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 ºC

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

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

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Component properties Fraction ºC

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. Component properties Temperature (ºC)

Wt % Cumm

Density

89

5

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

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) 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

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

November 2008 Rev. :1 Chapter : 1 Page : 4/34

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

0ºC min.

ASTM D86

Gap between the 5%vol of Light Gas Oil and 95% vol. of Kerosene

0ºC min.

ASTM D86

Overlap between the 95%vol of Light Gas Oil and 5% vol. of Heavy Gas Oil

20ºC max.

ASTM D86

Heavy Gas Oil flash point

65 ºC min. (note 2)

ASTM D93

Kerosene flash point

40 ºC min.

ASTM D93

Kerosene smoke point

20 mm min.

ASTM D1322

Kerosene density @ 15ºC

0.83 kg/l max.

ASTM D1298

Light Gas Oil cetane index

45 min.

ASTM D4737

Light Gas Oil flash point

65 ºC min.

ASTM D93

Light Gas Oil pour point

0 ºC max.

ASTM D97

Residue vaporizing below 360 ºC

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 130°C 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.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

1.3.1.1.

November 2008 Rev. :1 Chapter : 1 Page : 5/34

Design Case

ºC

Naphtha C5-165 0.7105 0.001

Boiling Range S.G 60/60F Total Sulfur Kinematic viscosity 37.8 ºC 50.0 ºC 70.0 ºC 98.9 ºC

cSt cSt cSt cSt

0.84 0.73

RVP

kPa

27.65

Flash Point Pour Point Freeze Point Cloud Point

ºC ºC ºC ºC

ASTM D86 0%Vol 5%Vol 10%Vol 30%Vol 50%Vol 70%Vol 90%Vol 95%Vol 100%Vol

ºC ºC ºC ºC ºC ºC ºC ºC ºC

ASTM D1160 (760 mmHg) 0%Vol 5%Vol 10%Vol 30%Vol 50%Vol 70%Vol 90%Vol 95%Vol 100%Vol

ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

1.3.1.2.

November 2008 Rev. :1 Chapter : 1 Page : 6/34

Maximum Naphtha

ºC

Naphtha C5-170 0.7143 0.001

Boiling Range S.G 60/60F Total Sulfur Kinematic viscosity 37.8 ºC 50.0 ºC 70.0 ºC 98.9 ºC

cSt cSt cSt cSt

0.84 0.73

RVP

kPa

26.27

Flash Point Pour Point Freeze Point Cloud Point

ºC ºC ºC ºC

ASTM D86 0%Vol 5%Vol 10%Vol 30%Vol 50%Vol 70%Vol 90%Vol 95%Vol 100%Vol

ºC ºC ºC ºC ºC ºC ºC ºC ºC

ASTM D1160 (760 mmHg) 0%Vol 5%Vol 10%Vol 30%Vol 50%Vol 70%Vol 90%Vol 95%Vol 100%Vol

ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

1.3.1.3.

November 2008 Rev. :1 Chapter : 1 Page : 7/34

Minimum Naphtha

ºC

Naphtha C5-160 0.7093 0.001

Boiling Range S.G 60/60F Total Sulfur Kinematic viscosity 37.8 ºC 50.0 ºC 70.0 ºC 98.9 ºC

cSt cSt cSt cSt

0.84 0.73

RVP

kPa

28.20

Flash Point Pour Point Freeze Point Cloud Point

ºC ºC ºC ºC

ASTM D86 0%Vol 5%Vol 10%Vol 30%Vol 50%Vol 70%Vol 90%Vol 95%Vol 100%Vol

ºC ºC ºC ºC ºC ºC ºC ºC ºC

ASTM D1160 (760 mmHg) 0%Vol 5%Vol 10%Vol 30%Vol 50%Vol 70%Vol 90%Vol 95%Vol 100%Vol

ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

1.3.1.4.

November 2008 Rev. :1 Chapter : 1 Page : 8/34

Maximum Kerosene

ºC

Naphtha C5-160 0.7093 0.001

Boiling Range S.G 60/60F Total Sulfur Kinematic viscosity 37.8 ºC 50.0 ºC 70.0 ºC 98.9 ºC

cSt cSt cSt cSt

0.83 0.73

RVP

kPa

28.20

Flash Point Pour Point Freeze Point Cloud Point

ºC ºC ºC ºC

ASTM D86 0%Vol 5%Vol 10%Vol 30%Vol 50%Vol 70%Vol 90%Vol 95%Vol 100%Vol

ºC ºC ºC ºC ºC ºC ºC ºC ºC

ASTM D1160 (760 mmHg) 0%Vol 5%Vol 10%Vol 30%Vol 50%Vol 70%Vol 90%Vol 95%Vol 100%Vol

ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

1.3.1.5.

November 2008 Rev. :1 Chapter : 1 Page : 9/34

Minimum Kerosene

ºC

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 ºC 50.0 ºC 70.0 ºC 98.9 ºC

cSt cSt cSt cSt

0.84 0.73

RVP

kPa

26.27

Flash Point Pour Point Freeze Point Cloud Point

ºC ºC ºC ºC

ASTM D86 0%Vol 5%Vol 10%Vol 30%Vol 50%Vol 70%Vol 90%Vol 95%Vol 100%Vol

ºC ºC ºC ºC ºC ºC ºC ºC ºC

ASTM D1160 (760 mmHg) 0%Vol 5%Vol 10%Vol 30%Vol 50%Vol 70%Vol 90%Vol 95%Vol 100%Vol

ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

1.3.1.6.

November 2008 Rev. :1 Chapter : 1 Page : 10/34

Maximum LGO

ºC

Naphtha C5-165 0.7117 0.001

Boiling Range S.G 60/60F Total Sulfur Kinematic viscosity 37.8 ºC 50.0 ºC 70.0 ºC 98.9 ºC

cSt cSt cSt cSt

0.84 0.73

RVP

kPa

27.17

Flash Point Pour Point Freeze Point Cloud Point

ºC ºC ºC ºC

ASTM D86 0%Vol 5%Vol 10%Vol 30%Vol 50%Vol 70%Vol 90%Vol 95%Vol 100%Vol

ºC ºC ºC ºC ºC ºC ºC ºC ºC

ASTM D1160 (760 mmHg) 0%Vol 5%Vol 10%Vol 30%Vol 50%Vol 70%Vol 90%Vol 95%Vol 100%Vol

ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

1.3.1.7.

November 2008 Rev. :1 Chapter : 1 Page : 11/34

Minimum LGO

ºC

Naphtha C5-165 0.7119 0.001

Boiling Range S.G 60/60F Total Sulfur Kinematic viscosity 37.8 ºC 50.0 ºC 70.0 ºC 98.9 ºC

cSt cSt cSt cSt

0.84 0.73

RVP

kPa

27.23

Flash Point Pour Point Freeze Point Cloud Point

ºC ºC ºC ºC

ASTM D86 0%Vol 5%Vol 10%Vol 30%Vol 50%Vol 70%Vol 90%Vol 95%Vol 100%Vol

ºC ºC ºC ºC ºC ºC ºC ºC ºC

ASTM D1160 (760 mmHg) 0%Vol 5%Vol 10%Vol 30%Vol 50%Vol 70%Vol 90%Vol 95%Vol 100%Vol

ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

1.3.1.8.

November 2008 Rev. :1 Chapter : 1 Page : 12/34

Maximum HGO

ºC

Naphtha C5-165 0.7118 0.001

Boiling Range S.G 60/60F Total Sulfur Kinematic viscosity 37.8 ºC 50.0 ºC 70.0 ºC 98.9 ºC

cSt cSt cSt cSt

0.84 0.73

RVP

kPa

27.17

Flash Point Pour Point Freeze Point Cloud Point

ºC ºC ºC ºC

ASTM D86 0%Vol 5%Vol 10%Vol 30%Vol 50%Vol 70%Vol 90%Vol 95%Vol 100%Vol

ºC ºC ºC ºC ºC ºC ºC ºC ºC

ASTM D1160 (760 mmHg) 0%Vol 5%Vol 10%Vol 30%Vol 50%Vol 70%Vol 90%Vol 95%Vol 100%Vol

ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

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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

ºC

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 ºC 50.0 ºC 70.0 ºC 98.9 ºC

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

ºC ºC ºC ºC

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

ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

1.3.2.2.

November 2008 Rev. :1 Chapter : 1 Page : 14/34

Maximum Naphtha

ºC

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 ºC 50.0 ºC 70.0 ºC 98.9 ºC

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

ºC ºC ºC ºC

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

ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

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1.3.2.3.

November 2008 Rev. :1 Chapter : 1 Page : 15/34

Minimum Naphtha

ºC

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 ºC 50.0 ºC 70.0 ºC 98.9 ºC

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

ºC ºC ºC ºC

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

ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

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November 2008 Rev. :1 Chapter : 1 Page : 16/34

Maximum Kerosene

ºC

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 ºC 50.0 ºC 70.0 ºC 98.9 ºC

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

ºC ºC ºC ºC

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

ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

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1.3.2.5.

November 2008 Rev. :1 Chapter : 1 Page : 17/34

Minimum Kerosene

ºC

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 ºC 50.0 ºC 70.0 ºC 98.9 ºC

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

ºC ºC ºC ºC

55.2

86.5 -26.6 -25.5 -27.1

137.0 8.5

153.2 53.0

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ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

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November 2008 Rev. :1 Chapter : 1 Page : 18/34

Maximum LGO

ºC

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 ºC 50.0 ºC 70.0 ºC 98.9 ºC

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

ºC ºC ºC ºC

52.4

87.6 -24.6 -23.4 -23.5

140.1 11.6

153.2 53.0

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ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

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1.3.2.7.

November 2008 Rev. :1 Chapter : 1 Page : 19/34

Minimum LGO

ºC

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 ºC 50.0 ºC 70.0 ºC 98.9 ºC

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

ºC ºC ºC ºC

53.4

90.1 -26.5 -25.8 -27.0

133.8 5.5

153.2 53.0

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ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

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ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

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November 2008 Rev. :1 Chapter : 1 Page : 20/34

Maximum HGO

ºC

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 ºC 50.0 ºC 70.0 ºC 98.9 ºC

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

ºC ºC ºC ºC

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

ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

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ºC ºC ºC ºC ºC ºC ºC ºC ºC

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

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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 (ºC)

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

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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 PFD’s stream numbers.

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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 ºC to 170 ºC. These TBP cut points correspond with minimum and maximum naphtha production cases, respectively. 1.4.3.1.1.

Maximum naphtha production

This flexibility case’s 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.

November 2008 Rev. :1 Chapter : 1 Page : 25/34

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1.4.3.2.

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Kerosene flexibility cut point

Kerosene normal cut point range of 165 ºC to 205 ºC 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 ºC to 200 ºC. 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 ºC to 210 ºC. 1.4.3.2.1.

Maximum kerosene production

Kerosene flows for this flexibility case (TBP cut range of 160 ºC to 210 ºC) are summarized in the table below:

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Table 15: Maximum kerosene production flexibility case.

November 2008 Rev. :1 Chapter : 1 Page : 27/34

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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.

November 2008 Rev. :1 Chapter : 1 Page : 28/34

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1.4.3.3.

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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 ºC 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 ºC 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 ºC to 340 ºC), minimum light gas oil production (TBP cut range of 210 ºC to 320 ºC) and maximum heavy gas oil production (TBP cut range of 320 ºC to 370 ºC). 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.

November 2008 Rev. :1 Chapter : 1 Page : 30/34

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1.4.3.3.2.

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Minimum light gas oil production

This flexibility case’s 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.

November 2008 Rev. :1 Chapter : 1 Page : 32/34

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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 (ºC)

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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Battery Limit Conditions

November 2008 Rev. :1 Chapter : 1 Page : 34/34

Operating Pressure 2 (Kg/cm g)

Operating Temperature (ºC)

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&ID’s: 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 50ºC up to 138-133ºC, 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 ºC up to 283-277ºC, 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-1109 HGO Pump around from P-1105

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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&ID’s: 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 120ºC, 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&ID’s: 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 ºC, 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 ¾” 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&ID’s: 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 fractionator’s 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 - 124º (top) to 349 - 354 ºC (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 ºC), after receiving injection of both corrosion inhibitor and neutralizer chemical, condenses totally through the Main Fractionator Condenser E-1111 at 50 ºC. 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 40ºC (controlled by 011-TIC-122) for the KTU.

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2.1.4.3.

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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 85ºC in E-1120 A-D.

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T-1101 bottom Residue (at 349-354 ºC) 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&ID’s: 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&ID’s: 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 55ºC 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 55ºC 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&ID’s: 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&ID’s: 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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3

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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2.2.2.

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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.

•

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.

2.3.5.

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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November 2008 Rev. :1 Chapter : 2 Page : 12/12

•

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.

•

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, allow heat exchanger to cool, recheck atmosphere for oxygen and hydrocarbon and hand over to maintenance.

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3.

DESCRIPTION OF UNIT CONTROL

3.1.

DESCRIPTION OF FLOW UNIT CONTROL 3.1.1.

November 2008 Rev. :1 Chapter : 3 Page : 1/38

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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3.1.1.11.

November 2008 Rev. :1 Chapter : 3 Page : 3/38

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&ID’s (8474L-011PID-0021-001 / 138).

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3.1.2.1.

November 2008 Rev. :1 Chapter : 3 Page : 4/38

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

P-1103 A/B Pump Protection tripped

011-UX-021

115

P-1104 A/B Pump Protection tripped

011-UX-022

116

P-1105 A/B Pump Protection tripped

011-UX-003

115

T-1103 Protection tripped

011-UX-004

116

T-1104 Protection tripped

011-UX-005A

134

H-1101 heater shutdown tripped

011-UX-026

131

D-1104 Inventory Isolation tripped

011-UX-017

112

T-1101 Protection tripped

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

P-1119 A/B Pump Protection tripped

011-UX-011

105

P-1101 A/B Pump Protection tripped

011-UX-018

104

P-1118 A/B Pump Protection tripped

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

This trip is manually reset by 11-UHSR-001 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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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)

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-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

Low low operating level Desalter A-1101-D-01.

011-LXALL-517

0.5 seconds

104

Low low oil operating level in transformer TR-01A

011-PXAHH-580

0.5 seconds

104

High-high oil pressure transformer TR-01A

in

in

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Actions: Action Tag No.

P&ID No.

Service

011-MXS-133

104

TR-01A transformed tripped

This trip is manually reset by 011-UHSR-133. 3.1.2.5.

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

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-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

Low low operating level Desalter A-1101-D-02.

011-LXALL-520

0.5 seconds

105

Low low oil operating level in 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

This trip is manually reset by 011-UHSR-028. 3.1.2.6.

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

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

in

in

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Initiators: Initiator

Time

P&ID

Cause

Tag No.

Delay

No.

011-LXALL-505

0.5 seconds

105

Low low operating level Desalter A-1101-D-02.

011-LXALL-518

0.5 seconds

105

Low low oil operating level in 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

This trip is manually reset by 011-UHSR-134. 3.1.2.7.

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

Purpose: In the event of any of the following: 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

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Initiator

Time

P&ID

Tag No.

Delay

No.

011-XHSC-002B

011-XHSC-002B

-

November 2008 Rev. :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

This trip is manually reset by 011-UHSR-026 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

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Initiator Tag No.

Time Delay

November 2008 Rev. :1 Chapter : 3 Page : 10/38

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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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-006 011-XV-010 reset is done via local push button 011-XHSR-010 011-XV-014 reset is done via local push button 011-XHSR-014 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-005A Heater trip 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

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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

Desalter Protection trip

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. 011-XV-008 reset is done via local push button 011-XHSR-008 011-XV-009 reset is done via local push button 011-XHSR-009 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-005A Heater trip 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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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. 011-XV-004 reset is done via local push button 011-XHSR-004 011-XV-005 reset is done via local push button 011-XHSR-005 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 011-UX-005A Heater trip 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

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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. 011-XV-007 reset is done via local push button 011-XHSR-007 011-XV-011 reset is done via local push button 011-XHSR-011 011-XV-012 reset is done via local push button 011-XHSR-012

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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: Desalter Protection trip 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

Desalter Protection trip

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.

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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

This trip is manually reset by 011-UHSR-020. 3.1.2.11.

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

Purpose: In the event of one of the following: 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

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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

This trip is manually reset by 011-UHSR-021. 3.1.2.12.

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

Purpose: In the event of one of the following: 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

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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 controller set to manual and output 0%

011-FQIC-026

125

Atmospheric residue to storage flow controller set to manual and output 0%

011-FQIC-027

125

Atmospheric residue to storage flow controller set to manual and output 0%

This trip is manually reset by 011-UHSR-025 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%

This trip is manually reset by 011-UHSR-009 3.1.2.14.

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

Purpose: In the event of any of the following: CDU emergency shutdown

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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

T-1101 Protection tripped

011-XXA-001

112

011-XV-001 Local panel trip alarm activated

011-UXA-002B

112

T-1101 isolated activated

auxiliary

This trip is manually reset by 011-UHSR-002 011-XV-001 reset is done via local push button 011-XHSR-001

console

ADP

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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)

Purpose: In the event of any of the following 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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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

This trip is manually reset by 011-UHSR-003 3.1.2.17.

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

Purpose: In the event of any of the following 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.

This trip is manually reset by 011-UHSR-004 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.

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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

This trip is manually reset by 011-UHSR-040. 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

Low low level in T-1103.

Actions: Action

P&ID No.

Service

117

T-1105 LGO inlet valve closed

Tag No. LV-019

This trip is manually reset by 011-UHSR-041

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.

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Initiators: Initiator

Time

P&ID

Tag No.

Delay

No.

011-LXALL-054

0.5 seconds

130

Cause

Low low level in T-1107.

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

This trip is manually reset by 011-UHSR-042 3.1.2.21.

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

Purpose: In the event of any of the following 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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Action Tag No.

P&ID No.

Service

FIC-013

103

Kerosene P/A flow control set to manual and output 0%

This trip is manually reset by 011-UHSR-023

3.1.2.22.

P-1105A/B HGO P/A pump protection (011-UX-022)

Purpose: In the event of any of the following 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.

This trip is manually reset by 011-UHSR-022

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.

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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%

This trip is manually reset by 011-UHSR-008 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

Desalter Protection trip

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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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

This trip is manually reset by 011-UHSR-018 3.1.2.25. P-1114 A/B stabilizer reflux and P-1115A/B stabilizer LPG pumps protection (011-UX-006) Purpose: In the event of any of the following: 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

Low low level in D-1104.

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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Action Tag No.

P&ID No.

Service

011-LIC-050

131

Sour water level controller set to manual and output of 0%

This trip is manually reset by 011-UHSR-006. 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

Low low level in D-1103.

Actions: Action No. LV-040

Tag

P&ID No.

Service

128

Water D-1103 outlet valve close

This trip is manually reset by 011-UHSR-014. 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

Low low level in T-1106.

116

Low low level in T-1104

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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%

This trip is manually reset by 011-UHSR-010 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

Low low level in T-1105.

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%

This trip is manually reset by 011-UHSR-012 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

Low low level in D-1103.

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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

This trip is manually reset by 011-UHSR-015. 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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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%

This trip is manually reset by 011-UHSR-016 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%

This trip is manually reset by 011-UHSR-024. 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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3.3.1.

November 2008 Rev. :1 Chapter : 3 Page : 31/38

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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3.3.6.

November 2008 Rev. :1 Chapter : 3 Page : 32/38

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 product’s 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) doesn’t 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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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&ID’s: -

8474L-011-PID-0021-112

-

8474L-011-PID-0021-125

RFCC P&ID’s: -

•

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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November 2008 Rev. :1 Chapter : 3 Page : 34/38

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

This description should be read in conjunction with the following: •

•

CDU P&ID’s: -

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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November 2008 Rev. :1 Chapter : 3 Page : 35/38

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

This description should be read in conjunction with the following: •

•

CDU P&ID’s: -

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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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

This description should be read in conjunction with the following: •

•

CDU P&ID’s: -

8474L-011-PID-0021-119

-

8474L-011-PID-0021-123

-

8474L-011-PID-0021-124

SWS P&ID’s:

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

•

November 2008 Rev. :1 Chapter : 3 Page : 37/38

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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3.5.

November 2008 Rev. :1 Chapter : 3 Page : 38/38

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: ½ 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 (½ 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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4.

November 2008 Rev. :1 Chapter : 4 Page : 1/1

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 Refer to Estimated Utility Consumption 8474L-011-CN-0003-001 / 002 included in attachment 1. 4.3. ELECTRICAL POWER Refer to Estimated Utility Consumption 8474L-011-CN-0003-001 / 002 included in attachment 1. 4.4. COOLING WATER Refer to Estimated Utility Consumption 8474L-011-CN-0003-001 / 002 included in attachment 1. 4.5. WATER Refer to Estimated Utility Consumption 8474L-011-CN-0003-001 / 002 included in attachment 1. 4.6. NITROGEN Refer to Estimated Utility Consumption 8474L-011-CN-0003-001 / 002 included in attachment 1. 4.7. PLANT AND INSTRUMENT AIR Refer to Estimated Utility Consumption 8474L-011-CN-0003-001 / 002 included in 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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5.

November 2008 Rev. :1 Chapter : 5 Page : 1/1

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

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

6.

NORMAL START-UP

6.1.

SUMMARY OF START-UP

November 2008 Rev. :1 Chapter : 6 Page : 1/6

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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November 2008 Rev. :1 Chapter : 6 Page : 2/6

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.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

6.3.

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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 vendor’s 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&ID’s 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 100ºC (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 100ºC 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 100ºC, revert to short path circulation and gradually raise the heater outlet temperature up to 270ºC maximum. Then, switch to intermediate path, maintaining heater outlet temperature at 270 ºC. All burners will require to be lighted prior to increase the temperature to 270ºC.

•

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 manufacturer’s 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

o

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.

o

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.

o

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.

o

Ensure desalter pressure controller is commissioned

o

Ensure that by-pass around the crude booster pump is lined up.

o

Open at 25% gate valve placed at P-1101 discharge line.

o

Start pump.

o

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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6.6.

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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:

•

o

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.

o

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.

o

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)

o

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 ºC. 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).

o

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.

o

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,

•

3

3

o

Reduce FQIC020 (LGO to storage) Set Point to 160 m /h and then to 3 108 m /h.

o

Reduce FQIC033 (Kerosene to Storage) Set Point to 33 m /h.

o

Reduce FQIC028 (HGO to Storage) Set Point to 42 m /h.

o

In the same time reduce the UIC031 Set Point from 2.8 to 1.4 MW and reduce the stripping steam flowrate.

3

3

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&ID’s 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:

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

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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 vendor’s 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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November 2008 Rev. :1 Chapter : 7 Page : 6/6

•

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.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

8.2.4

November 2008 Rev. :1 Chapter : 8 Page : 2/4

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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• 8.3.4.

November 2008 Rev. :1 Chapter : 8 Page : 3/4

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. 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. See point 3.3.6 for possible actions to be taken if products go out of specification. 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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10.

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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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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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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 ºC

AE/AT-004

LPG to gas recovery on RFCC

C5+ (pentane or heavier) content

1.5 % mol

AE/AT-005

Kerosene product from E-1114 to KTU

Freeze Point

- 47 ºC

AE/AT-006

Kerosene product from E-1114 to KTU

Specific Gravity @ 15 ºC

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.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

13.

November 2008 Rev. :1 Chapter : 13 Page : 1/1

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”.

•

8474L-000-JSD-1510-001, “Design and Engineering Information for Control and Instrumentation”.

•

8474L-000-DW-1510-001. “Control System Interconnection Diagram”.

13.3.

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

8474L-000-JSD-1510-001, “Design and Engineering Information for Control and Instrumentation”.

•

8474L-000-DW-1510-001. “Control System Interconnection Diagram”.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

November 2008 Rev. :1 Chapter : 14 Page : 1/6

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

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

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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

Cold preheat train (2/3)

8474L-011-PID-0021-102

Cold preheat train (3/3)

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

Hot preheat train (2/4)

8474L-011-PID-0021-107

Hot preheat train (3/4)

8474L-011-PID-0021-108

Hot preheat train (4/4)

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

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

November 2008 Rev. :1 Chapter : 14 Page : 3/6

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

Decoking station (2/3)

8474L-011-PID-0021-141

Decoking station (3/3)

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

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

November 2008 Rev. :1 Chapter : 14 Page : 4/6

Level instruments details (2/4)

8474L-011-PID-0021-303

Level instruments details (3/4)

8474L-011-PID-0021-304

Level instruments details (4/4)

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

Air cooler details (2/4)

8474L-011-PID-0021-402

Air cooler details (3/4)

8474L-011-PID-0021-403

Air cooler details (4/4)

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

Steam, condensate and boiler feed water distribution (2/5)

8474L-011-PID-0031-502

Steam, condensate and boiler feed water distribution (3/5)

8474L-011-PID-0031-503

Steam, condensate and boiler feed water distribution (4/5)

8474L-011-PID-0031-504

Steam, condensate and boiler feed water distribution (5/5)

8474L-011-PID-0031-505

Cooling water, demineralized water, service water and potable water distribution (1/4)

8474L-011-PID-0031-511

Cooling water, demineralized water, service water and potable water distribution (2/4)

8474L-011-PID-0031-512

Cooling water, demineralized water, service water and potable water distribution (3/4)

8474L-011-PID-0031-513

Cooling water, demineralized water, service water and potable water distribution (4/4)

8474L-011-PID-0031-514

Nitrogen, instrument air and plant air distribution (1/3)

8474L-011-PID-0031-521

Nitrogen, instrument air and plant air distribution (2/3)

8474L-011-PID-0031-522

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

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Nitrogen, instrument air and plant air distribution (3/3)

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

Flushing oil distribution (2/3)

8474L-011-PID-0031-562

Flushing oil distribution (3/3)

8474L-011-PID-0031-563

Closed drain system (1/7)

8474L-011-PID-0031-571

Closed drain system (2/7)

8474L-011-PID-0031-572

Closed drain system (3/7)

8474L-011-PID-0031-573

Closed drain system (4/7)

8474L-011-PID-0031-574

Closed drain system (5/7)

8474L-011-PID-0031-575

Closed drain system (6/7)

8474L-011-PID-0031-576

Closed drain system (7/7)

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

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL UNIT CDU (011)

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

General Underground Network (Sheet 3)

8474L-011-DW-1442-003

General Underground Network (Sheet 4)

8474L-011-DW-1442-004

General Underground Network (Sheet 5)

8474L-011-DW-1442-005

General Underground Network (Sheet 6)

8474L-011-DW-1442-006

General Underground Network (Sheet 7)

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)

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) 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. :1 Chapter : Page : 1/3

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL 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

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) 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