Recovery Plus Operating Manual

RELIANCE PETROLEUM LIMITED

OPERATING MANUAL RECOVERY PLUS

JAMNAGAR

UNIT 233

RECOVERY PLUS OPERATING MANUAL Table of Contents

1.0

General 1.1

1.2

Introduction

Glossary 1.3

2.0

3.0

4.0

Abbreviation

Unit Description 2.1

Design Basis

2.2

Process Flow Description and Controls

2.3

DCS Description

2.4

Design Flow Plan

2.5

Refinery Site, Underground Piping and Unit Layout Plan

2.6

Material Balance

2.7

Feed and Product Specifications

2.8

Catalyst and Chemicals Details

2.9

Utility conditions and requirement

Interconnectivity 3.1

Inter Unit Relationship

3.2

Inter Plant Relationship

3.3

Utility / Offsite Relationship

Preparing the Unit for Initial Start-up 4.1

Introduction

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4.2

Utility System Readiness

4.2.1

Piping Network

4.2.2

Commissioning of Utilities

4.3

Inspection of Equipments

4.3.1

Piping and Supports 4.3.1.1

Visual Inspection

4.3.1.2

Hydrostatic Test

4.3.1.3

Flushing

4.3.1.4

Air Blowing and Drawing

4.3.1.5

Tightness Test

4.3.2

Vessels

4.3.3

Exchangers

4.3.4

Pumps

4.3.5

Compressors

4.3.6

Instrumentation System

4.3.7

Electrical System

4.4

Chemical Cleaning and N2 Blaketing

4.5

Run-in Pumps

4.6

Run-in Compressors

4.7

Tightness Test and Inertisation

5.0

4.7.1

Tightness Test

4.7.2

Vacuum Test and Inertisation

4.8

Safety Checks Before Start-up

OPERATING MANUAL RECOVERY PLUS UNIT 233

Commissioning / Initial Start up 5.1

notification to other departments

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6.0

7.0

UNIT 233

5.2

Utilities Start-up

5.3

Outline of Initial Start-up

5.4

Evacuation of Air, Nitrogen and Water Removal

5.5

Charging of Lube Oil

5.6

Oil Circulation

5.7

Inventory Refrigeration Circuit with Refrigerant

5.8

Initial Compressor Start-up

Start up 6.1

General

6.2

Notification to Other Departments

6.3

Utilities Start-up

6.4

Outline of Initial Start-up

6.5

Compressor Start-up

Normal Shutdown 7.1

General

7.2

Notification to Other Departments

7.3

Preshutdown Preparation

7.4

General Outline of Normal Shutdown

7.5

Refrigeration Circuit Shut Down

7.6

Process Circuit Shut Down

7.7

Refrigerant Retained in Receiver

7.8

Post Shutdown Checks

7.9

Equipment Handing/Taking Over to/from Maintenance

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8.0

9.0

10.0

OPERATING MANUAL RECOVERY PLUS UNIT 233

Normal Operation 8.1

Process Principles

8.2

Process Variables

8.3

Control Philosophy & Key Analyses

Unit Safeguarding System 9.1

Relief Device Summary

9.2

Instrument Alarm

9.3

Instrument Trip

Emergency Shutdown 10.1

General

10.2

Interconnectivity During Emergencies

10.3

Process and Utility Failure

10.3.1 Power Failure 10.3.2 Loss of Cooling Water 10.3.3 Loss of Refrigerant 10.3.4 Loss of Instrument Air

11.0 Special Procedures 11.1 Initial Refrigerant Loading

12.0

Fire & safety 12.1

Introduction

12.2

Repair Work, Permit to Work System, Housekeeping and Maintenance on

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UNIT 233

12.3

Safety During Sample Withdrawal

12.3

Fire Fighting and Safety Equipment

12.5

Precautions for Entering any Contaminated or Inert Atmosphere

12.6

General RECOVERY PLUS Unit Safety Notes

12.7

Material Safety Data Sheet (MSDS)

13.0

Laboratory Requirements and Schedule

14.0

Major Equipment and Instruments’ Summary 14.1.1 Vessels 14.1.2 Shell and Tube Exchangers 14.1.3 Pumps 14.2

15.0

Instruments Summary

List of Reference Drawings PFD, P & ID, MFD, Plot Plan, PSFS, MSD, Area Protection Layout, Safety Equipment Layout, Safety Signs Layout, PIB#4 Gaseous Fire Extinguishing System

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1.O

GENERAL

1.1

Introduction The Aromatics plant at Jamnagar is designed to produce 1,200,000 tons of Paraxylene per annum and 150,000 tons of Orthoxylene from naphtha feed stock (2641 KTPA) available from Jamnagar Refinery Complex and Mixed Xylenes (80 KTPA) from Hazira. Feed Naphtha from the refinery consists of: 

Straight run naphtha



Delayed Coker naphtha



FCC heart cut Naphtha Paraxylene Plant basic technology has been provided by UOP. It will process special cut Naphtha (105 oC – 165 oC) to produce Paraxylene as the major product and other side cut products. These are as follows.



LPG

= 305

TPD



Light Reformate

= 752

TPD



Benzene

= 326

TPD



Toluene

= 300

TPD



Paraxylene

= 3600 TPD



Orthoxylene

= 450

TPD



Heavy aromatics to blend = 407

TPD



Heavy aromatics to fuel

=

48

TPD



Hydrogen

= 171

TPD

In addition some gases will go to fuel gas system.

RELIANCE PETROLEUM LIMITED JAMNAGAR

OPERATING MANUAL RECOVERY PLUS UNIT 233

Paraxylene plant in Jamnagar consists of the following units: 1.

Heavy Naphtha Unionfining Unit

Unit No.221

2.

Platformer Unit

Unit No.231

3.

Cyclemax Continuous Regeneration Unit

Unit No.232

4.

Recovery-Plus

Unit No.233

5.

PSA

Unit No.234

6.

Xylene fractionation unit (3 trains)

Unit No.241/242/243

7. Orthoxylene fractionation unit

Unit No. 251

8. Parex Unit (3 trains)

Unit No. 261/262/263

9. Isomar Unit (3 trains)

Unit No. 271/272/273

10. Tatoray Unit

Unit No.281

11. Aromatics Tankage

Unit No.201

12. Aromatic Blowdown

Unit No.202

Key Features As a part of the Jamnagar Refinery complex, aromatic plant is being established. A great emphasis has been placed on maximizing the ratio of Paraxylene to Benzene product. This serves to minimize the quantity of naphtha feed stock required per ton of Paraxylene product and avoids excess production of Benzene. A key element of UOP’s strategy is to maximize Paraxylene to Benzene ratio by controlling the Naphtha initial points and end points upstream in the refinery. Heavy Naphtha feed stock for Platforming unit is obtained from three sources as follows.

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OPERATING MANUAL RECOVERY PLUS UNIT 233

Boiling range a. Saturate Gas Concentration Unit Naphtha 105 to 165 oC b. Sydec Delayed coker Unit Naphtha

105 to 165 oC

c. FCC heart cut naphtha

105 to 180 oC

For naphtha streams initial boiling point of 105 oC has been selected and a wide gap specified. This cut point, combined with a sharp fractionation, will serve to drive most of the C7 paraffin’s up into the light naphtha storage, but retain most of Toluene in the heavy naphtha to be used for aromatics production via Platforming units. The 105 oC cut point also eliminates Benzene precursors from the Platforming unit feed stock. The end point of 165 oC will ensure that almost all C8 molecules and many C9 molecules will go into the heavy naphtha feed stock for aromatics production. To maximize Paraxylene production, it is important to retain all the C8 precursors and obtain just the right amount of C9 to generate enough C9 aromatics to fully load the Tatoray unit.

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1.2

OPERATING MANUAL UNIT 233

Glossary

Terms Absorption

-

Description The process by which one substance draws into itself another substances i.e. CO2 absorbed in K2CO3 solution, HC absorbed in lean oil from net gas stream, etc.

Accumulator

-

A vessel for the temporary storage of a gas or liquid usually used for collecting sufficient material for a continuous charge to some refining process.

Adsorption

-

The physical separation of multiple components by solid adsorbent. i.e. removal of moisture, CO2 from air by air dryer using silica / alumina as adsorbent.

API

-

An arbitrary scale expressing the gravity or density of liquid petroleum products. The measuring scale is calibrated in terms of degrees API. It may be calculated in terms of the following formula : Deg. API = (141.5/sp.gr. @60 °F) - 131.5

Aromatic

-

Derived from, or characterized by the presence of the benzene ring and having sweet odor. The name usually

applied

to

the

benzene

series

of

hydrocarbons; derived from the characteristic odor of the series; Paraxylene, Ethyl Benzene(EB), Tri-

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Terms

UNIT 233

Description methyl benzene(TMB), Para di-ethyl benzene(PDEB).

Aromatic

-

A naphtha rich in aromatics precursors

Naphtha Atom

-

The smallest complete particle of an element which can be obtained which retains all physical and chemical properties of the element.

Atomize

-

To divide a liquid into extremely minute particles, either by impact with a jet of steam or compressed air, or by passage through some mechanical device.

Back pressure

-

1. The pressure on the outlet or downstream side of a flowing system. 2. In an engine, the pressure which acts adversely against the piston, causing loss of power.

Barrel

-

A common unit of measurement of liquids in the petroleum industry; it equals 42 U.S. standard gallons.

Baume

-

Specific gravity of liquids expressed as degrees on the Baume scale. For liquids lighter than water, the formula is : Sp. gr. 60 F/600 F = 140 /(130+deg. Be) For liquids heavier than water, the formula is : Sp. gr. 60 F/600 F = 145 / (145 - deg. Be)

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Terms

UNIT 233

Description

Bleeding Blend

-

Diverting a small portion of the material contained in

-

a line or vessel, usually by opening a valve slightly. Any mixture prepared for a special purpose; e.g. the products of a refinery are blended to suit market

Boiling Point

-

requirements. The temperature at which a substance boils or is converted into vapor by bubbles forming within the

Boiling Range

-

liquid; it varies with pressure. The range of temperature, usually determined at atmospheric

pressure

in

standard

laboratory

apparatus over which the boiling or distillation of an oil commences, proceeds, and finishes. Bottoms

-

The liquid which collects in the bottom of a vessel / column / tank during processing/storage. i.e. column bottom

Byproduct

-

A secondary or additional product produce during production

of

Major

product,

not

of

primary

importance. i.e. Benzene byproduct in production of Paraxylene. Calibration

-

Determination of the accuracy of an instrument by finding its variation from true measurement.

Carryover

-

1. Relatively nonvolatile contaminating material which is carried over by the overhead effluent from a

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Terms

OPERATING MANUAL UNIT 233

Description fractionating column, absorber, or reaction vessel. It may be carried as liquid droplets or finely divided solids suspended in a gas/vapor/discrete liquid. 2. That portion of a finely divided catalyst

which

escapes the cyclones of cracking units. Catalyst

-

A substance which affects, provokes, or accelerates reactions without itself being altered.

Caustic Soda

-

Sodium hydroxide, a very strong alkali.

Centrifugal

-

Consists of one or more impellers mounted on a

Pump

(Volute

rapidly rotating shaft. The liquid enters the impellers

Type)

at the center, or ‘eye’, and is thrown outward at a high velocity into the volute of the pump casing. The function of the volute is to catch the impeller discharge and convert velocity head into pressure head while conducting the liquid to the discharge nozzle of the pump casing.

Compressor

-

A machine which draws in air or other gas, compress it and discharges it at a higher pressure.

Condensation

-

The act or process of changing a vapor to a liquid, or a lighter liquid to another and denser form by depression of temperature or increase of pressure.

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Terms

OPERATING MANUAL UNIT 233

Description cooling and liquefying oil vapors. Where the cooling medium used is air, the condenser is called an air condenser.

Conduction

-

The flow of heat by contact.

Convection

-

The flow of heat through liquid or gas by actual

-

mixing of the fluids A heat exchanger whose primary purpose is to

Cooler

reduce the temperature of one of the passing fluids. Cracking

-

A phenomenon by which large oil molecules are decomposed into smaller, lower boiling molecules; at the same time, certain of these molecules, which are reactive, combine with one another to give even larger molecules than those in the original stock. The more stable molecules leave the system as cracked gasoline, but the reactive ones polymerize, forming tar and even coke. Note: Cracking may be in either the liquid or vapor phase. When a catalyst is used to bring about the desired chemical reaction, this is called catalytic cracking; otherwise, it is assumed to be thermal

Crude Oil

-

cracking. A synonym for petroleum. A naturally occurring mixture consisting predominantly of hydrocarbons and/ or sulfur, nitrogen, and oxygen derivatives of

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Terms

OPERATING MANUAL UNIT 233

Description hydrocarbons which is removed from the earth in a liquid state or is capable of being, so removed.

Discharge Line

-

Product line usually under pressure due to a pumping force being applied.

Distillate

-

That portion of a liquid which is removed as a vapor and condensed during a distillation process.

Distillation

-

Vaporization

of

a

liquid

and

its

subsequent

condensation in a different chamber. The separation of one group of petroleum constituents from another by means of volatilization in some form of closed apparatus, such as a still, by the aid of heat. Drawoff

-

A connection which allows liquid to flow from the side or bottom of a vessel.

Effluent

-

Outflow from vessel/equipment/tank

Extraction

-

The process of separating a material, by means of a solvent, into a fraction soluble in the solvent (extract) and an insoluble residue.

Flammable

-

Capable of being easily set on fire; combustible.

Flash

-

1. A sudden release in pressure resulting in partial or complete vaporization. 2. A sudden burst of light; a

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Terms

OPERATING MANUAL RECOVERY PLUS UNIT 233

Description momentary blaze.

Flash Point

-

The lowest temperature at which vapors arising from the oil will ignite momentarily (i.e. flash) on application of a flame under specified conditions.

Flooding Flue Gas

-

In a fractionating column, the filling up of a liquid due

-

to high pressure drop across trays or packing. Gas from the combustion of fuel, the heating value of which has been substantially spent and which is therefore, discarded to the flue or stack.

Fuel Oil

-

Any liquid or liquefiable petroleum product burned for the generation of heat in a furnace or firebox, or for the generation of power in a engine (exclusive of oils

Header

-

with a flash point below 100 °F ) A common manifold in which a number of pipelines are united.

Heat

-

Exchanger

Apparatus for transferring heat from one fluid to another. Specifically, a piece of equipment having a tubular piping arrangement which effects the transfer of heat from a hot to a relatively cool material by conduction through the tube walls.

Heater

-

The furnace -and- tube arrangement which is the principal heating element in a processing unit.

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Terms Hydrocarbon

-

OPERATING MANUAL RECOVERY PLUS UNIT 233

Description A compound containing only hydrogen and carbon. The simplest hydrocarbons are gases at ordinary temperatures, but with increasing molecular weight, they change to the liquid form and finally to the solid state. They form the principal constituents of petroleum.

Impingement

-

The contact of flame on skin of radiant tubes in the furnace.

Induced Draft

-

Air drawn rather than forced into a furnace.

Inert gas

-

A noncombustible gas such as nitrogen or carbon dioxide.

Inhibitor

-

A substance the presence of which, in small amounts, in a petroleum product prevents or retards undesirable chemical changes from taking place in the product, or in the condition of the equipment in which the product is used. In general, the essential function of inhibitors is to prevent or retard oxidation or corrosion.

Knockout Drum

-

A drum or vessel constructed normally with baffles, through which a mixture of gas and liquid is passed to disengage one from the other. As the mixture comes in contact with the baffles, the impact frees

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Terms

UNIT 233

Description the gases and allows them to pass overhead; the heavier substance falls to the bottom of the drum.

Liquefied

-

Petroleum Gas

Light hydrocarbon material, gaseous at atmospheric temperature and pressure, held in the liquid state by pressure

to

facilitate

storage,

transport,

and

handling. Commercial LPG consists essentially of propane, butane, or mixtures thereof. Manifold

-

A piping arrangement which allows one stream of liquid or gas to be divided into two or more streams, or which allows several streams to be collected into one.

Molecule

-

Unit of matter; the smallest portion of an element or a compound which retains chemical identity with the same particular substance enmasse.

Multi-Stage

-

Centrifugal Pump Naphthene

Centrifugal pump which has two or more impellers mounted on the same shaft.

-

A saturated hydrocarbon having the general formula CnH2n and a cyclic molecular structure; i.e. cyclopropane, cyclo-butane, cyclo-pentane, cyclohexane.

Natural Gas

-

Naturally occurring mixtures of hydrocarbon gases and vapors, the more important of which are methane, ethane, propane, butane, pentane, and hexane.

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Terms

UNIT 233

Description

Olefin

-

An open chain, unsaturated hydrocarbon having one double bond. i.e. Ethylene C2H4

Orifice

-

A device for restricting the flow through a pipe. The difference in pressure on the two sides of an orifice plate can be used to measure flow through the pipe.

Packed Tower

-

A fractionating or absorber tower which is filled with small objects (packing material, i.e. rasching ring,) to effect an intimate contact between rising vapor and falling liquid.

Paraffin

-

That series of noncyclic hydrocarbons having the general formula CnH2n

, and having no double &

+ 2

triple bonds. i.e. Butane C4H10 , Hexane C6H14 , etc. .

Petrochemical

-

A naphtha lean in aromatics precursors

Naphtha Petroleum

-

A

material

occurring

naturally

in

the

earth,

predominantly composed of mixtures of chemical compounds of carbon and hydrogen with or without other nonmetallic elements such as sulfur, oxygen, nitrogen,

etc.

Petroleum

may

contain,

or

be

composed of, such compounds in the gaseous, liquid,

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Terms

OPERATING MANUAL UNIT 233

Description and / or solid state, depending on the nature of these compounds

and

the

existent

conditions

of

temperature and pressure. Petroleum

-

Naphtha

A generic term applied to refined, partly refined, or unrefined petroleum products and liquid products of natural gas, not more than 10 per cent of which distill below 175 °C, and not less than 95 percent of which distill below 240 °C, when subjected to distillation in accordance with ASTM Method D-86.

pH Value

-

The logarithm of the reciprocal of the hydrogen ion concentration. This indicates the acid or alkaline condition of a substance, pure water and neutral solutions having a pH of 7. Acid solutions have a pH less than 7 ; alkaline solutions, a pH greater than 7.

Polymer

-

Product of polymerization of normally gaseous olefin hydrocarbons.

Power pump

-

A reciprocating pump in which the liquid pistons are driven by other means than direct acting steam pistons and rods.

Preheater

-

Any form of equipment in which heat is applied to a material prior to its introduction into the main heating equipment. The application of heat is usually

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Terms

OPERATING MANUAL RECOVERY PLUS UNIT 233

Description accomplished by means of hot fluid which have to be cooled and whose heat would otherwise be wasted.

Pressure Drop

-

The decrease in pressure due to friction/plugging, which occurs when a liquid or gas passes through a pipe/filter/vessel, etc.

Pressure

-

Vessel

An enclosed container in which greater than atmospheric pressure is maintained.

Pump Priming

-

The filling of the liquid end of a pump with liquid to remove vapors present and eliminate the tendency to become vapor lock.

Purging

-

The displacement of one material with another in process equipment; frequently, displacement of hydrocarbon vapor with steam or inert gas.

Quench

-

To suddenly cool hot material discharging from a cracking coil, usually by injecting cool oil into the discharge line; its purpose is to check the cracking reaction quickly.

Radiation

-

The act of emitting energy, particularly rays of light or heat.

Reactor

-

The vessel in which the major part of a reaction or conversion takes place. In catalytic cracking it is the

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Terms

OPERATING MANUAL RECOVERY PLUS UNIT 233

Description enlarged space in which hot oil is converted to simpler compounds.

Reciprocating

-

Pump

A Positive displacement type of pump consisting of a plunger or a piston moving back and forth within a cylinder. With each stroke of the plunger or piston, a definite volume of liquid is pushed out through the discharge valves.

Reflux

-

In fractional distillation, that part of the distillate which may be returned to the column to assist in making a better separation into desired fractions is called Reflux. Reflux may be either circulating or induced. Circulating reflux is liquid/vapor which is withdrawn hot, normally cooled, and pumped back to the tower. Induced reflux is liquid formed within a fractionation tower by condensation of vapors by means of an internal cooling coil.

Residue

-

Heavy oil or bottoms left in the still after gasoline and other relatively low-boiling constituents have been removed.

Rich Oil

-

The oil drawn off the bottom of an absorber tower containing fractions absorbed from a gas.

Riser

-

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That portion of the bubble plate assembly which

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Terms

OPERATING MANUAL UNIT 233

Description channels the vapor and causes it to flow downward to escape through the liquid.

Rotary pump

-

A positive displacement pump used mainly to pump liquids which are either too viscous or too difficult to pick up suctions with a centrifugal pump. There are many types of rotary pump designs, one of the most common being the gear type - in which two gears mesh and rotate toward each other within a very close fitting casing. The liquid is trapped between the gear teeth and the casing and carried around to the discharge side of the pump. The meshing gear teeth prevent the liquid from returning to the suction side.

Rundown Tank

-

One of the tanks in which product is received from the plant and from which the product is pumped to larger tanks known as storage tanks. Rundown tank is also known as Receiving tank or Day tank, designed to store only one day’s production(with enough cushion) . If the product was received directly into the large storage tanks, the offspec. product due to plant upset would contaminate unnecessarily larger size product storage tank.

Scrubbing

-

Purifying a gas by washing with water or chemical; less frequently, the removal of entrainment. The

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Terms

OPERATING MANUAL UNIT 233

Description material to be purified is called a scrubber.

Separator

-

A holding vessel used to aid in the separation of light and heavy gravity material. i.e. Separator in reactor section separate liquid and recycle gas.

Simplex pump

-

A reciprocating pump that has one liquid cylinder on a single drive.

Sour Crude

-

Crude oil containing an abnormally large amount of sulfur compounds which, upon refining, liberate corrosive sulfur compounds.

Specific Gravity

-

The ratio of the weight of a volume of a body to the weight of an equal volume of some standard substance. In the case of the liquids and solids, the standard is water. In the case of gases, the standard is hydrogen or air.

Stabilizer

-

A fractionating tower for removing light hydrocarbons from an oil to reduce vapor pressure; particularly applied to gasoline.

Steam

-

Water in the vapor state.

Straight Run

-

Product of distillation of crude petroleum without subjected to cracking.

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Terms Stripping

-

UNIT 233

Description Removal of the lightest fractions from a mixture. The process is usually carried out by passing the hot liquid from a flash drum or tower into a stripping vessel or section (stripper), through which open steam or inert gas is passed to remove the more volatile components of the cut.

Suction Line

-

Intake

line

leading

from

vessel/storage

to

pump/compressor suction. Superheated

-

Water vapor above the saturation temperature at a given pressure.

Surge Drum

-

A vessel or accumulator which serves as a reservoir for liquid being pumped through a line, thereby overcoming fluctuations in the rate of flow caused by the pump.

Sweet

-

Having a good odor; pleasant to the sense of smell; negative to the doctor test. i.e. sweet naphtha lean in sulphur content.

Temperature

-

An

arbitrary

measurement

of

the

amount

of

molecular energy of a body, or the degree of heat possessed by it. It should be distinguished from heat itself. Heat is a form of energy; temperature is a measurement of its intensity.

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Terms

UNIT 233

Description

Thermocouple

-

The junction of two wires of dissimilar metals, which develops an electrical potential that is a function of the temperature; an instrument for measuring temperature by means of the electrical potential produced at a heated junction of two dissimilar metals.

Thermowell

-

A tube having one end closed, inserted into a vessel pipe, or furnace as protection for a thermocouple or thermometer bulb.

Throttling

-

To control a flow by operating a valve by hand ,making moves in small increments; such as closing a valve in the steam line of a boiler for controlling the flow of steam to any apparatus.

Treating

-

The contacting of petroleum products with chemicals to improve the quality.

Turnaround

-

Time necessary to clean and make repairs on refinery equipment after a normal run. It is the elapsed time between drawing the fires (shutting the unit down) and putting the unit on stream again.

Vapor Pressure

-

The pressure exerted by the vapors released from any material, at a given temperature, when enclosed in a vapor tight container.

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Terms

OPERATING MANUAL UNIT 233

Description

Vessel

-

A closed container to hold gas and/or liquid under pressure or vacuum. It may be used solely for storage, in which case it is often called a drum, e.g., butane drum, reflux drum, etc. Process vessels will permit volume fluctuations, settling of mixed stocks, demisting of vapors, or reactions (such as treaters or reactors).

Viscosity

-

The measure of the internal friction or the resistively to flow of a liquid. In measuring viscosity of petroleum products, the values of the viscosity are usually expressed as the number of seconds required for a certain volume of the oil to pass through a standard orifice under specified conditions.

Volatility

-

The extent to which liquids vaporize; the relative tendency to vaporize.

Water Hammer

-

The energy or impact developed by the sudden collapse of vapor bubbles.

Weathering

-

The exposure of crude oils or light oils to the weather, with subsequent evaporation of volatile constituents, resulting in loss; in some cases, oxidation and polymerizing effects are noted also, particularly with cracked and asphalt oils.

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Terms

OPERATING MANUAL RECOVERY PLUS UNIT 233

Description

Wet steam

-

Steam containing entrained water droplets.

Wet Gas

-

A gas containing a relatively high proportion of hydrocarbons which are recoverable as liquids.

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1.3

OPERATING MANUAL RECOVERY PLUS UNIT 233

Abbreviation Item 0 C 0 F Amps API ASME

Details Degree Centigrade Degrees Fahrenheit Amperes American Petroleum Institute American Society of Mechanical

ASTM BD BFW BPD Btu. Cat. Col. Cond. CS Dept. Div. EB Eng. EOR EP GC HC HP Kg/cm2.g Lab LPG Maint. MP MW MX OX PARAXYLENE

Engineers American Standard Testing Method Blow Down Boiler Feed water Barrels per day British thermal unit Catalyst Column Condensate Carbon steel Department Division Ethylbenzene Engineer End of run End boiling point (of a distillation) Gas chromotagraph Hydrocarbon High pressure Pressure Unit Laboratory Liquefied Petroleum Gas Maintenance Medium pressure Molecular weight Metaxylene Orthoxylene Paraxylene

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Item ,PX SAE SOR Supt. Xyl. Frac. PCC PIB

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Society of Automotive Engineers Start of Run Superintendent Xylene Fractionation Plant Control Center, control room Plant Interface Building

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2.0

UNIT DESCRIPTION

2.1

Design Basis The UOP RECOVERY PLUS system has been designed to improve the recovery of LPG and Reformate from Platforming Process Unit net gas streams. Increased hydrocarbon liquid recovery translates into improved liquid product yields and, therefore, higher production of more valuable products. Added benefits are improved LPG recovery. Under the design conditions, the RECOVERY PLUS system improves C5 + yields by 4 LV% and LPG yields by 0.5 LV% based on fresh feed H2 purity of the net gas is increased by 8 mol%.

2.2

Process Flow Description and Controls RECOVERY PLUS system is composed of a process circuit and a closed loop refrigeration circuit. The process circuit consists of a net gas stream and a slipstream of liquid from the platforming Unit Debutanizer column feed. The refrigeration circuit provides cooling to promote the absorption of LPG and reformate hydrocarbons that would normally exit the Platforming Process Unit in the net gas stream. The net gas & liquid streams are individually cooled & then enter the Absorber, MV-AY233-V01. Vapor & liquid separation occurs through counter current flow. The recovered liquid is sent to the Platforming process Unit’s Debutanizer column for stabilization prior to being sent to storage. The gas stream exits the RECOVERY PLUS system to chloride Treaters (MVAY231-V04 A/B). The RECOVERY PLUS system contains four circuits. a. Closed loop Refrigeration circuit b. Oil Reclaimer / oil separator circulation

RELIANCE PETROLEUM LIMITED JAMNAGAR

OPERATING MANUAL RECOVERY PLUS UNIT 233

c. Net Gas Circuit d. Liquid Circuit a) Closed loop Refrigeration circuit Starting at the Refrigerant Subcooler 233-S06, the propylene refrigerant (liquid) is pressured through LV014 and enters into the receiver / Economiser (233V03). From the Receiver / Economiser (233-V03), the vapor portion of the refrigerant is sent to a side port of the compressor (233 C01) through a back pressure control valve (PV 038). This ensured there is enough driving force between the 233-V03 and 233-C01 Suction during low load conditions. 233-V03 improves the efficiency of the Refrigeration compressor. The refrigerant remaining in 233-V03 is pressured to the Combined VaporLiquid Chiller (233-S03) via control valve LV002. The chilled liquid refrigerant is maintained 2” below the top of the tubes of the chiller. Frothing of the refrigerant in the chillers covers the rest of the tubes. Process fluids (H2 / HCBN) pass through the tubes of Combined Vapor-Liquid Chiller (233-S03) where they are cooled by evaporation of the refrigerant. The Disengaging drum on Top of the chiller shell allows any entrained liquid to be removed from the vaporized refrigerant. The vaporized refrigerant leaving the Chiller (233-S03) passes through PV012. PV012 controls the compressor 233-C01 suction pressure during startup only. During normal conditions PV012 is 100% open.

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UNIT 233

Within the compressor, refrigerant vapor comes in contact with circulating synthetic oil and the compressed gas/oil mixtures discharges from the compressor to the oil separator # 1, 233 V02. In the oil separator #1 (233-V02), the refrigerant disengaged from the oil and passes overhead though a series of coalescing elements where entrained oil is removed. The oil is recycled to the Compressor. Refrigerant is then sent through oil separator #2 233-V04, where oil is removed to below 10 ppm level. Oil build up in the 233-V04 is sent back into the 233-C01 suction via FO-004. Any entrained oil will settle in the chiller and is recovered in the Oil Reclaimer Circuit. The refrigerant leaves oil separator #2 & enters the shell side of the condenser 233-S05, where it exchanges heat with cooling water (tube side) & condenses. Condensed refrigerant drains from the condenser (233-S05) in to the tube side of the subcooler, 233-S06. In 233-S06, the condensed refrigerant is cooled further by the Rich oil leaving the liquid Exchangers, 233-S02 A/B. This subcooling allows the compressor capacity to increase without affecting the energy requirements. The subcooled refrigerant is collected in 233-V03 Receiver / Economiser. 233-V03 is designed to hold the total circuit charge at 90% level.

b) OIL RECLAIMER / OIL SEPARATOR CIRCULATION

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Entrained oil in the refrigerant stream settles in the Combined Vapor-Liquid Chiller (233-S03), where refrigerant boiling occurs. With liquid refrigerant boiling off at - 29 0C the heavier oil settles to bottom of the chiller. The drained oil / refrigerant mixture from 233-S03 goes to Oil Reclaimer (233-Vv07). The oil is reclaimed through a batch process of draining, boiling off the refrigerant and pumping the oil back to the suction of compressor 233-C01. The batch operation is controlled by a logic system. After compression, a refrigerant / oil mixture is discharged into the oil separator #1 (233 V02). The separation between the oil / gas mixture is achieved in the body

of the separator and further separation takes place in coalescing

elements positioned inside the separator close to the separator outlet. The bottom of the separator serves as an oil reservoir and is equipped with a level gauge (LG-012) for positive oil level indication. A temperature controlled oil heater (233-Y01) is inserted in the separator to maintain the oil temperature for proper oil viscosity and to minimize oil dilution by the refrigerant during compressor shutdown. Lube Oil is pumped from the 233-V02 by oil pump 233P02 A/B. The oil then flows through the shell side of the Lube oil coolers (233S04 A/B) oil passes through a 25 micron element filter 233-F01 A/B before the oil is fed to the bearings, balance piston, shaft seal, compression chamber and compressor slide valve actuator. c) NET GAS CIRCUIT The Net gas in (Rich Gas) passes through the tube side of the vapor exchanger (233-S01), where it is cooled by exchanging heat with NET OFF GAS (Lean

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Gas shell side). The RICH NET GAS IN then enters the tube side of the 233S03, where it is further cooled by exchanging heat with refrigerant (shell side). The temperature of the vapor out of the chiller is controlled by TIC-009. As the vapor outlet temp begins to decrease, TV 009 begins to open causing a position of the warm Lean oil to bypass the Liquid Exchangers (233-S02 A/B), and mix with the vapor entering the tube side of the Chiller, causing a change in the heat capacity of the fluid. If the temperature of the Vapor leaving the chiller is too warm, TV 009 will close. The partially condensed Net Gas, leaving the 233-S03 enters the lower section of Absorber 233-V01. The rich liquid is removed from the bottoms of 233-V01 on LIC-004. The Absorber off gas (NET OFF GAS) is then heated through the shell side of the vapor exchangers 233-S01 & is sent to chloride treaters 231V04 A/B. d) LIQUID CIRCUIT The liquid into the RECOVERY PLUS system is a slipstream from the Debutanizer column feed, and is controlled by FIC-002. This stream is pumped by 233-P01 A/B to the tube side of Liquid Exchanger 233-S02 A /B, where it is cooled by exchanging heat with the Absorber rich liquid (shell side). The lean liquid enters the second tube bundle of the Combined Vapor-Liquid Chiller, 233S03 and flows to the top of the Absorber. The temperature of the lean liquid entering the absorber is controlled by TIC-011.

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UNIT 233

As the temperature of the lean oil exiting the chiller, fluctuates, TIC-011 adjusts the compressor capacity control by varying the slide valve position. The rich oil is removed from the bottom of the Absorber, 233-V01 on level control LV-004. The net liquid is heated through the shell side of the subcooler 233-S06, and then flows to the Debutaniser feed Bottoms Exchanger 231-S05 A / B on pressure. 2.3

DCS Description Distributed Control System for Jamnagar Refinery Complex is of Foxboro I/A series 50 and is capable of plant wide automation. The architecture of the system will accommodate both functional and geographical distribution of the hardware, software, and database over the plant while allowing system wide access to the distributed data. The DCS hardware will be state of the art, microprocessor based design, that will be fully tested and reliable. It will permit control and data acquisition functions to be distributed to remote Plant Interface Buildings (PIBs) with operator-consoles located in Plant Control Centre (PCCs). As stated above all DCS hardware will be in the PIBs, all field inputs will be terminated in the PIBs, all controllers will be in the PIBs and field outputs will be from PIBs only. Monitoring and Control will be by Operator Console located in the PCC, which in turn is connected to all the PIBs through Fibre Optic Plantwide Control Network.

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UNIT 233

Foxboro I/A series 50: Following are the main hardware of the system. 

WP51B – Operator console with two 19” CRT, Keyboard, trackball and touchscreen.



CP30 & CP40 – Control processor for control and data acquisition.



AW51C – Engineering Station for configuration of the system.



FBM & FBC – Field I/O card.

The entire operator console will be mounted in two tier consoles in the PCCs. The hardware distribution and configuration of the Platforming Unit is as under: 

For HNUU (221), Platformer (231), CCR (232), Recovery Plus (233) and PSA (234), CP40.

FBMs/FBCs will be in PIB 4 and will be linked to

Aromatics PCC with Fibre optic cable. PIB 4 is a SCS having two operators console (two CRTs) for start-up and shutdown. 2.3.1

DCS Graphics Process graphics show process equipment, piping and the instrumentation and control.

They closely follow the project PFD’s and P&ID’s.

They will be

arranged in four hierarchy levels:  Plantwide (Level 1)

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 Complex (Level 2)  Unit (Level 3)  Detailed (Level 4) At each of these levels, the graphics provide the means to move up and down the graphic hierarchy, and also sideways. The Plantwide Level graphic shows an overview of the whole Reliance Jamnagar Refinery Plant. It displays the main plant areas, their statuses and primary plant data. There shall be no control or process information at this level. The main purpose of this display is for navigation to other displays. The Complex Level graphics show overview of the Aromatic complex of Reliance Jamnagar Refinery. Only the major flows and other important data specific to each area will be shown. There shall be no process control from this level. Additionally, the Complex Level graphics should indicate when a fault occurs at any point within the process, which will allow the operator to navigate to detailed graphic. The Platforming Unit Level graphics show most process equipment and major piping and instrumentation. All controllers, important process variables and general monitoring parameters are indicated at this level. ESD trips are also indicated. Facilities are provided for operator actions such as alarm acknowledgement, manipulation of control loops, operation of valves, pumps, etc. Each plant unit is represented by several unit level graphics. The graphics

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at this level follow the project PFD’s. Unit Level graphics are intended to be used most of the time for plant operations. The Detailed Level graphics show all instrument functions implemented in the I/A Series – indicating loops, monitoring functions, equipment statuses, trips, ESD’s, etc. Facilities are provided for alarm acknowledgement; access to all control loops, faceplates, groups and trends. The graphics at this level closely follow the project P&ID’s and indicate almost all P&ID level information. This level of graphics is used to pursue detailed information on the process and the instrumentation. 2.3.2

Graphic Displays The console subsystem has facility of viewing multiple windows on one screen enabling the operator to conveniently access and control all the necessary factors at the same time. The graphics shall consist of the following types and overall content:  Overview.  Plant graphics.  Group loop displays.  Loop display.  Trend display

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 Alarm and event summary At a minimum, the operator will be able to operate, via touch screen or “track ball” the control strategies i.e., change set points, control modes, Page linking to more detailed process graphics, as well as alarm summaries will be made from these overviews. The operator can call up directly, any group display covered by the overview screen.

In addition, linking will also be possible to:

2.3.3



Group loop display



Loop display



Alarm and event summaries

Group Displays Important analog measurements grouped according to the process will be implemented as vertical bar graphs. Measurements, such as pressure, temperature etc profiles will give a meaningful operator-overview of the normal/upset status of the plant. Bar graphs will include operator adjustable ‘set points’ and high/low alarms when measurement deviates from the desired ‘set point’. In this case, ‘Set point’ may include both controller set points and normal operating parameters for indication-only measurements.

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The group displays will consist of measurements and statuses presented in vertical bar graph formats. These are often referred to as “face plate” displays, since the vertical bar graphs are arranged in the manner of single-loop controller or indicator faceplates. The grouping is defined on logical grouping of related controllers and indicators within the process unit. The displays will indicate the following information per group:  Loop tag number and description.  Process variable (measurement, set point and output).  Status indication (on, off, run, stop, open, close, etc.).  Alarm status  Mode (auto/manual, remote/local (set point), tracking, etc.).  Units of measurement. The operator will be able to quickly address any point and make appropriate changes to mode, set point and output and so forth. This display will give the operator direct access to all status and parameters related to one loop, including the ability to change set points, modes of operation and give on/off output commands.

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Several of the operator actions will be password (preferred) or key-lock protected, such as:

2.3.4



Changing controller-tuning constants.



Controller configuration data.



Enable/disable of alarms, control actions, changing of alarm settings.

Trend displays In addition to trending shown on the loop displays, the DCS shall provide the capability of displaying both real time (short-term) and historical trending of process variables with a facility to change the trended variable on the trends display.

The trend displays are operator assignable to group in graphical

presentation with : 

Vertical axis – variable, including measured range/units.



Horizontal axis – time base.

All points shall be available on real-time trend with a minimum sample interval of one (1) second. 2.3.5

Alarm and Event Summary Either as a standard or a custom display, the DCS will provide a separate tabular listing of alarms and events, which can be called up by the operator with

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a single keystroke. Each alarm or event will be listed in order of occurrence and will include a buffer memory so that no alarms are lost. The alarm and event summary will include: 

Date and time.



Tag and service.



Alarm type and priority.



Alarm limit.



Current process variable with Engineering units.

Alarms acknowledge will be possible, using this display or the loop display.

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2.4

OPERATING MANUAL RECOVERY PLUS UNIT 233

Design Flow Plan

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2.5

OPERATING MANUAL RECOVERY PLUS UNIT 233

Refinery Site, Underground Piping and Unit Layout Plan

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2.6

OPERATING MANUAL UNIT 233

Material Balance INPUT Kg/Hr 169953 44578

Lean Oil Net Gas OUTPUT

Kg/Hr Hydrogen rich gas to refinery hydrogen 25309 header Rich oil to debutaniser Feed/Bottom 189222 exchanger at platforming NOTE: 2.7

Liquid recovered

19269 Kg/Hr

Feed and product Specification Component

Gas In

Gas Out

Liquid

Kg-mol/h H2O H2 C1 C2 C3 IC4 NC4 IC5 NC5

0.19 4836.2 201.03 417.11 299.61 34.86 36.50 4.89 5.11

0.114 4814.30 186.77 263.53 79.92 8.12 8.23 0.92 0.84

Recovered 0.07 21.90 14.26 153.58 219.67 26.74 28.27 3.98 4.27

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Component

Gas In

Kg-mol/h C5OLEFIN CP C6+ Total, Kg/hr Temperature, 0C Pressure, Kpag Molecular Weight 2.8

0.34 0.15 9.94 44578.07 37 3.601 7.63

OPERATING MANUAL UNIT 233

Gas Out

Liquid

0.07 0.02 0.77 25309.19 28.7 3.474 4.72

Recovered 0.27 0.13 9.17 19268.88 --------43.1

Chemicals - Details Chemical Propylene

Service Refrigerant

Required Quantity 250ft3 ( 7 m3 )

Specification for propylene product PROPERTY VALUE Propylene, vol.% Methane plus Ethane, vol. ppm Ethylene, vol. ppm C4 & Heavier, vol. ppm Acetylene, vol. ppm Butadiene, vol. ppm Methyl Acetylene + Propadiene, vol. ppm Hydrogen, vol. ppm Carbon Monoxide, vol. ppm Carbon Dioxide, vol. ppm Oxygen, vol. ppm Ammonia, vol. ppm Ammonia, wt. ppm Nitrogen (molecular), vol. ppm Sulfur, vol. ppm

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MAX / MIN 99.50min. 500max. 50 max. 20 max. 10 max. 10 max. 20 max. 20 max. 5 max. 5 max. 10 max. 12.1 max. 5.0 max. 30 max. 3 max. PAGE REVISIO N ISSUE

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PROPERTY VALUE Water, vol. ppm Green Oil, vol. ppm Carbonyl Sulfur (COS), vol. ppm Arsine, vol. ppm Phosphine, vol. ppm Propane 2.9

Utility conditions and requirement

2.9.1

Utility Conditions UTILITY

MAX / MIN 10 max. 1 max. 1 max. 0.03 max. 0.03 max. Balance

UTILITY BATTERY LIMIT CONDITIONS PRESSURE TEMPERATURE (KG/CM2G) Normal Design 4.5 2.5 3.0 7.0 3.0 7.0 3.0 7.0 7.0 10 7.7 10 7.7 10

Fresh CW Supply Fresh CW Return Desal, Water Potable Water Utility Water Plant Air Instrument Air Breathing Air Nitrogen Fuel Gas Import Fuel Gas Export LPG 2.9.2

OPERATING MANUAL

7 3.5 3.9 3.5

( 0C ) Normal Design 32 150 45 150 44 44 65 44 65 40 65 40 65 40 65

10.5 6.5

25 38

65 122

6.5

38

122

Utilities Requirements Reliance Estimated Utility Consumption

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Electric Power, KW (High Voltage >415V) Electric Power, KW (Low Voltage =