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Vendor Document No. TPC-DQR-002-TRM-OPS-013
ARAMIS Development Ltd
Rev. A
Page 1 of 237
TRAINING MODULE
CONTINUOUS CATALYTIC REFORMER (CCR) UNIT: 13
VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY (DQR) PROJECT DUNG QUAT, VIETNAM
Requisition Number:
8474L-000-CFB-XXXX-0001
Purchase Order Number:
8474L-000-CS01-17061
Equipment / Item Tag:
Not Applicable
Equipment / Item Description:
Not Applicable
TPC Document Number:
8474L-013-A5016-0000-001-003
Document Class:
X
A
19-OCT-07
Rev
Date DD-MMM-YY
Stamp
Comment given in this document does not relieve vendor of his/her responsibility for the correct engineering design and fabrication. This equipment or product shall be made as per the codes, requisition, specification, project procedures, and international standards.
Issue for review
Benoit Rabaud
Paul Walsh
JB Guillemin
Status
Written By (name & visa)
Check By (name & visa)
Approved By (name & visa)
Pages changed in this revision: Sections changed in last revision are identified by a vertical line in the margin DOCUMENT REVISIONS
TRAINING MODULE CONTINUOUS CATALYTIC REFORMER (CCR)
DOC NO: 8474L-013-A5016-0000-001-003 REV: A
DATE: 19/10/07
TRAINING MODULE
CONTINUOUS CATALYTIC REFORMER (CCR) UNIT: 13
A 19/10/07 REV DATE TRAINING DURATION
Benoit Rabaud Paul Walsh PREPARED BY CHECKED BY VENUE
JB Guillemin APPROVED BY
ATTENDANCE ATTENDEES REQUIREMENTS MODULE OBJECTIVES
INSTRUCTORS NAME/POSITION SUMMARY/AGENDA
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TRAINING MODULE CONTINUOUS CATALYTIC REFORMER (CCR)
DOC NO: 8474L-013-A5016-0000-001-003 REV: A
DATE: 19/10/07
IMPORTANT
THIS TRAINING MODULE HAS BEEN PREPARED BY ARAMIS FOR THE DUNG QUAT REFINERY. THIS MODULE MUST BE RECOGNIZED AS A TOOL AND GUIDE ONLY. IT WOULD BE IMPOSSIBLE TO ANTICIPATE AND PRESENT ALL POTENTIAL VARIABLES AND PROCESS CONDITIONS THAT OPERATIONAL PERSONNEL MIGHT BE EXPOSED TO. IT IS IMPERATIVE THAT THE READER ALWAYS AS CERTAIN THAT REFERENCE MATERIALS UTILIZED, WHILE PERFORMING OPERATIONAL DUTIES, CONFORM AT A MINIMUM TO THE LATEST ISSUE OF STANDARD OPERATING PROCEDURES, SAFETY CODES, ENGINEERING STANDARDS, AND GOVERNMENT REGULATIONS. SOME DESIGN FIGURES MIGHT NOT BE IN LINE DURING THE START-UP OF THE REFINERY.
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TRAINING MODULE CONTINUOUS CATALYTIC REFORMER (CCR)
DOC NO: 8474L-013-A5016-0000-001-003 REV: A
DATE: 19/10/07
TABLE OF CONTENT SECTION 1 : GENERAL description ........................................................................................... 11 1.1.
Purpose of the Unit ................................................................................................ 14
1.2.
Basis of Design ...................................................................................................... 19 1.2.1. Duty of Plant ............................................................................................... 19 1.2.2. Feed Characteristics ................................................................................... 19 1.2.3. Product Specifications ................................................................................ 19 1.2.3.1. Reformate...................................................................................... 19 1.2.3.2. Unstabilized LPG........................................................................... 20 1.2.3.3. Make Up H2 Gas............................................................................ 20 1.2.3.4. Fuel Gas ........................................................................................ 21 1.2.4. Utility/Power/Chemicals/Catalyst consumption .......................................... 21 1.2.4.1. Utility Consumption ....................................................................... 22 1.2.4.2. Chemicals...................................................................................... 32
1.3.
Glossary of terms and Acronyms........................................................................... 35 1.3.1. Acronyms .................................................................................................... 35 1.3.2. Glossary ...................................................................................................... 38
SECTION 2 : Process Flow Description ...................................................................................... 40 2.1.
Platforming Reaction Section................................................................................. 40 2.1.1. Feed preheater section............................................................................... 40 2.1.2. Charge heater and inter heaters................................................................. 40 2.1.3. Reactors...................................................................................................... 41 2.1.4. Reactor effluent........................................................................................... 41 2.1.5. Reactor effluent separator .......................................................................... 42 2.1.6. Recycle compressor ................................................................................... 42 2.1.7. Steam generation........................................................................................ 42 2.1.8. RECOVERY PLUS system......................................................................... 43 2.1.8.1. Refrigeration Circuit....................................................................... 43 2.1.8.2. Net Gas Circuit .............................................................................. 43 2.1.8.3. Liquid Circuit.................................................................................. 44 2.1.9. Net Gas Chloride Treaters.......................................................................... 44 2.1.10. Chemical injection ..................................................................................... 44 2.1.10.1. Chloride injection package X-1307.............................................. 44 2.1.10.2. Sulfide injection package X-1396 ................................................ 45
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2.1.10.3. Phosphate dosing drum X-1397 .................................................. 45 2.1.11. Debutanizer Section.................................................................................. 45 2.2.
Regeneration Section ............................................................................................ 46 2.2.1. Spent Catalyst Transfer .............................................................................. 47 2.2.2. Burn Zone / Reheat Zone ........................................................................... 48 2.2.3. Chlorination Zone........................................................................................ 49 2.2.4. Drying Zone ................................................................................................ 50 2.2.5. Cooling Zone............................................................................................... 51 2.2.6. Reduction Zone........................................................................................... 52 2.2.7. Regenerated Catalyst Transfer................................................................... 53 2.2.8. Lift gas & Fines removal circuit................................................................... 54 2.2.9. Normal Catalyst Addition ............................................................................ 56 2.2.10. Catalyst Change-out on the fly.................................................................. 57 2.2.11. Vent Gas Wash Tower .............................................................................. 59 2.2.12. Process Pressures and Environments...................................................... 61
SECTION 3 : Process control ...................................................................................................... 65 3.1.
Control Narrative & Operating parameters ............................................................ 65 3.1.1. Charge heater & inter-heaters temperature outlet control.......................... 65 3.1.2. Reactor Section Pressure Control .............................................................. 69 3.1.3. Separator D-1301 Level control.................................................................. 70 3.1.4. Steam Generation Controls ........................................................................ 71 3.1.5. Water Circulation Pumps Logic P-1303 A/B............................................... 73 3.1.6. Debutanizer T-1301 Temperature Control.................................................. 75 3.1.7. Catalyst Circulation Control ........................................................................ 75 3.1.7.1. Catalyst Flow Pushbutton.............................................................. 78 3.1.7.2. Catalyst circulation rate set point & set point ramping .................. 79 3.1.7.3. Lock Hopper Sequence................................................................. 79 3.1.8. Regeneration System Tower ...................................................................... 90 3.1.9. Regeneration Tower T-1351 Isolation Systems ......................................... 94 3.1.9.1. Regenerator Inventory Switch ....................................................... 98 3.1.10. Dust Collector Fines Unloading: ............................................................... 99 3.1.11. Catalyst Addition: .................................................................................... 102 3.1.12. Catalyst Change-out on the fly................................................................ 106 3.1.13. Inter-Unit Controls & Interfaces............................................................... 109 3.1.14. Operating Parameters............................................................................. 109
3.2.
Instrument List...................................................................................................... 110 Page 5 of 237
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3.3.
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Main Equipment ................................................................................................... 111 3.3.1. Heaters H-1301, H-1302, H-1303 & H-1304 ............................................ 111 3.3.2. Reactor R-1301, R-1302, R-1303 & R-1304 ............................................ 114 3.3.3. Recycle Compressor C-1301 & Steam Turbine CT-1301 ........................ 117 3.3.4. Debutanizer T-1301 .................................................................................. 119 3.3.5. Regeneration Tower T-1351..................................................................... 121 3.3.6. Nitrogen Seal Drum D-1357 ..................................................................... 126 3.3.7. Lock Hopper D-1358................................................................................. 127 3.3.8. Catalyst L-Valve Assemblies .................................................................... 130 3.3.9. Reduction Zone......................................................................................... 132 3.3.10. Disengaging Hopper D-1353 .................................................................. 134 3.3.11. Electric Heaters....................................................................................... 136 3.3.12. Vent Gas Tower T-1352.......................................................................... 138
SECTION 4 : Safeguarding devices .......................................................................................... 141 4.1.
Alarms and Trips .................................................................................................. 141
4.2.
Safeguarding Description..................................................................................... 141 4.2.1. CCR Platforming Reaction Section .......................................................... 141 4.2.1.1. Loss of Make up compressor (unit 12)........................................ 141 4.2.1.2. Heaters Protection (UX-001): ...................................................... 141 4.2.1.3. Recycle Compressor Protection (UX-002) .................................. 142 4.2.1.4. Separator pumps P-1301 A/B and Debutanizer pumps P-1302 A/B Protection (UX-003): ................................................................................. 142 4.2.1.5. Debutanizer Overhead Pumps P-1302 A/B Protection (UX-004)142 4.2.1.6. Debutanizer Isolation................................................................... 142 4.2.1.7. Air coolers Motor vibration protection.......................................... 143 4.2.2. CCR Regeneration Section ...................................................................... 143 4.2.2.1. Regenerator Automatic Shutdown Summary.............................. 143 4.2.2.2. Regeneration Tower Automatic Stops ........................................ 146 4.2.2.3. Lock Hopper D-1358 Abnormal Unload/Load Alarms................. 149 4.2.2.4. Lock Hopper Level Switch Malfunction Alarm............................. 150 4.2.2.5. Lock hopper Starting & Stopping Sequence ............................... 150 4.2.2.6. Catalyst Flow Interrupt Systems ................................................. 151 4.2.2.7. Regenerated Catalyst Lift Line Valve.......................................... 152 4.2.2.8. Regeneration Section Isolation Systems .................................... 152 4.2.2.9. Reduction Zone/Reactor #1 Differential Pressure system .......... 153 4.2.2.10. Vent Gas Wash Wash Tower T-1352 Protection ...................... 155 Page 6 of 237
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4.3.
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DATE: 19/10/07
Safeguarding Equipment ..................................................................................... 156 4.3.1. Pressure Safety Devices .......................................................................... 156
SECTION 5 : Fire & Gas Systems............................................................................................. 162 5.1.
Fire & Gas detection ............................................................................................ 162
5.2.
Fire Protection...................................................................................................... 169
SECTION 6 : Quality control...................................................................................................... 177 6.1.
Sampling connections .......................................................................................... 177
6.2.
On-line analyzers ................................................................................................. 181
SECTION 7 : Causes and effect................................................................................................ 183 7.1.
Cause & Effect Matrix: ......................................................................................... 183 7.1.1. Example from Cause and Effect Chart ..................................................... 183 7.1.1.1. Sheet 1: Reactor Heater H-1301/02/03/04 Shutdown (UX-001). 183
SECTION 8 : Operating practices.............................................................................................. 186 8.1.
Normal Operation................................................................................................. 186 8.1.1. Operating conditions................................................................................. 186 8.1.2. CCR Platforming Reaction Section .......................................................... 186 8.1.3. CCR Regeneration Section ...................................................................... 189 8.1.4. Guidelines for operation of the reactor section......................................... 193 8.1.4.1. Reaction loop pressure ............................................................... 193 8.1.4.2. Reactors inlet temperatures ........................................................ 194 8.1.4.3. Space velocity ............................................................................. 195 8.1.4.4. Chloride water balance................................................................ 195 8.1.5. Guidelines for the operation of the Debutanizer section .......................... 197 8.1.5.1. Debutanizer Overhead ................................................................ 197 8.1.5.2. Debutanizer Bottom..................................................................... 198 8.1.6. Operation Guidelines for CCR Regeneration Section .............................. 198 8.1.6.1. Reheat Zone and Chlorination Zone temperature ...................... 198 8.1.6.2. Chlorination Zone Gas Flowrate ................................................. 198 8.1.6.3. Lower Air Rates ........................................................................... 199 8.1.6.4. Lock Hopper Makeup Valve (Learning Valve) Adjustments ....... 199 8.1.6.5. Dust Collector reverse Jet Cleaning............................................ 200 8.1.6.6. Dust Collector Fines Unloading................................................... 200 8.1.6.7. Normal Catalyst Addition............................................................. 200 8.1.6.8. Filter Cleaning ............................................................................. 201 8.1.6.9. Catalyst Change-out on the fly .................................................... 202 Page 7 of 237
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8.2.
DOC NO: 8474L-013-A5016-0000-001-003 REV: A
DATE: 19/10/07
Start-up Procedure............................................................................................... 203 8.2.1. Start-Up Sequence ................................................................................... 204
8.3.
Shutdown Procedures.......................................................................................... 209 8.3.1. CCR Platforming Reaction Section shutdown .......................................... 210 8.3.2. CCR Regeneration Section Manual Shutdown ........................................ 211
8.4.
Emergency Shutdown .......................................................................................... 213 8.4.1. CCR Platforming Reaction Section .......................................................... 213 8.4.1.1. Loss of feed ................................................................................. 213 8.4.1.2. Loss of recycle compressor......................................................... 213 8.4.1.3. Instrument air failure.................................................................... 214 8.4.1.4. Cooling water failure.................................................................... 215 8.4.1.5. HP Steam failure ......................................................................... 216 8.4.1.6. Boiler Feed Water Failure ........................................................... 216 8.4.1.7. Electrical Power Failure............................................................... 216 8.4.1.8. Loss of refrigerant........................................................................ 217 8.4.1.9. Fuel Gas Failure .......................................................................... 217 8.4.1.10. Major Upset................................................................................ 217 8.4.2. CCR Regeneration Section ...................................................................... 218 8.4.2.1. Power Failure .............................................................................. 218 8.4.2.2. Instrument Air Failure .................................................................. 219 8.4.2.3. Plant air failure............................................................................. 219 8.4.2.4. Recycle compressor Failure........................................................ 219 8.4.2.5. Booster compressor failure ......................................................... 220 8.4.2.6. Cooling Water Failure.................................................................. 220 8.4.2.7. Explosion, fire, line rupture or serious leak ................................. 220 8.4.2.8. CCR Nitrogen Failure .................................................................. 220
SECTION 9 : HSE...................................................................................................................... 223 9.1.
Hazardous Areas ................................................................................................. 223
9.2.
Safety Equipment................................................................................................. 225
9.3.
Specific PPE ........................................................................................................ 225 9.3.1. Hydrogen Sulfide ...................................................................................... 226 9.3.2. Minimizing exposure to armomatics ......................................................... 226
9.4.
Chemical Hazards................................................................................................ 227 9.4.1. Hydrogen Sulfide Poisoning ..................................................................... 228 9.4.1.1. Acute Hydrogen Sulfide Poisoning.............................................. 228 9.4.1.2. Subacute Hydrogen sulfide Poisoning ........................................ 229 Page 8 of 237
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9.4.2. Benzene .................................................................................................... 229 9.4.2.1. Special Instruction: ...................................................................... 229 9.4.3. Toluene, Xyllene & Heavier armomatics .................................................. 229 SECTION 10 : Reference documents index.............................................................................. 232 10.1. Operating Manual/ Licensor Documentation ....................................................... 232 10.2. Arrangement Drawings, Layouts and Plot Plans ................................................. 232 10.3. Process Flow Diagrams ....................................................................................... 232 10.4. Piping and Instrumentation Diagrams.................................................................. 232 10.5. Equipment list....................................................................................................... 235 10.6. Main Equipment Data Sheet ................................................................................ 235 10.7. Instrument List...................................................................................................... 236 10.8. Cause & Effect Matrix .......................................................................................... 236 10.9. Safety Logic diagram ........................................................................................... 236 10.10.
Fire & Gas Cause & Effect Chart .............................................................. 236
10.11.
Fire & Gas Detectors Layout..................................................................... 236
10.12.
Fire Protection Layout ............................................................................... 236
10.13.
Hazardous Area Classification.................................................................. 236
10.14.
MSDS ........................................................................................................ 236
10.15.
Vendors Documentation............................................................................ 237
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TRAINING MODULE
CONTINUOUS CATALYTIC REFORMER (CCR) UNIT: 13
Course Content: Section 1 - General Description
X
Section 2 - Process Flow Description Section 3 - Process Control Section 4 - Safeguarding Devices Section 5 - Fire & Gas Systems Section 6 - Quality Control Section 7 - Cause & Effects Section 8 - Operating Procedures Section 9 - HSE Section 10 - Reference Document Index
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SECTION 1 : GENERAL DESCRIPTION The CCR is divided in 2 sections: •
Reaction Section or Platforming, which processes the hydrotreated straight run heavy naphtha from the naphta splitter of unit 12 to produce a high octane gasoline blending component. This is achieved by using a catalyst refining process to transform naphtenes into aromatics while minimizing the conversion of paraffins and aromatics. The main byproduct of this process, hydrogen, is then used in unit 12.
•
Regeneration section, which continuously regenerate the catalyst in 4 steps: o Burning of the accumulated coke o Oxychlorination – To disperse the catalyst metals and adjusting the catalyst chloride content o Catalyst Drying o Reduction – To change the catalyst metals to the reduced state
The CCR unit is located in the area 2 with the Naphta Hydrotreater Unit (NHT, 012) and the Light Naphta Isomerization Unit (ISOM, 023).
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LEGEND UNIT NUMBER
FUTURE
051
060
055
FUTURE CRUDETANK
038 / 056 FUTURE
060
060
051 036
051 / 054 / 055 051
035 031
039 059
040
032
CRUDEDISTILLATIONUNIT NAPHTHAHYDROTREATERUNIT CONTINUOUSCATALYTICREFORMERUNIT KEROSENETREATERUNIT RESIDUEFLUIDCATALYTICCRACKINGUNIT LPGTREATERUNIT
017 018 019
RFCCNAPTHATREATERUNIT SOURWATERSTRIPPINGUNIT AMINEREGENERATIONUNIT
020 021 022
SPENTCAUSTICNEUTRALISATIONUNIT PROPYLENERECOVERYUNIT SULPHURRECOVERYUNIT
023 024
LIGHTNAPTHAISOMERISATIONUNIT LCOHYDROTREATERUNIT
UNIT NUMBER 031 032 033 034
UTILITIESSYSTEMUNIT WATERSYSTEM( POTABLE, PLANT, DEMIN) STEAMGENERATION / DISTRIBUTIONSYSTEM COOLINGWATERSYSTEM SEAWATERINTAKESYSTEM
035 036 037
PLANTANDINSTRUMENTAIRSYSTEM NITROGENSYSTEM FUELGASSYSTEM
038 039
FUELOILSYSTEM CAUSTICSUPPLYSYSTEM ELECTRICALPOWERGENERATIONAND DISTRIBUTIONSYSTEM
040
051
PROCESSUNIT
011 012 013 014 015 016
033 024
37
019
057
021
012
013 020 022
013 014
011
023
058
SLUDGE FARM
FUTURE
UNIT NUMBER 051 054 055 056 057 058 059 060
OFFSITEFACILITIES REFINERYTANKAGE PRODUCTBLENDING FLUSHINGOIL SLOPS FLARESYSTEM EFFLUENTTREATMENTSYSTEM FIREWATERSYSTEM CRUDEOIL
Figure 1: 2D Refinery Plot Plan
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Figure 2: 3D Refinery Plot Plan Page 13 of 237
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1.1. Purpose of the Unit The function of the Platforming unit is to process the hydrotreated straight run heavy naphtha from NHT unit (012) to produce a high octane gasoline blending component. The catalytic reforming process is a catalytic refining process employing a bimetallic catalyst to upgrade low octane number naphthas to higher octane motor fuel blendings. The basic reaction of Platforming is to transform naphtenes into aromatics (most rapid and efficient reaction). The paraffins conversion is very small, and the aromatics hydrocarbons pass through the Platforming unit essentially unchanged. LPG is a valuable product so recovery of LPG in the naphtha complex is to be maximized and sent to the LPG spheres. Hydrogen rich gas is another product of the catalytic reforming reactions, required for the operation of units such as hydrotreatment units (NHT, 012), isomerisation (ISOM, 023).
Figure 3: Process Connections of the CCR
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Figure 4: Refinery Flow Scheme Page 15 of 237
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The Continuous Catalytic Regeneration section allows the reaction section to operate in high severity conditions. At such conditions, reforming catalyst deactivates more rapidly because coke lays down on the catalyst at a faster rate. So without a regeneration section, the reaction section would have to be shut down more often for regeneration to burn off this coke and restore the catalyst’s activity and selectivity. In the regeneration section, the catalyst is continuously regenerated while the Platforming reaction section continues to operate. The Catalyst Regeneration Section consists of a system of integrated equipment that is separate from, but still connected to, the reaction section. It performs two principal functions – catalyst circulation and catalyst regeneration – in a continuous circuit. First spent catalyst from the last Platforming reactor is circulated to the Catalyst Regeneration Section. In the Catalyst Regeneration Section, the spent catalyst is regenerated in four steps: •
Burning of the accumulated coke
•
Oxychlorination – for dispersing the catalyst metals and adjusting the catalyst chloride content
•
Catalyst drying
•
Reduction – for changing the catalyst metals to the reduced state
Finally, the regenerated catalyst is circulated back to the first Platforming reactor. The logic and sequence of this circuit are controlled by the Catalyst Regeneration Control System. In this manner, freshly-regenerated catalyst is continuously circulated through the Platforming reactors. This ensures that the Platforming reactor section operates economically with optimum catalyst performance at high-severity conditions and for long on-stream periods of operation.
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Figure 5: Unit 13 3D Drawings Page 17 of 237
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Figure 6: CCR Process Flow Scheme Page 18 of 237
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1.2. Basis of Design 1.2.1. Duty of Plant The plant capacity is 21100 BPSD (corresponding to 103496 kg/h) of heavy naphtha from NHT unit (012) and sweet naphtha. The CycleMax CCR regenerator has a capacity of 1000 lb/h of catalyst circulation. The Turndown of the CCR unit corresponds to 50% of the NHT unit (012) plus the sweet naphtha. Consequently, the capacity of unit is around 60% of the CCR design capacity.
1.2.2. Feed Characteristics (This applies to the reaction section only.) The Platformer is fed with hydrotreated Heavy Naphtha from Unit 012. The unit can also be fed with sweet heavy naphtha from TK-5104 during start-up in addition of the straight run hydrotreated heavy naphtha. The heavy naphtha from the NHT unit (Unit 012) will contain less than 0.5 wt ppm S (Sulfur) and less than 0.5 wt ppm N (Nitrogen).
1.2.3. Product Specifications 1.2.3.1. Reformate Reformate is sent to the storage TK-5107 for blending. The required reformate properties are the following: Property
Value
RONC
102 min
MON
91 min
C4 content (%vol)
1 max.
The molar composition of the reformate stream is the following: Compound
Reformate (mole %)
Ethane
ppm
Propane
0.02
i Butane
0.32
n Butane
0.92
i Pentane
1.87
n Pentane
1.25
C6 +
95.6
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RONC: Research Octane Number The most important characteristic of gasoline is its Research Octane Number or octane rating, which is a measure of how resistant gasoline is to premature detonation ( knocking). It is measured relative to a mixture of 2,2,4-trimethylpentane (an octane) and n-heptane. So an 87-octane gasoline has the same knock resistance as a mixture of 87% isooctane and 13% n-heptane. MON: Motor Octane Number The Motor Octane Numbe (MON) is a better measure of how the fuel behaves when under load. Its definition is also based on the mixture of isooctane and n-heptane that has the same performance. Depending on the composition of the fuel, the MON of a modern gasoline will be about 10 points lower than the RON. Normally fuel specifications require both a minimum RON and a minimum MON.
1.2.3.2. Unstabilized LPG The debutanizer net overhead liquid is treated in the LPG Chloride Treaters D-1308 A/B and then sent to storage TK-5212 A/B/C/D/E. C5+ content in LPG product shall not exceed 1.1%mol max. The molar composition of the unstabilized LPG stream is the following: Compound
Unstabilized LPG (mole %)
H2 O
0.006
H2
0.08
Ethane
0.21
Propane
36.61
i Butane
23.64
n Butane
33.87
i Pentane
0.88
n Pentane
0.05
C6 +
0.06
1.2.3.3. Make Up H2 Gas Net hydrogen produced in the Platforming Unit is recontacted in the Recovery Plus package (X-1301) and sent to chloride removal D-1302 A/B. After chloride removal, some of the net hydrogen is sent to the make-up gas multi-stage compressors (C-1202 A/B/C) in the NHT Unit (012), where it is pressurized up to the consumers (NHT, LCO HDT,
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Isomerization, NHT H2 storage drums) required pressure levels. Most of the net gas product is sent to Fuel Gas system (Unit 037) . The composition of hydrogen shall be the following in normal operation: Compound
Make up H2 (mole %)
H2
93.3
Ethane
2.5
Propane
1.4
i Butane
0.1
n Butane
0.1
i Pentane
0.04
n Pentane
0.02
C6 +
0.04
1.2.3.4. Fuel Gas Fuel Gas from the Debutanizer reflux drum can be sent to Fuel Gas Network (Unit 037). But normally, no flow is exported to FG network via the debutanizer reflux drum. Off gas from the debutanizer receiver is sent to the recovery plus system X-1301.
1.2.4. Utility/Power/Chemicals/Catalyst consumption
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Figure 7: Utilities Connections of the CCR
1.2.4.1. Utility Consumption The following describes the utility consumption of the ETP based on the following Estimated Utility Consumption Documents:
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8474L-013-CN-0003-001
Design Case - 100% Bach-Ho or Mixed Crude Max Gasoline or Distillate
8474L-013-CN-0003-002
Normal Case - 100% Bach-Ho Max Gasoline or Distillate
8474L-013-CN-0003-003
Normal Case - Mixed Crude Max Gasoline or Distillate
In the following, only the normal case – 100% Bach Ho Max Gasoline or Distillate is described. Note: In the following ( ): Intermittent Producer/Consumer +: Indicates Quantity Produced -: Indicates Quantity Consumed
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1.2.4.1.1. Electrical Power Electrical Power (kW) Item Tag
Description
Motor Load Rating
Elec. Mech. Running Oper. Load Load
PLATFORMING SECTION P-1301A
Seperator Pump
-53.5
P-1301B
Seperator Pump
(-53.5)
P-1302A
Debutanizer overhead pump
-12.2
P-1302B
Debutanizer overhead pump
(-12.2)
P-1303A
Circulating water pump
(-45.5)
P-1304A P-1304B P-1305 P-1306A P-1306B
Chemical Injection Pump (Part of X-1307) Chemical Injection Pump (Part of X-1307) Start-Up chemical injection pump (Part of X-1307) Sulfide injection pump (Part of X-1396) Sulfide injection pump (Part of X-1396)
-0.4 (-0.4) (-0.33) -0.3 (-0.3)
P-1307A
Surface condensor condensate pump
(-13.6)
P-1308
Net gas chloride pump
(-2.3)
P-1309A P-1309B P-1397A P-1397B M-1397
C-1301
Chloride transfer pump (Part of X-1307) Chloride transfer pump (Part of X-1307) Phosphate dosing pump (Part of X-1397) Phosphate dosing pump (Part of X-1397) Phosphate storage drum agitator (Part of X-1397) Spare lube oil pump
(-0.8) (-0.8) -0.3 (-0.3) -0.4
(-19) Page 24 of 237
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Electrical Power (kW) Item Tag
Description
Motor Load Rating
Elec. Mech. Running Oper. Load Load
Lube oil exhauster
-1.3
Oil conditioner
-1.4
Turning gear
(-2.4)
REGENERATION SECTION E-1303
Products condenser
-192
E-1304
Debutanizer bottoms cooler [1]
-22
E-1308
Debutanizer condenser
-24
E-1309
Net gas cooler
-24
X-1301
Recovery plus system
-1760
M-1398A
Sulfite storage drum agitator
-1.5
M-1398B
Sulfite storage drum agitator
-1.5
P-1351A
Caustic circulation pump
-14.6
P-1361B
Caustic circulation pump
(-14.6)
P-1352A P-1352B P-1353A P-1353B P-1354A P-1354B P-1398 P-1399
Chloride circulation pump (Part of X-1307) Chloride circulation pump (Part of X-1307) Caustic Injection pump (Part of X-1359) Caustic Injection pump (Part of X-1359) Water injection pump (Part of X-1360) Water injection pump (Part of X-1360) Sulfite dosing pump (Part of X-1398) Caustic dosing pump
-0.3 (-0.3) -0.3 -0.3 -1.8 (-1.8) -0.3 -0.3
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Electrical Power (kW) Item Tag
Motor Load Rating
Description
Elec. Mech. Running Oper. Load Load
(Part of X-1398) B-1361
Fines removal blower
-3
C-1361
Lift gas blower
-13
Aux. lube oil pump
(-0.1)
Regeneration blower
-100
Lube oil pump
-0.5
B-1353
Regeneration cooler blower
-27
H-1351
Reduction gas heater No.1
-203
H-1352
Reduction gas heater No.2
-79
H-1353
Regeneration heater
(-324)
H-1354
Air heater
-84
B-1352
Note: [1]: Items combined with same fans: E-1209+E-1304. Indicated electrical power corresponds to 50% of the total fans power for these 2 items.
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1.2.4.1.2. Steam Steam (T/h) Item No.
Description
HP STM
Condensate (T/h)
MP STM
LP STM
HP MP LP Vac. cond cond cond cond
Losses (T/h)
PLATFORMING SECTION P-1303B
Cooling water pump [2]
-2.9
2.9
P-1307B
Surface condensor condensate pump [3]
-1.40
1.40
C-1301
Recycle compressor [1]
-22.2
Main lube oil pump
22.2 -1.7
Lube oil heater
-0.1
Sealing main turbine (start-up)
E-1307
Debutanizer reboiler
1.7
(-0.1)
(0.1)
-5.8
SG-1301/ Convection section D-1304 [6]
0.1
5.8
21.9
0.2
0.8
J-1301
Steam jet ejector
(-1.2)
(1.2)
J-1302/3
Condensate ejectors [7]
-0.1
J-1304
Hogging ejector
(-0.2)
(0.2)
J-1305
Gland condenser ejector
-0.1
0.1
H-1301/ 2/3/4
CCR heaters [5]
(-20)
(20)
Tracing steam
-0.3
0.1
-0.1
0.3
0.1
REGENERATION SECTION E-1352
Booster gas heater
-0.1
0.1
Water injection TOTAL -28.0
-6.6
6.0
5.8
0.4
0.2
-0.8
0.8
21.5
-23.0
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Notes: [1]. Condensation turbine. Vacuum condensates. Indicated flowrate is for lean case with normal HP steam (shaft power = 4200 kW) [2]. Shaft power = 45.5 kW [3]. Shaft power = 19.6 kW [4]. Shaft power = 19.0 kW [5]. Purge steam total flowrate injected in all 4 heaters [6]. For summer fuel gas case [7]. Main steam condensate ejectors max normal consumption: 130kg/hr
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1.2.4.1.3. Cooling Water & Fresh Water Item No.
Cooling Water
Description
ΔT (°C)
3
m /h
Fresh Water (T/h)
PLATFORMING SECTION E-1306
Debutanizer bottoms train cooler
6.9
-59.3
E-1310
Debutanizer trim cooler
3.2
-136.3
E-1311
Steam surface condenser
8.0
-1132.0
E-1399
Sewer blowdown cooler
10.4
-4.8
P-1303A
Circulating water pump
0
-1.5
P-1303B
Circulating water pump
13
-1.5
P-1307A
Surface condenser condensate pump
0
-0.5
P-1307B
Surface condenser condensate pump
13
-0.5
C1301
Main lube oil pump
13
-0.5
Spare lube oil pump
0
-0.5
Cooling mineral oil coolers
4
-35.2
P-1301A
Separator pumps
13
-1.5
P-1301B
Separator pumps
13
-1.5
X-1301
Recovery plus system
5.6
-698.0
P-1302A
Debutanizer overhead pump
13
-1.5
P-1302B
Debutanizer overhead pump
0
-1.5
REGENERATION SECTION E-1354
Caustic cooler
13
-24.8
C-1351
Lift gas blower
13
-2.7
Aux lube oil pump
0
-0.5
Regeneration blower
13
-2.5
Lube oil pump
13
-05
Regeneration cooler blower
13
-1.1
B-1352
B-1353
TOTAL
-2108.7
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1.2.4.1.4. Instrument & Plant Air
Item No.
Inst. Air Nm3/h
Description
Plant Air (Nm3/h) Contin.
Intermit.
PLATFORMING SECTION Control valves and on/off valves [1]
-30
Analysers & chromatographs [2]
-1
X-1301
Recovery plus system
-40
C-1301
Recycle compressor
-12
REGENERATION SECTION A-1353
Air drier package [3]
-731
Control valves & on/off valves [4]
-92.3
TOTAL 906.3 Notes: [1]. Estimated consumption is based on 18 control valves (1.5 Nm3/h/control valve) and 3 on-off valves (0.45 Nm3/h/on-off valve) [2]. Estimated consumption based on 4 analysers / chromatographs (0.2 Nm3/h analysers & chromatographs) [3]. Air drier product air flowrate (585 Nm3/h) + 20% purge requirement for reactivation included [4]. Estimated consumption based on 25 control valves (1.5 Nm3/h/control valve) and 30 on/off valves (2 Nm3/h/on-off valve)
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1.2.4.1.5. Nitrogen - Bach Ho Max Distillates Case Item No.
Nitrogen (Nm3/h)
Description
Contin.
Intermit.
PLATFORMING SECTION Reactor section dryout [1]
(-1481)
Reactor section start-up [2]
(-1281)
Net gas section start-up [3]
(-235)
Reactor section shutdown [4]
(1281)
Net gas section shutdown [5]
(-235)
Net gas chloride treater alumina replacement [6]
(-89)
LPG chloride treater alumina replacement [7]
(-17)
Debutanizer section startup [8]
(-1016)
X-1301
Recovery plus system
[9]
C-1301
Secondary and tertiary seals
-82
Primary seal (start-up)
(-91)
REGENERATION SECTION Process nitrogen [10] [11]
-96.0
TOTAL -177.0
(-800) -1481
Notes: [1]: Total volume consumed as per UOP requirement = 2325 Nm3 [2]: Total volume consumed as per UOP requirement = 1473 Nm3 [3]: Total volume consumed as per UOP requirement = 270 Nm3 [4]: Total volume consumed as per UOP requirement = 2210 Nm3 [5]: Total volume consumed as per UOP requirement = 405 Nm3 [6]: Total volume consumed as per UOP requirement = 610 Nm3 [7]: Total volume consumed as per UOP requirement = 49 Nm3 [8]: Total volume consumed as per UOP requirement = 1167 Nm3 [9]: Start-up only. Consumption to be defined by vendor Page 31 of 237
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[10]: A peak of total requirement of 800 Nm3/hr required approx. 2 days per month and occurs in place of constant nitrogen consumption rate during that 2 day period. [11]: Dedicated CCR regeneration nitrogen supply from liquid nitrogen supply
1.2.4.1.6. Boiler Feed Water Item No.
BFW (T/h)
Description
HP BFW
MP BFW
LP BFW
0.0
0.0
PLATFORMING SECTION SG-1301/ Convection section D-1304
-23.0 TOTAL -23.0
1.2.4.1.7. Furnace and Boilers Furnaces & Boilers Item No.
Description
Duty MW
Efficiency Fuel Fired % MW
PLATFORMING SECTION H-1301
Charge heater
8.1
-13.3
H-1302
No.1 Interheater
12.7
-20.9
H-1303
No.2 Interheater
8.2
-13.7
H-1304
No.3 Interheater
6.8
-9.5
H-1301 /2/3/4
Convection section
18.0 TOTAL 52.8
0.0 -57.4
1.2.4.2. Chemicals The following table describes the chemical consumption of the CCR:
Page 32 of 237
Net gas chloride D-1302A treater No.1
DOC NO: 8474L-013-A5016-0000-001-003 DATE: 19/10/07
UOP MOLSIV adsorbent 9139A
D-1302B
Net gas chloride treater No.2
UOP MOLSIV adsorbent 9139A
D-1308A
LPG chloride treater No.2
UOP MOLSIV adsorbent 9139A
Remarks
Pick Flow (kg/hr)
REV: A
Average Flow kg/h
Concentration
Chemical
Description
Item
TRAINING MODULE CONTINUOUS CATALYTIC REFORMER (CCR)
Volume = 17.5 m3, 13088 kg, Density = 750 kg/m3 90 days life per volume
Volume = 2.5 m3, 1683 kg, Density=750 kg/m3
D-1308B
LPG chloride treater No.2
UOP MOLSIV adsorbent 9139A
X-1397
Boiler Chemical Dosing
Trisodium phosphate
10 wt%
1.62
XXX
Chloride injection
Perchloroethylene
Undiluted
0.1
110%
263 kg required for 30 days of operation
XXX
Caustic injection
Caustic
14.4 wt%
32.7
110%
71000 kg required for 90 days of operaton
XXX
Catalyst sulfiding
Diethylsulfide
Undiluted
0.07
110%
157 kg required for 90 days of operation
XXX
Chloride injection
Perchloroethylene
Undiluted
2.0
110%
4300 kg required for 90 days of operation
180 days life per volume
81 m3 installed volume, R-1301/ 2/3/4
45360 kg, CCR Catalyst
R-234
Density = 560 kg/m3 Losses = 0.55m3 / 90 days
X-1301
Recovery plus initial filling
Propylene
XXX
NaClO treating
Sodium sulfite
3680 kg total 23 wt%
5.5
120%
9600 kg of solid salts required Page 33 of 237
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Notes: 1. Common chloride storage for CCR platformer and CCR regeneration sections 2. Di-ethyl sulphide storage in NHT unit (X-1252) 3. Catalysed sodium sulphite acts as an oxygen scavenger 4. DMDS can be used alternatively to di-ethylsulfide. In this case an amount of 83 kg is required for 90 days of operaton. CCR Catalyst: The Type of catalyst used in the CCR reactors is UOP catalyst R234. Catalysts from R-230TM series are used to produce high octane reformate and hydrogen. R-234 catalyst is a low platinum version. Physical properties of R-230 series catalysts are the following: Circulating ABD (kg/m3): 537 Static ABD (kg/m3):
561
Nominal diameter (mm): 1.6 Shape:
Sphere
R-234 platinum, wt%:
0.290
R-230 series catalyst can be supplied in oxidized or reduced form. The following quantities of catalyst are required: Item No.
Service
Volume (m3)
R-1301
Reactor No.1
11.6
R-1302
Reactor No.2
13.5
R-1303
Reactor No.3
14.9
R-1304
Reactor No.4
15.9
CCR Regeneration Section
25.1
Total
81.0
Catalyst life is around 6 years. Addition of catalyst in continuous (0.55 m3) is required to compensate fines losses.
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1.3. Glossary of terms and Acronyms 1.3.1. Acronyms COMPANIES/ORGANISATIONS DQR DQIZMB EVN FW MOC MOSTE MPI SRV TPC
Dung Quat Refinery Dung Quat Industrial Zone Management Board Electricity Authority of Vietnam Foster Wheeler Energy Limited Ministry of Construction Ministry of Science, Technology and Environment Ministry of Planning and Investment Socialist Republic of Vietnam Technip Consortium
OTHERS ACE ADP AER
Application Control Environment Analyser Data Acquisition System Alarm Display Panel Application Engineers Room
AI
Analyser Indicator
AIT
Auto Ignition Temperature
MCC MCR MCS MOV Control System MDF
AMS
Asset Management System
MIS
ANSI
American National Standards institute
MMS
APC
Advanced Process Control
MMT
API
American Petroleum Institute CONTINUOUS CATALYTIC REFORMER (CCR) Analyser Speciality Contractor American Society of Mechanical Engineers
MOC
Minimum Maintained Temperature Madrid Operating Center
MOM
Minutes of Meeting
MOV
Motor Operated Valve
MP
Medium Pressure
MPT
Minimum Pressurization Temperature
MR
Material Requisition
MRR MSD MSDS MTBF
Marshalling Rack Room Material Selection Diagram Material Safety Data Sheet Mean Time Between Failures
ADAS
ARU ASC ASME ASP ASTM ATM BCS BEDD BFD
Analyser Systems Package American Society of Testing and Materials Asynchronous Transfer Mode Blending Control System Basic Engineering Design Data Block Flow Diagram
MC
Marshalling Cabinet
MCB
Main Control Building Motor Control Center Main Control Room MOV Control System Main Distribution Frame Management Information System Machine Monitoring System
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TRAINING MODULE CONTINUOUS CATALYTIC REFORMER (CCR)
BFW BL BOM
Boiler Feed Water Battery Unit Bill of Materials
MTTR MTO MTPA
BPC
Blending Properties Control
MVIP
BPCD
Barrels per Calendar Day
NACE
BPSD BRC
Barrels per Stream Day Blending Ratio Control
NCR NDE
CAD
Computer Aid Design
NFPA
DOC NO: 8474L-013-A5016-0000-001-003 REV: A
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Catenary Anchor Leg Mooring Commercial Bid Tabulation Control Complex Auxiliary CCAR Room CCC Central Control Complex CCR Continuous Catalytic Reformer CCTV Closed Circuit Television CD Chart Datum CONTINUOUS CATALYTIC CDU REFORMER (CCR) European Committee for CENELEC Electrotechnical Standardization CFC Chlorofluorocarbons Cooperative Fuel Research CFR (Engine) C&I Control and Instrumentation Computerized Maintenance CMMS Management System (Spent) Caustic Neutralization CNU Unit
NHT NIR
Mean Time To Repair Material Take-Off Metric Tonnes per Annum Multi Vendor Interface Program (Honeywell) National Association of Corrosion Engineers Non Conformance Report Non Destructive Examination National Fire Protection Association Naphtha Hydrotreater (Unit) Near Infrared Spectroscopy
NPSH
Net Positive Suction Head
NPV NTU OAS OJT
OSBL
Net Present Value Naphtha Treater Unit Oil Accounting System On Job Training Oil Movement and Storage Control System Oil Movement and Storage automation Operation Override Switch Operations Planning and Scheduling System Outside Battery Limit
OTS
Operator Training Simulator
CPI
Corrugated Plate Interceptor
PAGA
CSI DAF DAU DCS
Control Systems Integrator Dissolved Air Flotation Data Acquisition Unit Distributed Control System
PCB PFD PFM PDB
DEA
Diethanolamine
PGC
CALM CBT
OM&S OMSA OOS OPSS
PABX
Private Automatic Branch Exchange Public Address / General Alarm Printed Circuit Board Process Flow Diagram Path Find Module Project Documents Base Process Gas Chromatograph (Analysers)
PHD
Plant History Database
DMDS DMS
Detailed Environmental Impact Assessment Dimethyldisulfide Document Management System
PI PIB
DNV
Det Nork Veritas
PID
Plant Air Process Interface Building Piping and Instrument Diagram Project Implementation Manual Process Knowledge System (Honeywell DCS) Pipeline End Manifold Planning
DEIA
DPTD DQMIS DQRP DVM
Design, Pressure, Temperature Diagram Dung Quat Management Information System Dung Quat Refinery Project Digital Video Manager
PIM PKS PLEM PLG
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DWT
Dead Weight Tonnes
PMC
EL EOR
PMI PMT PO
Purchase Order
POC
Paris Operating Center
PP
Project Procedure
ERP ES ESD ETP ETS EWS FDC FAP
Equipment List End of Run Electronic Document Management System Electromagnetic Compatibility Engineering Procurement, Construction and Commissioning Enterprise Resource Planning Ethernet Switch Emergency Shut Down Effluent Treatment Plant Effluent Treatment System Engineering Work Station Feed Development Contract Fire Alarm Panel
Project Management Consultant Positive Material Identification Project Management Team
FAT
Factory Acceptance Test
FEL
Front End Loading
F&G FIU FIC
Fire and Gas System Field Interface Unit Flow Indicating Controller
FM
Factory Mutual (Approval body)
FOTC
Fibre Optic Termination Cabinet
EDMS EMC EPC
FTE GC GFT
Fail Safe Controller (Honeywell ESD) Fault Tolerant Ethernet Gas Chromatograph Ground Fault
HAZAN
Hazard Analysis Study
HAZOP
Hazard and Operability Study
HDT
Hydrotreater
HEI
Heat Exchange Institution
HHP HGO HIC HP HSE
High High Pressure (Steam) Heavy Gas Oil Hydrogen Induced Cracking High Pressure Health, Safety and Environment Heating Ventilation Air Conditioning Instrument Air International Civil Aviation Organisation
FSC
HVAC IA ICAO
PPB PPM PRU PWHT QA QC RA R&D
Parts per Billion Parts per Million Propylene Recovery Unit Post Weld Heat Treatment Quality Assurance Quality Control Risk Analysis Research and Development Real Time Database RDBMS Management System Residue Fluid Catalytic RFCC Cracking RFSU Ready for Start-Up RLU Remote Line Unit ROW Right of Way Refinery Performance RPMS Management System Resistance Temperature RTD Detector Real Time Data Base RTDB (System) RTU Remote Terminal Unit SAT Site Acceptance Test SBT Segregated Ballast Tanks Software Bypass Management SBMS System Supervisory Control and Data SCADA Acquisition SCC Satellite Control Complex Simulation Control SCE Environment SCR Satellite Control Room SDH Synchronous Digital Hierarchy SE Safety Earth S&E Safety & Environmental SGS Safeguarding System SOE
Sequence of Events
SOR
Start of Run
SOW
Scope of Work Page 37 of 237
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ICE
Instrument Clean Earth
SP
ICS
Integrated Control System
SPIR
IIP I/O IP
SPM SR SRU STC
Construction Standard
IRP IRR
Initial Interface Plan Input/Output Institute of Petroleum Instrumented Protective System Interposing Relay Panel Internal Rate of Return
Specification Spare Parts and interchangeability Record Single Point Mooring Scope of Supply Sulphur Recovery Unit
STD STEL
IS
Intrinsically Safe
SVAC
ISA ISE ISBL ISOM
Instrument Society of America Intrinsically Safe Earth Inside Battery Limit Isomerisation Unit
SWS TAS TBT
ITB
Invitation to Bid
TCF
ITP
Inspection and Test Plan
TCM
JB
Junction Box
TEMA
JCC
Jetty Control Complex
TGIF
JCR JSD JSS
Jetty Control Room Job Specification for Design Job Specification for Supply
TLCR TLCS TN
JVD
Joint Venture Directorate
TPS
KLOC KTU LAN LCO LCOHDT
Kuala Lumpur Operating Center Kerosene Treatment Unit Local Area Network Light Cycle Oil LCO Hydrotreater
TQM TS TWA UFD U/G
LDE
Lead Discipline Engineer
UL
Design Standard Short Term Exposure Limit Shelter Ventilation and Air Conditioning System (Analyser houses) Sour Water Stripping (Unit) Terminal Automation System Technical Bid Tabulation Temporary Construction Facilities Task Control Module Tubular Exchanger Manufacturers' Association Temperature Gauge Indication Facilities (Tankage) Truck Loading Control Room Truck Loading Control System Transmittal Note Total Plant Solution (Honeywell) Total Quality Management Terminal Server Time Weighted Average Utility Flow diagram Underground Underwriter Laboratories (Approval body)
IPS
Lower Exposition Limit (F&G, Analysers) Light Gas Oil Laboratory Information Management System
UPS
Uninterruptible Power Supply
VDU
Visual Display Unit
VPU
Vendor Package Unit
LIS
Laboratory Information System
WABT
LLU LP LPG LTU LPG
Local Line Unit Low Pressure Liquefied Petroleum Gas Treater Unit
WBS WHB YOC
LEL LGO LIMS
Weight Average Bed Temperature Wash Breakdown Structure Waste Heat Boiler Yokohama Operating Center
1.3.2. Glossary Refer to separate glossary.
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TRAINING MODULE
CONTINUOUS CATALYTIC REFORMER (CCR) UNIT: 13
Course Content: Section 1 - General Description Section 2 - Process Flow Description
X
Section 3 - Process Control Section 4 - Safeguarding Devices Section 5 - Fire & Gas Systems Section 6 - Quality Control Section 7 - Cause & Effects Section 8 - Operating Procedures Section 9 - HSE Section 10 - Reference Document Index
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SECTION 2 : PROCESS FLOW DESCRIPTION DRAWING TO BE INSERTED (DRAWING IN PROGRESS) Figure 8: CCR Block Flow Diagram A detailed description of each section of the CCR is shown bellow, sorted by main steps. 2.1. Platforming Reaction Section 2.1.1. Feed preheater section DRAWING TO BE INSERTED (DRAWING IN PROGRESS) Figure 9: Simplified PFD of the Reactors Section The platformer feed, hydrotreated heavy naphtha, coming from the Naphtha Splitter (Unit 12), enters the unit under flow control and is filtered to remove any particles which may plug the welded plate-type exchanger E-1301 where the feed is then routed. In normal operation, the feed is directly supplied from the Naphtha Splitter (T1202) via the Stripper Feed Naphtha Splitter Bottoms cooler (E-1206) in the unit 012. Before the feed is supplied to the combined feed exchanger E-1301, sulfide is injected by means of the sulfide injection pumps P-1306 A/B. Chloride is also injected periodically in the feed upstream E-1301 by means of the chloride/condensate injection pumps P-1304 A/B in the chloride injection package X-1307. A recycle hydrogen rich gas from the recycle compressor C-1301 is also supplied to the Combined Feed Exchanger E-1301 where it is mixed with the feed stream. The combined feed (liquid feed + recycle gas) is heated up by heat exchange with the reactor effluent from the last reactor R-1304 in E-1301. The combined feed is then sent to the Charge Heater H-1301 to be heated up to the desired temperature before entering the first reactor R-1301 in the reactor stack.
2.1.2. Charge heater and inter heaters The heat and reheat section consists of the Charge Heater and 3 Inter-heaters between the reactors. In the reactors, the chemical reactions that occur are mostly endothermic, and so the outlet temperature of each reactor is less than the inlet temperature. The function of the interheaters is to raise the temperature of each reactor’s effluent back up to reaction temperature for the next reactor: Rection effluent leaving the bottom of reactor No.1 R-1301 is heated up in interheater No.1 H-1302 and sent to the top of the reactor R-1302. Page 40 of 237
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Effluent from reactor 2 R-1302 is heated in interheater No.2 H-1303 and sent to reactor R-1303. Effluent from reactor 3 R-1303 is heated in interheater No.3 H-1304 and sent to reactor R-1304. The Charge Heater and the Interheaters in UOP Continuous Platforming Units are contained in a single, partitioned, multi-cell heater box. The heater box has a convection section to recover heat from the flue gas to generate HP steam. Fuel Gas used in the heaters firing systems is supplied from the Fuel Gas Header from unit 037. 2.1.3. Reactors In the reactors, the heated heavy naphta reacts on the catalyst to produce the high octane gasoline blend desired via 2 major types of reactions: hydrogen consuming reactions and hydrogen producing reactions. The reactor stack is composed of 4 reactors constructed together to form one large vessel. The bottom heads of the individual reactors are used to divide this vessel into separate reactors. In order to have a low pressure drop, the reactors design is radial flow: Hydrocarbon enters at the top of the reactor and flows across the catalyst bed from the outside to the inside of the reactor. Process vapors then flow through the center pipe and out the reactor. Catalyst enters at the top of the reactor, flows down through the reactor, and exits at the bottom. The reactor stack is equipped with reactor internals that permit catalyst transfer series flow through the stack; i.e. from one reactor to the next. Fresh regenerated catalyst is introduced at the top of the 1st reactor. The catalyst exiting the last reactor R-1304 is sent to the regeneration section. The temperature of the process vapor drops rapidly in going through the catalyst bed, since the reactions are very endothermic. Therefore, they must be reheated before they enter the next reactor to support further reactions. After reheating, the vapors go to the next reactor where the process is repeated. Recycle H2 gas from the recycle compressor is also injected at the bottom of the last reactor to sustain the hydrogen consuming reactions. 2.1.4. Reactor effluent Leaving the Reactor No.4 R-1304, the effluent is split into two streams: •
1 stream is used to heat up the recycle gas injected at the bottom of R1304 in the reactor purge exchanger E-1302
•
The other stream is cooled by exchange with the combined feed stream in the Combined Feed Exchanger E-1301.
These 2 streams are recombined downstream exchanger E-1301 and then further cooled in the Products Condenser E-1303. After cooling, the reactor effluent is sent to the Separator D-1301 where H2 rich vapour is separated from the liquid hydrocarbon, by using a wire mesh inside D1301 to catch any liquid entrainment. Page 41 of 237
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2.1.5. Reactor effluent separator The hydrogen rich stream is then compressed by the recycle compressor C-1301 and split into 2 streams: •
The majority of the gas stream is recycled back into the reaction section: Most of it is sent to the combined feed exchanger E-1301 for mixing with the platformer feed and a slip stream is sent back to the bottom of the reactor R-1304 after being heated up against R-1304 effluent in E-1302.
•
The remaining stream, so called Net Gas is cooled in the net gas cooler E1304 and then sent to the Recovery Plus system X-1301 to allow the recovery of LPG / Reformate which remain in the net gas stream. This Net Gas is mixed with off gas from the debutanizer receiver upstream the Recovery Plus Package X-1301.
Part of the Separator liquid is pumped by the separator pump P-1301 A/B to the recovery plus system where it is recontacted with the liquid effluents, while the other part is sent to the debutanizer feed/bottoms exchanger before being fed to the debutanizer T-1301. 2.1.6. Recycle compressor The recycle compressor C-1301 is driven by a steam turbine CT-1301 using HP steam from HP steam header. LP steam from the turbine exhaust is condensed against cooling water in the surface condenser E-1311. Condensate is then pumped by the surface condenser condensate pumps P-1307 A/B to the vacuum condensate system. 2.1.7. Steam generation DRAWING TO BE INSERTED (DRAWING IN PROGRESS) Figure 10: Simplified PFD of the Steam Generation Section HP Steam is available from interconnecting header. But HP steam is also produced using HP Boiler Feed Water (BFW) from Header: BFW is preheated in the convection section SG-1301 of the heater H1301/02/03/04 before entering the disengaging drum D-1306. Steam from this drum is then re-heated through the convection section of heaters, resulting in HP steam sent to the De-superheater DS-1301. In case of water flow drop, water from the steam disengaging drum D-1306 is recirculated to the steam convection section SG-1301 via the circulating water pumps P-1303 A/B (1 electric + 1 steam driven). From the disengaging drum, there is also a continuous blowdown of vapour/liquid to the continuous blowdown drum D-1304 and an intermittent blowdown of liquid to the intermittent blowdown drum D-1305. LP steam exits D-1304 where water is separated and directed to D-1305. In D1305, the collected water is sent to the sewer after being cooled in E-1399 against cooling water. Page 42 of 237
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2.1.8. RECOVERY PLUS system DRAWING TO BE INSERTED (DRAWING IN PROGRESS) Figure 11: Simplified PFD of Recovery Plus System The RECOVERY PLUS™ system contains (principally) the following circuits: 2.1.8.1. Refrigeration Circuit The refrigeration circuit in the RECOVERY PLUS™ system is a pressurized closed loop. The propylene refrigerant flows to the Combined Chiller X-1301-E-03 through a valve in which the pressure drop vaporizes a portion of the liquid refrigerant, and the resultant phase change chills it to the required operating temperature. The frothing of the refrigerant in the Chiller covers the rest of the tubes. Rich Net Gas and Lean Oil pass through their respective tube bundles, cooled by refrigerant evaporation. The vaporized refrigerant that leaves the Combined Chiller enters the suction of the Refrigerant Compressor X1301-C-01. Within the compressor, refrigerant vapor comes in contact with circulating synthetic lube oil, which aids compression while lubricating and cooling the Compressor. Mechanical energy and warm oil heat the refrigerant to a temperature well above the condensing point. The compressed gas/oil mixture discharges from the Compressor to the Oil Separator X-1301-V-02. In the Oil Separator, the refrigerant disengages from the oil and passes overhead through coalescing elements where entrained oil is removed. Oil buildup from the downstream side of these elements is sent back into the compressor suction by the lube oil pumps X-1301-P-01 A/B through the oil cooler X-1301-E-04 and the lube oil filters X-1301-F-02 A/B. The refrigerant leaves the top of the Oil Separator and enters the shell side of the Refrigerant Condenser X-1301-E-06, where it condenses against cooling water. The lower section of the Condenser acts as a refrigerant surge capacity. Condensed refrigerant drains from the Condenser and is cooled further in the Subcooler X-1301-E-05, before entering the Combined Chiller. A portion of the condensed refrigerant bypasses the Subcooler and is used in the thermosyphon Lube Oil Cooler, which cools the lube oil for return to the Compressor. The refrigerant from the Lube Oil Cooler is returned to the inlet of the Refrigerant Condenser. 2.1.8.2. Net Gas Circuit The NET GAS IN from the recycle compressor C-1301 passes through the Vapor Exchanger X-1301-E-02, where it is cooled by exchanging heat with the RICH NET GAS. The RICH NET GAS then enters the vapor side Page 43 of 237
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of the Combined Chiller where it is further cooled. Some condensation of heavier hydrocarbons occurs as the gas is cooled. Leaving the Chiller, the RICH NET GAS enters the Absorber below tray 10. Passing upward through the Absorber, the gas is contacted with the chilled Lean Oil which absorbs hydrocarbons from the gas. The H2 rich gas (LEAN NET GAS) leaves the top of the Absorber, is then heated in the shell side of the vapor exchanger and sent to the Net Gas Chloride Treaters D-132 A/B outside X-1301. 2.1.8.3. Liquid Circuit The Lean Oil (liquid hydrocarbon from the separator D-1301) flows to the Liquid Exchangers X-1301-E-01 A/B, where it is cooled by exchanging heat with the absorber rich liquid. The lean oil then enters the liquid tube side of the Combined Chiller where it is further cooled. Before entering the Absorber above tray 1. The liquid flows counter-current, absorbing hydrocarbon from the rising gas. Leaving tray 10, the liquid accumulates in the bottom of the Absorber and is sent to the liquid exchangers X-1301-E-01A/B by the rich oil pumps PX-1301-P-01 A/B where it is heated before being further warmed in the Subcooler. The LPG and reformate rich stream then flows to the Debutanizer Feed Bottoms Exchanger, outside X-1301.
2.1.9. Net Gas Chloride Treaters DRAWING TO BE INSERTED (DRAWING IN PROGRESS) Figure 12: Simplified PFD of the Net Gas Section Net gas from X-1301 is fed to the net gas chloride treaters D-1302 A/B after being mixed with reduction gas from CCR regeneration section. In D-1302 A/B the net gas flows through the absorbers in series and chloride components are removed on the beds of activated Alumina. The Net Gas Chloride Treaters outlet gas is then separated into two streams: •
1 stream is sent to the first stage of the NHT make up compressor suction drum in unit 012
•
1 stream is sent on pressure control, via 013-PV-004B to the fuel gas system (unit 037)
2.1.10. Chemical injection 2.1.10.1. Chloride injection package X-1307 Chloride and water (condensate collected in the water break tank) are injected into the feed stream to obtain optimum activity and selectivity of the catalyst. Page 44 of 237
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Chloride from storage D-1399 is injected into the feed upstream of the combined feed exchanger E-1301 by means of the Injection Pump P1305 (for startup) or the Chloride/Condensate Injection Pumps P-1304 A/B. 2.1.10.2. Sulfide injection package X-1396 Sulfide from sulfide storage drum D-1396 is injected via the sulfide injection pumps P- 1306 A/B in the Feed from NHT stripper at the inlet of the combined exchanger E-1301. 2.1.10.3. Phosphate dosing drum X-1397 Phosphate is injected from phosphate feed drum D-1397 via the phosphate injection pump P-1397 A/B to the Steam disengaging drum D1306.
2.1.11. Debutanizer Section DRAWING TO BE INSERTED (DRAWING IN PROGRESS) Figure 13: Simplified PFD of the Debutanizer Section The Debutanizer is used to control the vapor pressure of the gasoline by fractionating all but a predetermined amount of C4’s (butanes) overhead. The amount of butane left in the gasoline will help determine the vapor pressure of the gasoline. The liquid hydrocarbon from the following streams is mixed at the inlet of the Debutanizer Feed-Bottoms Exchanger E-1306 A/B/C/D : •
Liquid from RECOVERY PLUS system (X-1301)
•
Liquid from the separator (D-1301) via pumps P-1301 A/B
•
Liquid from Net gas chloride treaters (D-1302 A/B) via pump P-1308 (Normally no flow)
The mixed liquid is heated up against Debutanizer bottoms liquid in E-1306 A/B/C/D, and enters the Debutanizer T-1301 column above tray No. 21. The overhead from the Debutanizer is partially condensed in the aero-condenser E-1309 and the trim cooler E-1310 against cooling water, before reaching the debutanizer receiver D-1303 where vapour and liquid phases are separated. The hydrocarbon liquid is pumped from the Receiver by the Debutanizer Overhead Pumps P-1302 A/B, and split into two streams: •
One stream is returned as reflux to the Debutanizer,
•
The other stream, LPG product, is sent to the LPG Chloride Treaters D1308 A/B where it flows through the absorbers in series to remove chloride components on activated Alumina beds. Treated LPG is then sent to the LPG recovery unit (LRU, 016). Page 45 of 237
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The vapor phase (C4 and lighter) leaves the receiver and is routed to the recovery plus system. The sour water is removed from the Receiver boot and sent to the Sour Water Stripper Unit. The stripping vapors in the lower portion of T-1301 are provided by the steam reboiler E-1307, which uses HP steam as heating medium. The stabilized material, so called reformate, is removed from the bottom of the debutanizer and partially cooled in the Feed-Bottoms Exchanger E-1306 A/B/C/D. Further cooling is performed in the Debutanizer Bottoms Cooler E-1308 and Trim Cooler E-1305 A/B before reformate is being sent to storage. 2.2. Regeneration Section DRAWING TO BE INSERTED (DRAWING IN PROGRESS) Figure 14: Simplified PFD CCR Regeneration Section Catalyst regeneration consists of 4 steps. The first three steps – coke burning, oxychlorination, and drying – occur in the Regeneration Tower T-1351. The fourth step, reduction, occurs in the Reduction Zone atop the reactor stack. A 5th step, catalyst cooling, is not part of the regeneration but is required for proper catalyst transfer. This step occurs in the regeneration Tower.
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Figure 15: Regeneration Section Flow Scheme 2.2.1. Spent Catalyst Transfer DRAWING TO BE INSERTED (DRAWING IN PROGRESS) Figure 16: Simplified PFD CCR Regeneration Section (Dust Removal) Spent catalyst flows by gravity from the bottom of the last reactor to the Catalyst Collector. Catalyst flows downward into the Spent Catalyst L-Valve Assembly against an upward flow of nitrogen. At the L-Valve Asssembly, circulating nitrogen from the Lift Gas Blower C-1351 engages the catalyst and lifts it through the catalyst lift line to the Disengaging Hopper D-1353.
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In the Disengaging Hopper D-1353, additional circulating nitrogen from the Fines Removal Blower B-1351 separates catalyst chips and fines from the whole catalyst and carries them out to the top with the gas. The chips and fines are removed in the Dust Collector A-1352 and the nitrogen circulates back to the suction of the Fines Removal Blower B-1351 and the Lift Gas Blower C-1351. The Whole catalyst drops to the bottom of the Disengaging Hopper D-1353, and flows by gravity into the Regeneration Tower T-1351. The catalyst flows through and out of the Regeneration Tower by gravity. 2.2.2. Burn Zone / Reheat Zone The burning of coke from the catalyst occurs in the Burn Zone at the top of the Regeneration tower. Catalyst enters the regeneration towers where it flows downward between a vertical, cylindrical outer-screen and an inwardly tapered inner-screen. Hot regeneration gas, containing a low concentration of oxygen, flows radially from the outside to the inside of the catalyst bed. Coke burning occurs as the catalyst moves down in the bed. The coke burning should be complete when the catalyst exits the Burn Zone. The purpose of the tapered center-screen is: (1) To minimize the volume of catalyst behind the turn front where the catalyst is exposed to oxygen-deficient gas which is high in temperature and moisture. These are the conditions which promote catalyst surface area loss. (2) To concentrate the flow of regeneration gas at the top of the bed where coke burning is oxygen diffusion limited, a slower flow of gas is acceptable and residence time is of greater importance. The hot combustion gas mixes with the gas flowing up from the Chlorination Zone. This oxygen-rich chlorination gas supplies the oxygen for burning coke. The combined gases flow back to the Regeneration Blower B-1352. The Blower B-1352 recycles the gases through the Burn Zone piping loop to the sides of the Burn zone. Part of the gases are cooled in the regeneration Cooler E1355, which removes the heat generated by the coke burning by means of cooled air blown by the regeneration cooler blower B-1353. Downstream of E-1355 the Regeneration Heater H-1353 operates, if heat loss in the piping is greater than the heat of combustion, to heat the gas to the proper zone inlet temperature. The products of combustion are vented at the Regeneration Tower T-1351 inlet so as to provide a constant controlled temperature vent gas to the downstream chloride scrubbing equipment. Part of the vent gas are also removed from the recirculation circuit and are routed to the vent gas wash tower T-1352 in which the gas are neutralized by contacting them with caustic. After catalyst exits the Burn Zone it enters the Reheat Zone. In this zone the catalyst is contacted radially with hot combustion gas from the Regeneration Blower discharge B-1352. The purpose of this zone is to raise the temperature of the catalyst to that required in the chlorination zone. The flow rate of the reheat gas is typically 10% of the total regeneration gas flow. Page 48 of 237
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The Reheat Zone also provides additional residence time for oxygen diffusion limited coke combustion in case of coke breakthrough.
Figure 17: Regeneration Tower – Burn Zone
2.2.3. Chlorination Zone Oxidizing and dispersing the metals on the catalyst, and adjusting the chloride content on the catalyst base occur in the Chlorination Zone. The Chlorination Zone is located below the Burn Zone / Reheat Zone. Catalyst enters and flows downward in a cylindrical bed defined by an annular baffle. Hot air from the Drying Zone below flows upward into the region behind the annular baffle. At this point, vaporized organic chloride pumped by organic chloride injection pumps P-1352 A/B in the chloride injection package X-1307 is introduced to the gas through a distributor. The resulting chlorination gas then flows through the catalyst bed and exits into the Burn Zone.
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Figure 18: Regeneration Tower – Chlorination Zone
2.2.4. Drying Zone Catalyst drying occurs in the Drying Zone, below the chlorination zone. Catalyst enters and flows downward in a cylindrical bed. Hot drying gas flows upward through the catalyst bed. The drying gas is air from the Cooling Zone below and the instrument air Header. Both gases are dried to a very low moisture content in the Air Dryer A-1353 before entering the Regeneration Tower T-1351. These gases are mixed upstream the Air heater H-1354 which heats the gas to the proper inlet temperature. The gas from the cooling zone is hot, as it has been preheated by exchange with hot catalyst in that zone. This preheat reduces the net duty on the Air Heater. From the Drying Zone the drying air splits into two streams: •
1 entering the Chlorination Zone behind the annular baffle
•
1 exiting the Regeneration Tower and mixed to the vent gas from the electric heater H-1353 to the vent gas wash tower.
The split depends on the amount of air needed for coke burning. The flow rate of air that is needed for coke burning enters the chlorination Zone. Any excess air vents directly from the Regeneration Tower T-1351 on oxygen control. The air in excess of the coke burning requirement is needed in the Drying Zone for more complete moisture removal in that zone.
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Figure 19: Regeneration Tower – Chlorination Zone
2.2.5. Cooling Zone The Cooling Zone serves 2 functions, cooling the catalyst for downstream handling, and preheating a portion of the air to the Drying Zone. Cooling facilitates catalyst transfer by permitting isothermal catalyst lifting. The cooling gas is air from the Air Dryer A-1353. The Gas exits the zone and mixes with instrument air from the Air Dryer then enters the Air Heater before going to the Drying Zone. The split between air going to the Cooling Zone and air going directly to the Drying Zone determines the temperature of the catalyst exiting the Regeneration Tower T-1351.
Figure 20: Regeneration Tower – Chlorination Zone
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2.2.6. Reduction Zone Reducing the metals on the catalyst occurs in the reduction zone. The reduction zone is at the top of the Reactor Stack. Oxidized catalyst enters the top of the zone via the regenerated catalyst lift line. The catalyst flows downward through two cylindrical beds with a gas disengaging area between them. The catalyst exits the zone and enters the first Platforming reactor R-1301. The reduction gas is hydrogen rich booster gas from naphta hydrotreating unit (NHT unit 12). Reduction gas of intermediate temperature is supplied to the upper cylindrical bed by the electric heater H-1351 and flows co-current with the catalyst. Before being heated in H-1351, part of this reduction gas flows through the reduction gas exchanger E-1351. Part of the heated gas from H-1351 is fed to H-1352, so that reduction gas of higher temperature is supplied to the lower cylindrical bed by the electric heater H1352. This reduction gas flows counter-current to the catalyst flow. Both gases exit from the Reduction Zone via the gas disengaging area. The purpose of the dual zone reduction is to affect optimum and independently controlled reduction conditions for the proper performance of the catalyst. A low temperature reduction is performed in the upper bed, with the water of reduction being swept downward with the gas. The presence of moisture in this zone is not detrimental to catalyst performance due to the low temperature. In the lower zone, a high temperature reduction is performed under dry conditions. The moisture of reduction is swept away from the high temperature reduction front by the counter-current flow of gas. This is important, as the combination of high temperature and high moisture can lead to the metal agglomeration and improper metal reduction.
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Figure 21: Reduction Zone
2.2.7. Regenerated Catalyst Transfer DRAWING TO BE INSERTED (DRAWING IN PROGRESS) Figure 22: Simplified PFD of the CCR Regeneration Section – N2 Seal Drum From the Regeneration Tower T-1351, the catalyst flows by gravity into the Nitrogen Seal Drum D-1357 against a flow of nitrogen. Page 53 of 237
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From the Nitrogen Seal Drum the catalyst flows into the Lock Hopper D-1358. The Lock Hopper removes small batches of catalyst from the vessels above and transfers catalyst continuously into the Regenerated Catalyst L-Valve Assembly. At the L-Valve assembly, hydrogen-rich Booster Gas from the Naphta Hydrotreating Unit engages the catalyst and lifts it through the catalyst lift line to the Reduction Zone above the first Platforming reactor R-1301. The booster gas (Hydrogen rich gas from the NHT, unit 12) is first heated in E-1352 against MP steam before contacting the regenerated catalyst. The catalyst flows through the Reduction Zone to the top of the first reactor by gravity. The catalyst flows through and out each reactor by gravity until reaches the catalyst collector. This completes the transfer circuit. Catalyst flow between the reactors through equally spaced transfer lines designed to ensure even catalyst flow from all sides of each reactor. The catalyst circulation rate for the entire system is set by the Regenerator Control System (RCS) and its direct control of the regenerated catalyst lift rate. 2.2.8. Lift gas & Fines removal circuit DRAWING TO BE INSERTED (DRAWING IN PROGRESS) Figure 23: Simplified PFD of the CCR Regeneration Section – Lift gas & Fines removal The Spent Catalyst L-Valve Assembly, the Disengaging Hopper D-1353, the Dust Collector A-1352, the Fines Removal Blower B-1351, and the Lift Gas Blower C1351 make up the Lift Gas and Fines Removal Circuit. This circuit begins at the outlet of the Dust Collector A-1352 where a stream of filtered nitrogen gas is routed to both the Fines Removal Blower B-1351, and the Lift Gas Blower C-1351. Nitrogen from the Lift Gas Blower flows as lift gas to the Spent Catalyst L-Valve Assembly to fluidize the catalyst and carry it up the lift line. Nitrogen is added to the discharge of the Fines Removal Blower to account for the nitrogen lost to the Catalyst Collector and to the Regenerator T-1351. Nitrogen from the Fines Removal Blower discharge flows as elutriation gas to the Disengaging Hopper D-1353, to separate the fines from the whole catalyst in the elutriation pipe. The whole catalyst drops into the bottom of the Disengaging Hopper, while lift gas, elutriation gas, and fines leave the vessel through the upper end of the elutriation pipe. The circulating nitrogen gas stream leaving the Disengaging Hopper flows to the Dust Collector A-1352 for removal of the catalyst pills, chips and fines. The fines settle to the bottom of the Dust Collector. From the bottom of the Dust Collector the catalyst fines and chips are unloaded into a drum via the Fines Collection Pot D-1354. The Fines collection pot serves as a lock hopper to transfer the fines from the Dust Collector pressure to atmospheric pressure. Once filtered, the nitrogen gas flows out and the gas circuit is completed at the suction of the blowers.
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Figure 24: Lift gas & Fines removal Circuit
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2.2.9. Normal Catalyst Addition To replenish the catalyst removed as fines, fresh catalyst is periodically added into disengaging hopper D-1353. Catalyst is manually added into the catalyst addition funnel No.1 which is opened to atmosphere. Catalyst is then loaded into the Catalyst Addition Lock Hopper D-1352, which then is pressured with Nitrogen to match the spent catalyst lift system pressure. Catalyst is then unloaded into the catalyst transfer system upstream the disengaging hopper.
Figure 25: Catalyst Addition Lock Hopper No.1
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2.2.10. Catalyst Change-out on the fly To replace old CCR Platforming catalyst with a new load between scheduled turnarounds, another catalyst addition point is provided for this “changeout on-thefly”. The basic principle of the changeout is that while the Platforming Unit and Regeneration Section continue normal operation, old catalyst is continuously withdrawn and replaced with fresh catalyst: The old catalyst is removed below the Regeneration Tower just upstreamthe nitrogen seal drum, allowing the coke to be combusted before unloading. The fresh catalyst is added just below the withdrawal point, at the Nitrogen Seal Drum D-1357, via Catalyst Addition Lock Hopper No. 2 D-1356. Like for the normal catalyst addition, catalyst is manually added into the catalyst addition funnel No.2 which is opened to atmosphere. Catalyst is then loaded into the Catalyst Addition Lock Hopper No.2 D-1356, which then is pressured with Nitrogen to match the regenerated catalyst transfer pressure. Catalyst is then unloaded at the inlet of the N2 seal drum D-1357. At the Nitrogen Seal Drum a special valve and piping arrangement are used to allow for the catalyst replacement while maintaining normal gas communication between the Regeneration Tower and the Nitrogen Seal Drum.
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Figure 26: Catalyst Change out on the fly Page 58 of 237
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2.2.11. Vent Gas Wash Tower DRAWING TO BE INSERTED (DRAWING IN PROGRESS) Figure 27: Simplified PFD of the CCR Regeneration Section – Vent Gas Wash Tower A by-product of the regeneration process is the release of HCl and Chlorine. The regeneration gases from the regeneration tower, containing HCl and Cl2, are washed with a caustic solution in 2 stages. First the regeneration vent gases are contacted with the caustic in the Venturi Scrubber M-1351, where most of the HCl and the chlorine are removed. The second stage is accomplished in the tower T1352 where the rising acidic gases are contacted counter-currently with caustic. 20° Be caustic goes from header to caustic break tank D-1359 from where it is pumped by P-1353 A/B to be injected in caustic circulation loop. Cold Condensate from the water break tank D-1360 is added to caustic circulated via water injection pumps P-1354 A/B before entering the wash tower T-1352. The fresh caustic solution and the cold condensate are added to the caustic circulation loop upstream the caustic cooler. The cooled caustic is then split into 3 streams: •
Part of the caustic is injected in the lower part of the wash tower
•
Most of the caustic is injected in the upper part of T-1352 to flow down counter currently with the vent gas injected from the bottom of the tower.
•
The remaining part of the caustic circulation stream is contacted to the vent gas from the regeneration tower in the Venturi Scrubber M-1351 to cool the hot gas before entering the tower. This mixture is then injected into the bottom of the wash tower.
In the wash tower, the caustic solution flows down to the bottom of the Tower, contacting the acid gas flowing up and neutralizing it. The neutralized gas at the top of the tower is then vented to air. The caustic is then recirculated via the caustic recirculation pumps P-1351 A/B at the bottom of the tower. The flow of caustic is adjusted to maintain the total alkalinity of circulating caustic at 0.35 wt%, which should correspond to a pH level between 7.5 and 8.5. A continuous flowrate of this spent recirculated caustic is extracted of the loop at P-1351 A/B discharge to maintain neutralization products concentration in loop. The spent caustic drawn off contains NaClO which needs to be neutralized. This is done with sodium sulfite which acts as an oxygen scavenger. In case of Vent Gas Wash Tower T-1352 overflow, it will be collected in caustic sump TK-1399. Pump P-1399 is used to empty this sump and send the flow to spent caustic line to OWS. A 23 wt% sodium sulfite solution is prepared in D-1398. The sodium sulfite will neutralize the continuous purge from T-1352 and the intermittent flow from P-1399 in event of T-1352 overflow to TK-1399. This solution is injected in the sewer connection OWS downstream of P-1399 discharge to spent caustic line to OWS. The NaClO is neutralized in line by sodium sulfite via P-1398. Page 59 of 237
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Figure 28: Vent Gas Treating System
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2.2.12. Process Pressures and Environments The platforming section and the regeneration section operate at different pressures and under different environments (see figures 26 & 27), this implies that several inherent hazards must be overcome to transfer the catalyst safely between those 2 sections: •
First the low pressure equipment on the Regeneration Section must at all times be kept safe from the high pressure equipment in the Platforming Section
•
Second the hydrogen/hydrocarbon environment of the reaction section must at all times be kept safe from the oxygen-containing environment of the Regeneration Section
Through the design of the equipment and through the programmed sequences of the Regenerator Control System, the Regeneration Section accomplishes these tasks. The hydrogen/hydrocarbon and oxygen atmospheres are separated by the use of “nitrogen bubbles”. A nitrogen bubble is a region between hydrogen containing equipment and oxygen containing equipment maintained as a pure N2 atmosphere. This is accomplished by keeping the pure N2 region at a higher pressure than the equipment on either side of it. Nitrogen bubbles are maintained in the Regeneration Section just below the Reactors, i.e., the spent catalyst transfer system and the Disengaging Hopper D1353; and just below the regeneration tower T-1351, i.e., the Nitrogen Seal Drum. The reactor and regenerator pressures are kept separate by allowing a pressure gradient to exist across a standpipe of catalyst. The pressure drop is maintained by the flow of gas from high to low pressure though the resistance of a catalyst bed. Such pressure gradients are maintained between the Disengaging Hopper D1353 and the Regeneration Tower T-1351, and between zones within the Lock Hopper D-1358.
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Figure 29: Process Pressures
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Figure 30: Process Environment
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TRAINING MODULE
CONTINUOUS CATALYTIC REFORMER (CCR) UNIT: 13
Course Content: Section 1 - General Description Section 2 - Process Flow Description Section 3 - Process Control
X
Section 4 - Safeguarding Devices Section 5 - Fire & Gas Systems Section 6 - Quality Control Section 7 - Cause & Effects Section 8 - Operating Procedures Section 9 - HSE Section 10 - Reference Document Index
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SECTION 3 : PROCESS CONTROL The following is a description of the main controls of the CCR only. For a detailed description of the control loops and the controllers, refer to the Control Narrative, doc. No. 8474L-013-SP-1511-001 and the CCR unit operating manuals. 3.1. Control Narrative & Operating parameters 3.1.1. Charge heater & inter-heaters temperature outlet control This control is detailed for the crude charge heater H-1301. However, it is strictly the same for the inter-heaters H-1302, H-1303 & H-1304. The temperature at the outlet of the crude charge heater is a cascade control loop in which the temperature control system (013-TIC-001) is operating as a master controller in a cascade with the fuel gas firing controls based on fuel gas pressure (013-PIC-618): The outlet temperature is measured by TT-001 and transmitted to the temperature controller TIC-001, where it is compared to the set point. TIC-001 as a reverse action: its output signal decreases when the outlet temperature increases. Then the output signal from controller TIC-001 is used to reset the pressure controller PIC-618 which regulates the fuel gas pressure accordingly by acting on PV-618. The output from TIC-001 is routed to PIC-618 via high selector switch HS-012 which selects the highest signal between the temperature controller TIC-001 and the HIC-012, which is set at the minimum fuel gas pressure allowed for the burners. In case the reset signal from TIC-001 is too low, then the signal from HIC012 is selected to ensure the minimum fuel gas pressure is always maintained.
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Figure 31: Functional Description of H-1301 temperature outlet control
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Figure 32: Functional Description of H-1302 temperature outlet control
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Figure 33: Functional Description of H-1303 temperature outlet control
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Figure 34: Functional Description of H-1304 temperature outlet control
3.1.2. Reactor Section Pressure Control The purpose of the Separator D-1301 pressure control system (013-PIC-004) is to control the reactor section pressure. During normal operation, pressure controller 013-PIC-004 will operate in split range, gradually opening first the valve 013-PV-004B (in the 0-50% controller output range) at chloride treaters outlet to Fuel Gas system to maintain the compressor suction pressure. Then, in the 50-100% controller output range, the valve 013-PV-004A located upstream the RECOVERY PLUS system will be gradually opened to send excess gas to the Flare. In this range, the the valve 013PV-004B is still fully open.
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Figure 35: Functional Description of Reactor Suction Pressure Control
3.1.3. Separator D-1301 Level control The purpose of the Separator D-1301 level control system (013-LIC-002) is to control the level of the bottom of the separator, by means of a split range controller with three outputs. During normal operation, upon high level in the separator drum, level controller 013-LIC-002 will first open valve 013-FV-580 to ensure lean oil circulation in the RECOVERY PLUS system X-1301 (0-33% output range) This valve remains fully open in the 33-100% output range from 013-FV-580. On high level signal from LT-002, the level controller will then gradually open the valve 013-LV-002A (33-66% output range, the valve remains fully open in the 66100% range) and finally the valve 013-LV-002B (66-100% output range) to maintain liquid level in the separator and to feed the debutanizer T-1301. Both valves LV-002 A/B are located in the discharge line of the separator pumps P1301 A/B to the debutanizer feed/bottoms exchanger.
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The opening of the valve 013-FV-580 is also function of the lean gas flowrate (013-FT-565) which adjusts the 013-FIC-580 setpoint (and so the position of the valve 013-FV-580) in order to maintain constant the required rich net gas / lean oil molar ratio.
Figure 36: Functional Description of D-1301 level control
3.1.4. Steam Generation Controls Heater box has a convection section to recover heat from the flue gas. The heat that is recovered is used to generate steam. The objective of the steam generation controls is to control the level on Disengaging drum D-1306 at a constant setpoint, based on the high pressure steam demand (013-FT-615), as a major disturbance, like a feedforward variable,
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that impacts the level. Since the demand increases, the level decreases, with a consequent action to increase the boiler feed water flowrate (013-FT-616).
Figure 37: Functional Description of Steam Generation control The summing device receives the steam flow rate signal from FT-615 and add or substract from it the difference between the output of the steam drum level controller LIC-606 and the level setpoint. The resultant output signal from this summing function is the setpoint signal to the boiler feed water flow controller FIC-
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616. The later regulate the flow of BFW entering the convection section accordingly via FV-616. Besides, the temperature of the steam exiting the desuperheater DS-1301 is controlled by TIC-643 which regulates the flow of BFW entering DS-1301 by acting on TV-043.
3.1.5. Water Circulation Pumps Logic P-1303 A/B The water circulation pumps, electrical driven P-1303A and steam turbine drive P1303B, operation logic ensure an auto start in case of low flow at the pump’s discharge, once in AUTO mode.
Figure 38: Functional Description of Steam Generation control
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To put the water circulation circuit in service, when there is no flow, both pumps will be in Local position. It is up to the site operator to decide which pump to start, logically taking into account the necessary preparation activities before start up, especially for the turbine, i.e.: warm up, rearm the local mechanical lever if previously trip, etc. For the electrical, that no fault is present. If the electrical driven pump is the one to be started, the operator has to push the local start pushbutton, surveying the discharge pressure, eventually against closed valve and gradually open, etc. Once the low flow is satisfied, the site selector of the electrical driven pump can be changed to Remote position, and the auto/manual mode selector to Auto mode. If the turbine driven pump is the one selected to be started, once all the preconditions are satisfied (logically by means of the local start connected to the DCS) an order will be sent to open the steam admission valve FV-614. Once the Flow low setting is satisfied (proper coordination required with control room), the turbine driven pump can be placed to remote mode, and the auto/manual mode selector to Auto mode, and be ready to accept the auto start command due to flow drop. In the event that a total service stop is required, it can be performed in the following ways: •
Normally, if 1 pump is running & the other is ready to start (in remote & auto mode) change the auto/manual to Manual mode, & turn off the running pump. To restart, bring both pumps to local selection & follow the steps described above.
•
By placing both pumps in Local & stopping- either by means of the software DCS or local stop in the event that auto selection was left active (this is ensuring that any pump left in remote will take auto-start in low flow situations)
•
By changing to manual mode & stopping both pumps from DCS or locally if all activities are conducted on site.
Regardless of the method used, if a total stop is required, it is important to avoid a scenario where the running pump is stopped & the auto was left active with 1 of the pumps left in remote. Special considerations: •
In case none of the pumps are running the auto/manual selector shall be forced to manual. Once one of the pumps is running and the remote selected, the force is released.
•
In case that the interlock UX–001 (due to low-low flow FIT-613) both pumps trip and the auto / manual selector shall be forced to manual mode. The force is released once the interlock is reseated, and the start up bypassactivated period is ON, In order to allow the initial pumps start-up.
For further details on the pumps logic sequence, refer to the Control Narrative of the CCR Reaction Section, doc. No.: 8474L-013-SP-1511-001.
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3.1.6. Debutanizer T-1301 Temperature Control The temperature of the rectification section is controlled by net LPG production. Temperature controller 013-TIC-027 adjusts the setpoint of the LPG product flow controller 013-FIC-010 to maintain a constant temperature between trays N°7 and 8. This temperature controls the end point of the LPG product. 3.1.7. Catalyst Circulation Control The following is a summary of the controls used for the catalyst circulation. For a detailed description, refer to the licensor operating manual dedicated to the catalyst regeneration section doc. No. 8474L-013-ML-002-A.
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Figure 39: Catalyst Circulation Control The catalyst circulation rate for the entire system is set by the Regenerator Control System (RCS) and its direct control of the regenerated catalyst lift rate. The desired catalyst circulation rate is entered into the RCS and it generates an output signal that adjusts the catalyst circulation. Page 76 of 237
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The operator enters the setpoint at the control panel and should not enter a setpoint that results in a catalyst circulation rate above the allowable catalyst circulation rate. The lift line pressure drop is used as a control parameter because it varies directly with catalyst flux (catalyst flow rate) in the lift line. The rate of catalyst lifting, as performed by the L-Valve Assembly, is controlled by splitting a constant lift gas flow between the primary and secondary addition points. In practice, this is achieved by keeping the total lift gas flow constant and varying only the secondary lift gas rate. In addition to the above, the rate of change of the catalyst lift rate must be slow and controlled to maintain the stability of the process environment isolation systems utilized in the CycleMax design (discussed after). Large or rapid changes in catalyst lift rate could result in the contamination of the oxygen atmosphere in the Regeneration Tower T-1351 by hydrogen gas, or interruption of catalyst flow to the L-Valve Assemblies. Regenerated (oxidized) catalyst flows from the Regeneration Tower T-1351, through the Nitrogen Seal Drum D-1357, into the Lock Hopper by gravity. In the Lock Hopper, small batches are transferred from the Regeneration Tower to the Regenerated Catalyst L-Valve Assembly. Hydrogen – rich gas engages the catalyst and lifts it through the catalyst lift line to the Reduction Zone above the Platforming Reactors. The flow rate of the regenerated catalyst, and thus the entire system is set by an output signal from the RCS (generated according to the operator setpoint) to the Regenerated Catalyst Lift line differential pressure controller 013-PDIC-531. The output signal from the regenerated catalyst lift line 013-PDRC-531 resets the regenerated catalyst secondary lift gas 013-FRC-535 (Flow Recorder Controller) setpoint directly. The flow of secondary lift gas as set by the FRC controls the catalyst lifting via the L-Valve Assembly to the Reduction Zone. As lifted catalyst is replaced by catalyst from the Lock Hopper D-1358 Surge Zone, the level in that zone falls. Once the low level setting on level indicator is reached, the RCS initiates the transfer of one batch of catalyst from the Regeneration Tower to the Surge Zone via cycling of the Lock Hopper Zone. The Lock Hopper Zone load size is a known weight of catalyst, calibrated during the initial startup of the unit. The actual circulation rate is determined based on a running average of the frequency of Lock Hopper loads transferred. The regenerated catalyst lift line 013-PDRC-531 setpoint is then ramped up or down by the RCS to reach the point where the actual circulation matches the desired circulation rate entered by the operator into the RCS. Spent catalyst flows by gravity from the bottom of the last reactor R-1304 to the Catalyst Collector. Catalyst flows downward, against a low, upward flow of nitrogen, into the Spent Catalyst L-Valve Assembly. Circulating nitrogen form the Disengaging Hopper D-1353 engages the catalyst and lifts it, via the catalyst lift line, to the Disengaging Hopper above the Regeneration Tower T-1351. Since regenerated catalyst is being lifted to the reduction zone, spent catalyst is removed from the Platforming Reactors so as to maintain a level in the upper bed of the Reduction Zone atop the reactor stack. The LRC (Level Recorder Controller) 013-LIC-501 at the Reduction Zone sends a signal resetting the spent Page 77 of 237
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catalyst lift line PDRC (Pressure Differential Recorder Controller) 013-PDIC-510A setpoint via a signal selector. The signal selector also receives a signal from the Regenerator Control System. The output signal from the spent catalyst lift line PDRC resets the spent catalyst secondary lift gas FRC (Flow Recorder Controller) 013-FIC-512 setpoint via a signal selector. The selector also receives an output signal from the Reactor/Spent Catalyst Lift line PDRC 013-PDIC-510B. The flow of secondary lift gas as set by the FRC controls catalyst lifting rate via the L-Valve Assembly to the Disengaging Hopper D-1353. The signal selectors, and the secondary inputs they incorporate (limiters), are required to maintain the stability of the process environment isolation systems utilized in the CycleMax design. A large or rapid increase in catalyst lift rate could interrupt catalyst flow from the reactor. The low signal selector receiving input from the Reduction Zone LRC 013-LIC-501B also receives a signal from the Regenerator Control System. The latter signal is an adjustable ramping function designed to slowly increase the catalyst flow rate from 0% to 100% of the design catalyst circulation rate. This ramping is used by the Catalyst Flow Control in the RCS only when catalyst circulation is restarted from zero. At some point during the catalyst circulation ramp, the signal from the LRC will be less than that of the ramp function. At that point, the low signal selector will use the LRC signal as its output signal to spent catalyst lift line PDRC. The signal selector that receives input from the lift line PDRC also receives a signal from the Reactor/Spent Catalyst Lift Line (R/SCLL) PDRC. The latter signal serves to limit the magnitude and speed of catalyst lift rate changes for system stability. If the catalyst lift rate increases rapidly, the differential pressure between the lift pipe and the Reactor will increase (the bottom of the lift line being maintained at a higher pressure than the reactor) and the high upward flow of gas will impede catalyst flow downwards to the L assembly. Once the pressure differential increases to near that which will impede catalyst flow, the R/SCLL PDRC output will limit the catalyst lift rate by limiting the secondary lift gas flow.
3.1.7.1. Catalyst Flow Pushbutton The catalyst Flow Pushbutton starts and stops the transfer of regenerated catalyst from the Lock Hopper to the Reactors. The Catalyst Flow Pushbutton has only two positions: ON and OFF. Initially, the catalyst Flow Pushbutton is in the OFF mode. To start transferring catalyst, the regenerator must not be in a Hot Shutdown. Then, when the operator depresses the Catalyst Flow Pushbutton, the catalyst transfer starts. The catalyst regeneration control system (CRCS) starts the following systems: •
Lock Hopper Cycle
•
Makeup Valve Control
•
Catalyst Flow Control
•
Spent catalyst Lift Rate Limiter
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The Lock Hopper stops automatically when a Hot Shutdown occurs. The operator can manually stop the catalyst transfer at any time in order to begin the Hot Shutdown Procedure. If the Catalyst Flow Pushbutton is depressed while catalyst is transferring, then the transfer stops. The systems listed above are all stopped.
3.1.7.2. Catalyst circulation rate set point & set point ramping Refer to licensor operating manual 8474L-013-ML-002-A for the calculation of the set point. The CRCS utilizes the Catalyst Circulation Rate Setpoint to generate the setpoint for the Regenerated Catalyst Lift Line Differential Pressure Controller 013-PDIC-531. When catalyst flow is turned ON, the regenerated catalyst lift line ΔP controller setpoint is initially zero. The CRCS then ramps the setpoint to a value that is estimated to yield a circulation rate half that of the target catalyst circulation rate setpoint. If the Lock Hopper Surge Zone level was above 40% when Catalyst Flow was turned ON, the CRCS uses the Regenerated Catalyst Lift Line ΔP ramp rate entered on the Catalyst Flow Setup Screen. If the level was below 40%, the CRCS uses a 2% per minute ramp until the level rises above 40% for the first time. The Regenerated Catalyst Lift line ΔP controller setpoint is held at the estimated value until sufficient Lock Hopper Cycles occur for the calculation of the actual catalyst circulation rate. The CRCS then adjusts the setpoint, using the ramp rate from the Catalyst Flow Setup Screen, to achieve the target catalyst circulation rate, by adjusting the lift line ΔP controller setpoint. This ramp rate is set so as to gradually increase the Reduction Zone catalyst level, and thus gradually increase the spent catalyst lift rate. The rate of increase of the spent catalyst lift rate must be slow so that the spent catalyst lift line ΔP generated does not cause the ΔP between the L-Valve assembly and the Catalyst Collector to fall out of its control range. This ramp rate is also used during normal operations when the actual catalyst circulation rate differs by more than 10% from the setpoint. For initial operation of the unit this ramp rate should be set slow, 2-5% / min, then adjusted higher with greater operating experience. When the actual catalyst circulation rate and the catalyst circulation setpoint are within 10% of each other, the RCS will make incremental changes in the lift line ΔP setpoint based on the error in percent toward the desired circulation rate every time a Lock Hopper cycle is completed.
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The Lock Hopper System has 4 functions: •
Determines the actual catalyst circulation rate and adjusts the setpoint to the Regenerated Catalyst Lift Line Differential pressure Controller
•
Enables the Spent catalyst Lift Rate limiter
•
Ramps the two equalization valves open and closed over a predetermined pattern
•
Controls the makeup gas valve using 3 modes.
The lock Hopper D-1358 transfers catalyst from the Regeneration Tower T-1351 into the Regenerated Catalyst L-Valve Assembly. The catalyst is moved through the Lock Hopper Zone of the Lock Hopper in small batches. The Regenerator Control system controls the sequencing of this batch operation. The cycle time of this batch operation indicates the catalyst circulation rate. The more often the Lock Hopper Zone cycles, the faster the catalyst circulation rate. In this way, the flow of catalyst through the Lock Hopper monitors the catalyst circulation rate throughout the entire Reactor and Regenerator System. The Lock Hopper cycles through five basic steps in a sequence. Two of the steps, PRESSURE and DEPRESSURE, have two sub-steps. The Five basic steps in one cycle of the Lock Hopper are: 0. READY Lock Hopper Zone, full of catalyst and at Disengaging Zone pressure, waits for signal to start the cycle. 1. PRESSURE Lock Hopper Zone is pressured up in a programmed pattern to equalize the pressure between it and the Surge Zone. 2. UNLOAD Catalyst is unloaded from the Lock Hopper Zone to the Surge Zone. 3. DEPRESSURE Lock Hopper Zone is depressured in a programmed pattern to equalize the pressure between it and the Disengaging Zone. 4. LOAD Catalyst is loaded into the Lock Hopper Zone from the Disengaging Zone. At the end of the LOAD step, the Lock Hopper returns to the READY step. When this cycle repeats over and over again, catalyst moves through the Lock Hopper. 3 logic-operated valves control the pressuring and depressuring of the Lock Hopper Zone: 2 Equalization Valves and one Make Up Valve. Valve Page 80 of 237
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013-XV-547 (XV-25) is the Upper Equalization Valve between the Lock Hopper Zone and the Disengaging Zone. 013-XV-555 (XV-26) is the lower Equalization Valve between the Lock Hopper Zone and the Surge Zone. At no time during the cycle should both Equalization Valves be open at the same time. Valve 013-XV-548 (XV-27) is the Make Up Valve to the Surge Zone for pressuring up the Lock Hopper Zone with booster gas. Excess gas from depressuring the Lock Hopper Zone is vented from the Disengaging Zone. The Upper 013-XV-547 (XV-25) and Lower 013-XV-555 (XV-26) Equalization valves along with the Make Up Valve 013-XV-548 (XV-27) change position during the PRESSURE and DEPRESSURE steps. During the PRESSURE step, the upper Valve closes completely, the lower Valve opens fully, and the Make up Valve opens slightly more and then closes partially. During the DEPRESSURE step, the Lower Valve closes completely, the Upper Valve opens fully, and the Make up Valve closes slightly and then reopens partially. The opening and closing of these three valves is controlled by the Lock Hopper Control System in the Regenerator Control System. For the Upper 013-XV-547 (XV-25) and Lower 013-XV-555 (XV-26) Equalization Valves, their programmed patterns for opening and closing are always the same. These patterns are programmed in the CRCS and rarely changed. For the Make up Valve 013-XV-548 (XV-27), however, its programmed pattern for opening and closing can change. The Make up Valve can operate in any one of three different modes. All three modes have one goal: to supply make up gas for pressuring the Lock Hopper Zone while keeping the differential pressure between the Lock Hopper and the Regenerated Catalyst L-Valve Assembly stable. For further details on the 3 modes of the make up valves, refer to the vendor operating manual for the CCR Catalyst Regeneration Section, doc. No. 8474L-013-ML-002-A. Initial Cycle Sequence The initial Cycle Sequence starts the Lock Hopper in a special way when the Lock Hopper D-1358 is first started. This sequence compensates for the unpredictable conditions of pressure and catalyst level that exist in the Lock Hopper Zone, which depend on when the Lock Hopper was stopped. For these reasons, the initial Cycle Sequence starts the Lock Hopper in the DEPRESSURE-1 step to depressure the Lock Hopper Zone. The following are an outline of the logic steps, in the order of a normal cycle sequence from the READY step until the LOAD step.
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Figure 40: Lock Hopper Sequence Step STOP Page 82 of 237
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Figure 41: Lock Hopper Sequence Step READY (FROM LOAD) Page 83 of 237
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Figure 42: Lock Hopper Sequence Step PRESSURE-1 Page 84 of 237
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Figure 43: Lock Hopper Sequence Step PRESSURE-2 Page 85 of 237
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Figure 44: Lock Hopper Sequence Step UNLOAD Page 86 of 237
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Figure 45: Lock Hopper Sequence Step DEPRESSURE-1 Page 87 of 237
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Figure 46: Lock Hopper Sequence Step DEPRESSURE-2 Page 88 of 237
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Figure 47: Lock Hopper Sequence Step LOAD Page 89 of 237
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3.1.8. Regeneration System Tower The Regeneration Systems control the catalyst regeneration. The goal of catalyst regeneration is to restore the catalyst to a condition that is close as possible to fresh catalyst in a safe manner. The Regeneration Systems follow the logical requirements to achieve this goal. The operator starts and stops the Regeneration Systems using pushbuttons and switches. These pushbuttons and switches must be operated correctly to ensure the catalyst regeneration is done properly and safely. The Regeneration Systems help ensure that all of the process requirements are satisfied when a system is started or stopped. Depending on the actual conditions present, the Regeneration Systems can prevent a system from starting or it can automatically cause a system to stop.
Figure 48: Catalyst Regeneration Tower
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The operator controls the Regeneration Systems using the following: •
The Regenerator Run – Stop Pushbutton, which starts and stops the entire regenerator section. To start the Regenerator, the following conditions must be met:
Item
Condition
Spent catalyst isolation system
Valves XV-523 & XV-522 confirm closed Valve XV-524 confirms open
Regenerated Catalyst Isolation System
Valves XV-545 & XV-546 confirm closed Valve XV-544 confirms open
CCR Nitrogen header
Pressure not low
CCR nitrogen analyzer
Pressure not high
Regenerator inventory switch
Normal position
Emergency stop switch
Run position
Starting the Regenerator simply allows other Regeneration Systems to be started. It allows the Spent Catalyst and Regenerated Catalyst Isolation Systems to be opened, catalyst circulation to be started, and the Electric Heaters to be turned on. However, to start any of these systems, other conditions must be met and their respective pushbuttons must be depressed. The operator can manually stop the Regenerator at any time in order to begin the Cold Shutdown Procedure. If the Regenerator Run-Stop Pushbuttons is depressed while the regenerator is running, then the Regenerator stops and Cold Shutdown occurs.
Figure 49: System Control Modes while in Regenerator Stop Mode
•
The Spent or Regenerated Catalyst Isolation Pushbutton Page 91 of 237
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•
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The Nitrogen Pushbutton, which opens and closes the Nitrogen valve 013XV-535 to start and stop the flow of nitrogen to the cooling zone and drying zone of the regeneration tower. Nitrogen flow must first be started in order to begin the Start-up Procedures. The Nitrogen Valve must continue to remain open until it is allowable, according to the Startup Procedures, to open the Lower Air Supply Line Valve 013-XV-533. In the Shutdown Procedures, the Nitrogen Valve is open and it must remain open to keep the Regeneration Tower under a nitrogen environment.
•
The Air Pushbutton, which opens/closes the air valve 013-XV-534 to start/stop the flow of air to the regeneration section for the coke burning. Opening the Air Valve 013-XV-534 is an important step in the Start-up Procedures that should not be taken lightly. The Air Valve must remain closed until it is allowable, according to the Startup Procedures, to begin coke burning. The important point is that opening the Air Valve too early can cause serious damage to equipment and catalyst inside the Regeneration Tower. In the Shutdown Procedures, the Air Valve is closed and it must remain closed until to keep the Regeneration Tower under a nitrogen environment.
•
The Chloride Pushbutton, which opens/closes the chloride valves 013-XV538 to start/stop the organic chloride injection into the chlorination zone. Opening the Chloride Valve 013-XV-538 can be done only after normal catalyst circulation and catalyst regeneration have been started. That means, gas flow rates to each zone are normal, operating temperatures of each zone are normal, and the gas flowing to the cooling zone and drying zone is air. These conditions help ensure that the organic chloride will decompose when it is injected. The chloride valve cannot be opened during a Hot Shutdown, Cold Shutdown, or a Contaminated Nitrogen Shutdown. To open the chloride valve 013-XV-538, the following conditions must be met:
Item
Condition
Nitrogen valve
XV-535 is commanded closed and confirms closed
Regeneration gas heater outlet temperature
Not low
Air heater outlet temperature
Not low
For the organic chloride injection pump P-1352A to start, the following conditions must be met: Item
Condition
Chloride valve
XV-538 confirms opened
Chloride injection pump handswitch (local)
AUTO position Page 92 of 237
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Then the organic chloride injection pump will start automatically. The operator can adjust the organic chloride injection rate by using the stroke adjustment on the injection pump P-1352A. The operator should check the injection rate regularly using the sight glass on the organic chloride drum. The operator can manually start the Organic Chloride Injection Pump P1352A in order to inventory the injection line, only when the emergency stop switch is in the RUN position. After inventorying, the local pump handswitch should be in the AUTO position for normal operation. •
The Lower Air Supply Line Pushbutton, which opens/closes the lower air supply line valve 013-XV-533 to start/stop the flow of air to the cooling zone and drying zone required for the oxidizing and chloriding of the catalyst. Air flow must be started to the Cooling Zone and Drying Zone during the Start-up Procedures in order to begin oxidizing and chloriding the catalyst. In the Shutdown Procedures, the Lower Air Supply Line Valve is closed and it must remain closed to keep the Cooling Zone and Drying Zone under a nitrogen environment. In the Start-up Procedures, the Lower Air Supply Line Valve must remain closed until it is allowable, according to the Start-up Procedures, to begin oxidizing and chloriding the catalyst. The important point is that opening the Lower Air Supply Line Valve when there is coke below the Burn Zone can cause serious damage to equipment and catalyst inside the Regeneration Tower.
•
The Electric Heater Pushbuttons. There are four electric heaters – Regeneration Gas (H-1353), Air (H1354), Reduction Gas n°1 (H-1351), and reduction Gas n°2 (H-1352). Each Heater has an Electric Heater Pushbutton that starts and stops its electrical power. Each Electric Heater Pushbutton has only two positions: RESET and STOP. The RESET mode enables the heater’s power control system while the STOP mode disables power. An indicator on the control panel shows the position of the pushbutton. To start the Air and Regeneration Gas Heaters H-1353 & 1354, the following conditions must be met:
Item
Condition
Regenerator Run-stop Pushbutton
Run position
Process gas flow
Not low
Heater element skin temperature
Not high
Ground fault
None
Emergency stop switch
Not in stop position
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To start the Air and Regeneration Gas Heaters H-1353 & 1354, the following conditions must be met: Item
Condition
Process gas flow
Not low
Heater element skin temperature
Not high
Ground fault
None
Reduction zone bed temperatures
Not high
•
The Emergency Stop Switch. The Emergency Stop Switch controls power to all logic-operated valves and electric heaters in the Regeneration Section. The Emergency Stop Switch has two positions: RUN and Stop. RUN is the position of the Emergency Stop Switch during normal operation. The Emergency Stop Switch must be in the RUN position in order for the operator to control CRCS instrumentation. The Emergency Stop Switch must be in the RUN position or else no other system, including the Regenerator, can be in the RUN condition.
3.1.9. Regeneration Tower T-1351 Isolation Systems Isolation Systems keep the environment in the Regeneration Tower T-1351 separate from the hydrogen/hydrocarbon-containing environments present in the Reactor and Lock Hopper. The Regeneration Tower is an oxygen containing environment and so a potentially hazardous mixture would result if these sections were not separate. There are 2 isolation systems: •
The spent Catalyst isolation system is on the catalyst inlet to the Regeneration Tower, and it isolates the Regeneration Tower from the reactor
•
The Regenerated Catalyst isolation system is on the catalyst outlet from the Regeneration Tower, and it isolates the Regeneration Tower from the Lock Hopper D-1358.
Both isolation Systems are alike. Each has a “High Pressure Zone”, 2 isolation valves, a Pressure Valve and a differential pressure control valve. There are 2 differential pressure controllers. The top one is between the “high Pressure Zone” and the vessel above it. The bottom one is between the “High Pressure Zone” and the vessel below it. The spent Catalyst system does not have the lower differential pressure controller. It is assumed that the Disengaging Hopper will always be at a higher pressure than the regeneration Tower. These 2 differential pressures are the key indications that the Isolation System is keeping the environments above and below the Isolation System separate. Page 94 of 237
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Nitrogen purges into the “High Pressure Zone” on differential pressure control. The “High Pressure Zone” is at slightly higher pressure than both the vessel above and below the Isolation System. This “nitrogen bubble” prevents gases in the vessel above from leaking downward and it prevents gases in the lower vessel from leaking upward. If either the top or bottom differential pressure becomes too low, the ‘nitrogen bubble” in the high pressure zone may be lost. On the other hand, if the top differential pressure becomes too high, the flow of catalyst downward may be halted. So, it is very important that these two differential pressures – top and bottom – are controlled, measured and monitored accurately. First, each differential pressure, top and bottom, is controlled by one different pressure indicator-controller. One control valve, the nitrogen purge to the high pressure zone, controls both differential pressures by a signal selector. Second, each differential pressure, top and bottom, is measured by two independent differential pressure instruments. One of the instruments is the differential pressure indicator/controller that controls the differential pressure. The other instrument is for indication only. These instruments all operate simultaneously and provide two separate measurements of the differential pressure. And third, each differential pressure, top and bottom, is monitored by a 2 out of 2 voting circuit. This voting circuit is located in the Regenerator Control System. The two independent differential pressure indications are inputs to this voting circuit. If one indication is higher than the low differential trip setting then the voting circuit is satisfied. This is one of the requirements for opening the isolation system. If both indications are lower than the low differential trip setting, then the voting circuit is not satisfied. And if this condition persists for longer than a set period of time, the Isolation System will close (if it was open).
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Figure 50: Isolation Systems The Spent Catalyst Isolation Open Pushbutton opens the Spent Catalyst Isolation System and the Regenerated Catalyst Isolation Open Pushbutton opens the Regenerated Catalyst Isolation system. Both Isolation Systems must be open in order to circulate and regenerate catalyst. The pushbuttons have only 2 positions: OPEN and CLOSE. To open an isolation system (either upper or lower), the following conditions must be met: Page 96 of 237
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•
The regenerator Run Stop pushbutton is in “RUN”, and
•
One of the indicators for both the top and the bottom differential pressures are higher than the low differential trip settings (two of two voting system)
And for Spent catalyst isolation only: Reduction Zone above low level. Then, when the operator depresses the Isolation Open Pushbutton, that isolation system opens: First, its Pressure Valve is commanded closed and confirms closed. Then, its isolation valves are commanded open and confirm open. Its indicator changes from CLOSED to OPEN.
Figure 51: Regenerated Catalyst Isolation System (OPEN)
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Figure 52: Regenerated Catalyst Isolation System (CLOSE)
3.1.9.1. Regenerator Inventory Switch The Regenerator Inventory Switch bypasses the two logic requirements for opening the Regenerated Catalyst isolation System. This is useful before start up for loading catalyst into the regeneration section. The Regenerator inventory Switch has only two positions: INVENTORY and NORMAL. An indicator on the control panel indicates when the two logic requirements are bypassed. Then, when the operator depresses the isolation Pushbutton, the Regenerated Catalyst Isolation System will open.
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The Regenerator Inventory Switch should be in the NORMAL position during normal operation.
3.1.10. Dust Collector Fines Unloading: This operation is carried out by cycling the Fines Collection Pot through a programmed sequence, of LOAD and UNLOAD steps, controlled by the Regenerator Control System. The operator starts these steps by turning a handswitch, the Fines Collection Pot Switch, which has 3 positions: LOAD: In the LOAD position, the CRCS prepares the fines collection pot D-1354 and loads fines from the dust collector A-1352 OFF (mid-position): In the OFF position, the CRCS closes the fines collection pot D-1354. Fines cannot be loaded or unloaded. The switch must be turned through the “OFF” position when switching from “LOAD” to “UNLOAD” or back. UNLOAD: In the UNLOAD position, the CRCS prepares the fines collection pot and unloads fines into a catalyst drum. The following is a brief description of the sequence, for a complete description of the fines unloading operation, refer to the chapter 6 of the licensor operating manual doc. No. 8474L-013-ML-001-A. Steps
Operation
OFF
Normal reseting stage between cycles. The fines collection pot D1354 always starts the sequence from the OFF stage during which all valves are closed.
DEPRESS
Depressurize the fines collection pot D-1354 to atmospheric pressure: The Vent valve 013-XV-531 (XV-11 on the following figure) opens and depressures the Collection Pot D-1354 to atmosphere through a restriction orifice. The restriction orifice limits the rate of depressuring so as not to fluidize the dust in the vessel.
UNLOAD
Fines Collection Pot, full of fines, is unloaded into a catalyst drum, by opening of the UNLOAD valve 013-XV-530 (XV-12 on the figure).
PRESSURE
Pressurizes the fines collection pot with N2 from the spent catalyst lift / elutriation system to match the dust collector’s pressure. This stage contains 2 sub-stages: PRESSURE-1: Page 99 of 237
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Operation The pressure valve 013-XV-528 (XV-10) opens and pressures the Collection Pot to Dust Collector pressure through a restriction orifice. The pressuring flow also serves to blow back the internal screen at the vessel nozzle. PRESSURE-2: The pressure valve 013-XV-528 (XV-10) closes.
LOAD
Fines collection pot, empty of fines, is pressurized and loaded with fines from the dust collector A-1352, by opening of the Load Valve 013-XV-529 (XV-9). At the end of the UNLOAD step, the cycle can be repeated if more fines unloading is desired. Valves Interlock: A valve will not open or remain open unless the required interlock conditions are met. This is to prevent undesirable/dangerous valve combinations:
To Open
Closed Verification Required
013-XV-529 (Load)
013-XV-528 (Pressure), 013-XV-530 (Vent), 013-XV-531 (Unload)
013-XV-528 (Pressure)
013-XV-529 (Load), 013-XV-530 (Vent), 013XV-531 (Unload)
013-XV-530 (Vent)
013-XV-529 (Load), 013-XV-528 (Pressure)
013-XV-531 (Unload)
013-XV-529 (Load), 013-XV-528 (Pressure)
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Figure 53: Dust Collector Unloading
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3.1.11. Catalyst Addition: The catalyst addition system is controlled by the CRCS. The operator adds fresh catalyst into the Disengaging Hopper D-1353 via the Spent Catalyst Lift System using the Catalyst Addition Lock Hopper N°1 System. The catalyst Addition Lock Hopper n°1 System consists of a Catalyst Addition Funnel n°1 D-1351 , Catalyst Addition Lock Hopper n°1 D-1352, and four valves. The Catalyst Addition Funnel is open to the atmosphere and can be filled with catalyst from drums. The Catalyst Addition Lock Hopper fills with catalyst and can be pressured up to transfer the catalyst into the Catalyst transfer System. The 4 logic operated valves that allow the Catalyst Addition Lock Hopper to be depressured, loaded, pressured up, and unloaded during the addition of catalyst are: •
Load Valve
013-XV-526
•
Pressure Valve
013-XV-527
•
Vent Valve
013-XV-520
•
Unload Valve
013-XV-519
Figure 54: Catalyst Addition Lock Hopper No.1 Page 102 of 237
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There are several inherent hazards when adding catalyst safely from drums into the Catalyst Transfer System: •
First, since the Catalyst Transfer System operates under a nitrogen pressure equal to the reactor pressure, it cannot be opened directly to the atmosphere.
•
Second, since the fresh catalyst has no coke (and the spent catalyst obviously does) it must be added slowly enough to avoid an upset in the coke burning operation of the Regeneration Tower T-1351.
•
Third, since the Catalyst Addition Lock Hopper D-1352 should be filled only when it is completely empty (to avoid overfilling and thus closing valves on catalyst), the time allowed for unloading the Catalyst Addition Lock Hopper D-1352 must be coordinated with the cycling of the Lock Hopper D-1358.
By the addition procedures and through the controlled sequence of the CRCS, the Catalyst Addition System accomplishes these tasks. The catalyst addition operation consists of cycling the Catalyst Addition Lock Hopper through a sequence of LOAD and UNLOAD steps. The operator starts these steps by turning the Catalyst Addition Switch, which has 3 positions: LOAD: In the LOAD position, the CRCS prepares the Catalyst Addition Lock Hopper so the operator can load it with catalyst. OFF (mid-position): In the OFF position, the CRCS closes the Catalyst Addition Lock Hopper. Catalyst cannot be loaded or unloaded. The switch must be turned through the OFF position when switching from LOAD to UNLOAD or back. UNLOAD: In the UNLOAD position, the CRCS prepares the Catalyst Addition Lock Hopper and unloads catalyst into the Spent Catalyst Lift System. The stages of the catalyst lock hopper N°1, described below, are monitored and controlled by the CRCS. Step
Operation
OFF
Normal resting stage between cycles. The catalyst addition lock hopper N°1 D-1352 sequence always starts from the OFF stage. All 4 valves are closed.
PRESSURE
Purges and pressures the catalyst lock hopper N°1 D-1352 with Nitrogen to match the spent catalyst lift system pressure PRESSURE-1 (Pressure-Up): Only Pressure Valve (013-XV-527) is OPEN to allow N2 to pressure the system. PRESSURE-2: Page 103 of 237
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Step
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Operation All valves are CLOSED (pressure valve is CLOSED) PRESSURE-3 (Purge): Only Vent Valve (013-XV-520) is OPEN PRESSURE-4: All 4 valves are CLOSED (vent valve is CLOSED) PRESSURE-5 (Pressure-Up): Only Pressure Valve (013-XV-527) is OPEN to allow N2 to pressure the system. PRESSURE-6: All 4 valves are CLOSED (pressure valve is CLOSED)
UNLOAD
Catalyst addition lock hopper N°1 D-1352, full of catalyst, is unloaded into the spent catalyst lit system Only Unload Valve (013-XV-519) is OPEN
HOLD
Waits for the signal from the field switch to start LOAD All 4 valves are CLOSED
DEPRESS
De-pressures catalyst addition lock hopper N°1 D-1352 to atmospheric pressure. Only Vent Valve (013-XV-520) is OPEN to depressure the system to atmosphere
LOAD
Catalyst addition lock hopper, empty of catalyst, is loaded with catalyst from the addition funnel No.1 D-1351 Only the Load Valve (013-XV-526) is OPEN The catalyst Addition Lock Hopper n°1 is sized to hold one drum of catalyst. Only one drum should be loaded into the funnel for each LOAD step. At the end of the UNLOAD step, the cycle can be repeated if more catalyst addition is desired. Lock Hopper Cycle Counter: The Lock Hopper Cycle Counter counts the number of times the Lock Hopper loads while the Unload Valve of the Catalyst Addition Lock Hopper is confirmed open. Each time the Lock Hopper D-1358 loads, some catalyst is unloaded from the Catalyst Addition Lock Hopper n°1 D-1352. In order to empty the Catalyst Addition Lock Hopper n°1, the Lock Hopper D-1358 must load a set number of times equal to the number selected at the CRCS. When the Lock Hopper has cycled the set number of times, the Catalyst Addition Lock Hopper n°1 is considered to be empty. NOTE: Catalyst Addition Lock Hopper n°1 can be confirmed by tapping lightly on the side of the vessel. If it is determined to still contain catalyst, repeat the UNLOAD step Page 104 of 237
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before conducting the next LOAD step and select a higher number of Lock Hopper cycles at the CRCS. Spent Catalyst Lift Line Pressure Differential: The spent catalyst lift line differential pressure is monitored during the UNLOAD step. When the catalyst addition hopper n°1 D-1352 is being used to reload the Regeneration Tower, that is when the Lock Hopper is not cycling, the absence of a lift line pressure differential is used as an indication that the addition Hopper n°1 is empty. Starting the sequence: The Catalyst Addition Lock Hopper n°1 D-1352 cycle can be started when the following conditions have been met: 1) the emergency stop switch is in the RUN position, and 2) valve power is available. To ensure that the catalyst addition hopper is empty, the initial cycle must start with the UNLOAD sequence. The UNLOAD sequence empties the Catalyst Addition Lock Hopper n°1 to the spent catalyst lift system. If the UNLOAD Sequence is successful, the cycle can continue to perform the LOAD sequence. The LOAD sequence prepares the Catalyst Addition Lock Hopper n°1 D-1352 so that the operator can load it with catalyst. Stopping the sequence: The operator can stop the Catalyst Addition Lock Hopper n°1 sequence by placing the field switch in the OFF position during all steps but during steps HOLD or DEPRESS. If the sequence is in step HOLD or DEPRESS when the field switch is placed in the OFF position, the system will hold in step HOLD until the field switch in the LOAD position. The sequence returns to the OFF stage (step 0) immediately on either of the following conditions: 1) Emergency Stop switch in the STOP position, or 2) valve power becomes unavailable. Valve Interlocks: The valve interlock system prevents certain valve position combinations which could cause a hazardous situation. To open
Closed Verification Required
013-XV-526 (LOAD)
013-XV-527 (PRESSURE), 013-XV-519 (UNLOAD)
013-XV-527 (PRESSURE)
013-XV-526 (LOAD) 013-XV-520 (VENT) 013-XV-519 (UNLOAD)
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To open
Closed Verification Required
013-XV-520 (VENT)
013-XV-527 (PRESSURE) 013-XV-519 (UNLOAD)
013-XV-519 (UNLOAD)
013-XV-526 (LOAD) 013-XV-527 (PRESSURE) 013-XV-520 (VENT)
3.1.12. Catalyst Change-out on the fly The following only describes the logic of the catalyst addition system No.2, however, to perform the changeout on-the-fly, a specific procedure shall be followed. This procedure is detailed in § 4.5 of the chapter 6 of the licensor operating manual doc. No. 8474L-013-ML-001-A. This catalyst addition system is also controlled by the CRCS and is extremely similar to the catalyst addition with the catalyst addition hopper N°1. Just like the catalyst addition lock hopper n°1, the catalyst Addition Lock Hopper n°2 System consists of a Catalyst Addition Funnel n°2 D-1355, Catalyst Addition Lock Hopper n°2 D-1356, and four valves. The Catalyst Addition Funnel is open to the atmosphere and can be filled with catalyst from drums. The Catalyst Addition Lock Hopper fills with catalyst and can be pressured up to transfer the catalyst into the Catalyst transfer System. The 4 logic operated valves that allow the catalyst addition lock hopper No.2 to be de-pressured, loaded, pressured-up, and unloaded during the addition of catalyst are: •
Load valve
013-XV-542
•
Pressure valve
013-XV-540
•
Vent valve
013-XV-541
•
Unload valve
013-XV-543
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Figure 55: Catalyst Addition Lock Hopper No.2 The same inherent hazards than for the normal catalyst addition applies to the catalyst addition lock hopper No.2: •
Seal Drum under N2 pressure Æ It cannot be opened directly to atmosphere
•
Addition lock hopper shall be filled only when completely emptied and so the catalyst addition must be coordinated with the circulation. Page 107 of 237
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By the addition procedures and through the controlled sequence of the CRCS, the Catalyst Addition System accomplishes these tasks. Like for the other catalyst addition, this catalyst addition operation consists of cycling D-1356 through a sequence of LOAD and UNLOAD steps. The operator starts these steps by turning the catalyst addition hand-switch, which has 3 positions: LOAD, OFF & UNLOAD just like for D-1352. The catalyst addition consists of the following steps controlled by the CRCS: Step
Operation
OFF
Normal resting stage between cycles. The catalyst addition lock hopper N°2 D-1356 sequence always starts from the OFF stage. All 4 valves are closed.
LOAD
Catalyst addition lock hopper, empty of catalyst is de-pressured and loaded with catalyst from the addition funnel. DE-PRESSURING: Only the vent valve 013-XV-541 is OPEN to vent to ATM. LOADING: Only the load valve 013-XV-542 is OPEN. OFF: All 4 valves are CLOSED (load valve is closed)
UNLOAD
Catalyst addition lock hopper, full of catalyst, is pressured up with nitrogen and unloaded into the nitrogen seal drum D-1357. PRESSURING-1: Only the pressure valve 013-XV-540 is OPEN to allow N2 into D-1356. PRESSURING-2: All 4 valves are CLOSED (pressure valve is closed) UNLOADING-3: Only the unload valve 013-XV-543 is OPEN At the end of the UNLOAD step, the cycle can be repeated if more catalyst addition is desired. Nitrogen Seal Drum Level Indicator: The level in the Seal Drum is monitored during the UNLOAD step. A low level in the Seal Drum indicates that it can accept a drum of catalyst without overfilling. If the Seal Drum overfilled, then the Unload valve would close on catalyst. Automatic Shutdown Sequence: Page 108 of 237
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All 4 logic-operated valves close automatically when a Cold Shutdown or Contaminated Nitrogen Shutdown occurs. Any of the four valves that are open when the shutdown occurs will close, regardless of the step the Catalyst Addition Lock Hopper is in. After any automatic shutdown the operator must restart operation in the UNLOAD sequence to ensure that the addition hopper has fully unloaded before proceeding. Valve Interlocks: The valve interlock system prevents certain valve position combinations that could cause a hazardous situation. If the Pressure Valve 013-XV-540 or the Unload Valve 013-XV-543 is not confirmed closed, then the Vent Valve and the Load Valve cannot be opened. This temporarily halts the LOAD step. When the Pressure Valve and the Unload Valve confirm closed, the catalyst addition sequence resumes. If the Vent Valve 013-XV-541 or the Load Valve 013-XV-542 is not confirmed closed, then the Pressure Valve and the Unload Valve cannot be opened. This temporarily halts the UNLOAD step. When the Vent Valve and the Load Valve confirm closed, the catalyst addition sequence resumes.
3.1.13. Inter-Unit Controls & Interfaces The following signals are exchanged with other units: a. Signals from Other Units to CCR 037-AI-001: FG to burner flow indicators. This signal is transmitted from FG Unit (037) to compensate - with the gas MW - the mass flowrate indicators of FG to the heaters firing system (013-FI-618/619/620/621). b. Signal from CCR to other units 013-FXALL-004: Low Low Flow Recycle Gas Flow. This signal is transmitted to Make-up Gas Compressor C-1202A Shutdown (012-UX-006).
3.1.14. Operating Parameters For operating conditions of the CCR refer to the following Process Flow Diagrams: 8474L-013-PFD-0010-001
CCR Platforming Unit – Reactors Section
8474L-013-PFD-0010-002
CCR Platforming Unit – Net Gas Section
8474L-013-PFD-0010-003
CCR Platforming Unit – Debutanizer Section
8474L-013-PFD-0010-004
CCR Platforming Unit – Steam Generation Section
8474L-013-PFD-0010-005
CCR Platforming Unit – Chloride, Condensate and Sulfide Injection Section
8474L-013-PFD-0010-010
CCR Platforming Unit – CCR Regeneration Section
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8474L-013-PFD-0010-011
CCR Platforming Unit – CCR Regeneration Section
8474L-013-PFD-0010-012
CCR Platforming Unit – CCR Regeneration Section
8474L-013-PFD-0010-013
CCR Platforming Unit – CCR Regeneration Section
3.2. Instrument List Refer to the attached Extracted instrument list.
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3.3. Main Equipment 3.3.1. Heaters H-1301, H-1302, H-1303 & H-1304 The Charge Heater and the Interheaters in UOP Continuous Platforming Units are contained in a single, partitioned, multi-cell heater box. The heater box has a convection section to recover heat from the flue gas to generate HP steam. The charge heater aims at raising the temperature of the combined feed up to the required temperature by the reactor. The function of the inter-heaters is to raise the temperature of each reactor’s effluent back up to reaction temperature for the next reactor. Heaters H-1301, H-1302, H-1303 & H-1304 No. Required
1
Manufacturer
Kirchner Italia SpA
Type of Heater
Box type with convection section Process Design Conditions (Lean Feed Case)
Heater Section
Radiant H-1301
H-1302
H-1303
H-1304
Heat Absorption (MW)
9450
14900
9740
6760
Fluid
HC+H2
HC+H2
HC+H2
HC+H2
Flowrate (kg/hr)
133255
133255
133255
133255
Pressure Drop (kg/cm2g)
0.19
0.24
0.25
0.25
Inlet Temperature (°C)
481
441
479
501
Outlet Temperature (°C)
549
549
549
549
Inlet Pressure (kg/cm2g)
5.11
4.63
4.18
3.72
Outlet Pressure (kg/cm2g)
4.92
4.39
3.93
3.47
Heater Section
Convection Economizer
Steam Generator
Superheater
Heat Absorption (MW)
3,140
9,860
2400
Fluid
Water
Water / Steam
Steam
Flowrate
20235
268274
1924 Page 111 of 237
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Heaters H-1301, H-1302, H-1303 & H-1304 2
(kg/cm g) Pressure Drop (kg/cm2g)
0.04
1.73
0.24
Inlet Temperature (°C)
112
259
259
Outlet Temperature (°C)
238
259
417
Inlet Liquid Flowrate (kg/hr)
20235
268274
Inlet Vapour Flowrate (kg/hr)
19224
Inlet Pressure (kg/cm2g)
46.14
47.83
46.10
Outlet Pressure (kg/cm2g)
46.10
46.10
45.86
Outlet Liquid Flowrate (kg/hr)
20235
247349
Outlet Vapour Flowrate (kg/hr)
20925
19224
Combustion Design Conditions (Lean Feed Case) Type of Fuel
Normal Summer
Excess Air (%)
15
Calculated heat release (LVH) (MW)
67.4
Fuel efficiency (LVH)
92
Flue Gas leaving the radiation section (°C)
787
Flue Gas leaving the convection section (°C)
157
Required emissions (mg/Nm3) (corrected to 3% O2)
NOx: 350 CO: 50 Sox: < 10 ppm Particles: 100
Burner Type
Gas, Low Nox, Natural Draft
Pilot Type
Self inspiriting
Pilot Capacity (MIN)
22000
Fuel
Fuel Gas Page 112 of 237
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Heaters H-1301, H-1302, H-1303 & H-1304 Mechanical Design Conditions Section
H-1301
H-1302
H-1303
H-1304
Tube arrangement
U-type
U-type
U-type
U-type
Tube outside diameter (mm)
114.3
88.9
114.3
114.3
No. of parallel flow streams
35
69
39
39
Number of tubes
35
69
39
39
Overall tube length (mm)
28790
28790
28790
22790
No. of bare tubes
35
69
39
39
Tube layout
In-line
In-line
In-line
In-line
Section
Lower SG
Upper SG
SSH
ECO
Tube arrangement
Horizontal
Horizontal
Horizontal
Horizontal
Tube outside diameter (mm)
114.3
114.3
114.3
114.3
No. of parallel flow streams
8
8
4
2
Number of tubes
48
72
12
12
effective tube length (mm)
19000
19000
19000
19000
No. of bare tubes
36
No. of extended surface tubes
12
72
24
72
Type of extended Solid Fins surface
Solid Fins
Solid Fins
Solid Fins
Tube layout
Staggered
Staggered
Staggered
Staggered
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Figure 56: Heaters 3D view
3.3.2. Reactor R-1301, R-1302, R-1303 & R-1304 The reactor stack is composed of 4 reactors constructed together to form one large vessel. The bottom heads of the individual reactors are used to divide this vessel into separate reactors On top of the highest reactor is the catalyst reduction zone. The purpose of the reactor is to contact the feed with the regenerated catalyst to lead to the high octane products desired. Reactor Stack R-1301, R-1302, R-1303 & R-1304 Design conditions / Operating Conditions: Reduction Zone inlet
15 kg/cm2g at 549°C / 5.9 kg/cm2g at 531°C
R-1301 inlet
8.0 kg/cm2g at 549°C / 5.0 kg/cm2g at 549°C
R-1302 inlet
7.0 kg/cm2g at 549°C / 4.5 kg/cm2g at 549°C Page 114 of 237
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Reactor Stack R-1301, R-1302, R-1303 & R-1304 R-1303 inlet
6.5 kg/cm2g at 549°C / 4.0 kg/cm2g at 549°C
R-1304 inlet
6.0 kg/cm2g at 549°C / 3.5 kg/cm2g at 549°C
Feed Flowrate (Lean Feed Case) (Nm3/hr)
133255
Recycle Gas Flowrate (Lean Feed Case) (Nm3/hr)
180
Max ΔP across each inter. head (kg/cm2g)
1.4
3
Total Reactor Volume (m )
60
3
Catalyst Volume (m ) Reduction Zone inlet (V1)
2.93
R-1301 inlet (V2)
11.6
R-1302 inlet (V3)
13.5
R-1303 inlet (V4)
14.9
R-1304 inlet (V5)
15.9
Catalyst Collector (V6)
1.21
Reactor Head Diameter (mm) Reduction Zone inlet
1325 OD
R-1301 inlet
2150 OD
R-1302 inlet
2150 OD
R-1303 inlet
2150 OD
R-1304 inlet
2150 ID
Reactors Length (TL to TL) (mm): Reduction Zone inlet
4780
R-1301 inlet
6600
R-1302 inlet
7600
R-1303 inlet
8300
R-1304 inlet
8400
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Isometric View of the Reactor Figure 57: Reactor Stack Page 116 of 237
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3.3.3. Recycle Compressor C-1301 & Steam Turbine CT-1301 The purpose of the recycle compressor is to compress the H2 rich stream from the top of the separator D-1301 and to mainly recycle it to the combined feed exchanger E-1301, while the remaining is sent to the Recovery Plus System and the bottom of the reactor stack. The recycle compressor C-1301 is driven by a steam turbine CT-1301 using HP steam from HP steam header. Recycle Compressor C-1301 No. Required
1
Manufacturer & Model
Thermodyn & RD7B
Normal Capacity (kg/hr)
49,856 2
Design Inlet Pressure (kg/cm g)
3.50
2
Normal Inlet Pressure (kg/cm g)
2.5
2
Design outlet pressure (kg/cm g)
7.50
Normal outlet Pressure (kg/cm2g)
6.7
Design Inlet Temperature (°C)
46
Normal Inlet Temperature (°C)
46
Design Outlet Temperature (°C)
120.5
Normal Outlet Temperature (°C)
118
Design Speed (RPM)
6892
Design kW required at driver
3720
Process Control
Speed Variation from 70% to 105% Steam Turbine CT-1301
No. Required
1
Manufacturer & Model
Thermodyn & 5MCS
Turbine Type
Condensing
Normal Shaft Power (kW)
3998
Normal Speed (RPM)
7121
Normal HP steam Inlet Flow (kg/hr)
19900
Normal HP steam Inlet Pressure (kg/cm2g)
42.3
Normal Exhaust Pressure (kg/cm2g)
0.4
Normal HP steam Inlet Temperature (380°C)
380
Design / Normal Steam Rate (kh/kW.H)
5.16 / 4.98
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Figure 58: Recycle Compressor C-1301
Figure 59: Steam Turbine CT-1301 Page 118 of 237
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3.3.4. Debutanizer T-1301 In the debutanizer, LPG and reformate are separated. The debutanizer uses HP steam as heating fluid in its reboiler. Debutanizer T-1301 Length (TL to TL) (mm)
24400
Loading Point
Above tray #21
Tray Identification
Top (tray 1 -20)
Bottom (tray 21 – 30)
Vessel ID (mm)
1050
1800
Tray Spacing (mm)
600
600
Valve
Valve
Operating Pressure (kg/cm g)
9.87
10.11
Operating Temperature (°C)
265
265
Vapor Flowrate (kg/hr)
22921
38069
Liquid Flowrate (kg/hr)
18613
130394
Type of Tray 2
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Figure 60: Debutanizer T-1301 Page 120 of 237
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3.3.5. Regeneration Tower T-1351 The Regeneration Tower and its internals are made of stainless steel. The Regeneration Tower T-1351 contains five separate zones – the Burn Zone, Reheat Zone, Chlorination Zone, Drying Zone, and Cooling Zone. Catalyst enters the top of the Regeneration Tower T-1351 via a number of symmetrical pipes and flows by gravity into the Burn Zone. The Burn Zone is an annular catalyst bed between a truly vertical outer screen and an inwardly sloping inner screen. The outer screen is welded at the bottom to the vessel wall of the Regeneration tower and it is connected at the top to the vessel wall by a wire mesh. At the bottom of the outer screen where it is attached, there are a number of horizontal slots to allow for free drainage of the area behind the outer screen. A slip-stream from the Regeneration Blower B-1352 enters the Regeneration Tower T-1351 at the top of the outer screen as direct seal gas. A sealed, annular plate below the inlet of the slip-stream from the Regeneration Blower B-1352 prevents the gas from flowing downwards into the Burn Zone hence forcing it upwards. The wire mesh atop the outer screen allows for this direct seal gas to flow over the top of the outer screen and enter the catalyst bed from the top without catalyst falling behind the outer screen. This seal gas flow is to prevent catalyst fluidization at the top of the annulus. The top of the inner screen is attached to the top head of the Regeneration Tower T-1351. At the bottom, the inner screen fits around guide vanes to prevent sideways movement. Regeneration gas enters the Burn Zone through the inlet nozzle outside of the outer screen and it exits through the outlet pipe at the top of the inner screen. Both screens are specially made with smooth, vertical screen bars to minimize catalyst breakage and plugging. But periodically these screens must be cleaned to ensure good gas flow through them. The Reheat Zone is directly below the Burn Zone, and catalyst flows by gravity into it. Like the Burn Zone except smaller, the Reheat Zone is an annular catalyst bed between the outer screen and the inner screen. It is separated from the Burn Zone by a baffle located outside of and near the bottom of the outer screen. The baffle is perforated by a number of small holes to allow for free drainage of the area above the baffle. Gas enters the Reheat Zone through the inlet nozzle outside of the outer screen and it exits upward inside the inner screen and into the Burn Zone. Inside the inner screen are special thermocouples to measure the temperature of the regeneration gas at various points down the catalyst bed. Except for the two thermocouples that measure the temperature in the Reheat Zone, all the rest measure temperatures in the Burn Zone. These "bed" temperatures give a very good indication of changes in the coke burning in the Burn Zone and should be recorded on a regular basis. There is a single thermocouple located at the catalyst exit of the Reheat Zone. This is called the Chlorination Zone thermocouple as it indicates the temperature of the gas exiting this zone. This temperature gives a good indication if there is any coke combustion in the Chlorination Zone. Page 121 of 237
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Below the screens, guide vanes direct the catalyst by gravity flow into the Chlorination Zone. The Chlorination Zone is a cylindrical catalyst bed inside an annular baffle that is attached to the wall of the Regeneration Tower. Gas enters the Chlorination Zone from the Drying Zone through perforations in the plate separating the two zones. The gas first enters an annular region defined by the vessel wall and an annular baffle. At this point organic chloride is introduced to the gas via two chloride distributors set 180° apart. The annular baffle is specially designed to provide uniform gas flow down the outside of the baffle and up through the catalyst bed. Gas exits the zone upward into the inside of the inner screen at the Reheat Zone. The Drying Zone is below the Chlorination Zone, and catalyst flows by gravity into it through a conical funnel and a distributor. Like the Chlorination Zone, the Drying Zone is a cylindrical catalyst bed inside an annular baffle. Gas enters the Drying Zone through the inlet nozzle in the wall of the Regeneration Tower. The annular baffle is specially designed to provide uniform gas flow down the outside of the baffle and up through the catalyst bed. Gas exits the zone through the drying air outlet nozzle in the wall of the Regeneration Tower above the catalyst bed, and the aforementioned perforations in the plate separating the Drying Zone from the Chlorination Zone. One Drying Zone gas outlet is the inlet to the Chlorination Zone. The other Drying Zone gas outlet nozzle is a vent that exhausts excess drying gas from the Regeneration Tower through a control valve. The cylindrical distributor leading to the Drying Zone is pierced in four locations by vapor tunnels. These tunnels allow for vapor equalization between the area enclosed by the distributor and the area outside the distributor. This communication is important to ensure even gas distribution across the cylindrical bed of the Drying Zone. The Cooling Zone is below the Drying Zone, and catalyst flows by gravity into it through a conical funnel and a distributor. Like the Drying Zone, the Cooling Zone is a cylindrical catalyst bed inside an annular baffle. Gas enters the Cooling Zone through the inlet nozzle in the wall of the Regeneration Tower. The annular baffle is specially designed to provide uniform gas flow down the outside of the baffle and up through the catalyst bed. Gas exits the zone through a cooling gas outlet nozzle in the wall of the Regeneration Tower above the catalyst bed. As above, the cylindrical distributor leading to the Cooling Zone is pierced in four locations by vapor tunnels. These tunnels allow for vapor equalization between the area enclosed by the distributor and the area outside the distributor. This communication is important to ensure even gas distribution across the cylindrical bed of the Cooling Zone. For inspection purposes, access to the various zones is gained through the top of the vessel via the Burn Zone gas outlet nozzle. The inside of the inner screen is accessible immediately through the outlet nozzle. At the bottom of the inner screen, where the catalyst guide vanes attach to a cylindrical support, there is a manway for further access to the lower zones of the tower. Access to the Drying Zone and Cooling Zones is achieved by the use of a removable cone in the center of the conical funnels.
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Figure 61: Regeneration Tower (Burn Zone & Reheat Zone) Page 123 of 237
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Figure 62: Regeneration Tower (Chlorination Zone) Page 124 of 237
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Figure 63: Regeneration Tower (Drying & Cooling Zone) Page 125 of 237
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3.3.6. Nitrogen Seal Drum D-1357 The Nitrogen Seal Drum D-1357 and its internals are made of carbon steel. Catalyst enters at the top of the Seal Drum into a gas Disengaging Zone (used primarily for Catalyst Change-out on the Fly). The catalyst then passes through a standpipe into a Purge Zone and then out of the vessel. Nitrogen enters the purge zone and flows upward through the standpipe and the catalyst bed in the disengaging zone then out the catalyst inlet. Nitrogen also flows downward through the catalyst bed in the purge zone and out of the catalyst outlet. The normal function of this vessel is to provide a nitrogen addition point clear of catalyst for the Regenerated Catalyst Isolation System (Nitrogen Bubble), but serves an additional purpose for the optional Catalyst Change-out on the Fly. During Catalyst Change-out on the Fly, the Nitrogen Seal Drum D-1357 serves to receive and purge air from fresh catalyst loaded into the unit. Fresh catalyst enters the seal drum catalyst inlet via a Catalyst Addition Hopper D-1356 and passes through the drum as during normal operation. The difference is that the catalyst is added batchwise rather than continuously. The nitrogen flow path is also similar to normal operation except gas exits the vessel from the top via the gas bypass nozzle rather than the catalyst inlet. The reason for this is that during catalyst change-out the gas equalization between the seal drum D-1357 and the Regeneration Tower T-1351 is provided through this bypass line. The internal diameter of the N2 Seal Drum is 900 mm and the length (Tangent Line to Weld Line) is 2200 mm.
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Figure 64: Nitrogen Seal Drum
3.3.7. Lock Hopper D-1358 The Lock Hopper D-1358 and its internals are made of killed carbon steel. The Lock Hopper contains three separate zones – the Disengaging Zone, Lock Hopper Zone, and Surge Zone. Catalyst enters at the top of the Lock Hopper via a Restriction Orifice. This orifice serves to limit the instantaneous catalyst withdrawal from the Regeneration Tower T-1351 to an acceptable rate. Below the Restriction Orifice are the 3 catalyst zones. The top zone is called the Disengaging Zone, the middle zone is called the Lock Hopper Zone, and the bottom zone is called the Surge Zone. The zones are Page 127 of 237
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designed to operate together to transfer catalyst in small batches and to raise the pressure surrounding the catalyst. All three zones operate under an environment of Platforming booster gas, but at two different pressures. The Disengaging Zone operates at nearly Regeneration Tower T-1351 pressure, the Surge Zone operates at nearly Regenerated Catalyst LValve Assembly (Reactor No. 1) pressure, and the Lock Hopper Zone cycles between these two pressures. A pressure instrument indicates the pressuring and depressuring of the Lock Hopper Zone. The Disengaging Zone has two gas nozzles – an equalization nozzle for gases from the Lock Hopper Zone and a vent nozzle equipped with a screen for venting excess gases. The Lock Hopper Zone has one gas nozzle – an equalization nozzle equipped with a screen that is for gases from the Surge Zone and to the Disengaging Zone. And the Surge Zone has two gas nozzles – an equalization nozzle equipped with a screen for gases to the Lock Hopper Zone and a nozzle for the makeup gas to the Lock Hopper. For inspection purposes, there is one manway in the Surge Zone. Also, there are inspection handholes to the bottom of the standpipe in each zone. The three sections of the Lock Hopper are connected with body flanges that can be opened as needed for access.
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Figure 65: Lock Hopper D-1358 Page 129 of 237
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3.3.8. Catalyst L-Valve Assemblies There are 2 L-Valve Assemblies, located at the base of each catalyst lift line, that fluidize and transport catalyst using lift gas. The Spent Catalyst L-Valve Assembly transports spent catalyst from the bottom of the Platforming reactor stack to the top of the regeneration section. The Regenerated Catalyst L-Valve Assembly transports regenerated catalyst from the bottom of the regeneration section back to the top of the Platforming reactor stack. Both L-Valve Assemblies are identical in most essential respects, including metallurgy and geometry. Both assemblies are made of the same material as the catalyst lift pipe that is carbon steel. Catalyst enters the assembly via a vertical pipe and then reaches a horizontal section. The horizontal section continues until it intersects the catalyst lift line proper. The length of the horizontal section is such that the catalyst slope that forms will not reach the lift line. Lift gas is supplied to the assembly at 2 locations. The primary lift gas is introduced at the bottom of the lift pipe, and the secondary lift gas is introduced at the side of the vertical pipe upstream of the horizontal section. At three of the four gas inlets, a screen is provided to prevent the catalyst from backing up into the lift gas supply line. This screen is not present in the Secondary Lift Gas line of the Spent Catalyst L-Valve assembly since plugging of this screen would send a false high signal to the Spent Catalyst Lift Line and Isolation System controllers. At the bottom of each lift pipe, a removable spool piece is provided in order to facilitate clearing the lift pipe if the catalyst slumps and can not be lifted by the lift gas flow. The L-Valve Assembly must be kept clean of debris, hydrocarbon liquid, or foreign materials, because these can influence catalyst lifting. The removable spool piece allows the L-Valve Assembly to be cleaned if needed.
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Figure 66: L-Valve Assembly
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3.3.9. Reduction Zone The Reduction Zone and its internals are made of Cr-Mo alloy steel. The Reduction Zone vessel sits atop the reactor stack, and catalyst exits to the first Platforming reactor directly below it via catalyst transfer lines. The Reduction Zone actually consists of two zones, an Upper and Lower Reduction Zone. Both zones are cylindrical catalyst beds inside annular baffles that are attached to the wall of the vessel. Gas enters the Reduction Zone through two inlet nozzles in the wall of the vessel. The upper reduction zone gas enters above the catalyst bed of the Upper Reduction Zone, flows through the bed, and exits the vessel through a nozzle behind the annular baffle of the Upper Reduction Zone. The annular baffle is specially designed for proper disengagement of the reduction gas from the catalyst to prevent entrainment. The lower reduction zone gas enters the vessel behind the annular baffle of the Lower Reduction Zone. The annular baffle is specially designed for uniform gas flow down the outside of the baffle and up through the catalyst bed. Gas exits the vessel through the same nozzle as the upper reduction zone gas. The gas outlet nozzle, and the immediate downstream piping, are set at an upward slope as an additional safeguard to prohibit any entrained catalyst from leaving the vessel. Access to the Reduction Zone is provided by a manway located in the Reduction Surge Zone.
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Figure 67: Reduction Zone
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3.3.10. Disengaging Hopper D-1353 The Disengaging Hopper D-1353 and its internals are made of killed carbon steel. The Disengaging Hopper is a cylindrical vessel with an elutriation pipe down the center at the top. The spent catalyst lift line enters the side of the elutriation pipe, bends downward, and ends as an open pipe. Catalyst and lift gas enter through the lift line and flow down into the center of the elutriation pipe. Elutriation gas enters through a nozzle in the side of the Disengaging Hopper and flows upward through the elutriation pipe. Catalyst chips, fines and some whole pills are carried with the gas out the top of the elutriation pipe. Whole catalyst pills drop to the bottom of the Disengaging Hopper D-1353 where it is a surge inventory of spent catalyst for the Regeneration Tower T-1351. The Disengaging Hopper D-1353 is sized to hold the excess catalyst from the reactors during start-up. This excess is due to the catalyst bed density change with the commencement of catalyst circulation. For inspection purposes, there is one manway on the side of the Disengaging Hopper.
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Figure 68: Disengaging Hopper D-1353
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Figure 69: Elutriator
3.3.11. Electric Heaters Electric Heaters are used to heat up three gas streams: regeneration gas, drying air, and reduction gas. These heaters are of the immersion type. The gas flows around the outside of the heater bundle, which fills the process piping. The bundle sheaths contain electrical elements. The bundle sheath temperatures are monitored by thermocouples that shut down the heater on high temperature. Gas must be flowing across the bundle during normal operation, or else the elements may overheat and burn up. The elements have an unheated length that includes the portion of the bundle that does not see gas flow. The terminal box is located a specified distance from the heater flange, and a cooling baffle is added between the two, to minimize heat conduction to the box. The Regeneration Heater H-1353 is a single-bundle design. For the Air Heater H1354 and the Reduction Gas Heaters H-1351 / 1352, multiple bundles in series may be required because of duty requirements.
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Figure 70: Electric Heaters Single Bundle
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Figure 71: Electric Heaters Double Bundle 3.3.12. Vent Gas Tower T-1352 The Vent Gas Wash Tower T-1352 is a cylindrical tower, with a packed bed of 19 mm diameter carbon Raschig rings, to remove HCI and chlorine from the regeneration vent gas. The tower is constructed of carbon steel. A distributor located above the packed bed insures that the packed bed remains wetted with caustic. A spray nozzle, located below the packed, bed, insures that the support grid and vessel walls below the packing are wetted. The regeneration gas passes through the packed bed where it is scrubbed of HCI and chlorine. The scrubbed gas then passes through a mesh blanket, located at the top of the tower, which serves as a demister pad. A spray nozzle, located below the mesh blanket, provides for intermittent washing of the mesh with clean condensate. T-1352 should be filled with water while the packing is loaded through the top manway to prevent breakage of the rings. Page 138 of 237
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The length of the wash tower is 9600 mm (TL to TL) and its internal diameter is 1000 mm.
Figure 72: Vent Gas Wash Tower T-1352
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TRAINING MODULE
CONTINUOUS CATALYTIC REFORMER (CCR) UNIT: 13
Course Content: Section 1 - General Description Section 2 - Process Flow Description Section 3 - Process Control Section 4 - Safeguarding Devices
X
Section 5 - Fire & Gas Systems Section 6 - Quality Control Section 7 - Cause & Effects Section 8 - Operating Procedures Section 9 - HSE Section 10 - Reference Document Index
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SECTION 4 : SAFEGUARDING DEVICES 4.1. Alarms and Trips Refer to attached Alarm & Trips List. 4.2. Safeguarding Description 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. The following is a description of the auto-trip systems of the CCR as well as the control systems of the catalyst regeneration section that prevent any hazardous conditions from occurring. For a complete description of the safeguarding of the CCR, refer to the licensor’s operating manuals doc No. 8474L-013-ML-001-A (CCR Platforming Reaction Section) & 8474L-013-ML-002-A (CCR Catalyst Regeneration Section).
4.2.1. CCR Platforming Reaction Section For the auto-trips of the CCR Platforming reaction section, refer to the Cause & Effects Matrix of the unit, doc. No. 8474L-013-DW-1514-201.
4.2.1.1. Loss of Make up compressor (unit 12) In case of Make Up Compressors (C-1202 A/B/C) failure, the pressure control system of Unit 013 will open the Net gas to fuel gas valve 013-PV004B. The Separator D-1301 off gas valve to flare (013-PV-004A) will be fully open. 4.2.1.2. Heaters Protection (UX-001): In case of loss of recycle gas flow (FXALL-004A/B/C/D) the 4 reactors heaters H-1301/2/3/4 will be partially shut down (burners shut down and pilots left on), and the feed to the combined feed exchanger E-1301 will be stopped (Feed inlet valve closed). In case of loss of circulating water flow (FXALL-613 A/B), then the heaters will also be partially shutdown. If the low low flow persists, then the water circulating pump P-1303A and the steam turbine for the pump water circulating pump P-1303B will be tripped. Page 141 of 237
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The heaters are completely shutdown in the event the CCC emergency shutdown push button UXHS-001-A is pressed or CCC bypass contact ESD pushbutton UXHS-001-C is pressed. This trip is reset from DCS by UHSR-001 except for the valve controlling the feed to the exchanger E-1301 which is reset via local pushbutton XHSR-011. 4.2.1.3. Recycle Compressor Protection (UX-002) In case of high high level in the separator drum (2 out of 3 voting), then the recycle compressor C-1301 is shutdown. This trip is reset from DCS via UHSR-002. 4.2.1.4. Separator pumps P-1301 A/B and Debutanizer pumps P-1302 A/B Protection (UX-003): P-1301 A/B are tripped in the event of low low level in the separator drum to prevent the pumps from running empty. In the same way, the debutanizer pumps P-1302 A/B are tripped in the event of low low level in the debutanizer receiver D-1301. All the pumps are reset from DCS via UHSR-003. 4.2.1.5. Debutanizer Overhead Pumps P-1302 A/B Protection (UX-004) P-1302 A/B are tripped in the event of: •
Local ESD via pushbutton,
•
D-1303 Isolation valve is closed,
•
D-1303 Isolation local close pushbutton
•
CCC close pushbutton
The D-1303 isolation valve is closed in the event of: •
Local ESD via pushbutton,
•
Isolation local close pushbutton
•
CCC close pushbutton
This trip is reset from DCS via XHSR-010 pushbutton. 4.2.1.6. Debutanizer Isolation In the event of: •
The local ESD pushbutton
•
Low low level in T-1301
•
Local close pushbutton
•
CCC close pushbutton
Then the debutanizer isolation valve XV-005 is closed, LV-003 (debutanizer bottoms to storage) is closed and the condensate flow valve from the debutanizer reboiler FV-009 is closed. Page 142 of 237
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This trip is reset locally via XHSR-023. 4.2.1.7. Air coolers Motor vibration protection All the air coolers of the Platforming Section (E-1303 A-H, E-1304 A/B, E1308 A/B & E-1309 A/B) will trip in case of high vibrations sensed in their motor. This trip is reset locally.
4.2.2. CCR Regeneration Section 4.2.2.1. Regenerator Automatic Shutdown Summary The Catalyst Regeneration Control System (CRCS) prevents improper or unsafe conditions by executing an automatic shutdown. There are four automatic shutdowns having their own usage, causes and results: a Hot Shutdown, a Cold Shutdown, and a Contaminated Nitrogen Shutdown and a Protection PES Hardware Shutdown. Hot Shutdown A Hot shutdown occurs when the conditions in the Regeneration Section require that catalyst regeneration be stopped but nor that the Regeneration Section be cooled, nor that the isolation Systems be closed. This avoids delays in reheating the Regenerator Section prior to restarting. It also minimizes valve wear and catalyst attrition.
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Cold Shutdown A Cold Shutdown occurs when the conditions in the Regeneration Section require that catalyst regeneration be stopped, the Regeneration Section be cooled, and the Isolation system be closed. This reduces the temperatures in the Regeneration Section and prevents cross-mixing of the hydrogen/hydrocarbon environment of the reaction section and the oxygen-containing environment of the Regeneration Section.
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Contaminated nitrogen shutdown A contaminated Nitrogen Shutdown occurs when the independent nitrogen header is contaminate, requiring that catalyst regeneration be stopped, the Regeneration Section be cooled, and the Isolation Systems be closed. In addition, the Contaminated Nitrogen Shutdown prevents contaminated nitrogen form entering the lower section of the Regeneration Tower by closing the Nitrogen Valve 013-XV-535, the Pressure Valve of the regenerated Catalyst Isolation System 013-XV-544, and the control valve for the nitrogen purge to the Nitrogen Seal Drum. When a contaminated Nitrogen Shutdown occurs, the CRCS not only initiates four actions but also begins a Cold Shutdown that then leads to a Hot Shutdown.
4.2.2.2. Regeneration Tower Automatic Stops The regenerator stops automatically when any of the following conditions occur: Item
Condition
Spent Catalyst Isolation System
Either Isolation Valve XV-523 or XV-522 does not confirm closed when they should be closed OR Nitrogen Valve XV-524 does not confirm open when it should be open
Regenerated Catalyst Isolation System
Either Valve Isolation Valve XV-24 or XV-22 does not confirm closed when they should be closed OR Nitrogen valve XV-23 does not confirm open when it should be open
CCR Nitrogen Header
Low Pressure
CCR Nitrogen Header
High Contaminants
Regenerator Run-Stop Pushbutton
“STOP” by manual operation
Emergency Stop Switch
“STOP” by manual operation
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Nitrogen Pushbutton
The Nitrogen Valve 013-XV-535 closes automatically when a contaminated Nitrogen Shutdown occurs. In this way, contaminated nitrogen is prevented from entering the bottom of the Regeneration Tower. Air pushbutton The Air Valve 013-XV-534 closes automatically when a Hot Shutdown, a Cold Shutdown, or a Contaminated Nitrogen Shutdown occurs. This keeps air out of the Regeneration Tower when catalyst circulation and catalyst regeneration are stopped during these shutdowns. The operator can manually closes the Air Valve without any preconditions when doing the Hot Shutdown Procedure. If the Air Pushbutton is depressed while the Air Valve is open, then the Air Valve closes. Lower Air Supply Line Pushbutton The Lower Air Supply Line Valve 013-XV-533 closes automatically when a Hot Shutdown, a Cold Shutdown occurs, or a Contaminated Nitrogen Shutdown occurs. This keeps air out of the Drying Zone when catalyst circulation and catalyst regeneration are stopped during these shutdowns. The operator can manually close the Lower Air Supply Line Valve 013XV-533 without any preconditions when doing the Hot Shutdown Procedure. If the Lower Air Supply Line Pushbutton is depressed while the Lower Air Supply Line Valve is open, then the Lower Air Supply Line Valve closes. Chloride Pushbutton The Chloride Valve closes automatically when a Hot Shutdown, cold Shutdown, or a Contaminated Nitrogen Shutdown occurs. The Chloride valve closes automatically if any condition required to open the Chloride Valve and start the Injection pump is not met while the Chloride Valve is open, that is: Item
Condition
Nitrogen Valve
013-XV-535 is not confirmed closed
Regeneration Gas Heater
Outlet Temperature Low (410°C)
Air Heater
Outlet Temperature Low (460°C) Page 147 of 237
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Chloride Valve
013-XV-538 is not confirmed open
Chloride Flow
Below low trip setting for more than 30 sec
Emergency Stop Switch
Stop Position
If the pump Handswitch is in the AUTO position, then the injection Pump stops automatically too. The operator can manually close the Chloride Valve 013-XV-538. If the Chloride Pushbutton 013-XL-537 is depressed when the Chloride Valve is open, then the Chloride Valve closes, the Injection Pump is disabled and the Chloride injection Low Flow Alarm is disabled. Electric heaters The Regeneration Gas and Air electric heaters stop automatically when a Cold Shutdown or a Contaminated Nitrogen Shutdown occurs. Hot, Cold and Contaminated Nitrogen Shutdowns do not shut off the Reduction Gas Heaters. The Reduction Gas Heaters are not affected by the Regenerator Run-Stop Pushbutton. Each of the electric heaters can individually stop automatically. If any condition required for starting the heater is not met while the heater is on, then that heater alone stops. The operator can manually stop each of the electric heaters. If the Electric Heater Pushbutton is depressed when the heater is on, then that electric heater stops. Its indicator changes from RESET to STOP.
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Emergency Stop Switch If the Emergency Stop Switch is turned to the STOP position, a Cold Shutdown occurs and each logic-operated valve immediately moves to its fail-safe position. Turning the Emergency Stop Switch to the STOP position may be required as a last resort. But in normal operations this is not recommended. This is because all of the valves move at once and neither the operator nor the CRCS controls the sequence of the movement. Moving the switch to the STOP position stops the following systems and disables them from being started: 1. Regeneration System (Isolation Systems, Catalyst Lift Systems) 2. Catalyst Flow interrupt Systems 3. Chemical Systems (Nitrogen, Air, Chloride) 4. Lock Hopper Control (Lock Hopper Cycle, Catalyst Flow control, Makeup valve control) 5. Catalyst Addition Hoppers 6. Fines Collection Pot 7. Heaters (Air, Regeneration Gas, Reduction Gas)
4.2.2.3. Lock Hopper D-1358 Abnormal Unload/Load Alarms There are 4 alarms that alert the operator of a problem with the loading and unloading of the Lock Hopper D-1358. If any alarm sounds during two consecutive Lock Hopper cycles, then a Hot Shutdown occurs. Each of the four alarm timer settings can be adjusted from 0-120 sec using the Catalyst Flow Setup Screen.
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Fast unload Alarm The Fast Unload Alarm alerts the operators that the Lock Hopper Zone is unloading too quickly. The alarm is activated by the Fast Unload Timer. The Fast Unload Timer starts to count down when entering the UNLOAD step. The alarm will sound if the Lock Hopper Zone unloads to below the low-level instrument before the Fast Unload Timer times out. Slow Unload Alarm The Slow Unload Alarm alerts the operator that the Lock Hopper Zone is unloading too slowly. The alarm is activated by the Slow Unload Timer. The Slow Unload Timer starts to count down when the Fast Unload Timer times out. The alarm will sound if the Lock Hopper Zone does not unload to below the low-level instrument before the Slow Unload Timer times out. Fast Load Alarm The Fast Load Alarm alerts the operator that the Lock Hopper Zone is loading too quickly. The alarm is activated by the Fast Load Timer. The Fast Load timer starts to count down when entering the LOAD step. The alarm will sound if the Lock Hopper Zone Loads up to the high level instrument before the Fast Load Timer times out. Slow Load Alarm The Slow Load Alarm alerts the operator that the Lock Hopper Zone is loading too slowly. The alarm is activated by the Slow Load Timer. The Slow Load timer starts to count down when the Fast Load Timer times out. The alarm will sound if the Lock Hopper Zone does not load up to the high level instrument before the Slow Load Timer times out.
4.2.2.4. Lock Hopper Level Switch Malfunction Alarm The Lock Hopper Level Switch Malfunction Alarm alerts the operator of a level instrument malfunction. If the low level instrument in the Lock Hopper Zone indicates a low level and the high level instrument simultaneously indicates a high level for more than a prescribed period of time (normally two seconds), then the level Switch Malfunction Alarm will sound. The Alarm causes a Hot Shutdown.
4.2.2.5. Lock hopper Starting & Stopping Sequence The Lock Hopper cycle can be stopped at any time, either by an operator’s action or either of the following conditions: (i) Catalyst Pushbutton is switched to OFF or (ii) Hot Shutdown Page 150 of 237
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For the other alarms associated to the lock hopper, refer to the licensor operating manual doc. No. 8474L-013-ML-002-A.
4.2.2.6. Catalyst Flow Interrupt Systems The catalyst flow from the Reactor and from the Lock Hopper Surge Zone can be interrupted to prevent low levels in those vessels. The CRCS controls the operation of these systems and catalyst flow will be allowed or interrupted automatically when certain conditions exist. During shutdowns, the systems prohibit catalyst transfer in order to maintain catalyst inventory in the Reactor and the Lock Hopper Spent Catalyst Flow Interrupt The catalyst flow from the Reactor will be interrupted in two ways depending on the level at the top of the Reactor: If the Reduction Zone LRC (Level Recorder Controller) 013-LIC-501 indicates a low level (~10%), the CRCS resets the Spent Catalyst Lift Rate Limiter controller to zero via the low signal selector. At the same time, the secondary lift gas control valve (FC) 013-FV-512 is close. When the Reduction Zone level rises above 50% then the Spent Catalyst Flow Interrupt will clear: the spent Catalyst Secondary Lift Gas Valve opens and the Spent Catalyst Lift Rate Limiter begins ramping up, allowing lifting to resume. If the reduction Zone level continues to drop below the low level indicator switch point and reaches 0%, the spent catalyst isolation will trip, causing the two isolation valves 013-XV-523 & 522 to close and the nitrogen pressure valve 013-XV-524 to open. This results in a Hot Shutdown. Regenerated Catalyst Flow Interrupt The catalyst flow from the Lock Hopper Surge Zone will be interrupted if the catalyst level in the Surge Zone falls below 10%. If a low-low level 013-LALL-507 is indicated by the Surge Zone LR (Level Recorder) the CRCS resets the Regenerated Catalyst Lift Line ΔP controller to zero catalyst flow. At the same time, the secondary lift gas control valve 013FV-535 (FC) is closed. When the catalyst level in the surge zone rises above 40% then the Regenerated Catalyst Flow Interrupt will clear: the Regenerated Catalyst Secondary Lift Gas Valve opens and the Spent Catalyst Lift Rate Limiter begins ramping up, allowing lifting to resume. When there is a low-low level in the Lock Hopper surge zone (0%), only the Regenerated Catalyst Flow Interrupt is activated, this does not result in any shutdown of the closing of the Regenerated Catalyst Isolation system.
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4.2.2.7. Regenerated Catalyst Lift Line Valve The valve 013-XV-018 in the regenerated catalyst lift line at the top of the reactor serves to isolate the Platforming Unit reactors from the Regeneration Section under certain circumstances. It is also useful in preventing gases from the reactor from flowing back into the lift line. The valve may be closed manually from the control room, or automatically by the CRCS. There are two conditions that will automatically signal the CRCS to close the lift line valve: 2. The temperature of regenerated catalyst lift line, as measured by the lift line skin 013-TIC-507, is above the high temperature trip setting (190°C). This indicates a back flow of Reduction Zone gas or Reactor gas as a result of a lift line rupture. 3. The flow of gas to the Reduction gas heater n°1 (013-FI-549) AND regenerated catalyst lift gas are below the low-low flow trip point. 4.2.2.8. Regeneration Section Isolation Systems An isolation System (either Spent or regenerated catalyst) closes automatically when: 1. A cold Shutdown occurs (Regenerator Run/Stop to Stop) 2. Both of the indicators for the top or the bottom differential pressures are lower than the low differential trip settings (two of two voting system). The indicators must be low for a time longer than the set amount of time. 3. (For Spent Catalyst Isolation only.) Reduction Zone catalyst is below the low level point. 4. Contaminated Nitrogen Shutdown occurs When an isolation System closes, first, its Isolation Valves are commanded closed and confirm closed. Next, its pressure valve is commanded open and confirms open. If its Isolation valves do not confirm closed within the time period of its Purge Delay Timer (usually 10 seconds), a cold Shutdown occurs and its pressure valve is commanded open anyway. If the Pressure Valve does not confirm open, a Cold Shutdown also occurs. Any time either isolation system is tripped closed, a Hot Shutdown will occur. The isolation system will continue to give this signal for one minute at the end of which the Regeneration System can be restarted. An exception to the above is when the Spent Catalyst isolation is tripped by a low level in the Reduction Zone. In this case no Hot Shutdown shall occur so the level can be re-established. An isolation System closes automatically when a Contaminated Nitrogen Shutdown occurs. Then, only the upper isolation system closes as described above. The lower isolation system closes differently. Not only are its isolation valves commanded closed, but so are its pressure valve Page 152 of 237
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and the control valve for the nitrogen purge to the purge zone. In this way, contaminated nitrogen is prevented from entering the bottom of the Regeneration Tower. The operator can manually close both isolation systems at any time depressing the Isolation system close Pushbutton, or of the operator depresses the Regenerator Run-Stop Pushbutton, then a Cold Shutdown occurs. This closes the isolation Systems.
4.2.2.9. Reduction Zone/Reactor #1 Differential Pressure system The gas flows entering the Reduction Zone are on flow control. The pressure of the reactor R-1301 is controlled in the Platforming unit. The normal control scheme maintains the Reduction Zone at a slightly higher pressure than reactor R-1301 by controlling the valve 013-PDV-502 in the Reduction Zone vent gas line (valve A in the following figure). The CRCS monitors the DP between the Reduction Zone and Reactor R1301 using a separate differential pressure transmitter (013-PDIC-503) than the one used for control (013-PDIC-502). If the ΔP becomes too low or two high, there is a shutdown system incorporating 3 shut off valves operated by solenoids. The shut off valves are located in the Reduction gas line from the Booster Gas coalescer A-1351 (013-XV-551, valve B in the figure), in the Reduction Zone Vent gas line (013-XV-525, valve C in the figure) and in the standby (recycle) gas line to the reduction zone (013-XV-517, valve D).
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Figure 73: Reduction Zone/Reactor #1 Differential Pressure system During normal operation, if the ΔP decreases below the shutdown setting (013-PDSLL-503): •
Reduction zone vent valve closes
•
Recycle gas purge to reduction zone (standby gas) valve opens
•
Booster gas to reduction zone remains open
This safeguard insures that the Reduction Zone pressure is always higher than that of Reactor R-1301. This prevents the back flow of heavy hydrocarbons to the Reduction Zone that could lead to high temperatures and coke formation.
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During normal operation, if the ΔP increases above the shutdown (013PDSHH-503) setting: •
Booster gas to reduction zone closes
•
Reduction zone vent valve remains open
•
Recycle gas purge to reduction zone (standby gas) valve remains open
This safeguard insures that the Reduction Zone does not over-pressure. With the Reduction Gas flow stopped, the Reduction Zone electric heaters will trip on low gas flow thus causing a hot shutdown of the Regenerator. The lift gas flow will continue into the Reduction Zone and should be sufficient to prevent a low ΔP shutdown situation. When resetting the valve in the Reduction Gas line to the Reduction Zone after a high ΔP shutdown, ensure that the Reduction Zone vent gas line is open. The valves must be manually re-set in the field before normal Reduction zone and Regenerator operation can resume.
4.2.2.10. Vent Gas Wash Wash Tower T-1352 Protection Overpressure Protection To protect the wash tower from overpressurization caused by a flooded bed, failure of the level instrument, or a restricted vent line, a liquid leg and tower gas bypass line are provided. The liquid leg is located such that if the wash tower pressure builds, a high level alarm in the line will sound and shut down the circulating caustic, caustic injection pumps, and water injection pumps. As the tower pressure builds and pushes the caustic into the liquid leg, the tower gas bypass line distributor will be exposed and allow gas to bypass the tower. A siphon breaking vent is provided in the liquid leg to prevent the entire caustic inventory or the tower from being educted out the liquid leg. Diversion Valves To protect the Vent Gas Wash Tower T-1352 from rapid corrosion and to protect against possible combustion of the Carbon Raschig ring packing, the vent gas is bypassed around the Vent Gas Wash Tower if the circulating caustic flow is lost. The circulating caustic to the Venturi Scrubber M-1351 normally cools the vent gas before entering the wash tower. If this flow is lost, a valve in the Vent Gas Wash Tower bypass opens and a valve in the vent line upstream of the Venturi Scrubber M1351 is closed. In the event this shutdown is activated, the Regenerator also is shutdown to protect the environment from HCl and Cl2 emissions.
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4.3. Safeguarding Equipment 4.3.1. Pressure Safety Devices Over pressuring of the equipment occurs in many ways. The basic cause of power pressure is imbalance in heat and material flow in the equipment or piping. Pressure safety devices have been installed to protect and/or section against over pressure.
TAG No.
Description
013-PSV -301-A 013-PSV -301-B 013-PSV -324-A 013-PSV -324-B 013-PSV -301-C
Relief Valve (Pilot) Relief Valve (Pilot) Relief Valve (Pilot) Relief Valve (Pilot) Relief Valve (Pilot)
013-PSV -644-A
Type
Location
PID:
RV
SEPARATOR D-1301
017
RV
SEPARATOR D-1301
017
RV RV
IN NET GAS COOLER E1304 IN NET GAS COOLER E1304
RV
SEPARATOR D-1301
Relief Valve (Pilot)
RV
REGENERATION TOWER T-1351
013-PSV -645-A
Relief Valve (Pilot)
RV
LOCK HOPPER D-1358
013-PSV -330 013-PSV -331 013-PSV -302-A 013-PSV -302-B 013-PSV -303-A 013-PSV -303-B 013-PSV -305-A 013-PSV -305-B 013-PSV -307 013-PSV -924
Relief Valve (Pilot) Relief Valve (Pilot) Relief Valve (Spring) Relief Valve (Spring) Relief Valve (Spring) Relief Valve (Spring) Relief Valve (Spring) Relief Valve (Spring) Relief Valve (Spring) Relief Valve (Spring)
RV
OUTLET DEBUTANIZER T1301
RV
REFLUX TO P-1302A/B
013-PSV -654 013-PSV
RV RV
NETGAS CHLORIDE TREATER D-1302A/B NETGAS CHLORIDE TREATER D-1302A/B
019 019 017 8474L-013A0103-4110002-014 8474L-013A0103-4110002-016 8474L-013PID-0090-001 8474L-013PID-0090-001 020 020
RV
DEBUTANIZER T-1301
023
RV
DEBUTANIZER T-1301
023
RV RV
LPG CHLORIDE TREATERS D-1308A/B LPG CHLORIDE TREATERS D-1308A/B
Setting (kg/cm2g)
024 024
RV
FUEL GAS DRUM D-1309
027
RV
NET GAS CHLORIDE TREATER P-1308
020
Relief Valve (Spring)
RV
VAPOR TO DESUPERHEATER
Relief Valve
RV
TURBINE CIRCULATING
8474L-013A0103-0110001-059 8474L-013Page 156 of 237
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Type
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TAG No.
Description
-655
(Spring)
013-PSV -650-B
Relief Valve (Spring)
RV
STEAM DISENGAGING DRUM D-1306
013-PSV -650-A
Relief Valve (Spring)
RV
STEAM DISENGAGING DRUM D-1306
013-PSV -823
Relief Valve (Spring)
RV
CHEM AND CONDT INJ P1304A/B
013-PSV -822
Relief Valve (Spring)
RV
CHEM AND CONDT INJ P1304A/B
013-PSV -825
Relief Valve (Spring)
RV
START-UP CHEM INJ PUMP P-1305
013-PSV -348-B 013-PSV -348-A
Relief Valve (Spring) Relief Valve (Spring)
013-PSV -803
Relief Valve (Spring)
RV
PHOSPHATE INJ PUMP P1397A
013-PSV -804
Relief Valve (Spring)
RV
PHOSPHATE INJ PUMP P1397B
013-PSV -807
Relief Valve (Spring)
RV
SULFIDE INJ PUMP P1306A
013-PSV -808
Relief Valve (Spring)
RV
SULFIDE INJ PUMP P1306B
013-PSV -410-B 013-PSV -410-A 013-PSV -312 013-PSV -150
Relief Valve (Spring) Relief Valve (Spring) Relief Valve (Spring) Relief Valve (Spring)
013-PSV -833
Relief Valve (Spring)
013-PSV -429-A 013-PSV -429-B 013-PSV
Relief Valve (Spring) Relief Valve (Spring) Relief Valve
RV RV
RV RV RV RV RV RV RV RV
DATE: 19/10/07
Setting (kg/cm2g)
Location
PID:
WATER PUMP B
A0103-0110001-059 8474L-013A0103-0110001-059 8474L-013A0103-0110001-059 8474L-200A0103-4046001-151 8474L-200A0103-4046001-151 8474L-200A0103-4046001-151
CONT BLOWDN DRUM D1304 CONT BLOWDN DRUM D1304
N2 BLANKETED SULFIDE STOR DRUM N2 BLANKETED SULFIDE STOR DRUM CCR PLATFOR PROC U SURFAC CONDNSR TURBINE CIRCULATING WATER PUMP B CHLORIDE TRANSFER PUMPS P-1309A/B
032 032 8474L-200A0103-4046001-261 8474L-200A0103-4046001-261 8474L-200A0103-4046001-211 8474L-200A0103-4046001-211 037 037 034 8474L-013PID-0041-075 8474L-200A0103-4046001-151
N2 BLANKETED CHLORIDE 016 STOR DRUM N2 BLANKETED CHLORIDE 016 STOR DRUM LUBE OIL SUPPLY C-1301 8474L-013Page 157 of 237
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Type
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TAG No.
Description
Location
-714
(Spring)
013-PSV -711
Relief Valve (Spring)
RV
LO DISCHARGE PUMP C1301-P-01B
013-PSV -707
Relief Valve (Spring)
RV
LO DISCHARGE PUMP C1301-P-01A
013-PSV -774
Relief Valve (Spring)
RV
INTER CONDENSER E1312
013-PSV -776
Relief Valve (Spring)
RV
STEAM TO CONDENSER E-1311
013-PSV -771
Relief Valve (Spring)
RV
LS FROM TURBINE SHAFT LEAKAGES
013-PSV -662
Relief Valve (Spring)
RV
LEAN NET GAS FROM X1301-V01
013-PSV -663
Relief Valve (Spring)
RV
LUBE OIL FROM X-1301F2A
013-PSV -664
Relief Valve (Spring)
RV
LUBE OIL FROM X-1301F2B
013-PSV -665
Relief Valve (Spring)
RV
LUBE OIL FROM X-1301E04
013-PSV -668
Relief Valve (Spring)
RV
LUBE OIL FROM X-1301P01B
013-PSV -667
Relief Valve (Spring)
RV
LUBE OIL FROM X-1301P01A
013-PSV -669
Relief Valve (Spring)
RV
RF FROM X-1301-E06
013-PSV -670
Relief Valve (Spring)
RV
MOTOR OIL PUMP X-1301P03A
013-PSV -671
Relief Valve (Spring)
RV
MOTOR OIL PUMP X-1301P03B
013-PSV -660
Relief Valve (Spring)
RV
RICH OIL FROM X-1301E01A
013-PSV -661
Relief Valve (Spring)
RV
LEAN OIL FROM X-1301E03
DATE: 19/10/07
Setting (kg/cm2g)
PID: A0103-1011001-002 8474L-013A0103-1011001-002 8474L-013A0103-1011001-002 8474L-013A0103-1011001-007 8474L-013A0103-1011001-007 8474L-013A0103-1011001-107 8474L-013A0103-4110001-006 8474L-013A0103-4110001-008 8474L-013A0103-4110001-008 8474L-013A0103-4110001-008 8474L-013A0103-4110001-009 8474L-013A0103-4110001-009 8474L-013A0103-4110001-010 8474L-013A0103-4110001-013 8474L-013A0103-4110001-013 8474L-013A0103-4110001-004 8474L-013A0103-4110-
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TAG No.
Description
Type
DOC NO: 8474L-013-A5016-0000-001-003 REV: A
Location
013-PSV -666-A
Relief Valve (Spring)
RV
LUBE OIL FROM X-1301V02
013-PSV -666-B
Relief Valve (Spring)
RV
LUBE OIL FROM X-1301V02
013-PSV -640-A
Relief Valve (Spring)
RV
REDUCTION GAS EXCHANGER E-1351
013-PSV -640-B
Relief Valve (Spring)
RV
REDUCTION GAS EXCHANGER E-1351
013-PSV -641
Relief Valve (Spring)
RV
CTLYST ADDITION LOCK HOPPER D1352
013-PSV -643
Relief Valve (Spring)
RV
FINES COLLECTION POT
013-PSV -642-A
Relief Valve (Spring)
RV
DUST COLLECTOR A-1352
013-PSV -642-B
Relief Valve (Spring)
RV
DUST COLLECTOR A-1352
013-PSV -644-B
Relief Valve (Spring)
RV
REGENERATION TOWER T-1351
013-PSV -645-B
Relief Valve (Spring)
RV
LOCK HOPPER D-1358
013-PSV -646
Relief Valve (Spring)
RV
BOOSTER GAS COALESCER A-1351
013-PSV -852
Relief Valve (Spring)
RV
CAUSTIC INJECTION X1359
013-PSV -853
Relief Valve (Spring)
RV
CAUSTIC INJECTION X1359
013-PSV -842
Relief Valve (Spring)
RV
CAUSTIC INJECTION X1360
013-PSV -843
Relief Valve (Spring)
RV
CAUSTIC INJECTION X1360
013-TSV -330 013-TSV
Relief Valve (Thermal) Relief Valve
RV RV
DEBUTANIZER BOT TRIM CLR E-1305A CWS TO E-1310
DATE: 19/10/07
Setting (kg/cm2g)
PID: 001-005 8474L-013A0103-4110001-009 8474L-013A0103-4110001-009 8474L-013A0103-4110002-007 8474L-013A0103-4110002-007 8474L-013A0103-4110002-008 8474L-013A0103-4110002-009 8474L-013A0103-4110002-009 8474L-013A0103-4110002-009 8474L-013A0103-4110002-014 8474L-013A0103-4110002-016 8474L-013A0103-4110002-017 8474L-200A0103-4046001-351 8474L-200A0103-4046001-351 8474L-200A0103-4046001-391 8474L-200A0103-4046001-391 022 025
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Type
DOC NO: 8474L-013-A5016-0000-001-003 REV: A
TAG No.
Description
-331 013-TSV -337-A 013-TSV -337-B 013-TSV -346 013-TSV -338 013-TSV -140 013-TSV -141 013-TSV -925 013-TSV -926 013-TSV -927 013-TSV -928
(Thermal) Relief Valve (Thermal) Relief Valve (Thermal) Relief Valve (Thermal) Relief Valve (Thermal) Relief Valve (Thermal) Relief Valve (Thermal) Relief Valve (Thermal) Relief Valve (Thermal) Relief Valve (Thermal) Relief Valve (Thermal)
013-TSV -721
Relief Valve (Thermal)
RV
LO FILTER OUTLET C1301-F-01B
013-TSV -722
Relief Valve (Thermal)
RV
LO FILTER OUTLET C1301-F-01A
013-TSV -773
Relief Valve (Thermal)
RV
AFTER CNDNSR OUT C1301-E-1313
013-TSV -913 013-TSV -916
Relief Valve (Thermal) Relief Valve (Thermal)
013-TSV -648
Relief Valve (Thermal)
RV
LIFT GAS BLOWER OIL COOLER
013-TSV -647
Relief Valve (Thermal)
RV
CAUSTIC COOLER E-1354
RV RV RV RV RV RV RV RV RV RV
RV RV
Location CWS CIRCUIT SURFACE CONDENSER CWS CIRCUIT SURFACE CONDENSER CWR FROM SEVER BLOWDOWN COOLER
DATE: 19/10/07
Setting (kg/cm2g)
PID: 034 034 032
AT GRADE
035
INTERFACE RECYCLE COMPRESSOR INTERFACE RECYCLE COMPRESSOR SEAL SYSTEM PUMP P1301 A SEAL SYSTEM PUMP P1301 B SEAL SYSTEM PUMP P1302 A SEAL SYSTEM PUMP P1302 B
8474L-013PID-0041-075 8474L-013PID-0041-075 8474L-013PID-0041-090 8474L-013PID-0041-090 8474L-013PID-0041-090 8474L-013PID-0041-090 8474L-013A0103-1011001-002 8474L-013A0103-1011001-002 8474L-013A0103-1011001-007 8474L-013PID-0041-090 8474L-013PID-0041-090 8474L-013A0103-4110002-005 8474L-013A0103-4110002-018
PUMP BEARING RADIAL P1303A PUMP BEARING RADIAL P1303B
For further information on the discharge parameters for each relief valve, refer to the flare discharge summary doc. No. 8474L-200-NM-0006-001.
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DOC NO: 8474L-013-A5016-0000-001-003 REV: A
DATE: 19/10/07
TRAINING MODULE
CONTINUOUS CATALYTIC REFORMER (CCR) UNIT: 13
Course Content: Section 1 - General Description Section 2 - Process Flow Description Section 3 - Process Control Section 4 - Safeguarding Devices Section 5 - Fire & Gas Systems
X
Section 6 - Quality Control Section 7 - Cause & Effects Section 8 - Operating Procedures Section 9 - HSE Section 10 - Reference Document Index
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DOC NO: 8474L-013-A5016-0000-001-003 REV: A
DATE: 19/10/07
SECTION 5 : FIRE & GAS SYSTEMS 5.1. Fire & Gas detection Refer to the following documents: 8474L-012-DW-1950-001 Fire & Gas Detector Layout NHT/CCR/ISOM 8474L-012-DW-1960-001 Escape Routes Layout NHT/CCR/ISOM
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DATE: 19/10/07
Figure 74: Fire & Gas Detectors Layout (1/2) Page 163 of 237
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Figure 75: Fire & Gas Detectors Layout (2/2) Page 164 of 237
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DATE: 19/10/07
Figure 76: Detectors Layout Legend Page 165 of 237
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DATE: 19/10/07
Figure 77: Detectors inside X-1301
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DATE: 19/10/07
Figure 78: Escape Route Layout (1/2)
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DATE: 19/10/07
Figure 79: Escape Route Layout (2/2)
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DATE: 19/10/07
Figure 80: Legend for Escape Route Layout 5.2. Fire Protection Refer to the following document: 8474L-012-DW-1933-001 Fire Protection Equipment Layout NHT/CCR/ISOM 8474L-012-DW-1933-002 Safety Equipment Layout NHT/CCR/ISOM
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DATE: 19/10/07
Figure 81: Fire Protection Equipment Layout (1/2) Page 170 of 237
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DATE: 19/10/07
Figure 82: Fire Protection Equipment Layout (2/2) Page 171 of 237
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DATE: 19/10/07
Figure 83: Fire Protection Equipment Layout Legend Page 172 of 237
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DOC NO: 8474L-013-A5016-0000-001-003 REV: A
DATE: 19/10/07
Figure 84: Safety Equipment Layout (1/2) Page 173 of 237
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DATE: 19/10/07
Figure 85: Safety Equipment Layout (2/2) Page 174 of 237
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DATE: 19/10/07
Figure 86: Safety Equipment Layout Legend (Complete Area, i.e. NHT/CCR/ISOM)
Page 175 of 237
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DOC NO: 8474L-013-A5016-0000-001-003 REV: A
DATE: 19/10/07
TRAINING MODULE
CONTINUOUS CATALYTIC REFORMER (CCR) UNIT: 13
Course Content: Section 1 - General Description Section 2 - Process Flow Description Section 3 - Process Control Section 4 - Safeguarding Devices Section 5 - Fire & Gas Systems Section 6 - Quality Control
X
Section 7 - Cause & Effects Section 8 - Operating Procedures Section 9 - HSE Section 10 - Reference Document Index
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DOC NO: 8474L-013-A5016-0000-001-003 REV: A
DATE: 19/10/07
SECTION 6 : QUALITY CONTROL In order to ensure that the products resulting from the operation of this unit are on spec, the unit facilities are provided with sample connections to analyse the process streams. Continuous monitoring of the plant performance by analysing the product streams also helps detect and prevent from major problems. The first subsection displays tables listing the sample connections, the associated process stream, the properties to be analyzed along with methodology and the frequency of operation. In addition, on-line analysers sample process streams on a continuous basis to make sure products are on specs and to trip the process in case of deviation. The second subsection describes the on-line analysers of this unit. 6.1. Sampling connections The following tables describe the sampling connections of the CCR Platforming Reaction Section:
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DATE: 19/10/07
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DATE: 19/10/07
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DATE: 19/10/07
The following table describes the sampling connections of the CCR Regeneration Section:
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DATE: 19/10/07
6.2. On-line analyzers The on line analyzers in the CCR are describe in the table below:
Analyser Tag
Service
Physical Property Analysed
Normal value of analyzed component
P&ID
013-AI-002
Separator Recycle Gas
Hydrogen
85.23 Mole%
017
013-AI-003
Recycle Gas
Moisture
0.0005 to 0.0025 Mole%
017
013-AI-605
Charge heater
Oxygen
XXX
028
013-AI-606
No.1 interheater
Oxygen
XXX
029
013-AI-607
No.2 interheater
Oxygen
XXX
030
013-AI-608
No.3 interheater
Oxygen
XXX
031
013-AI-502
Regeneration gas / Regeneration Oxygen heater outlet
XXX
115
013-AI-503
Regeneration air blower
Oxygen
XXX
115
013-AI-504
Caustic Solution (P-1351 A/B)
pH
XXX
122
For further details on the CCR Platforming section analysers, refer to the analysers datasheets: •
013-AI-002: Doc. No. 8474L-013-PDS-AE-001
•
013-AI-003: Doc. No. 8474L-013-PDS-AE-003
•
013-AI-605: Doc. No. 8474L-013-PDS-AE-002
•
013-AI-606: Doc. No. 8474L-013-PDS-AE-002
•
013-AI-607: Doc. No. 8474L-013-PDS-AE-002
•
013-AI-608: Doc. No. 8474L-013-PDS-AE-002
For further details on the CCR Regeneration section analysers (013-AI-502/503/504), refer to the licensor operating manual doc. No. 8474L-013-ML-002-A.
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DOC NO: 8474L-013-A5016-0000-001-003 REV: A
DATE: 19/10/07
TRAINING MODULE
CONTINUOUS CATALYTIC REFORMER (CCR) UNIT: 13
Course Content: Section 1 - General Description Section 2 - Process Flow Description Section 3 - Process Control Section 4 - Safeguarding Devices Section 5 - Fire & Gas Systems Section 6 - Quality Control Section 7 - Cause & Effects
X
Section 8 - Operating Procedures Section 9 - HSE Section 10 - Reference Document Index
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DOC NO: 8474L-013-A5016-0000-001-003 REV: A
DATE: 19/10/07
SECTION 7 : CAUSES AND EFFECT
7.1. Cause & Effect Matrix: Refer to the following documents: •
Cause and Effect Chart, 8474L-013-DW-1514-201
7.1.1. Example from Cause and Effect Chart To better understand how the Cause & Effect Matrix shall be read, an example is given, which details the information that can be extracted from a sheet of the Cause & Effect Diagram. It shall be read in conjunction with the corresponding sheet of the Cause & Effect Diagram. 7.1.1.1. Sheet 1: Reactor Heater H-1301/02/03/04 Shutdown (UX-001) The following causes trigger the logic UX-001: Cause Description of the Event: No.:
Equipment Involved:
Event Detected / Located in Activated via: PID:
1
CCC ESD pushbutton
H-1301/2/3 /4
UXHS-001-A
048
2
CCC bypass contact emergency SD pushbutton
H-1301/2/3 /4
UXHS-001-C
048
3
Low low flow of recycle gas [1]
FXALL-004A/B/C
015
4
Low low flow of circulating water [2] [5]
FXALL-613 A/B
033
[1]: the cause No.3 is activated only if 2 out of the 2 alarms are activated. Moreover, the effect generated by this cause will occur after a time delay adjustable between 0 and 30s (initial setting at 15s). [2]: the cause No.3 is activated only if 2 out of the 3 alarms are activated. Moreover, the effect generated by this cause will occur after a time delay adjustable between 0 and 30s (initial setting at 15s). [5]: Time delay of 30s. So the effect associated will occur only if the condition persists. The above causes lead to the following effects:
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Effect Description of the Effect: No.:
DOC NO: 8474L-013-A5016-0000-001-003 REV: A
DATE: 19/10/07
Triggered by Cause No.
Effect Equipment Executed Involved: via:
Located in PID:
1
Total reactor heater shutdown [3] via logic UX-601
1, 2
H-1301/2 /3/4
XS-609
2
Partial reactor heater shutdown [4]
3, 4
H-1301/2 /3/4
XS-610
3
Close (C) the valve on the feed line to the combined feed exchanger
3
XV-011
XSY-011
015
4
Trip the circulating water pump P-1303A [5]
4
P-1303A
MXS-601
033
5
Send a signal to close the steam 4 valve FV-614 [5]
FV-614
FSY-614
033
6
Trip the steam turbine TP1303B [7]
TP-1303B
XSY-630
033
4
[3]: This effect activates the logic UX-601 that corresponds to the total reactor heater shutdown (burners and pilots shutdown). [4]: This effect activates the logic UX-602 that corresponds to the partial reactor heater shutdown (burner shutdown and pilots left on). [7]: The steam turbine need to be locally re-armed. Maintenance Override Switches (MOS) and Operation Override Switches (OOS) associated with the instruments triggering the trip and allowing the operator to bypass the corresponding conditions leading to the above described effects: Instrument
OOS
MOS
UXHS-001-A
N/A
N/A
UXHS-001-C
N/A
N/A
N/A Æ this conditions cannot be de-activated during operation
FHS-004
FXALL-004A/B/C FXALL-613 A/B
FHS-613
FHS-613-A
Resets: •
From DCS: Push button UHSR-001 (see PID 048) resets the effects 1, 2, 4, 5 and 6.
•
Locally: Pushbutton XHSR-011 resets the valve XV-011. Page 184 of 237
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DOC NO: 8474L-013-A5016-0000-001-003 REV: A
DATE: 19/10/07
TRAINING MODULE
CONTINUOUS CATALYTIC REFORMER (CCR) UNIT: 13
Course Content: Section 1 - General Description Section 2 - Process Flow Description Section 3 - Process Control Section 4 - Safeguarding Devices Section 5 - Fire & Gas Systems Section 6 - Quality Control Section 7 - Cause & Effects Section 8 - Operating Procedures
X
Section 9 - HSE Section 10 - Reference Document Index
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DOC NO: 8474L-013-A5016-0000-001-003 REV: A
DATE: 19/10/07
SECTION 8 : OPERATING PRACTICES 8.1. Normal Operation 8.1.1. Operating conditions For operating conditions of the CCR during normal operation, refer to the following Process Flow Diagrams: 8474L-013-PFD-0010-001
CCR Platforming Unit – Reactors Section
8474L-013-PFD-0010-002
CCR Platforming Unit – Net Gas Section
8474L-013-PFD-0010-003
CCR Platforming Unit – Debutanizer Section
8474L-013-PFD-0010-004
CCR Platforming Unit – Steam Generation Section
8474L-013-PFD-0010-005
CCR Platforming Unit – Chloride, Condensate and Sulfide Injection Section
8474L-013-PFD-0010-010
CCR Platforming Unit – CCR Regeneration Section
8474L-013-PFD-0010-011
CCR Platforming Unit – CCR Regeneration Section
8474L-013-PFD-0010-012
CCR Platforming Unit – CCR Regeneration Section
8474L-013-PFD-0010-013
CCR Platforming Unit – CCR Regeneration Section
The following is a description of the normal operation line up of CCR in the LEAN FEED CASE only.
8.1.2. CCR Platforming Reaction Section 103,496 kg/hr of hydrotreated heavy naphtha, coming from the Naphtha Splitter (Unit 12), enters the unit at 10.1 kg/cm2g and 118°C. In normal operation, the feed is directly supplied from the Naphtha Splitter (T1202) via the Stripper Feed Naphtha Splitter Bottoms cooler (E-1206) in the unit 012. Sulfide from the storage drum in the NHT unit is injected into this feed by means of the sulfide injection pumps P-1306 A/B and the feed is then routed to the combined feed exchanger E-1301 29,762 kg/hr of recycle hydrogen rich gas at 118°C and 6.7 kg/cm2g from the recycle compressor C-1301 is also supplied to the Combined Feed Exchanger E1301 where it is mixed with the feed stream. In E-1301, 133,255 kg/hr of combined feed (liquid feed + recycle gas) is heated up to 481°C by heat exchange with 133,293 kg/hr of reactor effluent at 3.3 kg/cm2g and 521°C from R-1304 bottom.
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133,255 kg/hr of heated combined feed is then sent to the Charge Heater H-1301 where it is heated up to 549°C and sent to the 1st reactor R-1301 at 5.0 kg/cm2g. The effluent exits the 1st reactor at 441°C and 4.8 kg/cm2g and is sent to the 1st inter-heater H-1302 where it is heated up back to 549°C and sent to the 2nd reactor R-1302 at 4.5 kg/cm2g. The effluent leaves the bottom of the 2nd reactor at 479°C and 4.2 kg/cm2g and are heated up to 549°C in the 2nd inter-heater H-1302 before being sent back to the reactor stack in the 3rd reactor R-1303 at 4.0 kg/cm2g. The effluent leaving the reactor R-1303 at 501°C and 3.8 kg/cm2g are heated up to 549°C in the last inter-heater H-1304 and sent back to the last reactor R-1304 at 3.5 kg/cm2g. 133,435 kg/hr of reactor effluent leaves the last reactor R-1304 at 521°C and 3.3 kg/cm2g and is split into 2 streams: •
142 kg/hr of this stream are used to heat up the recycle gas injected at the bottom of R-1304 in the reactor purge exchanger E-1302, and exits the later at 181°C.
•
133,293 kg/hr of the R-1304 effluent are cooled down to 114°C by exchange with the combined feed stream in the Combined Feed Exchanger E-1301.
These 2 streams are recombined downstream exchanger E-1301 and are sent at 114°C and 2.7 kg/cm2g to the product condenser E-1303 where the reactor effluent cooled down to 46°C. After cooling, reduction gas and booster gas coalescer liquid from the regeneration section are injected into the reactor effluent which is then sent to the Separator D-1301 at 46°C and 2.1 kg/cm2g. In D-1301, 49856 kg/hr of H2 rich vapour is separated from the liquid hydrocarbon and is sent to the recycle compressor C-1301at 46°C and 2.5 kg/cm2g. The hydrogen rich stream is then compressed by the recycle compressor C-1301 up to 6.7 kg/cm2g and 118°C and split into 2 streams: •
29942 kg/hr of the compressed gas stream is recycled back into the reaction section: 29762 kg/hr are sent to the combined feed exchanger E-1301 to mixing with the platformer feed and 180 kg/hr are sent back to the bottom of the reactor R-1304 via E-1302 where it is heated to 316°C against R-1304 effluent before reaching the reaction section.
•
The remaining stream, 19,914 kg/hr of so called Net Gas is cooled doen to 47°Cin the net gas air cooler E-1304 before being sent to the Recovery Plus system X-1301 at 6.4 kg/cm2g.
LP steam from the compressor turbine exhaust is condensed against cooling water in the surface condenser E-1311. Condensate is then pumped by the surface condenser condensate pumps P-1307 A/B to the vacuum condensate system. HP steam is produced in the convection section of the reactor heater using HP Boiler Feed Water (BFW) from Header. Page 187 of 237
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83582 kg/hr of liquid hydrocarbon from the separator drum D-1303 are pumped by the separator pump P-1301 A/B and is split into 2 streams: 66018 kg/hr at 12.3 kg/hr and 46°C are sent to the recovery plus system X-1301 where it is re-contacted with the liquid effluents, while the other part, 17564 kg/hr, is sent to the debutanizer feed/bottoms exchanger before being fed to the debutanizer T-1301. The incoming net gas from the recycle compressor to X-1301 is mixed with 1089 kg/hr of Off Gas from the debutanizer receiver D-1303 and the resulting Net Gas, 1003 kg/hr, flows to the recovery plus package X-1301 at 46°C and 6.4 kg/cm2g. 8023 kg/hr of net gas at 38°C and 5.3 kg/hr from X-1301 is fed to the net gas chloride treaters D-1302 A/B after being mixed with reduction gas from CCR regeneration section. In D-1302 A/B the net gas flows through the absorbers in series and chloride components are removed on the beds of activated Alumina. The Net Gas Chloride Treaters outlet gas is then separated into two streams: •
4603 kg/hr of outlet gas are sent to the 1st stage of the NHT make up compressor suction drum in the unit 012;
•
3449 kg/hr are sent to the fuel gas system.
The liquid Reformate/LPG rich stream exiting the Recovery Plus Package is mixed with the separator liquid sent to the debutanizer feed/bottoms exchanger and the resulting stream, 96532 kg/hr of feed at 30°C and 12.3 kg/cm2g, is preheated to 175 kg/hr against the debutanizer bottoms product in E-1306 A/D before being fed to the debutanizer T-1301 above the tray #21. 21586 kg/hr of overhead at 61°C and 9.8 kg/cm2g from the Debutanizer is partially condensed in the aero-condenser E-1309 (outlet temperature = 50°C) and the trim cooler E-1310 (outlet temperature = 38°C) against cooling water, before reaching the debutanizer receiver D-1303 at 9.3 kgcm2g where vapour and liquid phases are separated. The hydrocarbon liquid from the debutanizer receiver is pumped by the Debutanizer Overhead Pumps P-1302 A/B, and split into two streams : •
1428 kg/hr are returned as reflux to the Debutanizer at 38 °C and 16.3 kg/cm2g,
•
The other stream, 3220 kg/hr of LPG product, is sent to the LPG Chloride Treaters D-1308 A/B where it flows through the absorbers in series to remove chloride components on activated Alumina beds. Treated LPG is then sent to the LPG recovery unit (LRU, 016) at 38°C and 14.0 kg/cm2g.
The vapor phase (C4 and lighter) leaves the receiver and is routed to the recovery plus system.
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The stripping vapors in the lower portion of T-1301 are reheated by the HP steam reboiler E-1307 from 214°C to 230°C. The stabilized material of T-1301, 92224 kg/hr of Reformate, is removed from the bottom of the debutanizer at 214°C and 10.2 kg/cm2g and cooled down to 70°C in the Feed-Bottoms Exchanger E-1306 A/B/C/D. Further cooling is performed in the Debutanizer Bottoms Cooler E-1308 (outlet temperature = 50°C) and Trim Cooler E-1305 A/B (outlet temperature = 38°C) before reformate is being sent to storage at 3.5 kg/cm2g.
8.1.3. CCR Regeneration Section Spent catalyst flows by gravity from the bottom of the last reactor to the Catalyst Collector. Catalyst flows downward into the Spent Catalyst L-Valve Assembly where 210 kg/hr of circulating nitrogen at 96°C and 3.5 kg/hr from the Lift Gas Blower C-1351 engages the catalyst and lifts it through the catalyst lift line to the Disengaging Hopper D-1353. In the Disengaging Hopper D-1353, 53 kg/hr of additional nitrogen at 38°C and 8.5kg/cm2g from the CCR nitrogen header and 2935 kg/hr of circulating nitrogen from the Fines Removal Blower B-1351 separates catalyst chips and fines from the whole catalyst and carries them out to the top of the disengaging hopper with the gas. 3177 kg/hr of a mixture of chips, fines and nitrogen are sent to the dust collector A-1352 were the fines and chips are removed from the gas. The fines settle to the bottom of the Dust Collector. From the bottom of the Dust Collector the catalyst fines and chips are unloaded into a drum via the Fines Collection Pot D-1354. Once filtered, the nitrogen gas flows out to the suction of the fines removal blower B-1351 and the lift gas blower C-1351. The Whole catalyst drops to the bottom of the Disengaging Hopper D-1353, and flows by gravity into the Regeneration Tower T-1351. In the Burn zone, hot regeneration gas, containing a low concentration of oxygen, flows radially from the outside to the inside of the catalyst bed. The hot combustion gas mixes with the gas flowing up from the Chlorination Zone. This oxygen-rich chlorination gas supplies the oxygen for burning coke. 21008 kg/hr of combined gases flow back to the Regeneration Blower B-1352 at 509°C and 2.4 kg/cm2g. The Blower B-1352 recycles the gases through the Burn Zone piping loop to the sides of the Burn zone: •
1555 kg/hr of gases at 517°C and 2.5 kg/cm2g are sent back to the burn zone;
•
3208 kg/hr of gases at 517°C and 2.5 kg/cm2g are sent back to the reheat zone.
21588 kg/hr of the gases are cooled from 517°C to 483°C in the regeneration Cooler E-1355.
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Downstream of E-1355 the gases are not heated in the regeneration electric heater H-1353 and are sent to the Regeneration Tower T-1351 inlet at 477°C and 2.5 kg/cm2g. 580 kg/hr of gases are also sent to the vent gas wash tower. In the chlorination zone, hot air from the Drying Zone below flows upward into the region behind the annular baffle. At this point, 4 kg/hr of vaporized organic chloride pumped by organic chloride injection pumps P-1352 A/B from the chloride injection package X-1307 is introduced to the gas at 177°C and 2.5 kg/cm2g. The resulting chlorination gas then flows through the catalyst bed and exits into the Drying Zone. The drying gas for the drying zone is air from the Cooling Zone below and the instrument air Header. 748 kg/hr of instrument air at 36°C and 7.5 kg/cm2g from the instrument air header are dried in the Air Dryer A-1353 before entering the Regeneration Tower T-1351: 525 kg/hr of dried gas enters the cooling zone, while 223 kg/hr of dried gas are mixed with 461 kg/hr of dry air from the regeneration tower and sent to the air electric heater H-1354 which heats the dried air from 360 to 585°C before sending it at the flowrate of 682 kg/hr to the drying zone. From the Drying Zone the drying air splits into two streams: •
1 entering the Chlorination Zone behind the annular baffle
•
1 exiting the Regeneration Tower: 259 kg/hr of vent gas at 456°C are sent to the wash tower via mixing with the regeneration bower vent gas.
The cooling gas is 525 kg/hr of air from the Air Dryer A-1353. The Gas exits the zone and mixes with instrument air from the Air Dryer then enters the Air Heater before going to the Drying Zone. From the Regeneration Tower T-1351, the catalyst flows by gravity into the Nitrogen Seal Drum D-1357 against 12 kg/hr of nitrogen. From the Nitrogen Seal Drum the catalyst flows into the Lock Hopper D-1358. From the top of the lock hopper, 130 kg/hr of lock hopper gas are sent at 149°C and 2.7 kg/cm2g to the CCR Platforming Section to mixing with the reactor R-1304 effluent upstream the product condenser E-1303. 100 kg/hr of booster gas from the booster gas header are injected into the surge zone of the lock hopper. At the L-Valve assembly, 57 kg/hr of hydrogen-rich gas from engages the catalyst in 2 different points (51 kg/hr at the first point and 6 kg/hr at the second point) and lifts it through the catalyst lift line to the Reduction Zone above the first Platforming reactor R-1301. 580 kg/hr of booster gas are filter in the coalescer A-1351 from where the coalesced liquid is drained to the CCR Platforming reaction section for mixing with the reactor effluent upstream the separator D-1303. 157 kg/hr of filtered booster gas is then heated from 108 to 177°C in E-1352 against MP steam before contacting the regenerated catalyst. 385 kg/hr of filtered booster gas from the coalescer is not heated and sent directly to the reduction gas exchanger. The catalyst flows through the Reduction Zone to the top of the first reactor by gravity. Before being heated in H-1351, 385 kg/hr of reduction gas flows through the reduction gas exchanger E-1351. Page 190 of 237
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202 kg/hr of reduction gas at 377°C is supplied to the upper cyclindrical bed by the electric heater H-1351 and flows co-current with the catalyst. 183 kg/hr of the gas at 396°C from H-1351 is fed to H-1352, where it is heated to 531°C to be supplied to the lower cylindrical bed. This reduction gas flows counter-current to the catalyst flow. Both gases exit from the Reduction Zone via the gas disengaging area, from where 270 kg/hr of reduction gas are sent to CCR Platforming Section for mixing with the reactor effluent upstream the separator D-1303. The catalyst flows through and out each reactor by gravity until reaches the catalyst collector. This completes the transfer circuit. Catalyst flow between the reactors through equally spaced transfer lines designed to ensure even catalyst flow from all sides of each reactor. Wash tower: 32 kg/hr of 20° Be caustic goes from header to caustic break tank D-1359 from where it is pumped by P-1353 A/B to be injected in caustic circulation loop at 1 kg/cm2g. 789 kg/hr of cold Condensate (50°C) from the water break tank D-1360 is added to caustic solution at 2.5 kg/cm2g via water injection pumps P-1354 A/B before entering the wash tower T-1352. The fresh caustic solution and the cold condensate are added to the caustic circulation loop upstream the caustic cooler E-1354 where 41287 kg/hr of caustic solution are cooled from 41 to 39°C. The caustic solution is then divided into 3 streams: •
4129 kg/hr of caustic are injected (at 0.0 kg/cm2g) in the lower part of the wash tower T-1352
•
24772 kg/hr of caustic are injected (at 0.0 kg/cm2g) in the upper part of the T-1352
•
12386 kg/hr of caustic are directly contacted to 839 kg/hr of regeneration tower vent gas at 470°C in the Venturi Scrubber. 13225 kg/hr of the resulting mixture is then injected into the bottom of the vent gas wash tower T-1352 at 45°C.
From the top of the wash tower, 858 kg/hr of washed gas are vented to atmosphere at 41°C. Meanwhile, 41268 kg/hr of caustic are pumped by P-1351 A/B from the bottom of the wash tower to be recirculated. From this stream, 802 kg/hr are continuously extracted and discharged to the OWS after having received an injection of sulfite. The caustic injection is adjusted to maintain the total alkalinity of the circulating caustic at 0.35%, which should correspond to a pH level of between 7.5 and 8.5. The pH is monitored continuously by an on-line pH meter. The total alkalinity (NaOH equivalent) is monitored by lab analysis of a daily circulating caustic sample. Increasing the caustic injection will increase the total alkalinity of the circulating caustic.
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The flow of spent caustic withdrawn is adjusted to maintain the total solids of the circulating caustic at 1%. The total solids level of the circulating caustic is monitored by lab analysis of a daily sample. Increasing the spent caustic withdrawal will decrease the total solids of the circulating caustic as more makeup condensate will be required to maintain liquid level in the wash tower. Total solids include dissolved and suspended solids. There should be essentially no suspended solids present. it is very important to monitor and control the pH and total alkalinity of the circulating caustic. If the caustic is allowed to become acidic, rapid corrosion of the vent gas scrubbing system can result. In the event that proper pH control is not maintained, the Venturi Scrubber is the area where corrosion is most likely to be found. The line downstream of the Venturi Scrubber to the bottom of the Vent Gas Wash Tower can also show corrosion. These areas, and the walls of the VGWT, should be examined during turnarounds. Provision has been made to inject condensate to the spray nozzle below the mesh blanket (in T-1352). This flow is intermittent: The flow rate and time in operation is set by what is required to dissolve any salt build-up on the Mesh Blanket. When the pressure across the mesh blanket reaches a high alarm setpoint differential (013-PDAH-537A), open the globe valve for 15 minutes to spray the deposit with condensate. Stop flow and check the pressure differential. Repeat the washing procedure until the pressure differential returns to its clean mesh value.
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8.1.4. Guidelines for operation of the reactor section The following table describes the design operating conditions of the CCR Platforming Reaction Section:
During normal operation, the unit must be operated so that two main objectives are achieved. These are the production of the various product streams at proper specification and the protection of the Platforming Catalyst. These objectives can only be achieved on a long term basis if good control is exercised on the unit. Such control requires that the unit weight balance (100 + 2 wt. %), accurate analyses be reported on feed and product streams, the feed be properly treated to remove contaminants, and unit operation be smooth at proper catalyst water/chloride balance with a minimum of upsets. 8.1.4.1. Reaction loop pressure Hydrogen partial pressure is the basic variable because of its inherent effect on reactions rates. But for the ease of understanding total reactor pressure can be used. Due to catalyst distribution in the reactors, it is usually close to the last reactor (R-1304) inlet pressure (013-PI-001). All the hydrogen producing reactions are enhanced by low pressure. Page 193 of 237
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Decreasing the reactor pressure will: •
Increase the hydrogen and reformate yield
•
Increase the catalyst coking rate
•
Decrease the temperature requirement to make the product octane
The reactor pressure has no theoretical lower limitations, however there is little flexibility since the unit and the recycle compressor are designed for a given pressure. Lowering the operating pressure below the design pressure results in higher pressure drop and is limited by the recycle compressor design power. 8.1.4.2. Reactors inlet temperatures Catalyst activity is directly related to reactor temperature. Thus the most direct operating variable available for the operator, to control product quality and yields, is the reactors inlet temperature (013-TIC-001, 013TIC-003, 013-TIC-005, 013-TIC-007). As the Platforming is equipped with a Continuous Regeneration section, the coke amount on the catalyst is maintained at a constant low level through the continuous regeneration. Consequently a temperature adjustment is required only: •
To change the reformate octane.
•
To process a different feed quantity.
•
To process a different feed quality.
•
To balance a temporary loss of activity due to a temporary poisoning
•
To balance catalyst ageing which occurs slowly over several years
An increase of temperature (Weighted Average Inlet Temperature) has the following effects, assuming the space velocity (i.e. the feed rate) and feed characteristics stay unchanged, it: •
Increases octane
•
Decreases the yield of C5+ fraction
•
Decreases the H2 purity
•
Increases the coke laydown
At constant temperature, the ageing of the catalyst (caused by the numerous regenerations, the possible metal deposit, the unavoidable upsets) results in a slight but steady loss the activity (i.e. of octane). A slight increase of temperature through the life of the catalyst makes up for this activity loss.
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8.1.4.3. Space velocity The inverse of the liquid hourly space velocity i.e. (LHSV)-1 is linked with the residence time of the feed in the reactor. The space velocity then affects directly the kinetics of the reforming reactions. When changing feed rate, an important recommendation derives from the above: •
Always decrease reactor inlet temperature first and then decrease feed flow rate afterwards.
•
Always increase feed flow rate first and then increase temperature afterwards.
Lowering the space velocity (higher residence time) has then the same effects as increasing the temperature i.e., it : •
Increases octane
•
Decreases the yield (of C5+ fraction)
•
Decreases the H2 purity
•
Increases the coke deposit
If temperature increase is limited (by heater design duty or anything else), lowering space velocity (i.e. decreasing flow rate) can give an additional boost to octane. Operators must keep in mind that each time liquid feed rate is changed a temperature correction must be applied if octane has to be maintained. When feed is increased, temperature must be raised and conversely, when feed is reduced temperature must be lowered. Hydrogen to hydrocarbon ratio Hydrogen to hydrocarbon ratio (H2/HC) is defined as the moles of pure hydrogen in the recycle gas per moles of naphtha charged to the unit. •
Lowering the H2/HC ratio will:
•
Decrease the hydrogen partial pressure
•
Increase coke formation
•
Have little effect on product quality or yields
Regarding the little effect on product quality or yields of H2/HC variations, and the inherent limitations due to the Recycle Compressor characteristics (power, suction flow, …), H2/HC ratio adjustments should not be considered as a major operating variable. However, it is highly recommended to operate with a H2/HC ratio equal (or greater than) the design value (2.9 for design case).
8.1.4.4. Chloride water balance Control of the catalyst chloride-water balance for optimum catalyst selectivity and maximum product octane or maximum aromatics production is one of the most critical areas of Platforming unit operation. Page 195 of 237
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The water and chloride injection amounts may seem to be insignificant by virtue of their size, but are actually very important items in the maintenance of the unit chloride-water balance and hence proper unit operation and catalyst activity. Uncontrolled injection rates of either water or chloride will severely handicap stable operation. The water injection tank D-1301 and gauge glasses should be rigorously calibrated, chloride blends carefully prepared, and injection rates frequently checked (using stroke of pumps P-1304 A/B and/or P-1305). Under normal conditions, the injection rates may vary from week, but, in most cases, will be continuous. The water and organic chloride injection rates will be determined by monitoring the recycle gas water and hydrogen chloride content, the chloride and water content of the naphtha charge, the selectivity of the catalyst (aromatics in the product primarily) and the chloride content on the spent catalyst (as CCR section is installed). The HCI content of the recycle gas should be monitored once a shift with gas tubes, i.e., HCl Draeger tubes. With the proper water injection rate the HCl in the recycle gas should be approximately 2 mole ppm. The moisture content of the recycle gas can be obtained on a continuous basis through use of the moisture analyzer installed on that stream (013AI-003). A general rule of thumb for correlation of water in the recycle gas is that one weight ppm of water in the charge will give approximately three molal ppm water in the recycle gas. The continuous moisture analyzer operation should be frequently cross checked with this rule of thumb to insure its continued proper performance. Any discrepancies on laboratory analyses should be checked. As this unit is equipped with a CCR section, the control of catalyst chloride levels can be as precise as operational diligence and spent catalyst chloride analyses permit. The following approximate values should be used as operating guidelines: •
Normal water injection rate: 4 to 4.5 wt-ppm of naphtha feed (using stroke of P-1304 A/B)
•
Target moisture level in the recycle gas: 15 ot 25 mol-ppm (analyser 013-AI-003)
•
HCl in recycle gas: 2 mol-ppm (by HCl Draeger tube)
In case water content in the recycle gas exceeds 50 mol-ppm, severity must be lowered to protect catalyst against quick deactivation. Such water upset must be corrected: the operation of the NHDT unit Stripper (T-1201) and Splitter (T-1202) or the source of water contamination must be investigated.
For considerations on the feed quality and the process poisons as well as for the complete troubleshooting guidelines, refer to the CCR Platforming Reaction Section licensor operating manual 8474L-013-ML-001-A.
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The following table summarizes the effects of process variables:
8.1.5. Guidelines for the operation of the Debutanizer section Analytical results on the overhead and bottoms products are generally used as basis to adjust the Debutanizer operation, i.e., changes to reboiler duty, and sensitive tray (N°8) temperature (cutpoint between LPG and platformate). The feed temperature to the Debutanizer T-1301 is not directly controlled, as it results from the heat exchange in the Feed-Bottoms Exchanger E-1306 A/B/C/D. In normal operation it is important that the manual by-pass (on the hot side) of this exchanger be fully closed in order to: •
Maximize heat recovery in the exchanger,
•
Prevent from having a high vapor pressure product (platformate) to be sent to storage at a high temperature.
8.1.5.1. Debutanizer Overhead The Debutanizer overhead pressure is controlled by degassing vapor from the overhead Receiver D-1303. The pressure has an effect on both LPG product and stabilized reformate properties. An increase in pressure increases naphtha vapor pressure while maximizing the recovery of LPG. The Debutanizer overhead pressure should be controlled at approximately 9.8 barg in normal operation. The temperature of the rectification section is controlled by net LPG production. Temperature controller 013-TIC-027 adjusts the setpoint of the LPG product flow controller 013-FIC-010 to maintain a constant temperature between trays N°7 and 8. This temperature controls the end Page 197 of 237
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point of the LPG product. An increase in the setpoint of controller 013TIC-027 shall increase the LPG product flowrate and consequently increase both the end point of the LPG and the initial boiling point of the stabilized platformate product. 8.1.5.2. Debutanizer Bottom The reboiler is manually adjusted (by the setpoint of the condensate flow controller 013-FIC-009) to perform the required cutpoints and separation between LPG and stabilized platformate. Increasing this duty will increase the separation between the two products (reducing both C4- content in platformate and C5+ content in LPG).
For more information on the normal operation, especially for specific procedures, refer to the operating manual of the licensor, do. No. 8474L-013-ML-001-A.
8.1.6. Operation Guidelines for CCR Regeneration Section 8.1.6.1. Reheat Zone and Chlorination Zone temperature It is extremely important to closely monitor the burn profile in the Burn Zone of the Regenerator T-1351. The burn profile will change with the operating parameters of the CCR: Spent Catalyst coke, catalyst circulation rate, Regen Gas Flow rate, and burn zone oxygen content. Usually, the peak temperature (and hence the burn front) is at the second to third TI from the top of the Burn Zone. The last two Temperature Indicators (TIs) in the Burn Zone should read approximately the same, indicating no burning. The two TIs in the Reheat Zone should be approximately the same as the Burn Zone Gas outlet temperature. The Chlorination Zone TI should read approximately the same as the Reheat Zone. If the peak of the profile moves down the Burn Zone, this is an indication that the residual coke may no longer be burned off in the Burn Zone where it should be. If this situation is not remedied immediately, coke can slip from the Burn Zone into the Chlorination Zone. Coke that burns in the oxygen-rich (21%) atmosphere of the Chlorination Zone will generate sufficiently high temperatures to damage the catalyst and the internals of the chlorination zone causing an extended Regenerator Shutdown. If coke slips from the Burn Zone, the Reheat Zone temperature will rise sharply as the coke burns in that zone. If coke slips further, the chlorination Zone Temperature will rise sharply as the coke readily burns in that zone. 8.1.6.2. Chlorination Zone Gas Flowrate The gas flow into the chlorination zone is not measured directly but rather calculated from the difference between the total air to the Cooling and Page 198 of 237
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Drying Zones and the excess air vented from the Drying Zone. This flow is displayed as a point in the DCS with a low flow alarm at 25% of the meter maximum. Sufficient gas flow is required through the Chlorination in order to insure that the chloride is properly and evenly dispersed onto the catalyst. In some modes of operation such as low coke operation, this flow will decrease. Caution should be exercised if the Chlorination Zone flow is allowed to drop below 25% of the design value. This could result in poorly-chlorided catalyst. Likewise, an increase in Chlorination Zone flow to a value higher than the design rate indicates a high coke burning operation which may require an increase in oxygen concentration or a decrease in catalyst circulation rate. 8.1.6.3. Lower Air Rates The rate of air flow to the Drying Zone of the Regenerator T-1351 can be adjusted in proportion to catalyst circulation rate. If the CCR is operating, for example, at 80% of design catalyst circulation rate then the Drying Air Rate can be decreased to 80% of design. Continued operation at decreased catalyst circulation rates with 100% of the design drying air rate will result in poor utilization of the chloride injected to the Regenerator. The rate of air to the cooling Zone of the Regenerator must always be sufficient to maintain a catalyst temperature of 150°C in the Nitrogen Seal Drum. There are, however, constraints on the extent to which these air rates can be decreased. These are: (1) The design ratio of air to catalyst must be maintained for proper drying and cooling of catalyst (2) The minimum flow of air through the Electric Air Heater H-1354 must always be satisfied. (3) The minimum flow of air through the Chlorination Zone must always be satisfied These constraints mean that there will be a turndown limit for the lower air rate that should not be exceeded. 8.1.6.4. Lock Hopper Makeup Valve (Learning Valve) Adjustments If the operating conditions of the CCR Platforming unit (feedrate, pressure) change significantly, it may be necessary to adjust the makeup valve ramp curve being used to stabilize the LH Surge Zone/Regen LValve ΔP and stabilize the regenerated catalyst lift. Refer to licensor operating manual doc. No. 8474L-013-ML-002-A for more information.
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For a detailed description of the preventive maintenance actions to carry out on the CCR catalyst regeneration section as well as special procedures, refer to the chapter 6 of the licensor operating manual doc. No. 8474L-013-ML-002-A.
8.1.6.5. Dust Collector reverse Jet Cleaning During normal operations, the operator cleans the filter elements in the Dust Collector A-1352 using the reverse jet pushbutton. An alarm sounds when pressure drop across the Dust Collector is high – about 125 mm H2O – and cleaning is required. The operator may then depress the pushbutton to initiate reverse-jet cleaning. When the operator depresses the pushbutton, a cleaning sequence occurs automatically. The sequence blows nitrogen backwards through all the elements and dislodges the fines. The fines drop to the bottom of the Dust collector A-1352. The fines stay in the bottom head until they are unloaded into the Fines Collection Pot (usually once per week). Reverse jet cleaning should be done as soon as the pressure drop alarm sounds. If the pressure drop across the Dust Collector A-1352 becomes too high, the reverse jet sequence may not be able to clean the filter elements. And if the pressure drop changes very significantly before and after cleaning, then spent catalyst lifting and the fines removal may suffer. After cleaning, the pressure drop across the Dust collector should return to normal.
8.1.6.6. Dust Collector Fines Unloading Periodically (usually once per week), the operator must unload the Dust Collector fines into an empty catalyst drum. Fines are transported from the Dust Collector A-1352 to Fines Collection Pot D-1354. This vessel and its associated piping are required to safely remove the fines from the elevated pressure of collector, which must remain in service at all times. An empty drum should be used each time the Dust Collector is unloaded. The operator must keep in mind that the catalyst fines may be pyrophoric. Care must be taken to minimize their exposure to air during unloading. Thus, for the dust collector emptying, the operator shall line up the hydrogen/hydrocarbon analyzer (normally lined-up to the N2 header) to the fines removal blower B-1351 suction line and ensure the there is neither hydrogen nor hydrocarbon present while the dust collector is unloaded.
8.1.6.7. Normal Catalyst Addition The operator must add fresh catalyst periodically to the Regeneration Section to replenish catalyst removed as fines. Over time, as more and more fines are removed, the catalyst level in the Disengaging Hopper decreases. To keep the normal operating level in the Disengaging Page 200 of 237
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Hopper, the operator adds fresh catalyst into the Disengaging Hopper D1353 via the Spent Catalyst Lift System using the Catalyst Addition Lock Hopper N°1 System. The catalyst Addition Lock Hopper n°1 System consists of a Catalyst Addition Funnel n°1 D-1351 , Catalyst Addition Lock Hopper n°1 D-1352, and four valves. The Catalyst Addition Funnel is open to the atmosphere and can be filled with catalyst from drums. The Catalyst Addition Lock Hopper fills with catalyst and can be pressured up to transfer the catalyst into the Catalyst transfer System. In addition to fresh catalyst, whole catalyst pills screened from the fines collected in the Dust Collector can be added using the Catalyst Addition System. This is possible because the coke content of the whole pills and the spent catalyst will be roughly the same, and any left over fines will be removed in the Disengaging Hopper D-1353. A second function provided by the Catalyst Addition System is reloading of the Regeneration Tower. Whenever the Regeneration Tower T-1351 is unloaded for maintenance, the catalyst can be reloaded by using the addition system in conjunction with the Spent Catalyst Lift System. For a complete description of the catalyst addition operation, refer to the section 3 of the present document and to the chapter 6 of the licensor operating manual Doc. No. 8474L-013-ML-001-A.
8.1.6.8. Filter Cleaning Very fine catalyst dust that is carried out with the vent gas from the Reduction Zone or the Lock Hopper Disengaging Zone is collected in filters. When the differential pressure across a filter approaches 1 psi (14 kPa), the filter is plugged and its elements need to be replaced or cleaned. Since the standard design includes two filters in parallel, the spare filter (with clean elements) can be brought online immediately and the used filter elements can be replaced or cleaned while normal operation continues. The operator must keep in mind several important factors and precautions when cleaning or replacing the elements in a Filter. First, since the filter operates under a pressured, hydrogen rich environment, it must be isolated, depressured and inerted before it is opened. Second, since the catalyst dust may be pyrophoric, care must be taken to minimize their exposure to air during the cleaning and replacement of the elements. For a complete description of the filter changing/cleaning procedure, refer to the licensor operating manual Doc. No. 8474L-013-ML-001-A.
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8.1.6.9. Catalyst Change-out on the fly The catalyst changeout on the fly allow the old CCR catalyst to be changed between 2 scheduled turnarounds without the need to shutdown the Platforming unit. Basically catalyst is withdrawn downstream the regeneration tower and new catalyst is loaded in the nitrogen seal drum D-1357 via the catalyst addition lock hopper No.2 D-1356. A specific procedure shall be followed to change the catalyst. In particular, this procedure involves catalyst circulation rate reduction to prevent a loss of performance in the Platforming unit and switching of the regeneration tower from White Burn mode to Black Burn mode. The logic sequence of the catalyst addition is presented in section 3 of the present document and can be found in details, along with the complete procedure to perform this changeout, in the § 4.5 of the chapter 6 of the licensor operating manual doc. No. 8474L-013-ML-001-A.
For more information on the operating conditions of the CCR regeneration section during normal operation and especially for all troubleshooting guidelines, refer to the § 4.8 of the chapter 6 of the licensor operating manual doc. No. 8474L-013ML-001-A.
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8.2. Start-up Procedure For a detailed description of the start-up procedure, refer to specific procedures into the CCR Operating Manuals: •
CCR Platforming Reaction Section Operating Manual: 8474L-013-ML-001-A
•
CCR Catalyst Regeneration Section Operating Manual: 8474L-013-ML-002-A
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8.2.1. Start-Up Sequence
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Note: There are two procedures used to start up the regeneration section. The Black Catalyst Start Up Procedure MUST be used for the initial start up of the Regeneration Section. For subsequent start ups, the Black Catalyst Start Up Procedure must also be used if there is ANY possibility that carbonized catalyst is present in the Regeneration Tower T-1351 below the Burn Zone. Otherwise, the White Catalyst Start Up Procedure may be used. So the white catalyst start up procedure may be used for subsequent start ups of the Regeneration Section, but only under certain conditions: 1. the Regenerator had previously been operating in white burn mode 2. the regeneration section was shutdown in accordance with the Hot Shutdown or Cold Shutdown procedure 3. no catalyst was transferred from the Regeneration Tower during or after these shutdowns, then coked catalyst in the Regeneration Tower will be present only in the Burn Zone and so the White Catalyst Start Up procedure may be used.
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8.3. Shutdown Procedures For a detailed description of the shutdown procedure, refer to specific procedures into the CCR Operating Manuals: •
CCR Platforming Reaction Section Operating Manual: 8474L-013-ML-001-A
•
CCR Catalyst Regeneration Section Operating Manual: 8474L-013-ML-002-A
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8.3.1. CCR Platforming Reaction Section shutdown
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8.3.2. CCR Regeneration Section Manual Shutdown The manual shutdown procedures may be used for a planned shutdown or for a shutdown necessitated by an event like one of the following: 1. Sudden rise in the temperature of the bed thermocouples in the Burn Zone and the Reheat Zone, at the Burn Zone outlet, or the Drying Zone outlet. 2. Malfunctioning oxygen analyzer 3. Loss of the electric heaters 4. cooling water failure 5. Platforming reactor section Shutdown
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8.4. Emergency Shutdown Emergencies which occur in the Platforming unit must be recognized and acted upon immediately. The operators and supervisory personnel should carefully study in advance, and become thoroughly familiar with, the proper steps to be taken in such situations. Some of the emergency conditions described here will not only result in a unit shutdown, but if the situation is not handled properly, can lead to serious damage to the catalyst and equipment. It is strongly recommended that the emergency procedures and the automatic shutdown systems be understood by all persons involved in the operation. In general, the objective of the emergency procedures is to avoid damage to equipment and catalyst.
8.4.1. CCR Platforming Reaction Section
8.4.1.1. Loss of feed Loss of hydrotreated naphtha feed is detected by the low flow alarm 013FAL-003. In this case the operator shall reduce the heaters H-1301 to 1304 duty to compensate for this loss of feed and avoid overheating the material in the heaters tubes and the tubes themselves.
8.4.1.2. Loss of recycle compressor Total loss of recycle gas flow: In order to protect catalyst from coking, in case of loss of recycle gas flow, detected by low low flow switches 013-FXALL-004 A/B and C (2 of 3 voting system), the following will occur automatically : •
Closure of the shutoff valves on fuel gas to the heaters H-1301 to 1304 (013-XV-603 / 605), and opening of the bleed valve 013-XV604 to flare (the pilots will stay lit),
•
Closure of the naphtha feed to the combined feed naphtha exchanger valve (013-XV-011) and 013-FV-003.
In parallel, the operator should perform the following actions 1 and 2 as quickly as possible to protect equipment and catalyst : In order to cool down the heaters faster, maximize the air combustion rate (fully open burners registers) and fully open stack damper (013-HV-620). 1. Introduce steam into the heater boxes for its cooling effect. 2. Block in the separator off-gas valve 013-PV-004B. Shutdown the Make Up Compressors and block in the manual valves to C-1202 A/B/C suction so that system pressure will be maintained.
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3. Follow the normal shutdown procedure in blocking in the separator D1301 and Debutanizer. Switch the NHT Splitter (T-1202) bottoms to storage. Be sure to stop organic chloride and water injection to the combined feed. 4. Restart the compressor if possible, or find out what is wrong. Remember that with no flow through the furnace, the material in the heater tubes may become excessively hot, and if it is put through the reactors, it could result in deactivation of the catalyst. Thus, when a compressor is started after such a shutdown, immediately check the reactor inlet temperatures. If they are 15°C higher than the normal operating temperature (reactors inlet temperatures before shutdown), stop the recycle flow and continue cooling the heaters with purging steam until the reactor inlet temperatures, with recycle flow, are below 495°C. 5. When the compressor C-1301 is again in service, proceed with a normal startup.
Partial loss of recycle gas flow: In case the recycle gas flow drops to a value higher than the shutdown threshold for switches 013-FXALL-004 A/B and C, continued operation is possible provided that the following actions are done immediately to protect the catalysts : 1. Lower the heater outlet temperature 10-15°C for all reactors. 2. Reduce the reactor charge rate (013-FIC-003) to that permissible with the remaining flow of recycle gas. In particular, hydrogen to hydrocarbon ratio must be checked to be sure it is above the minimum required for operation. Temperature adjustments can be made for continued operation after laboratory or other tests indicate changes are required.
8.4.1.3. Instrument air failure The following events should occur automatically as the pneumatic operated valves go to their safety position (fail close or fail open) : 1. The fuel gas and pilot gas shutoff valves to all fired heaters will fail closed. The common stack damper 013-HV-620 will stay in its current position (with a tendency to open). 2. The CCR should go into a Hot Shutdown. All valves will go to a fail safe position, except for B-type valves. The B-type will fail in their current position and can be manually closed. 3. Charge to the Platformer would stop as valve 013-FV-003 fails in the closed position. Page 214 of 237
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4. The Recycle Compressor C-1301 should continue to operate. 5. The level control valves for all vessels and Debutanizer bottom will fail closed and these levels will begin to rise rapidly. 6. The net gas valves 013-PV-004A (to flare) and 013-PV-004B (to FG) from the Platformer will fail closed to maintain the unit pressure in the Reactor section. 7. The Debutanizer overhead receiver net liquid control valve (013-FV0110) will fail closed and the reflux control valve (013-FV-011) will fail open placing the column on total reflux. The overhead pressure (net overhead vapor) control valve (013-PV-012) will fail closed to maintain column pressure. 8. Other pump minimum flow line control valves will fail open. Action to be taken by Operators: TRY TO RESTORE THE INSTRUMENT AIR SUPPLY AS QUICKLY AS POSSIBLE. 1. Verify that the fired heaters H-1301 to 1304 have shutdown and the fuel gas and pilot gas tight shutoff valves have closed. Block in the fuel gas at the burners/pilots. 2. Block in the feed naphtha block valves of 013-FV-003. Stop the injection of organic chloride and condensate if these were going before the instrument air failure (pumps P-1304 A/B and P-1305). 3. Verify that the Recycle Compressor C-1301 has continued to operate. If C-1301 has also shutdown for some reason, see procedure for loss of Recycle Compressor. 4. Stop the Separator bottoms pump (P-1301 A/B) and block in its discharge valve. Drain liquid to the closed drain if necessary to lower the level in the Separator (D-1301) to a safe level. The liquid levels in other drums can be lowered in the same manner if necessary. 5. Watch other drum levels and use control valve bypasses as necessary to control levels in safe ranges. 6. Conduct the remainder of the shutdown according to the normal shutdown procedures as much as possible.
8.4.1.4. Cooling water failure In the event of a cooling water failure, a complete shutdown of the unit is required. Since most of the heat is removed with aircoolers, the shutdown can be conducted in a controlled and smooth manner, except stop heaters H-1301 to 1304 and charge to the unit immediately. However, the time for the shutdown is limited due to the loss of cooling for the lube oil systems of the compressors, the loss of interstage and spillback cooling
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of the Make Up compressors (unit 012), the loss of cooling in the condensing turbine which drives the Recycle Gas Compressor. The Recycle Compressor C-1301 has to be shutdown (or will automatically trip) when the discharge temperature becomes too high. For a partial cooling water failure it may only be necessary to reduce the naphtha feed rate to the unit to theextend required to maintain reasonable receivers and products temperatures downstream of water cooled exchangers.
8.4.1.5. HP Steam failure The following will happen simultaneously. •
The steam driven compressor C-1301 will stop (refer to § 2.3 for consequences of a loss of recycle gas),
•
The reboiling of the Debutanizer T-1301 will stop.
Stop the Platforming unit according to the normal shutdown procedure.
8.4.1.6. Boiler Feed Water Failure Boiler feed water (BFW) feeds the steam generation in heaters H-1301 to 1304 convection zone. In case of failure of BFW supply from battery limit, the level in the Steam Disengaging Drum will decrease and will imply the stop of the Circulating Water Pumps P-1303 A/B. The loss of the Circulating Water Pumps, detected by low low flow switches 013-FSLL-613 A/B (2 of 2 voting system), will automatically partially stop the heaters H-1301 to 1304 (after a time delay) by : •
Closure of the shutoff valves on fuel gas to the heaters H-1301 to 1304 (013-XV-603 / 605).
•
Opening of the bleed valve 013-UV-604 to flare (the pilots will stay lit).
Stop the Platforming unit according to the normal shutdown procedure.
8.4.1.7. Electrical Power Failure In case of electrical power failure all pumps, air coolers and will trip. A sustained power failure will require a complete shutdown of the unit, using the following guidelines: 1. Block in the feed to the Combined Feed Exchanger E-1301 (by closing 013-FV-003). Reroute the NHT Splitter (T-1202) bottoms to the storage area as necessary. 2. Shutdown all fired heaters and block in the fuel gas supply to each burner.
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3. Keep the Recycle Compressor C-1301 (turbine driven) in operation to cool down the reaction section. 4. The separator D-1301 level (013-LIC-002) will increase if the Separator Pumps P-1301 A/B are shutdown. Lower this level to the closed drain, if necessary. This level should not be allowed to increase high enough to cause liquid to accumulate in the Recycle Compressor suction line. 5. The overhead pressure for the Debutanizer will increase by the effect of loss of the reflux pumps P-1302 /AB (while the reboiler E-1307 is still in service). In this case, the operator shall reduce and cut off the reboiler E-1307 (closure of the HP steam supply to the reboiler). The Debutanizer column will cool down automatically. 6. Proceed with an orderly shutdown of the unit by following the normal shutdown prcedures as much as possible.
8.4.1.8. Loss of refrigerant LOSS OF REFRIGERANT MAY BE A DANGEROUS SITUATION! The system should be shut down immediately, and the reason for the loss located. A leak to the atmosphere is hazardous and appropriate precautions should be made. The Lean Oil and Net Gas should be stopped and bypassed, and the system should be depressurized if the leak cannot be fixed immediately.
8.4.1.9. Fuel Gas Failure In case of fuel gas failure, heaters H-1301 to H-1304 will automatically shutdown due to low low pressure detection at burners and pilots lines. The reactors temperatures and the Debutanizer feed temperature will drop, thus leading to off-spec production. The naphtha feed to the unit has to be stopped and the recycle gas circulation should be maintained. If the fuel gas cannot be restored rapidly, proceed with a normal shutdown.
8.4.1.10. Major Upset The following procedures only apply to those situations which are deemed controllable to the extent that the safety of the refinery personnel is in no way compromised. Not all such emergencies can be handled in the same manner; however, in general TRY TO ELIMINATE THE HYDROCARBON (FUEL) TO THE FIRE OR LEAK by isolating the affected area (and depressuring to the flare) as much as possible. In case of explosion, fire, line rupture or serious leak, do the following (if possible):
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1. Use the Emergency Shutdown switch 013-HS-001A to shutdown the fired heaters H-1301 to 1304. The outside operator should verify that the fuel gas to the heaters tops if he can reach the heater safely. He should also block in the fuel gas to each burner, if possible. 2. Stop the naphtha charge to the Platformer by closing and blocking-in at 013-FV-003. Wherever the fire, leak, or line rupture is located, try to isolate that section of the unit from all other sections. 3. If possible allow the Recycle Compressor C-1301 to operate for a few minutes after the fired heaters H-1301 1304 are shutdown. 4. Shutdown all other fired heaters in the affected area with their emergency shutdown switches. Block in the fuel gas to each burner, if possible. 5. After a few more minutes of operation following the H-1301 to 1304 shutdown, top the Recycle Compressor C-1301. 6. Use the separator off-gas valve 013-PV-004A to depressure the unit to the flare. 7. If the leak or line rupture is in a fired heater, introduce snuffing steam to the heater and try to eliminate the source of the fuel for the fire. Do not close the heater damper (013-HV-620). 8. When the unit has depressured to the flare, purge the unit with nitrogen by introducing it at the discharge of C-1301 if possible. Do not evacuate the unit. 9. Follow other normal shutdown procedures as much as possible.
8.4.2. CCR Regeneration Section The following situations necessitate immediate shutdown of the Regeneration Section as described below. These items supplement the conditions that would require a manual shutdown. In any of the following situations: air addition to the Regeneration Tower must be stooped IMMEDIATELY. When an automatic Hot Shutdown, Cold Shutdown, or Contaminated Nitrogen Shutdown is initiated, the Control System should stop this air addition automatically by closing the Air Valve. In any case, to help ensure that no air addition does occur, close the manual block valve in the air line upstream of the Air Valve 013-XV-534 IMMEDIATELY.
8.4.2.1. Power Failure Upon power, all electrical equipment around the CCR will stop. This includes all motordriven, the net gas compressors, all air blowers and the electric heaters. Depending on the extent of the power failure, a plantwide shutdown is usually necessary. The CRCS will initiate a Hot Shutdown of the CCR due to low Regeneration gas flow.
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Due to the low differential between the Reduction Zone and Reactor #1 caused by the loss of Booster gas, standby recycle gas will be routed to the Reduction Zone. The operator should insure that the Regenerator Run/Stop button is in “Stop” mode such that both isolation systems will close. The CCR should then be shut down in accordance with the Cold Shutdown procedures.
8.4.2.2. Instrument Air Failure Upon instrument air failure, all control valves in the Regeneration Section move to the fail-safe positions. In most cases, the fail-safe position is the closed position. However, the two Regeneration Tower vent control valves (i.e., the Burn Zone vent and the excess air vent) stay in the positions they were in at the time of the instrument air failure in order to maintain Tower pressure control. And the control valves for nitrogen to the Air Heater H-1354 and the recycle gas purge to the Catalyst collector at the bottom of the Platforming Reactor and to the Reduction Zone will open to maintain purge flows. All logic-operated valves in the Regeneration Section will also move to the fail-safe positions upon instrument air failure. For both isolation systems, the two isolation valves in the catalyst line will close and the nitrogen purge vale will open to isolate the Regeneration Tower. These actions will initiate a Hot Shutdown. The Air Valve 013-XV-534 will close and the Nitrogen Valve 013-XV-535 will open to purge the Regeneration Tower with nitrogen. Complete the Shutdown of the Regeneration Section in accordance with the manual Hot Shutdown Procedure. Attempt to maintain the Regenerator pressure at its normal operating pressure.
8.4.2.3. Plant air failure Upon plant air failure, the combustion air flow to the Air Heater will be lost suddenly. This will initiate an automatic Hot Shutdown. Complete the shutdown of the unit in accordance with the manual Hot Shutdown Procedure. 8.4.2.4. Recycle compressor Failure Upon Recycle Compressor failure, recycle gas flow to the Reduction Zone atop the Platforming reactor and to the Catalyst Collector at the bottom of the Platforming reactor will also be lost. These purges keep these areas free of naphtha (to prevent coking) and should be restarted as soon as possible. Restart the Recycle Compressor as soon as possible. If the recycle compressor cannot be restarted, shutdown the Platforming reactor section in accordance with UOP shutdown procedures.
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Complete the shutdown of the Regeneration Section in accordance with the manual Hot Shutdown Procedure. 8.4.2.5. Booster compressor failure Upon Booster compressor failure, booster gas flow to Regenerated Catalyst L-Vale Assembly will be lost suddenly. This will initiate an automatic Hot Shutdown. Also, booster gas flow will be lost to the Reduction Gas Heaters H-1351/1352, causing them to shutdown. Standby recycle gas to the reduction zone should begin automatically. Maintain recycle gas flow to the Reduction Zone atop the Platforming reactors and to the catalyst collector at the bottom of the Platforming reactors. Complete the shutdown of the Regeneration Section in accordance with the manual Hot Shutdown Procedure. Because of the loss of flow, however, the Reduction Gas Heater will not be in operation. If catalyst has slumped to fill the Lock Hopper Surge Zone, restart the Regenerator using the Black Catalyst Startup procedure. 8.4.2.6. Cooling Water Failure Upon cooling water failure, cooling to the Regeneration Blower and to the Circulating Caustic Cooler E-1354 will be lost suddenly. Shut down the Regeneration Section in accordance with the Cold Shutdown Procedure. 8.4.2.7. Explosion, fire, line rupture or serious leak Do the following if possible: 1. Turn the Emergency Stop switch to the Stop position 2. Isolate the affected area of the unit. Block in the high pressure hydrogen system (booster gas) as required to accomplish this. Maintain the booster gas supply as lift gas (if possible) to the Reduction Zone via the Regenerated Catalyst L-Valve Assembly. Maintain recycle gas flow to the Reduction Zone atop the Platforming reactors and to the Catalyst Collector at the bottom of the Platforming reactors. 3. Complete the Shutdown of the Regeneration Section in accordance with the manual Cold Shutdown procedure when time permits.
8.4.2.8. CCR Nitrogen Failure Loss of nitrogen to the Regeneration Section is a serious emergency. The Regeneration Section cannot be safely operated without a constant supply of nitrogen at the design pressure and purity; restart nitrogen to the Regeneration Section as soon as possible. Upon Nitrogen failure, the nitrogen header pressure to the Regeneration section will be lost suddenly. This will initiate an automatic Cold Shutdown. Also, all of the nitrogen purge gas flows to the Regeneration Section will be lost. Page 220 of 237
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Close the manual valve in the air supply line to the Regeneration Section upstream of the Air Valve 013-XV-534. Complete the shutdown of the Regeneration Section in accordance with the manual cold Shutdown procedure. However, there will be no nitrogen purge to the Air Heater to cool the Regeneration Tower T-1351 and the Regeneration Tower will cool more slowly. Maintain operation of the Regeneration Blower B-1352. The Regeneration Tower will gradually depressure through the seals of the Regeneration Blower B-1352. After a loss of nitrogen, ensure that the nitrogen header is purged free of any contaminants before resuming the nitrogen supply to the Regeneration Tower T-1351. NOTE: In the event of loss of nitrogen to the Regeneration Tower T-1351, the operator should insure that all valves in the vent line are open to the atmosphere (if T-1352 is bypassed). This is to prevent the cooling catalyst pulling a vacuum on the tower.
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TRAINING MODULE
CONTINUOUS CATALYTIC REFORMER (CCR) UNIT: 13
Course Content: Section 1 - General Description Section 2 - Process Flow Description Section 3 - Process Control Section 4 - Safeguarding Devices Section 5 - Fire & Gas Systems Section 6 - Quality Control Section 7 - Cause & Effects Section 8 - Operating Procedures Section 9 - HSE
X
Section 10 - Reference Document Index
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SECTION 9 : HSE 9.1. Hazardous Areas Refer to the following documents: 8474L-012-DW-0051-001 Plot Plan - Naphta Hydrotreater Unit 012 - Continuous Catalytic Reformer Unit 013 - Isomerisation Unit 023 8474L-012-DW-1920-001 Hazardous Area Classification Drawing NHT/CCR/ISOM
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North part of the unit 013
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South part of the unit 013
Figure 87: Hazardous Area Classification Diagram Page 224 of 237
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Figure 88: Hazardous Area Classification Legend 9.2. Safety Equipment Refer to 8474L-012-DW-1933-001, Safety Equipment Layout, in section 5 of this document. 9.3. Specific PPE Specific protective equipment, other than the minimum personal protective equipment (safety shoes, hard hat, safety spectacles and coverall), required for the handling of chemicals & catalysts listed in section 1 of this document are detailed in the MSDS of each chemical. Such MSDS must be provided by the vendor and serve as reference. It is of the utmost importance that all employees involved in the CCR unit read and understand the following MSDS before proceeding to work. No work or operation should be allowed to commence before all employees involved have demonstrated knowledge of how to prevent themselves from the chemical hazards they my face in the unit and which PPE are required according to the circumstances. List of MSDS: •
Naphtha
•
Reformate (can be identified as “Reformate Still Bottoms”)
•
LPG, Sweetened Page 225 of 237
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Hydrocarbons C1-4
•
Hydrogen
•
Hydrogen sulfide
•
Benzene
•
Toluene
•
Xylene
•
Platforming Catalyst
•
Chloriding agent
•
Sulfiding agent
•
Caustic
•
Oxygen Scavenger (for BFW)
•
Chloride Treating Material
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9.3.1. Hydrogen Sulfide The best method for prevention of H2S poisoning is to stay out of areas known or suspected to contain it. The sense of smell is not an infallible guide as to the presence of H2S, for although the compound has a distinct and unpleasant odor (rotten eggs), it will frequently paralyze the olfactory nerves to the extent that the victim does not realize that he is breathing it. This is particularly true of higher concentrations of the gas. Fresh air masks or gas masks suitable for use with hydrogen sulfide must be used in all work where exposure is likely to occur. Such masks must be checked frequently to make sure that they are not exhausted. People who must work on or in equipment containing appreciable concentrations of H2S, must wear fresh air masks and should work in pairs so that one may effect a rescue or call for help should the other be overcome. As mentioned above, the atmosphere in which people work should be checked from time to time for appreciable concentrations of H2S. REMEMBER - JUST BECAUSE YOUR NOSE SAYS IT'S NOT THERE, DOESN'T MEAN THAT IT IS NOT.
9.3.2. Minimizing exposure to armomatics Operating and laboratory personnel involved in obtaining samples should wear chemical-type safety goggles or shield, protective apron or laboratory coat, solvent resistant gloves and approved respiratory protective equipment where ambient concentrations exceed allowable limits. This protective equipment is not, however, a substitute for safe working conditions, proper ventilation, good personal practices, and proper maintenance of both operating and safety equipment. In all cases, skin contact (especially eyes) and inhalation must be minimized.
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Sampling liquid hydrocarbons always requires some care to limit personal exposure and release to the atmosphere. Even greater care is needed when the liquid to be sampled contains aromatic hydrocarbons, especially benzene. Unocal/UOP's current design calls for flow-through sampling points which utilize closed sample containers whenever aromatics are present. In order to minimize vaporization, hot hydrocarbon streams must be routed through a cooler before drawing a sample. In all sampling situations, the personnel involved should be instructed to remain at arm's length from the sample container and to situate themselves upwind of the container if at all possible. These simple precautions will greatly minimize exposure to the hydrocarbon vapors. Other specific PPE will be described in this section upon availability of such MSDS. 9.4. Chemical Hazards The material safety datasheet for chemicals mentioned in chemicals/catalyst consumption in Section 1 of this document will be provided by vendor and serves as reference. These datasheets clearly explains what are the risks encountered with each chemical. It is of the utmost importance that all employees involved in this unit read and understand the following MSDS before proceeding to work. No work or operation should be allowed to commence before all employees involved have demonstrated knowledge of the chemical hazards they my face in the unit. List of MSDS: •
Naphtha
•
Reformate (can be identified as “Reformate Still Bottoms”)
•
LPG, Sweetened
•
Hydrocarbons C1-4
•
Hydrogen
•
Hydrogen sulfide
•
Benzene
•
Toluene
•
Xylene
•
Platforming Catalyst
•
Chloriding agent
•
Sulfiding agent
•
Caustic
•
Oxygen Scavenger (for BFW)
•
Chloride Treating Material Page 227 of 237
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9.4.1. Hydrogen Sulfide Poisoning Hydrogen sulfide is both an irritant and an extremely poisonous gas. Breathing even low concentrations of hydrogen sulfide (H2S) gas can cause poisoning. Many natural and refinery gases contain more than 0.10 mol-percent H2S. The current OSHA permissible exposure limits are 20 mol-ppm ceiling concentration and 50 mol-ppm peak concentration for a maximum 10 minute exposure. The Platforming process recycle gas and Debutanizer overhead gas can contain up to 20 mol-ppm H2S. These gases must NEVER be inhaled. One full breath of high concentration hydrogen sulfide gas will cause unconsciousness and could cause death, particularly if the victim falls and remains in the presence of the H2S. The operation of any unit processing gases containing H2S remains safe, provided ordinary precautions are taken and the poisonous nature of H2S is recognized and understood. No work should be undertaken on the unit where there is danger of breathing H2S, and one should never enter or remain in an area containing it without wearing a suitable fresh air mask. 9.4.1.1. Acute Hydrogen Sulfide Poisoning Breathing air or gas containing more than 500 mol-ppm H2S can cause acute poisoning and possibly be fatal. Symptoms of Acute Poisoning The symptoms of acute H2S poisoning are muscular spasms, irregular breathing, lowered pulse, odor to the breath and nausea. Loss of consciousness and suspension of respiration quickly follow. Even after the victim recovers, there is still the risk of edema (excess accumulation of fluid) of the lungs which may cause severe illness or death in 8 to 48 hours. First Aid Treatment of Acute Poisoning Move the victim at once to fresh air. If breathing has not stopped, keep the victim in fresh air and keep him quiet. If possible, put him to bed. Secure a physician and keep the patient quiet and under close observation for about 48 hours for possible edema of the lungs. In cases where the victim has become unconscious and breathing has stopped, artificial respiration must be started at once. If a Pulmotor or other mechanical equipment is available, it may be used by a trained person; if not, artificial respiration by mouth-to-mouth resuscitation must be started as soon as possible. Speed in beginning the artificial respiration is essential. Do not give up. Men have been revived after more than four hours of artificial respiration. If other persons are present send one of them for a physician. Others should rub the patient's arms and legs and apply hot water bottles, blankets or other sources of warmth to keep him warm. After the patient is revived, he should be kept quiet and warm, and remain under observation for 48 hours for the appearance of edema of the lungs. Page 228 of 237
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9.4.1.2. Subacute Hydrogen sulfide Poisoning Breathing air or gas containing H2S anywhere between 10 to 500 molppm for an hour or more may cause subacute or chronic hydrogen sulfide poisoning. Symptoms of Subacute Poisoning The symptoms of subacute H2S poisoning are headache, inflammation of the eyes and throat, dizziness, indigestion, excessive saliva, and weakness. These can be the result of continued exposure to H2S in low concentrations. Edema of the lungs may also occur. First Aid Treatment of Subacute Poisoning Keep the patient in the dark to reduce eyestrain and have a physician treat the inflamed eyes and throat. Watch for possible edema. Where subacute poisoning has been suspected, the atmosphere should be checked repeatedly for the presence of H2S by such methods as testing by odor, with moist lead acetate paper, and by Tutweiler H2S determination to make sure that the condition does not continue. 9.4.2. Benzene Benzene will be present in the Platforming process. Benzene is extremely toxic. 9.4.2.1. Special Instruction: If clothing (including gloves, shoes) becomes contaminated with benzene, the clothing should be removed immediately. Wash any skin areas exposed to benzene with soap and water. Take a complete bath if the body area is wetted with benzene. Do not wear clothing that has been wet with benzene until the garment has been decontaminated by washing or dry cleaning. Wearing clothing that has been wet with benzene almost assures that the person will inhale benzene vapors over a long period of time, resulting in potential health hazards. Avoid draining benzene to the concrete or into the sewers where it can vaporize and create a health hazard. If benzene is accidentally spilled, flush it from the concrete and sewer catch basin with large quantities of cold water. Do not use hot water or steam which aggravates the vaporization of benzene. If you must enter an area of high benzene vapor concentration resulting from a spill, wear appropriate respiratory protection, such as self-contained breathing apparatus or an air mask with external supply. Though not specifically a health hazard, an environmental problem can result from benzene entering the sewer, since benzene is much more soluble in water than any other hydrocarbon. This places an extra load on the effluent treating system.
9.4.3. Toluene, Xyllene & Heavier armomatics These aromatic compounds are also present in the Platforming Process These compounds are moderately toxic and are believed to not have the destructive Page 229 of 237
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effect on the blood-forming organs as does benzene. If clothing (including gloves, shoes, etc.) becomes wet with such aromatics, remove the clothing, bathe and put on fresh clothing. Avoid breathing aromatic vapors.
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DATE: 19/10/07
TRAINING MODULE
CONTINUOUS CATALYTIC REFORMER (CCR) UNIT: 13
Course Content: Section 1 - General Description Section 2 - Process Flow Description Section 3 - Process Control Section 4 - Safeguarding Devices Section 5 - Fire & Gas Systems Section 6 - Quality Control Section 7 - Cause & Effects Section 8 - Operating Procedures Section 9 - HSE Section 10 - Reference Document Index
X
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SECTION 10 : REFERENCE DOCUMENTS INDEX 10.1. Operating Manual/ Licensor Documentation CCR Platforming Reaction Section
8474L-013-ML-001-A
CCR Catalyst Regeneration Section
8474L-013-ML-002-A
10.2. Arrangement Drawings, Layouts and Plot Plans 8474L-012-DW-0051-001 Plot Plan - Naphta Hydrotreater Unit 012 - Continuous Catalytic Reformer Unit 013 - Isomerisation Unit 023 8474L-012-DW-1960-001 Escape Route Drawing - Unit 012 - Continuous Catalytic Reformer Unit 013 - Isomerisation Unit 023 10.3. Process Flow Diagrams 8474L-013-PFD-0010-001
Reactors Section
8474L-013-PFD-0010-002
Net Gas Section
8474L-013-PFD-0010-003
Debutanizer Section
8474L-013-PFD-0010-004
Steam Generation Section
8474L-013-PFD-0010-005
Chloride Condensate And Sulfide Injection Section
8474L-013-PFD-0010-010
CCR Regenerator Section
8474L-013-PFD-0010-011
CCR Regenerator Section
8474L-013-PFD-0010-012
CCR Regenerator Section
8474L-013-PFD-0010-013
CCR Regenerator Section
10.4. Piping and Instrumentation Diagrams 8474L-013-PID-0021-010
Charge Heater
8474L-013-PID-0021-011
N°1 Interheater
8474L-013-PID-0021-012
N° 2 Interheater
8474L-013-PID-0021-013
N°3 Interheater
8474L-013-PID-0021-014
Reactors
8474L-013-PID-0021-015
Combined Feed Exchange
8474L-013-PID-0021-016
Chloride and Condensate Injection
8474L-013-PID-0021-017
Separator
8474L-013-PID-0021-018
Recycle Compressor
8474L-013-PID-0021-019
Recovery Plus System
8474L-013-PID-0021-020
Net Gas Chloride Treaters Page 232 of 237
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8474L-013-PID-0021-021
Debutanizer Feed Bottoms
8474L-013-PID-0021-022
Debutanizer Bottoms Coolers
8474L-013-PID-0021-023
Debutanizer
8474L-013-PID-0021-024
LPG Chloride Treaters
8474L-013-PID-0021-025
Debutanizer Overhead System
8474L-013-PID-0021-026
Debutanizer Receiver
8474L-013-PID-0021-027
Fuel Gas Supply
8474L-013-PID-0021-028
Charge Heater Firing
8474L-013-PID-0021-029
N° 1 Interheater Firing
8474L-013-PID-0021-030
N° 2 Interheater Firing
8474L-013-PID-0021-031
N° 3 Interheater Firing
8474L-013-PID-0021-032
Steam Disengaging Drum
8474L-013-PID-0021-033
Convection Section
8474L-013-PID-0021-034
Surface Condenser
8474L-013-PID-0021-035
Vaccum System
8474L-013-PID-0021-036
Phosphate Dosing Package
8474L-013-PID-0021-037
Sulfide Injection
8474L-013-PID-0021-048
CCR Interlock Details
8474L-013-PID-0021-050
E-1303 Air Cooler Details
8474L-013-PID-0021-051
E-1304 Air Cooler Details
8474L-013-PID-0021-052
E-1308/E-1309 Air Cooler Details
8474L-013-PID-0021-060
CCR Sample Connection Details
8474L-013-PID-0021-070
CCR Level Connection Details
8474L-013-PID-0021-071
CCR Level Connection Details
8474L-013-PID-0021-072
CCR Level Installation Typicals
8474L-013-PID-0021-080
CCR Regeneration Details
8474L-013-PID-0021-100
Regeneration / UOP interface
8474L-013-PID-0021-101
CCR Regeneration Section Tie-In Connection list
8474L-013-PID-0041-075
C-1301 INTERFACE – RECYCLE COMPRESSOR
8474L-013-PID-0041-090
CCR Pump Auxiliaries Details
8474L-012-PID-0031-901
Flare and Fuel Gas
8474L-012-PID-0031-902
Flare And Fuel Gas
8474L-012-PID-0031-904
Flare And Fuel Gas
8474L-012-PID-0031-905
Flare And Fuel Gas
8474L-012-PID-0031-911
Closed Drain Collection
8474L-012-PID-0031-912
Closed Drain Collection Page 233 of 237
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8474L-012-PID-0031-913
Closed Drain Collection
8474L-012-PID-0031-914
Closed Drain Collection
8474L-012-PID-0031-915
Closed Drain Collection
8474L-012-PID-0031-921
HP MP & LP Steam
8474L-012-PID-0031-922
HP MP & LP Steam
8474L-012-PID-0031-923
HP MP & LP Steam
8474L-012-PID-0031-924
HP MP & LP Steam
8474L-012-PID-0031-925
HP MP & LP Steam
8474L-012-PID-0031-931
Cooling Water Service Water and Potable Water
8474L-012-PID-0031-932
Cooling Water Service Water and Potable Water
8474L-012-PID-0031-933
Cooling Water Service Water and Potable Water
8474L-012-PID-0031-934
Cooling Water Service Water and Potable Water
8474L-012-PID-0031-935
Cooling Water Service Water and Potable Water
8474L-012-PID-0031-941
Plant Air Instrument Air & Nitrogen
8474L-012-PID-0031-942
Plant Air Instrument Air & Nitrogen
8474L-012-PID-0031-943
Plant Air Instrument Air & Nitrogen
8474L-012-PID-0031-944
Plant Air Instrument Air & Nitrogen
8474L-012-PID-0031-945
Boiler Feed Water & Condensate Header
8474L-012-PID-0031-946
Boiler Feed Water & Condensate Header
8474L-012-PID-0031-951
Caustic
8474L-012-PID-0031-955
Closed Drain System
8474L-012-PID-0031-961
Utility Distribution - Oily Water System
8474L-012-PID-0031-965
Utility Distribution - Oily Mist System
8474L-012-PID-0031-990
Battery Limit
8474L-013-A0103-4110-002-002 Mechanical Flow Diagram Legend and Instrument identification 8474L-013-A0103-4110-002-003 Mechanical Flow Diagram Unit Specific Instrumentation 8474L-013-A0103-4110-002-004 Mechanical Flow Diagram Unit Specific Details and Notes 8474L-013-A0103-4110-002-005 Mechanical FLow Diagram Miscellaneous Details and Notes 8474L-013-A0103-4110-002-006 Mechanical Flow Diagram Reduction Gas Heaters X1350 8474L-013-A0103-4110-002-007 Mechanical FLow Diagram Reduction Zone (Reactor) X-1350 8474L-013-A0103-4110-002-008 Mechanical Flow Diagram Catalyst Collector X-1350 Page 234 of 237
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8474L-013-A0103-4110-002-009 MECHANICAL FLOW DIAGRAM DISENGAGING HOPPER X-1350 8474L-013-A0103-4110-002-010 MECHANICAL FLOW DIAGRAM FINES AND LIFT BLOWERS X-1350 8474L-013-A0103-4110-002-011 MECHANICAL FLOW DIAGRAM AIR DRIER AND REGENERATION COOLER X-1350 8474L-013-A0103-4110-002-012 MECHANICAL FLOW DIAGRAM REGENERATION HEATER 8474L-013-A0103-4110-002-013 MECHANICAL FLOW DIAGRAM CHLORIDE INJECTION AND AIR HEATER 8474L-013-A0103-4110-002-014 MECHANICAL FLOW DIAGRAM REGENERATION TOWER X-1350 8474L-013-A0103-4110-002-015 MECHANICAL FLOW DIAGRAM NITROGEN SEAL DRUM X-1350 8474L-013-A0103-4110-002-016 MECHANICAL FLOW DIAGRAM LOCK HOPPER X1350 8474L-013-A0103-4110-002-017 MECHANICAL FLOW DIAGRAM BOOSTER GAS X1350 8474L-013-A0103-4110-002-018 MECHANICAL FLOW DIAGRAM CAUSTIC CIRCULATION & INJECTION X-1350 8474L-013-A0103-4110-002-019 MECHANICAL FLOW DIAGRAM VENT GAS WASH TOWER X-1350 8474L-013-A0103-4110-002-020 MECHANICAL FLOW DIAGRAM NITROGEN, RELIEF AND UTILITY HEADERS X-1350 8474L-013-A0103-4110-002-021 MECHANICAL FLOW DIAGRAM MISCELLANEOUS UTILITY HEADERS X-1350 10.5. Equipment list TO BE ADDED LATER 10.6. Main Equipment Data Sheet 8474L-013-PDS-R-1301-001
Reactors R-1301/2/3/4 Datasheet
8474L-013-PDS-T-1301-001
Debutanizer T-1301 Datasheet
8474L-013-PDS-T1352-101
Vent Gas Wash Tower Datasheet
8474L-013-PDS-D-1357-105
Nitrogen Seal Drum D-1357 Datasheet
8474L-013-A1001-0110-001-202
Heater H-1301/2/3/4 Datasheet
8474L-013-A1001-1011-001-014
Recycle Compressor C-1301 Datasheet
8474L-013-A1001-1011-001-015
Steam Turbine CT-1301 Datasheet
8474L-013-A1002-1011-001-018
C-1301 Performances Curve
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10.7. Instrument List Refer to attached extracted instrument list of unit 013: Unit 013 Extracted Instrument List.xls 10.8. Cause & Effect Matrix 8474L-013-DW-1514-201 10.9. Safety Logic diagram 8474L-XX-XXXX-XXX 10.10. Fire & Gas Cause & Effect Chart NOT AVAILABLE 10.11. Fire & Gas Detectors Layout 8474L-012-DW-1950-001 Fire & Gas Detector Layout NHT/CCR/ISOM 10.12. Fire Protection Layout 8474L-012-DW-1933-001 Fire Protection Equipment Layout NHT/CCR/ISOM 8474L-012-DW-1933-002 Safety Equipment Layout NHT/CCR/ISOM 10.13. Hazardous Area Classification 8474L-012-DW-1920-001 Hazardous Area Classification Drawing NHT/CCR/ISOM 10.14. MSDS List of MSDS: •
Naphtha
•
Reformate (can be identified as “Reformate Still Bottoms”)
•
LPG, Sweetened
•
Hydrocarbons C1-4
•
Hydrogen
•
Hydrogen sulfide
•
Benzene
•
Toluene
•
Xylene
•
Platforming Catalyst Page 236 of 237
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•
Chloriding agent
•
Sulfiding agent
•
Caustic
•
Oxygen Scavenger (for BFW)
•
Chloride Treating Material
DOC NO: 8474L-013-A5016-0000-001-003 REV: A
DATE: 19/10/07
10.15. Vendors Documentation 8474L-013-A0102-4110-001-001
PROCESS FLOW DIAGRAM OF RECOVERY PLUS SYSTEM
8474L-013-A0102-4110-001-002
PROCESS FLOW DIAGRAM OF RECOVERY PLUS SYSTEM
8474L-013-A3501-4110-001-001
X-1301 Control System Description
8474L-013-A5016-4110-001-001
X-1301 Operation & Maintenance Manual
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