some systems in order to avoid a miss operation that could lead to a system
blockage if affected valves are not closed /opened in the appropriate order.
These devices allows, for instance, to take out of service one PSV after the spare
one have been released.
The full list and description of the interlocking devices installed on this unit is
included in 8474L-300-SP-1397-001.

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INSTRUMENT DATA
10.1.
CONTROL VALVES AND INSTRUMENTS

For Self Pressure Regulator Valves and Control Valves data sheets refer to the
following documents:
8474L-011-SP-1541-001 Data Sheet - Control Valve, Unit 011.
8474L-011-SP-1542-003 Data Sheet - Self Pressure Regulator Valve,Unit

011.
10.2.
ORIFICE PLATES
For Oriffice Plate and Restriction Orifice Plate Data Sheets refer to the following
documents:
8474L-011-SP-1546-001 Data Sheet - Restriction Orifices, Unit 011.
8474L-011-SP-1546-002 Data Sheet Orifice Plates, Unit 011.

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11.
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Page
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SUMMARY OF MAJOR EQUIPMENT
11.1.
EQUIPMENT LIST
For Crude Unit Equipment list refer to the 8474L-300-EL-001 included in
attachment 5.
11.2.
CRUDE CHARGE HEATER, H-1101

Crude charge heater function is to increase the temperature of the crude oil up to
the conditions required of the main fractionator, T-1101.
This process heater consists of two sections: a convective part and a radiation one.
Radiation section is divided into two separate cells. Each cell has 8 burners. All of
them are capable of working with Fuel Gas, Fuel Oil and both fuels simultaneously.
Additionally, the heater is provided with a steam coil to raise the temperature of the
steam used on the main fractionator, T-1101, and the side strippers: T-1102, T1103 and T-1104.
For further information about the heater, refer to the following documents, which
have been included in the attachment 5:
8474L-011-A1001-0110-001-001, H-1101 Data Sheet.
8474L-011-A1006-0110-001-001, Burner Data Sheet
8474L-011-A1106-0110-001-002, Blowers Data Sheet
8474L-011-A1005-0110-001-002, Blower Performance Curve
8474L-011-A2001-0110-001-001, General Arrangement
11.3.
DESALTERS PACKAGE, A-1101

Desalters purpose is to remove the inorganic salts existing in the crude oil fed to
the unit. The crude desalting process is thoroughly described in the sections 2.1.2
and 2.2.1 of this operating manual, and on the Process Description - 8474L-011A3501-0814-001-001 issued by the package vendor.
Desalters package consist of the following main items:
A-1101-D-01, First stage desalter (including two transformers).
A-1101-D-02, Second stage desalter (including two transformers).
A-1101-M-01, First stage static mixer.
A-1102-M-02, Second stage static mixer.
011-PDV-503, First stage mixing valve.
011-PDV-506, Second stage mixing valve.
For further information about the Desalters Package, refer to the following
documents, which have been included in the attachment 5:
8474L-011-A3501-0814-001-001,
Process Description.
8474L-011-A1001-0814-001-002,
Desalters Vessel Data Sheet.
8474L-011-A1001-0814-001-003 and 004, Static Mixer Data Sheet
8474L-011-A1006-0814-001-001 and 002, Emulsifying Valves Data Sheet.

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8474L-011-A0102-0814-001-001, Process Flow Diagram with Heat and

Material Balance
8474L-011-A2001-0814-001-002, General Arrangement.
11.4.
VACUUM PACKAGE, A-1102

Vacuum system maintains a reduced pressure in the Dryers by using steam
ejectors, where medium pressure steam is used as motive fluid. Vacuum package
purpose and performance have been thoroughly explained on the sections 2.1.7
and 2.2.2 of this operating manual.
The Vacuum package, A-1103, consists of the following equipment:
A-1102-J-01 A/B/C
Fist stage ejector
A-1102-J-02 A/B/C
Second stage ejector
A-1102-E-30
Pre-condenser (Vacuum drier pre-condenser)
A-1102-E-31
Inter-condenser (First stage after-condenser)
A-1102-E-32
After-condenser (Second stage after-condenser)
011-PV-546
Recycle control valve
For further details of equipment operating and design data, and performance
conditions, refer to the following project documents, which have been included in
attachment 5:
8474L-011-A1001-0850-001-002, Equipment Data Sheets.
8474L-011-A3102-0850-001-001, Control Valve Calculation Sheet.
8474L-011-A2001-0850-001-001, General Arrangement.
8474L-011-A0102-0850-001-001, Process Flow Diagram (Flexibility design

case).
8474L-011-A0102-0850-001-003, Process Flow Diagram (Normal case).
8474L-011-A0102-0850-001-002,
intermediate case).
Process
Performance requirements:
Ejectors per stage working for maximum flow case: 3
Ejectors per stage working for normal flow case: 2
Flow
Diagram
(Flexibility

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12. ANALYSIS
12.1.
SAMPLING AND TESTING SCHEDULE

The sampling and testing schedule is summarized un the following tables:
Table 23: Sampling connection SC-3B-001, SC-18-001, SCC-6-001 A/H, SCC-6002 A/H, SC-12-001 and SC-20-001.

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Table 24: Sampling connections SCC-5B-001 and SCC-5B-002

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Table 25: Sampling connection SCC-5B-003, SCC-5B-004. SCC-5A-005 and

SCC-5B-006.

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Table 26: Sampling connection SCC-5A-007, SCC-5B-008, SCC-5A-009 and

SCC-5A-011.

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Table 27: Sampling connection SCC-5B-012, SCC-5B-013, SCC-5B-014, SCC5B-015 and SCC-5B-016.

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12.2.
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ON LINE ANALYSERS
The on line analyzers in the CDU unit are describe in the table below:
Analyzer
tag
Physical
property
analyzed
Service
Normal value of
analyzed
component
AE/AT-001
Flue gas from crude charge heater H-1101

radiant section
Oxygen content
in flue gas
0-10 % vol.
AE/AT-002
Oil in water
Oil content
0-1 % vol.
AE/AT-003
Kerosene product from E-1114 to KTU
Flash Point
38 - 51 C
AE/AT-004
LPG to gas recovery on RFCC
C5+ (pentane or
heavier) content
1.5 % mol
AE/AT-005
Freeze Point
- 47 C
AE/AT-006
Specific Gravity
@ 15 C
0.775 0.840
For further details refer to the vendor data sheets:
8474L-011-SP-1561-001 for Pentane analyzer, 011-AE/AT-004.
8474L-011-SP-1562-011 for Oxygen analyzer, 011-AE/AT-001.
8474L-011-SP-1563-004 for Specific gravity analyzer, 011-AE/AT-006.
8474L-011-SP-1563-006 for Flash Point analyzer, 011-AE/AT-003.
8474L-011-SP-1563-018 for Freeze Point analyzer, 011-AE/AT-005.
8474L-011-SP-1564-007 for Oil in Water analyzer, 011-AE/AT-002.

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PROCESS CONTROL
13.1.
DISTRIBUTED CONTROL SYSTEM

For a further description of the D.C.S. refer to the following project documents:
8474L-000-JSS-1511-001,
Specification.
8474L-000-JSD-1510-001, Design and Engineering Information for Control

and Instrumentation.
8474L-000-DW-1510-001. Control System Interconnection Diagram.
13.2.
Distribution
Control
System
Technical
INSTRUMENT PROTECTIVE SYSTEM AND SAFEGUARDING SYSTEMS

For a further description of the I.P.S., and Emergency Shutdown System, E.S.D.,
refer to the following project drawings and documents:
8474L-000-JSS-1511-001, Emergency Shutdown Control Centre.

13.3.
CONTROL CENTRE
For a further description of the Control Centre refer to the following project
documents and drawings:


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14. DRAWINGS
14.1.
PLOT AND HAZARDOUS AREAS CLASSIFICATIONS PLANS

Refer to following drawings, which have been included into attachment 6:
Plot Plan Unit 11 Crude Distillation /Unit 14 Kerosene Treater

/ Unit 37 Fuel Gas System
8474L-011-DW-0051-001
General Hazardous Areas Classification
8474L-011-DW-1920-002
14.2.
PROCESS FLOW DIAGRAMS AND MATERIAL SELECTION DIAGRAMS

Refer to following drawings, which have been included into attachment 6:
Table 28 List of Process Flow Diagrams
1.COLD PREHEAT AND DESALTERS (BACH HO)
8474L-011-PFD-0010-001
2.HOT PREHEAT AND HEATER (BACH HO)
8474L-011-PFD-0010-002
3.MAIN FRACTIONATOR/STRIPPER (BACH HO)
8474L-011-PFD-0010-003
4.DRIERS/ EJECTOR SYSTEM (BACH HO)
8474L-011-PFD-0010-004
5.OVERHEAD/RUNDOWN SYSTEMS (BACH HO)
8474L-011-PFD-0010-005
6.NAPHTHA STABILISER (BACH HO)
8474L-011-PFD-0010-006
7.SCHEMATIC- CDU PREHEAT (BACH HO)
8474L-011-PFD-0010-007
8.MASS BALANCE (BACH HO)
8474L-011-PFD-0010-008
1.COLD PREHEAT AND DESALTERS (DUBAI)
8474L-011-PFD-0010-009
2.HOT PREHEAT AND HEATER (DUBAI)
8474L-011-PFD-0010-010
3.MAIN FRACTIONATOR/STRIPPER (DUBAI)
8474L-011-PFD-0010-011
4.DRIERS/ EJECTOR SYSTEM (DUBAI)
8474L-011-PFD-0010-012
5.OVERHEAD/RUNDOWN SYSTEMS (DUBAI)
8474L-011-PFD-0010-013
6.NAPHTHA STABILISER (DUBAI)
8474L-011-PFD-0010-014
7.SCHEMATIC- CDU PREHEAT (DUBAI)
8474L-011-PFD-0010-015
8.MASS BALANCE (DUBAI)
8474L-011-PFD-0010-016
Table 29 List of Material Selection Diagrams

1.COLD PREHEAT AND DESALTERS
8474L-011-MSD-0011-001
2.HOT PREHEAT AND HEATER
8474L-011-MSD-0011-002

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3.MAIN FRACTIONATOR/STRIPPER
8474L-011-MSD-0011-003
4.DRIERS/ EJECTOR SYSTEM
8474L-011-MSD-0011-004
5.OVERHEAD/RUNDOWN SYSTEMS
8474L-011-MSD-0011-005
6.NAPHTHA STABILISER
8474L-011-MSD-0011-006
14.3.
PIPING AND INSTRUMENT DIAGRAMS

Refer to the following drawings, which have included in attachment 6:
Table 30 List of Process P&ID's
Cold preheat train (1/3)
8474L-011-PID-0021-101
8474L-011-PID-0021-102
8474L-011-PID-0021-103
Crude oil desalting (1/2)
8474L-011-PID-0021-104
Crude oil desalting (2/2)
8474L-011-PID-0021-105
Hot preheat train (1/4)
8474L-011-PID-0021-106
8474L-011-PID-0021-107
8474L-011-PID-0021-108
8474L-011-PID-0021-109
Crude charge heater convection section
8474L-011-PID-0021-110
Crude charge heater radiant section
8474L-011-PID-0021-111
Main fractionator
8474L-011-PID-0021-112
Top pumparound
8474L-011-PID-0021-113
Kerosene stripper
8474L-011-PID-0021-114
LGO stripper section
8474L-011-PID-0021-115
HGO stripper section
8474L-011-PID-0021-116
LGO dryer section
8474L-011-PID-0021-117
HGO dryer section
8474L-011-PID-0021-118
Desalting water (1/2)
8474L-011-PID-0021-119
Desalting water (2/2)
8474L-011-PID-0021-120

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Ejector system (1/2)
8474L-011-PID-0021-121
Ejector system (2/2)
8474L-011-PID-0021-122
Dryer accumulator (1/2)
8474L-011-PID-0021-123
Dryer accumulator (2/2)
8474L-011-PID-0021-124
Atmospheric residue rundown system
8474L-011-PID-0021-125
Tempered water system
8474L-011-PID-0021-126
HGO rundown system
8474L-011-PID-0021-127
Overhead system
8474L-011-PID-0021-128
Kerosene rundown system
8474L-011-PID-0021-129
Naphtha stabiliser
8474L-011-PID-0021-130
Stabiliser condenser system
8474L-011-PID-0021-131
Full range Naphtha rundown
8474L-011-PID-0021-132
Combustion air system
8474L-011-PID-0021-133
H-1101 Fuel Gas system
8474L-011-PID-0021-134
H-1101 Fuel Oil system
8474L-011-PID-0021-135
Chemical injection (1/2)
8474L-011-PID-0021-136
Chemical injection (2/2)
8474L-011-PID-0021-137
Crude charge heater / H-1101 heater firing
8474L-011-PID-0021-138
Crude recirculation, LSO and HSO headers
8474L-011-PID-0021-139
Decoking station (1/3)
8474L-011-PID-0021-140
8474L-011-PID-0021-141
8474L-011-PID-0021-142
Sootblowers System
8474L-011-PID-0021-143
Process area. Battery limits (1/2)
8474L-011-PID-0021-201
Process area. Battery limits (2/2)
8474L-011-PID-0021-202
Sampling systems details
8474L-011-PID-0021-301
Level instruments details (1/4)
8474L-011-PID-0021-302

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8474L-011-PID-0021-303
8474L-011-PID-0021-304
8474L-011-PID-0021-305
LP steam connection details
8474L-011-PID-0021-306
FLS and nitrogen connection details
8474L-011-PID-0021-307
CD connection details
8474L-011-PID-0021-308
Desalter instrumentation details (1/2)
8474L-011-PID-0021-309
Desalter instrumentation details (2/2)
8474L-011-PID-0021-310
Air cooler details (1/4)
8474L-011-PID-0021-401
8474L-011-PID-0021-402
8474L-011-PID-0021-403
8474L-011-PID-0021-404
Table 31 List of Utilities Distribution P&ID's
Utility area battery limits
8474L-011-PID-0031-203
Steam, condensate and boiler feed water distribution (1/5)
8474L-011-PID-0031-501
8474L-011-PID-0031-502
8474L-011-PID-0031-503
8474L-011-PID-0031-504
8474L-011-PID-0031-505
Cooling water, demineralized water, service water and potable

water distribution (1/4)
8474L-011-PID-0031-511

8474L-011-PID-0031-512

8474L-011-PID-0031-513

8474L-011-PID-0031-514
Nitrogen, instrument air and plant air distribution (1/3)
8474L-011-PID-0031-521
8474L-011-PID-0031-522

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8474L-011-PID-0031-523
Fuel oil, fuel gas and pilot gas distribution
8474L-011-PID-0031-531
Flare system (1/3)
8474L-011-PID-0031-541
Flare system (2/3)
8474L-011-PID-0031-542
Flare system (3/3)
8474L-011-PID-0031-543
Caustic system
8474L-011-PID-0031-551
Flushing oil distribution (1/3)
8474L-011-PID-0031-561
8474L-011-PID-0031-562
8474L-011-PID-0031-563
Closed drain system (1/7)
8474L-011-PID-0031-571
8474L-011-PID-0031-572
8474L-011-PID-0031-573
8474L-011-PID-0031-574
8474L-011-PID-0031-575
8474L-011-PID-0031-576
8474L-011-PID-0031-577
Closed drain vessel
8474L-011-PID-0031-578
Oily water pit (not issued)
8474L-011-PID-0031-581
Oil mist distribution (1/2)
8474L-011-PID-0031-591
Oil mist distribution (2/2)
8474L-011-PID-0031-592
Table 32 Pump details P&ID's
Pump details (1/5)
8474L-011-PID-0041-601
Pump details (2/5)
8474L-011-PID-0041-602
Pump details (3/5)
8474L-011-PID-0041-603
Pump details (4/5)
8474L-011-PID-0041-604
Pump details (5/5)
8474L-011-PID-0041-605

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14.4.
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OTHER DRAWINGS
Refer to the following drawings:
Table 33 Other drawings
Substation SS8B Single Line Diagram
8474L-011-DW-1652-118
Underground Key Plan
8474L-011-DW-1442-001
General Underground Network (Sheet 2)
8474L-011-DW-1442-002
8474L-011-DW-1442-003
8474L-011-DW-1442-004
8474L-011-DW-1442-005
8474L-011-DW-1442-006
8474L-011-DW-1442-007
OWS- Manhole and Catch Basin Schedule
8474L-011-DW-1453-001
OW- Manhole, OWS-Sump CD and Valve Pit Schedule
8474L-011-DW-1453-002
Fire Water Distribution (1/3)
8474L-011-PID-1931-001
(1/3)
Water Spray Systems (2/3)
8474L-011-PID-1931-001
(2/3)
Water Spray Systems Controls (3/3)
8474L-011-PID-1931-001
(3/3)

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
1.
BASIS OF DESIGN
1.1.
1.2.
1.2.1.
1.2.2.
1.3.
1.3.1.
1.3.2.
1.4.
1.4.1.
1.4.2.
1.4.3.
1.5.
1.6.
2.
DUTY OF PLANT
FEED CHARACTERISTICS
Bach Ho crude
Dubai crude
PRODUCT SPECIFICATIONS
Product Properties Bach Ho case
Product Properties Dubai case
MATERIAL BALANCES
Bach Ho crude
Dubai crude
Flexibility cases
BATTERY LIMIT CONDITIONS
GAS AND LIQUID EFFLUENTS
DESCRIPTION OF PROCESS
2.1.
PROCESS FLOW DESCRIPTION
2.1.1.
Crude Preheat
2.1.2.
Desalters
2.1.3.
Crude Heater
2.1.4.
Crude Distillation
2.1.5.
Stabilizer Section
2.1.6.
Dryers
2.1.7.
Vacuum Section
2.1.8.
Chemical Package
2.2.
THEORY OF THE PROCESS
2.2.1.
Desalter package
2.2.2.
Vacuum package
2.3.
ALTERNATIVES OPERATIONS
2.3.1.
Steam stripped kerosene operation
2.3.2.
One Desalter operation
2.3.3.
LGO dryer bypass
2.3.4.
HGO dryer bypass
2.3.5.
E-1102 and E-1104 isolation.
3.
DESCRIPTION OF UNIT CONTROL

3.1.
3.1.1.
3.1.2.
3.2.
3.3.
3.3.1.
3.3.2.
3.3.3.
3.3.4.
3.3.5.
3.3.6.
3.3.7.
3.3.8.
3.3.9.
3.4.
3.4.1.
3.4.2.
3.4.3.
3.4.4.
3.5.
DESCRIPTION OF FLOW UNIT CONTROL

Description of main control
Shutdown philosophy
OPERATING CONDITIONS
PROCESS VARIABLES
CDU feed rate
Fired heater outlet temperature
Main fractionator overhead temperature
Main fractionator pressure.
Pumparounds.
Specification Adjustement.
Stripping Steam in the Main fractionator column.
Overflash
Stabilizer temperature
INTER-UNIT CONTROL SCHEME
Atmospheric Residue from the CDU to the RFCC
Full Range Naphtha from the CDU to the NHT
LCO HDT feed control
Stripped water from the SWS to the CDU
UNINTERRUPTIBLE POWER SUPPLY
November 2008
Rev.
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DUNG QUAT REFINERY
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UNIT CDU (011)
3.6.
4.
UTILITY, CHEMICAL AND CATALYST REQUIREMENTS

4.1.
4.2.
4.3.
4.4.
4.5.
4.6.
4.7.
4.8.
4.9.
5.
SUMMARY OF START-UP
FINAL PREPARATIONS
PURGING AND INERTING
HEATER START-UP
HEATING UP
STREAMING PRODUCTS
NORMAL OPERATION
NORMAL SHUTDOWN
7.1.
7.2.
7.3.
7.4.
7.5.
7.6.
7.7.
8.
PLANT CHECK-OUT
LINE FLUSHING
WATER CIRCULATION
LEAK TEST (AT 8 KG/CM2)
H-1101 HEATER DRY-OUT
CHEMICAL CLEANING
NORMAL START-UP
6.1.
6.2.
6.3.
6.4.
6.5.
6.6.
6.7.
7.
FUEL
STEAM
ELECTRICAL POWER
COOLING WATER
WATER
NITROGEN
PLANT AND INSTRUMENT AIR
CHEMICALS
CHEMICAL HANDLING
PREPARATION FOR INITIAL START-UP

5.1.
5.2.
5.3.
5.4.
5.5.
5.6.
6.
COMPLEX CONTROL DESCRIPTION
SUMMARY OF SHUTDOWN
REDUCTION OF FLOWRATES
SHUTDOWN OF HEATERS AND HEAT OFF.
FLUSHING OF UNIT
STEAMING OUT AND PREPARATION FOR MAINTENANCE
KEROSENE STRIPPER REBOILER FOR MAINTENANCE
DESALTERS ISOLATION FOR MAINTENANCE
EMERGENCY SHUTDOWN PROCEDURES

8.1.
8.2.
8.3.
8.3.1.
8.3.2.
8.3.3.
8.3.4.
8.4.
8.5.
8.6.
8.7.
8.8.
8.9.
8.10.
GENERAL EMERGENCY SHUTDOWN

POWER FAILURE
STEAM FAILURE
L.P. Steam Failure
M.P. Steam Failure
H.P. Steam Failure
Complete Steam Failure
INSTRUMENT AIR FAILURE
COOLING WATER FAILURE
FUEL GAS SYSTEM FAILURE
FUEL OIL SYSTEM FAILURE
PILOT GAS SYSTEM FAILURE
NITROGEN FAILURE
MECHANICAL FAILURE
November 2008
Rev.
:1
Chapter : Page
: 2/3

DUNG QUAT REFINERY
OPERATING MANUAL
UNIT CDU (011)
9.
SAFETY EQUIPMENT AND PROCEDURES

9.1.
PRESSURE SAFETY DEVICES
9.2.
ALARM SETTINGS
9.3.
TRIP SETTINGS
9.4.
TRIP SYSTEM CHART
9.5.
CAUSE AND EFFECT DIAGRAM
9.6.
MATERIAL HAZARD DATA SHEETS
9.7.
SAFEGUARDING MEMORANDUM
9.7.1.
Heat exchanger tube rupture
9.7.2.
Chemical injection packages, A-1104.
9.7.3.
Desalter Package A-1101
9.7.4.
Kerosene pump around and rundown systems
9.7.5.
LGO pump-around and rundown systems
9.7.6.
HGO pump around and rundown systems
9.7.7.
T-1101 accumulator drum, D-1103, Interphase controller (011-LIC-040) failure
9.7.8.
T-1107 reflux drum, D-1104, Water boot level controller (011-LIC-050) failure.
9.7.9.
T-1107 closed drain connection
9.7.10. D-1106 oil level, 011-LIC-028 fails on P-1120 A/B starting
9.7.11. Interlocking devices
10.
10.1.
10.2.
11.
11.1.
11.2.
11.3.
11.4.
12.
12.1.
12.2.
13.
13.1.
13.2.
13.3.
14.
14.1.
14.2.
14.3.
14.4.
INSTRUMENT DATA
CONTROL VALVES AND INSTRUMENTS
ORIFICE PLATES
SUMMARY OF MAJOR EQUIPMENT
EQUIPMENT LIST
CRUDE CHARGE HEATER, H-1101
DESALTERS PACKAGE, A-1101
VACUUM PACKAGE, A-1102
ANALYSIS
SAMPLING AND TESTING SCHEDULE
ON LINE ANALYSERS
PROCESS CONTROL
DISTRIBUTED CONTROL SYSTEM
INSTRUMENT PROTECTIVE SYSTEM AND SAFEGUARDING SYSTEMS
CONTROL CENTRE
DRAWINGS
PLOT AND HAZARDOUS AREAS CLASSIFICATIONS PLANS
PROCESS FLOW DIAGRAMS AND MATERIAL SELECTION DIAGRAMS
PIPING AND INSTRUMENT DIAGRAMS
OTHER DRAWINGS
November 2008
Rev.
:1
Chapter : Page
: 3/3

8474L-011-Manual (1-48)

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VIETNAM OIL AND GAS CORPORATION

CRUDE DISTILLATION UNIT

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

Total Sulfur (Wt %)

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

1.3. PRODUCT SPECIFICATIONS

C5 content in LPG rich stream

1.5 mol% max.

C4 content in Full Range Naphtha

0.3 wt% max.

Gap between the 5%vol of Kerosene

Gap between the 5%vol of Light Gas

Overlap between the 95%vol of Light

Heavy Gas Oil flash point

Kerosene flash point

Kerosene smoke point

Kerosene density @ 15C

0.83 kg/l max.

Light Gas Oil cetane index

Light Gas Oil flash point

Light Gas Oil pour point

Residue vaporizing below 360 C

10% vol. max.

ASTM D1116 (note 1)

Product Properties Bach Ho case

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

Product Properties Dubai case

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

1.4. MATERIAL BALANCES

TBP cut point (C)

Full Range Naphtha / Kerosene

Kerosene / Light Gas Oil

Light Gas Oil / Heavy Gas Oil

Heavy Gas Oil / Atmospheric residue

% Wt of feed (water included)

Light Gas Oil

Heavy Gas Oil

% Wt of feed (water included)

Light Gas Oil

Heavy Gas Oil

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

Naphtha flexibility cut point

Maximum naphtha production

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

Minimum naphtha production

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)