Naptha Cracking Plant Operation PDF

SECTION RELIANCE INDUSTRIES LIMITED
MODULE NO. CKR-PR-P-001
PROCESS DESCRIPTION AND UTILITIES
CKR-PR-P-011
CHECKED BY N.S.P APPROVED BY B. DAS
Process description and Utilities
PAGE REV ISSUE DATE AUTHOR
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Preface
This operating manual gives general guidelines for the understanding and operation of the Cracker Plant. It provides basic information on the process , utilities, effluent treatment and emergencies. This shall be read with other Standard Operating Procedures to understand precisely the operation and control methodology of the plant. It is recognised that several improvements can be made to this manual for more efficient operation of the plant. Any such changes shall be communicated to the Manager in charge for proper updating and revision.
Aut or
.M.!rishna
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CONTENTS!
1 N"L # NAP$T$A CRACKER PLANT AT RIL% $A&IRA Introduction $eed %tock 'ther Products Chemicals, Additives And Catalysts Products %pecification Process Description Cracking $urnaces +%C main furnace and recycle furnace ,uench fittings -uench 'il Tower .$' %tripper /$' %tripper -uench 1ater Tower 3ilution %team generation system 3istillate stripper -uench 1ater Circulation Circuit -uench 'il Circulation Circuit Pan 'il Circulation Circuit Cracked gas compression ,Acid gas removal, 3ehydration 3emethaniser system P%A +nit 3eethaniser C# Acetylene hydrogenation system 6thylene fractionation 3epropaniser C& MAP3 hydrogenation system %econdary and tertiary deethanisers Propylene fractionation 3ebutaniser C( hydrogenation and Au7. C( hydrogenation 6thylene refrigeration system Propylene 8efrigeration %ystem 9asoline .ydrogenation +nit %pent Caustic '7idation +nit +tilities
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"." ".# ".& ".( ".) #.*" #.*# #.*& #.*( #.*) #.*0 #.*2 #.*4 #.*5 #."* #."" #."# #."& #."( #.") #."0 #."2 #."4 #."5 #.#* #.#" #.## #.#& #.#( #.#) #.#0 #.#2 &
&." &.# &.& &.( &.) &.0 &.2 &.4 &.5 (.* (." (.# (.& ) )." ).# ).& ).( ).) ).0 0 2 2." 2.# 4.*
C1 %ystem %team %ystem Condensate and oiler feed water system $uel gas system :itrogen, plant air, instrument air system %ervice 1ater system 3M 1ater system $ire water system 6lectrical Power systems Plant 6ffluents and disposal Methods /i,uid effluents %olid effluents 9aseous effluents 6mergencies Power failure ;I% / ':/<= %team failure IA failure C1 failure -1 failure -' failure 6,uipment /ist 8elief and blowdown system $lare system at '% / $ire and 9as 3etection %ystem
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MODULE NO. CKR-PR-P-001 RELIANCE INDUSTRIES LIMITED
1(1 INTRODUCTION
The :9/ > :aphtha Cracker plant is designed to product ),**,*** metric tonnes per annum of polymer grade ethylene from cracking :aphtha and :9/. %ubse,uently, the plant was engineered to increase the capacity from ),**,*** MTA to 2,**,*** MTA. It is designed to crack :aphtha, :9/, A9' and C#>C& recycle and fresh streams. .owever, the 2,**,*** MTA capacity of ethylene is produced by cracking of low aromatics naphtha only. Also, the recycle streams like C#,C&,C), C0?C4 raffinate from aromatics plant and hydrogenated mi7 C( are cocracked with :aphtha in the furnaces. The minimum propylene production capacity is &,#*,*** MTA for an optimum cracking severity of &."" !%$A for the designed on stream time of 4*** hours per year. The plant is able to produce .P ethylene vapour at )4kg>cm#g ,/P vapour ethylene at #2 kg>cm#g. and ethylene as li,uid at ?54*C for storage in atmospheric tank. The plant also includes two I$P units C( hydrogenation unit for processing mi7ed C( and 9.+ unit for the treatment of gasoline generated during cracking. $or the production of high purity hydrogen, one P%A unit is installed supplied by +'P, +%A.
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1
1('
)EED STOCKS
The cracker plant is designed on the basis of single light naphtha feed stock as defined below @ %9 3istribution Curve " P "*A )*A 5*A $ P PONA ! Paraffins :aphthalenes Aromatic 'lefins Bol. .ydrogen, 1TA %ulphur PPM wt>wt 8BP kg>cm#a .owever, plant is @ *.2 @ *C @ () @ 04 @ "** @ "&* @ ")* *T 2(A Min. alance "*A Ma7. ".*A ").# 4** ma7. *.5( ma7. capable in using other feed stacks
:9/>A9',C#>C&, recycle hydrogenated C( mi7, C) from 9.+ and C0?C4 raffinates from aromatics.
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DESI"N SPECI)ICATION O) N"L )EEDSTOCK!

Particu+ars %pecific 9ravity A%TM distillation@ I P )*A $ P P':A analysis@ Paraffins :aphthenes Aromatic 'lefins %ulphur 8eid Bapour pressure /ead Chloride Colour Note ! The i?Paraffins may be present up to )*A by wt. of total Paraffins Unit ? C C C vol. A vol. A vol. vol. ppm wt>wt kg>cm#a ppm wt>wt ppm wt>wt %aybolt *.2& () 5) ")* )5 #0 ") nil 4** *.) *.*2) # Design
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DESI"N SPECI)ICATION O) C'#C, )EEDSTOCK! Co-ponents Co+our Methane 6thane Propane utanes A mol A mol A mol A mol Units *.2 2).)( #".50 ".) Design
DESI"N SPECI)ICATION O) C,#C. )EEDSTOCK! Co-ponents 6thane Propane n? utane i? utane Pentane 1(, Ot er Products! Units A mol A mol A mol A mol A mol Design *.54A (5.*#A &(.&"A "(.2"A *.54A
1hile main products form cracker plant are ethylene and propylene, there are a number of lesser products. These are listed below @ /et ane! The plant is able to produce )** kg>hr of methane vapour at #2 kg>cm#g and ambient temperature. It is intended to be used as ballast gas M69 plants $0drogen! The high purity hydrogen produced form P%A unit is intended for captive use for Acetylene, MAP3 , C( mi7 and gasoline
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hydrogenations. The e7cess hydrogen is e7ported to '% / for use in aromatics, PTA C P6 Plants. )ue+ Oi+! The fuel oil component product during li,uid feed stocks are rich in carbon inde7. This can be used as feestock for carbon block manufacture.
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Et ane 1 Propane! The ethane and propane produced form ethylene and propylene fractionation system is cracked in recycle furnaces or along with :aphtha in four main furnaces. 67cess of ethane and propane after vaporisation can be dumped in to fuel gas. Also provision for e7port of ethane >propane mi7 is also provided. .owever, li,uid propane from propylene fractionation system is preferentially e7ported to '% / for storage to act as back up fuel during emergency ;or= during start?up of the plant. C2 /i3(! C) Mi7ture reported from gasoline in depentaniser unit after hydrogenation of diolefins impurities is recycled to furnace for cracking along with :aphtha. C4-C5 Cut ! C0?C4 after treatment in gasoline hydrogenation unit for the improvement of stability, octane no. sulphur is romine number and fed as feedstock for aromatics plant for the
separation of benDene, toluene and 7ylene. )ue+ "as ! $uel 9as which is a mi7 of primarily methane and hydrogen is fed to furnaces for providing heat for cracking. The e7cess of
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the re,uirement is sent to '% / for use in fuel in gas turbines, dowtherm heaters, BCM furnaces etc. $0drogenated C. /i3 ! utadiene rich C( mi7 from li,uid cracking is hydrogenated in main and au7. C( hydrogenation units to remove butadiene to e7tinction is sent to '% / to the sold as industrial /P9 ;or= e7cess of the maker is cracked in main furnaces along with :aphtha. 1(. C e-ica+s% Cata+0sts and additi6es! 1(.(1 C e-ica+s! Many chemicals are used at different parts of the plant for the smooth and efficient of the plant. They are listed as below @ "= Ammonia i= 3eaerator ;B5**= ii= -1 Tower '>. ;C?##*= Caustic ;#*A= i= 3ilution steam stripper ;not used= ii= Condensate polishing unit for regeneration iii= Caustic tower .C/ ;#*A= i= Condensate polishing unit for regeneration ii= %C' effluent neutralisation 3M3% i= +%C main furnaces with :aphtha ii= +%C recycle furnaces with 3ilution steam .ydraDine i= 3eaerator Trisodium Phosphate i= Main C 8ecycle furnace steam drums Methanol
#=
&= (= )= 0= 2=
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4= 5= "*= ""= "#=
"&= "(=
i= As re,uired in cold sections Corrosion inhibitor 3P "4** i= Process water stripper ? C#0* Antifoulant 3'8$ 5(&0# I= 3epropaniser C?)"* 6mulsion reaker 3'8$ 6 (*#( i= C?##* ,uench water tower :eutralising Amine 3P "52 i= C?##* -uench water tower Antio7idant 3'8$ ("* i= 8aw pyrolysis gasoline feed ii= C) product iii= C5 product iv= 8aw C0?C4 cut Corrosion Inhibitor 3'8$ #**# CI i= 9.+ %tripper Antipolymerant ;Trial on= i= Caustic tower Unit C#%$&e' G%( De) '#%to# Se$on'%# 'e) '#%to# C1 A$et -ene ) '#o5en%tion C* MAPD H '#o5en%tion C2 M%in %n' %"6i-i%# ) '#o5en%tion 7IRST (t%5e C2 M%in : A"6i-i%# ) '#o5en%tion II (t%5e
1(.('
1 1 * 2 3
Cata+0sts and Desiccants!

Item No. V *+0 A,B
V 23* A,B R-231 A,B,C R231 A,B R-3*1 A,B,C R-/018 R-/0*
T !e Mo-e$"-%# (ie.e EPG 11/0 %n' A-"min% B%--( Mo-e$"-%# (ie.e EPG 1,/ 4 %n' A-"min% B%--( G 3/ E C%t%- (t( %n' A-"min% B%--( LD 1+* $%t%- (t %n' A-"min% B%--( LD 193 : A-"min% B%--( LD 1+1 : A-"min% B%--(
So"#$e UOP UOP SUD CHEMIE UCIL P#o$%t%- (e P#o$%t%- (e
R-/018 R-/02
P#o$%t%- (e
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1
+ / G%(o-ine ) '#o5en%tion I (t%5e G%(o-ine ) '#o5en%tion II (t%5e
R-+10 A,B R-+20
LD 193 : A-"min% B%--( LD 123 ;o# "!!e# <e' %n' ALUMINA <%--( 1=R *09C %n' %-"min% <%--( ;o# -o>e# <e'
P#o$%t%- (e P#o$%t%- (e
1.5 Prod#ct speci$ications% SPECI)ICATION O) POL7/ER "RADE ET$7LENE PRODUCT!

Co-ponents 6thylene Methane E 6thane C& and .eavier 'ther 'lefins Acetylene Propadiene .ydrogen C' C'# '7ygen :itrogen :' Ammonia Carbon '7ysulphide %ulphur 1ater Methanol Chlorides Acetone Methylacetylene Arsine Carbonyl Units A mol ppm mol>mol ppm mol>mol ppm mol>mol ppm mol>mol ppm mol>mol ppm mol>mol ppm mol>mol ppm mol>mol ppm mol>mol ppm mol>mol ppm mol>mol ppm mol>mol ppm mol>mol ppm wt>wt ppm wt>wt ppm mol>mol ppm mol>mol ppm mol>mol ppm mol>mol ppm wt>wt ppm mol>mol 55.5) )** "* "* ) ) "* *.# ) ) )* ) ) *.*# " " ) # # ) *.*& ) "uaranteed 8a+ues min ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 E3pected (* ma7
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SP&'()('A*(+N +) P+,-M&. /.AD& P.+P-,&N& P.+DU'*%

Co-ponents Propylene 6thane 6thylene Propane C( and .eavier Acetylene utenes utadiene Methyl acetylene plus Propadiene .ydrogen C' C'# '7ygen Ammonia Carbon '7ysulphide 'ther :on condensibles %ulphur 1ater Methanol 9reen 'il Arsine Phosphine Isopropanol Units A mol ppm mol>mol ppm mol>mol ppm mol>mol ppm mol>mol ppm mol>mol ppm mol>mol ppm mol>mol ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm mol>mol mol>mol mol>mol mol>mol mol>mol wt>wt mol>mol mol>mol wt>wt wt>wt mol>mol mol>mol wt>wt wt>wt mol>mol 55.4 &* "* alance # " # # "* #* *.*) ) # ) *.*# &** " # ) *.*& *.*& &) "uaranteed 8a+ues min ma7 ma7 ma7 ;as C(s= ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7 ma7
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SPECI)ICATION O) $7DRO"EN PRODUCT!
Co-ponents .ydrogen C' C'# Ammonia Mercury '7ygen Total %ulphur 1ater C.(s, C#.0s .# Argon Acetylene
Units A mol ppm mol>mol ppm mol>mol ppm mol>mol mg>m& ppm mol>mol ppm wt>wt mg>m& ppm mol>mol
"uaranteed 8a+ues 55.5 min ) ma7 ) ma7 " ma7 " ma7 ) ma7 *.) ma7 ) ma7 alance "* ma7
SPECI)ICATION O) /ET$ANE PRODUCT! Co-ponents Methane 6thylene .ydrogen Carbon Mono7ide Acetylene Units A mol A mol A mol A mol ppm mol>mol "uaranteed 8a+ues 5).* min ".* ma7 &.* ma7 ".* ma7 )* ;"= ma7
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SPECI)ICATION O) C. STREA/S! A( /i3ed C. Strea- 9:e;ore C&s and /igher C5s ", &? utadiene =( 0drogenation<! 67pected Balue *.")A wt ma7 *.(A wt ma7 )#A wt min and )0A wt ma7
$0drogenated C. Streautadiene 3imer ;C4= content@ "* ppm wt ma7 )** ppm ma7
Trimer ;9reen 'il= content@ none SPECI)ICATION $7DRO"ENATED=@ Components 3istillate 8esidue C5s and lighter C0s enDene 3iene value Copper %trip Corrosion 67isting 9um +nits A wt A mol A mol A mol mg>"**ml Balues ".) alance ".#A ma7 *.&A ma7 # ma7 " after ( ma7 O) C2 PRODUCT 9PARTIALL7
heptane wash SP&'()('A*(+N +) 0-D.+/&NA*&D '6/'! 'U*% C5s C5s?#***C C0?C4 Total %ulphur
Co-ponents
A mol A mol
Units
8a+ues alance ".* ma7

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ppm wt
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romine number Thiophene F%G Copper %trip Corrosion 3iene Balve 67isting 9um 3istillate 8esidue '7idation %tability
gr>"** gr ppm wt mg>"** ml after heptane wash A Minutes
*." *.) ma7 IA :il
".) ma7 ;A%TM 3? 0#= 50* min with ) ppm antio7idant
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SPECI)ICATION O) P7ROL7SIS )UEL OIL! PARTICULARS Asphaltene 8amsbottom Carbon Ash %ulfur %odium MCI $lash Pt Pour Pt :'T6% @ ". Typical values are ,uoted #. ased on no sodium being present in the plant feeds. UNITS A wt A wt A wt A wt ppm wt deg C deg C
L)O H*.# H*.) H*.*) H*.*5 H"* "#) 5*?"** H*.*
$)O &*?)* #*?)* H*.*) H*.*5 H"* I"#) I"** I)*.*
P)O ")?#* "*?");"= H*.*) H*.*5 H"*;#= I"#) I"** I").*
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MODULE NO. RELIANCE INDUSTRIES LIMITED CKR-PR-P-001
PROCESS DESCRIPTION
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'(00 PROCESS DESCRIPTION! This section contains a description of the process flow during normal operation with the 8I/ J67pansion CaseK $663%T'C!. The description should be read in conLunction with process flow diagrams *&#**")?2)3?*" to "*. '(01 CRACKIN" )URNACES A total of ") cracking furnaces are provided to achieve the re,uired annual ethylene and propylene production. Twelve of these furnaces, .?""* t* .?"5* and .?"5#, "5( and "50, described as +%C ;ultra selective conversion= furnaces are utilised to crack li,uid naphtha fresh feed and .?""* to .?"5* for :aphtha and A9' both and the li,uid recycle streams generated within the plant or from the aromatics unit i.e. hydrogenated C(s, hydrogenated C)s and C0?C4 raffinate. The remaining three furnaces, .?""", .?"#" and .?"&" described as +%C recycle furnaces are installed to crack gaseous ethane and propane feedstocks which are recovered and recycled from the recovery section. $our of the +%C furnaces .?""*, "#*,"&* and "(*, can be utilised for ethane > propane co?cracking with naphtha while one of the +%C recycle furnaces is being decocked.
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The naphtha feedstock is stored in '% /, tanks and pumped to the battery limit at "*.) kg>cm#g. .ydrogenated C)Gs and C0? C4 raffinate for recycle cracking can also be supplied from '% / storage as C)?C42 ma7 naphtha fresh feed line. The total flow of C)?C4Gs blended into the :aphtha is regulated. The naphtha li,uid blend is preheated by e7change with circulating ,uench water in the :aphtha feed .eater, 6?*(". .ydrogenated C(Gs for recycle cracking can be obtained from storage or directly from the hydrogenation units. A separate hydrogenated C(Gs header is provided and the flow to each fresh feed furnace can be independently controlled. The hydrogenated C(Gs are blended with the :aphtha upstream of the furnace convection section. The combined :aphtha li,uid blend is fed through the +%C furnace convection section and partly vaporised. 3ilution steam is added downstream to the hydrocarbon feed stream to complete vaporisation. A weight ratio hydrocarbon is utilised. The li,uid hydrocarbon feed is divided e,ually into si7 streams before being fed to the +%C furnace convection section. the hydrocarbon fed is preheated by the furnace flue gas in the fifth from bottom bank of the si7?bank convection section. %lightly superheated dilution steam form the 3ilution %team %tripper, C?#2*, overhead and from the au7iliary dilution steam stripper, C?4* overhead is split into si7 streams and fed to the of *.) steam to
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dilution steam superheating coils located in the second from bottom bank of convection section. Three streams from each of the hydrocarbon and dilution steam coils are combined into one and mi7ed in a sparger to complete the vaporisation of hydrocarbon. There are two spargers per furnace. 'ne outlet is taken from each sparger and split into three streams. The si7 streams of hydrocarbon and dilution steam mi7ture are further heated in the fourth and then first bank of the convection section. Three streams of heated hydrocarbon and dilution steam mi7ture at the outlet of the first bank are combined into one mi7ing fitting. There are tow mi7ing fittings per furnace. $our outlets are taken from each mi7ing fitting, and each outlet is split into eight radiant coils. 6ach radiant coil is fitted with a critical flow venturi noDDle. The boiler feed water from the 3eaerator is preheated in the si7th ;top= bank of the +%C $urnace convection section and fed to the steam drums, B?""* to "5*, "5#, "5( and "50. The saturated steam generated in +%M and T/M e7changers is superheated in the third bank of the convection section. The recycle ethane feed to the +%C 8ecycle $urnaces is vaporised by heat e7change against demethaniDer feed, in 6? (0", and heated against propylene refrigerant, in 6?("", while recycle propane feed is vaporised against circulating ,uench water in 6?)(#. The ethane and propane is mi7ed and further
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heated against circulating ,uench water, in 6?*"", before being fed to the +%C recycle furnaces. 3ilution steam is added in a weight ratio of *.& steam>hydrocarbon. The ethane and propane mi7ed feed is split into four streams before being fed to the +%C 8ecycle $urnace Convection section. The mi7ed hydrocarbon feed is preheated by the furnace flue gas in the fourth ;top= bank of the four?bank convection section. %lightly superheated steam from the dilution steam generator is inLected into each hydrocarbon stream at the outlet of the fourth bank. The four mi7ed streams are further heated in the first ;hottest= bank of the convection section. Two streams of the heated hydrocarbon and dilution steam mi7ture are combined at the outlet of the first bank into one mi7ing fitting. There are two mi7ing fittings per recycle furnace. Two outlets are taken from each mi7ing fitting, and each feeds a separate radiant coil. 6ach radiant coil is fitted with a critical flow venturi :oDDle. The boiler feedwater form the deaerator is preheated in the third bank of the +%C 8ecycle $urnace convection section and fed to the steam 3rums, B?""","#" and "&". The saturated steam generated in +%M e7changers is superheated in the second bank of the convection section.
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oth types of furnaces are vertical radiant tube typeN the +%C $urnace employs 0( J+K coils with inlet and outlet at the top of the radiant bo7. The +%C recycle furnace employs four JMK type radiant coils with inlet and outlet also at the top of the radiant bo7. The +%C $urnaces each have &# floor fired burners. The burners are designed for gas firing only. The +%C 8ecycle $urnaces have both wall and floor burners. oth floor and wall burners are gas fired. There are "0 floor fired burners and &# wall burners per furnace. The feedstocks are thermally cracked in the furnaces where dilution steam to feed ratios and furnace effluent temperature are carefully controlled to achieve the desired olefin distribution and yield. The furnace effluents are cooled rapidly by heat e7change against boiler feed water in steam generating +%M e7changers, 6?""* to "5*, "5#,"5( and "50 A?. C O?-, and 6? "")>"#)>"&) A?3, and T/M 67changers, 6?""" to "5", "5&,"5) and "52. 8apid ,uenching of the furnace effluent is necessary to prevent degradation of olefins into undesirable components. The high pressure steam generated in +%M and T/M e7changers is superheated in the convection section before being used, mainly for compressor turbine drivers.
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'(0' USC )res ;eed and Rec0c+e )urnace >uenc )ittings The -uench $ittings, P?""* to "5* and P?"5#, "5( and "50, on the +%C fresh feed furnaces and P?""">"#" on the +%C 8ecycle $urnaces are provided to reduce the temperature of the furnace effluent before entering the ,uench oil tower, C?#"* and .eavy $uel 'il %tripper, C?#&*, respectively. .?"&" effluent enters C? #"* board on material balm to re,uirement . The temperature reduction, or ,uenching, is achieved by contacting individual furnace effluent streams with ,uench oil in specially designed fittings. '(0, >uenc Oi+ To?er The -uench from 'il the Tower, C?#"* of condenses the the fuel oil to
components and recovers higher level heat by cooling furnace effluent discharge ,uench fittings appro7imately "*&*C. It is divided into the following three sections, each of which has a specific operating purpose -uench 'il Circulating %ection Pan 'il Circulating %ection 8ectifying %ection
'(0,(1 >uenc Oi+ Circu+ating 9Scru::ing Section<

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The effluents from the +%C $urnace and +%C 8ecycle $urnace -uench $ittings flow to the -uench 'il Tower. The effluent from all of the +%C -uench $ittings and the new +%C 8ecycle $urnace -uench $itting, P?"&" are routed via the top section of the .eavy $uel 'il %tripper C?#&*. The vapour and li,uid portions of the effluent stream are separated in the bottom of the -uench 'il Tower and .eavy $uel 'il %tripper. The combined vapours rise through the bottom section of the -' tower contains four trays and a distributor. The -uench oil distributor is positioned below the chimneys of the pan oil collection pan. The -uench 'il Circulating Pumps, P?#"* A> >C, discharge through the -uench 'il $ilters, P?#"* A> >C which remove any coke particles, before heat is recovered from the oil. A slip stream of hot ,uench oil is fed to the three +%C recycle furnace -uench fittings to better control the outlet temperature from the three -uench fittings. .eat is recovered from the ,uench oil in the 3ilution %team 9enerator > -uench 'il 8eboilers, 6?#2" A>.. The cooled ,uench oil then flows to the all of the +%C $urnace -uench $ittings and the scrubbing section of the -uench oil tower.
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'(0,(' Pan Oi+ Circu+ation Section The pan oil ;P'= circulating section of the -uench 'il Tower condenses a portion fuel oil together with any vaporised ,uench oil and also cools the cracked gas. The circulating section contains ten trays, the pan oil collector pan, and the pan oil distributor. Bapour, cracked gas, and steam enter the bottom of this section through the chimneys in the pan oil collector pan. The pan oil from the collector pan flows to the Pan 'il Circulating Pump, P? #"" A> from where it is pumped and circulated to obtain heat recovery. A portion of the uncooled pan oil is sent to the distributor spray in the -uench 'il Tower scrubbing section. Another uncooled portion of the pan oil is fed to the light fuel oil stripper, C?#(* on flow control and the balance is cooled in the pan oil user e7changers. The cooled pan oil is reintroduced into the -uench 'il Tower pan oil circulating section via the pan oil distributor. '(0,(, Recti;0ing Section /ight $uel 'il components contained in the vapours entering the rectifying section are condensed in this section to prevent their transfer to the -1 tower and thereby maintain the end point of the raw P<8'/<%I% gasoline. The re,uired fractionation in this particular section is accomplished by using gasoline reflu7 from the base of the -uench 1ater Tower, C?##* on a flow control.
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The light fuel oil components are collected on the draw ? off tray and flow controlled to the light fuel oil stripper, C?#(*. 'verhead vapour from the stripper returns to the rectifying section. The -uench 'il Tower overhead, at appro7imately "*&*C, is sent to the -uench 1ater Tower, C?##*. '(0. $ea60 )ue+ Oi+ Stripper The .eavy $uel 'il %tripper, C?#&* strips the light ends from the heavy $uel 'il and returns to the -uench 'il Tower. The stripping effect is achieved by contacting ,uench oil with the +%C recycle furnaces vapour effluent in the -uench $ittings, P?""" and P?"#", and passing the combined mi7ture into the .eavy $uel 'il %tripper, C?#&*, where separation into vapour and li,uid is achieved. The separation of light and heavy ends in the .eavy $uel 'il %tripper results in a return of light ends into the -uench 'il Tower and build?up of a large middle boiling range ,uench oil inventory as re,uired for circulation and optimum heat recovery. The heavy fraction separated out in the .eavy $uel 'il %tripper bottom contains all the asphaltenes and tar which are formed in the cracking operation. The heavy fuel oil stripper bottoms li,uid is pumped by .eavy $uel 'il Product Pumps, P?#&* A> and delivery to plant battery limits.
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to product blending, cooling
SECTION
'(02 Lig t )ue+ Oi+ Stripper The /ight $uel 'il %tripper, C?#(* regulates the ,uench oil ,uality and optimises the heat recovery in the -uench 'il Tower. The light $uel 'il %tripper is fed from two sources. The main source is the draw off tray in the ,uench oil tower rectification section, the second source is the recycle stream form the pan oil circuit. %tripping of the light components is effected by dilution steam inLection, which enters below the bottom tray. The stripped vapour returns to the rectification section of the -uench 'il Tower. The light fuel oil product passes from the bottoms to the /ight $uel 'il Product Pumps, P?#(* A> , which discharge it to the fuel oil blending, cooling and delivery system. '(04 >uenc *ater To?er The cracked gas from the rectification section of the -uench 'il Tower passes into the -uench 1ater Tower, C?##*. In this tower, the gas is further cooled to (*.0*C, by direct contact with circulating ,uench water. 6ffective contact and cooling of the gas with ,uench water are attained by returning the circulating ,uench water through distributors in the tower middle and top sections. $or this service, two packed beds are provided for contacting the gas and ,uench water.
CHECKED BY N.S.P APPROVED BY B. DAS Process description and Utilities PAGE REV ISSUE DATE AUTHOR 2" 0 0 22/06/2012 BMK
SECTION
The flow and distribution of ,uench water into the middle and top sections is regulated by flow controllers reset by the temperature of middle section overhead and top section overhead, respectively, to attain cooling of the cracked gas and to provide a hot ,uench water supply for process reboiling and heating. In this tower, dilution steam and the gasoline fraction of the cracked gas are condensed. The condensed hydrocarbon and water are separated in the bottom section, which contains a series of chevron?type plate baffles for the settling out of the water and hydrocarbon phases. Part of the separated gasoline is used as reflu7 to the -uench 'il Tower and the balance feeds the distillate %tripper, C?#)*. Most of the hot water from the base of this tower is circulated through various process heaters and reboilers before returning to the ,uench water tower, while the balance is fed to the dilution steam generation system. '(0@ Di+ution Stea- "eneration S0steMost of the dilution steam contained in the furnace effluent is condensed in the -uench 1ater Tower. The reuse of steam condensate collected form both the condensation of dilution steam in the -uench 1ater Tower and in the cracked gas
SECTION
2
compression
system
minimises
the
demineraliDed
water
makeup re,uirements and reduces the load on the waste water effluent treatment system. 1ater is circulated by the -uench 1ater Circulating Pumps, P? ##* A> >C, to the dilution steam generation system. The water is first delivered to the water stripper feed filter, P?#0" A>b, which removes trace solids such s pipe scale and coke that impair the effectiveness of the downstream coalescer. The filtered water enters the water stripper feed coalescer, B? #0# A> , where free hydrocarbon droplets are separated from the water. These hydrocarbons are returned to the -uench 1ater Tower from the top of the coalescer. The water from the coalescer is heated by e7change against dilution steam blowdown in the 3ilution %team %tripper blowdown cooler > stripper feed heater, 6?#)5. The water then passes through the water stripper feed heater, 6?#)4, where it is heated against pan oil. It then enters the water stripper C? #0*, where it is stripped of dissolved hydrocarbons, acid gases, and ammonia. %tripping steam is provided from the 3ilution steam %tripper overhead. The overhead vapours flow to the ,uench water tower. The dilution steam stripper feed pumps, P?#0* A> , deliver the water stripper bottoms to the two dilution steam strippers. The
SECTION
main portion of the process water is routed to the 3%% tower, C? #2*, and en?route is heated by e7change against &.) kg>cm#g level steam in 6?#05. The water then passes through the 3ilution %team %tripper $eed .eater :o.", 6?#04, where it is heated against pan oil. The preheated condensate enters the 3ilution %team %tripper, C?#2*, above the top tray. The 3%% tower, C?#2* bottoms are reboiled against ,uench oil in the 3ilution %team %tripper > -uench 'il 8eboiler, 6?#2" A>., and against "# kg>cm#g level steam in 3ilution %team %tripper > %team 8eboiler, 6?#2* A>3. The remaining portion of the process water stream is routed to the au7iliary 3%% tower, C?#4* and en?route is preheated against steam condenste in the au7iliary dilution steam stripper feed heater, 6?#25. The preheated process water enters the au7iliary 3ilution steam stripper C?#4* above the top tray. C? #4*, bottoms are reboiled against "# kg>cm#g steam in the au7iliary dilution steam stripper reboiler, 6?#4* A>C. Most of the generated dilution steam flows to the cracking furnaces, where it is used for dilution of hydrocarbon feed, decoking of furnace tubes, or operating a furnace on hot standby without hydrocarbon feed. A small portion is used for stripping in the light fuel oil stripper and /P 1ater %tripper. Appro7imately ) percent of the steam produced is returned to the 1ater %tripper for use as stripping steam.
SECTION
/MP steam inLection into the dilution steam header maintains sufficient superheat to avoid condensation in the piping to the furnaces. /MP steam can also be used directly to supplement the dilution steam to the furnaces. The blowdown, the net bottoms against stream from C?#2*, is cooled first in the 3ilution lowdown > 1ater %tripper $eed .eater, then water in the 3ilution %team 9enerator cooling %team 9enerator
lowdown Cooler, 6?#2&, before being discharged to the oily water sewer. The blowdown from C?#4* is cooled against cooling water before being discharged to the oily water sewer. '(05 Disti++ate Stripper The 3istillate %tripper, C?#)*, debutaniDes the gasoline
collected in the bottom section of the -uench 1ater Tower and first three stages of cracked gas compression, before it is fed to the gasoline hydrotreating unit. 9asoline from the -uench 1ater Tower is fed to the stripper by a slip stream from the ,uench oil tower reflu7 pump, P?#"" A> while the feed from the cracked gas second stage suction drum is pumped by distillate stripper feed pump, P?#&* A> . C(Gs and light ends from the 3istillate stripper are returned to the cracked gas compressor via the -uench 1ater Tower.
33 0 0 22/06/2012 BMK
SECTION
The 3istillate %tripper is reboiled by pan oil in the 3istillate %tripper 8eboiler, 6?#)*. The gasoline product from the bottom is pumped via the 3istillate %tripper ottoms Pump, P?#)* A> . Most of the gasoline from this pump goes to the 9.+. A portion is recycled back to the -uench 'il Tower to provide additional reflu7 inventory. The stream is sent to the -uench 'il Tower Pan 'il section ;rather than to the top of the tower= to ensure that any heavy components are fractionated out. '(0A >uenc *ater and Pan Oi+ circuits -uench water is circulated to the following users from the -uench 1ater tower, C?##*, via the ,uench water circulation pumps, P?##* A>C, at a temperature of appro7. 4#*C @ 67changer :o. @ 6?*"" 6?*(" 6?*)" A> 6?#"* 6?#") 6?&(* 6?&)5 6?&0* A> 6?("* 6?(&5 6?((* A>C
3escription 6thane > Propane recycle heater :aphtha feed heater A9' feed heater no." $uel oil cooler -uench water steam heater 1eak caustic heater Condensate stripper feed heater Condensate stripper reboiler 3emethaniDer prestripper reboiler 3emetahniDer prestripper bottoms heater 3eethaniDer 8eboiler
SECTION
2
6?)&* 6?)&) 6?)(* A>3 6?)(# 6?2&"
%econdary deethaniDer reboiler Tertiary deethaniser reboiler Propylene tower au7iliary reboiler Propane recycle vaporiser 1ash oil condenser
Two of the e7changers, 6?2&" and 6?#"*, provide an additional heat input to the ,uench water and a third e7changer, 6?#"), utilises steam to adLust the ,uench water temperature. The remaining users accept the waster heat from the ,uench water system. After interchanging heat with the -1 users, all of the ,uench water is cooled in the primary ,uench water cooler, 6?##* A>g, down to a temperature of )(.(*C. The bulk of this water is fed to the lower packed section of the -1 tower. The remainder is further cooled in the secondary ,uench water cooler, 6?#&* A>., down to a temperature of &2.4*C before being fed to the upper packed section of the -1 tower. Pan oil is circulated to the following users from the ,uench oil tower via pan oil circulation pumps, P?#"" a> @? E3c anger No( Description 6?#04 6?#)4 6?#)*
3ilution %team %tripper $eed .eater :o." 1ater %tripper feed .eater 3istillate %tripper 8eboiler
SECTION
2
6?)"*
3epropaniDer 8eboiler
The final Pan 'il temperature of "#"*C is controlled by diverting pan oil flow to the pan oil trim cooler, 6?#"5, before the pan oil is recirculated back to the middle section of the ,uench oil tower. '(10 Co-pression#Acid "as Re-o6a+#De 0dration The water saturated hydrocarbon overhead form the ,uench water tower is fed to the cracked gas ;C 9= first stage suction drum, B?&"*. The C.9. first stage condensate Pump, P?&"* A> , discharges the li,uid transferred from drum B?&#* and any slugs of li,uid carryover in the cracked gas back to the ,uench water tower. The vapour from this drum flows to the first stage of the cracked gas compressor, ?&**. 1ash oil is inLected into the suction line of each compression stage by the wash oil InLection Pump, P?&** A> . 1ash oil is inLected to keep the impeller blade tip wet, thus preventing polymer accumulation. The first three stages of compression are each followed by an aftercooler and a discharge drum used to separate water > hydrocarbon condensate from vapour. .eat is reLected to cooling water in each aftercooler. The first stage aftercooler, 6?&"*, effluent is combined with gasoline hydrogenation unit vents in the #nd stage suction drum, B?&#* before entering the #nd stage of compression. The condensate
36 0 0 22/06/2012 BMK
SECTION
stripper overhead Loins the second stage aftercooler, 6?&#*, into the &rd stage suction drum, B?&&*. The li,uid form the C.9. Third stage 3ischarge 3rum, B?&&), is successively cascaded to the C9. Third stage suction drum and then to C.9. second stage suction drum, which is designed to separate the hydrocarbon condensate from the water. The hydrocarbon condensate from the C9 second stage suction drum is sent to the 3istillate stripper, while the water is routed to the C9 "st stage suction drum. The oily water is pumped via P?&"* A> to the ,uench 1ater Tower, C?##*. To prevent C.9. compressor surging, two minimum flow bypasses are provided. The first bypass protects the first three stages of compression, and the second bypass protects the fourth stage. The first minimum flow bypass is provided form the third stage discharge drum to the first stage suction drum. The recycle automatically protects the compressor by keeping the flow above surge point during reduced capacity operation. The third stage discharge gas is passed through a caustic wash followed by a water wash in the caustic tower, C?&(*. The acid free tower effluent is combined with the vents from the ethylene rectifier and secondary demethaniser reflu7 drums and fed to the C 9 $ourth %tage 3rum, B?&(*. The drum
SECTION
overhead feeds the $ourth Compression %tage. The discharge effluent is cooled in the C 9 $ourth %tage Aftercooler, 6?&(), by cooling water and passed to the Cracked 9as 8ectifier, C?&)*, which fractionates the heavy ends and reduces the gas flow to the demethaniser system. 8eflu7 for the rectifier is provided by hydrocarbon condensed in the C 9 8ectifier 'verhead Condenser, 6?&)), using propylene refrigerant. The C 9 8ectifier 8eflu7 3rum, B?&(0, is designed to separate the hydrocarbon condensate from water. The water from the C 9 $ourth %tage %uction 3rum and C 9 8ectifier 8eflu7 3rum is sent to the Third %tage %uction 3rum. ottoms from the C 9 8ectifier are discharged to the $ourth %tage %uction 3rum. The $ourth %tage %uction 3rum condensate is routed to the Condensate %tripper $eed Coalescer, B?&)5, for the removal of free water. The water is collected in a boot and sent to the Third %tage %uction 3rum. The hydrocarbon stream is heated against ,uench water in the Condensate %tripper $eed .eater, 6?&)5, to prevent hydrate formation and then fed to the Condensate %tripper, C?&0*. In the %tripper, c#s and lighter are recovered overhead and sent to the C. 9 . Third %tage %uction 3rum. The Condensate %tripper ottoms Pump, P?&0* A> , delivers the remaining hydrocarbons to the 3epropaniDer, C?)"*. %tripping vapour is produced by ,uench water in the Condensate %tripper 8eboiler, 6?&0* A> .
3! 0 0 22/06/2012 BMK
SECTION
The second minimum flow bypass line, taken from the C.9. 8ectifier overhead, is recycled to the C.9. $ourth %tage %uction 3rum. A small stream taken from upstream of the C.9. $ourth %tage Aftercooler is used to heat this gas to avoid hydrate formation across the kick?back minimum flow control valve. In addition, a bypass stream to the third stage discharge is provided to ensure ade,uate vapour loading on the 8ipple trays of the Caustic Tower during reduced capacity operation. '(10(1 Acid "as Re-o6a+
The caustic wash operation is installed to remove hydrogen sulphide and carbon dio7ide from the cracked gas in order to meet product ,uality re,uirements on the ethylene and propylene products. Also, the removal of these acid gases protects downstream catalytic operations, since some acid gas components are known to be catalyst poisons. Acid gases are also removed to avoid corrosion and the possible formation of C'# ice within the cold process systems. These acid gases, which are produced in the cracking furnaces, are removed by scrubbing the gas from the C. 9. third %tage 3ischarge 3rum with circulating caustic solutions in the Caustic Tower, C?&(*. The tower is divided into four sections. The three bottom sections provide for caustic scrubbing of the cracked gas. The bottom section uses weak caustic, the middle uses medium caustic, and the top circulates strong caustic. The
SECTION
fourth section, at the top of the tower, is the water wash section, which prevents caustic carryover into the cracked gas $ourth %tage %uction 3rum. The acidic cracked gas enters the caustic tower below the bottom section where it is contacted with weak caustic solution. The weak caustic is circulated by the weak caustic circulating pump, P?&(# A> , then heated against ,uench water in the weak caustic .eater, 6?&(*, prior to making contact with the acidic cracked gas. This ensures that the cracked gas does not fall below its dew point, which would cause hydrocarbon condensation. The cracked gas flows upward, contacting the medium caustic, and then the strong caustic solution. These streams are recirculated A> , and respectively. %pent caustic solution is contained in the caustic tower bottoms section, where by any hydrocarbon condensate > polymer oils are separated out via an overflow weir into a separate hold?up compartment. The spent caustic is mi7ed with aromatic gasoline from the discharge line of the 8ecirculating 9asoline Pump, Q&(2 A> , via the spent caustic >aromatic gasoline mi7er, P?&(& and is then fed to the spent caustic deoiling drum, B?&(#. by the Medium Caustic Circulating Pump, P?&(& strong caustic circulating Pump, P?&(( A> ,
40 0 0 22/06/2012 BMK
SECTION
%eparation of entrained oil from the spent caustic, and some hydrocarbon degassing, is achieved in the deoiling drum. The recovered li,uid hydrocarbons are discharged on level control to ,uench water tower. The drum pressure floats on the C9 #nd stage suction 3rum pressure. The deoiled spent caustic is then discharged to the spent caustic 3egassing 3rum, B?&(&, which operates at neat?atmospheric pressure. The residual hydrocarbon gas is flashed to the flare system, and the spent caustic is finally pumped to the steam stripper, C?""*" via the steam stripper feed preheater 6?""*". In the steam stripper benDene and other entrained aromatics are stripped with live /P steam which is inLected below the bottom tray. The overhead vapour from the tower is recycled back to the -1 tower, via the water !.'. 3rum, B?""*#, which collects any slugs of water that may be carried over. The aromatics free spent caustic bottoms stream is pumped by the steam stripper bottoms pump, P?""*( A> o7idation unit for further treatment. In the event that the steam stripper is out of commission the raw spent caustic li,uor can be sent to the spent caustic holding tank, T?""*" A> , and subse,uently recycled to the steam stripper utilising the spent caustic feed recycle pump, P?""*" A> . to the spent caustic
41 0 0 22/06/2012 BMK
SECTION
$resh caustic is delivered from offsite as a #* wt. percent solution to the concentrated caustic tank, T?&(*. Makeup caustic is drawn from the tank by the concentrated caustic pump, P?&(" A> , and charged to the caustic tower via the caustic diluent mi7er, P?&(", where it is mi7ed with spent wash water to produce a "* percent caustic solution. The wash water is supplied from the caustic tower wash water loop. The consumption of caustic depends on the ,uantity of C'# and .#% in the feed to the tower and on the residual concentration of :a'. in the spent caustic solution. The Caustic Pump, P?&(" A> , supplies the re,uired makeup caustic to the Caustic Tower and is used for p. control in the dilution steam generation system. The make?up caustic to the caustic tower is combined with the return circulating strong caustic, whereby the strong caustic circulating pump provides mi7ing of the two streams. 67cess strong caustic overflows from the caustic strong section to the medium section via an e7ternal downflow pipe on the strong caustic chimney tray. In turn, the e7cess medium caustic solution overflows to the weak caustic section via an internal dowflow pipe on the medium caustic chimney tray. Means for aromatic gasoline ;C0?C4 cut= inLection is provided into the top of each of the caustic scrubbing sections. InLection of gasoline into the suction of the strong caustic circulating
SECTION
pump is on a continuous basis. The aromatic gasoline acts as a solvent for any polymers being accumulated on the trays and passes down with the spent caustic to the 3eoiling 3rum, B?&(# where it is separated and discharged to the -uench 1ater tower. The neutralised cracked gas passes to the wash water section where it is cooled by reLecting heat to the circulating wash water stream. 3eaerated boiler feedwater is used as a makeup supply to the wash water section. The wash water is circulated by the wash water circulating pump, P?&() A> , which directs the water through the wash water cooler, 6?&(", where it is cooled against cooling water. The cooled wash water flows to the top tray of the Caustic Tower. In the event of a cracked gas compressor shutdown, li,uid in each section of the tower will fall from the 8ipple trays towards the bottom of each section. $or the top section, the e7cess wash water will accumulate in the wash water chimney tray. The strong caustic chimney tray is capable of holding the maLority of the dumping li,uid from the strong caustic section, following the provision of a control valve provided on the e7ternal downflow pipe to the medium caustic section which is to close when the cracked gas compressor trips. The bottoms compartment below the C 9 $eed noDDle provides e7cess li,uid holding capacity for the e7cess strong caustic solution, and all of the li,uid from the medium and weak caustic sections.
SECTION
'(10(' C " De 0dration The cracked effluent from the overhead of the C 9 8ectifier 8eflu7 3rum is fed to one of two cracked gas dehydrators, B? &2* A> . These fi7ed?bed dehydrators are each composed of a main bed and a guard bed. oth beds are filled with molecular sieve. 1hile one dehydrator is operating the second is either being reactivated or is in a standby position. The desiccant in the main bed is designed for a #( hour operating cycle at the end of bed life. The desiccant in the guard section provides additional protection time before water breakthrough. At the end of each cycle, the standby dehydrator is put into service and the operating dehydrator is switched over to reactivation. 8eactivation of the desiccant is accomplished with reactivation gas ;a methane>hydrogen mi7ture= by upward flow through the beds. $resh reactivation gas is supplied from the 3emethaniDer %ystem. It is first heated against reactivation gas effluent in the 8eactivation 9as $eed > 6ffluent 67changer, 6?&2", and is then further heated by .P steam in the 8eactivation 9as .eater, 6? &2#. The hot gas passes upward through the dehydrator, heating the bed and desorbing the water from the molecular
SECTION
sieve. The effluent passes to the 8eactivation 9as $eed>6ffluent 67changer where heat is released to cooling water. The cooled effluent enters the 8eactivation 9as %eparator, B?&2", where water and hydrocarbon li,uids, removed from the desiccant, are separated from the reactivation gas. The gas is then returned to the fuel gas system, and the oily water gas is then returned to the fuel gas system and the oily water is discharged to the -uench 1ater Tower. The hot reactivated is discharged to the -uench 1ater Tower. The hot reactivated desiccant is then cooled to the normal temperature with cold residue gas which is cooled and chilled in the 8eactivation 9as $eed Cooler, 6?&2&, and in the 8eactivation 9as $eed Chiller, 6?&2(, respectively. '(11 De-et aniBer S0steThe 3emethaniDer system consists of two parallel feed chilling trains and three stages of fractionation @ the 3emethaniDer Prestripper, C?("*, the 3emethaniDer, C?(#*, and the 8esidue 9as 8ectifier, C?(&*. There are two parallel sets of precoolers. 6ach set consists of three heat e7changers, through which the total cracked gas feed from the dehydrators is cooled and partially condensed prior to the first li,uid fraction being separated in the 3emethaniDer Prestripper $eed 3rum, B?("*, and the 3emethaniDer Prestripper Parallel $eed 3rum, B?("(. The first parallel set of precoolers are the 3emethaniDer Precooler :o.",
SECTION
6?(*", and 3emethaniDer Parallel Precooler :o.", 6?(*2, which use?0.2 C propylene refrigerant as coolant. $urther cooling of the cracked gas occurs in the 3emethaniDer ottoms 8eheater, 6?(&4, and its parallel reheater, 6?(*4, which utilise the 3emethaniDer net bottoms stream as coolant. In 3emethaniDer Precooler :o.#, 6?(*#, and its parallel precooler, 6?(*5, the cracked gas mi7ture is cooled by ?#&.& C propylene refrigerant. The li,uid condensed at this point contains some methane and C#s and the maLor portion of the C& and heavier componentsN it is separated from the vapour in the 3emethaniDer Prestripper feed drum, B?("*, and its parallel drum, B?("(. The li,uid streams from these drums are combined and fed to the demethaniDer Prestripper, C?("*, as the bottom feed for removal of methane. The vapour from the 3emethaniDer Prestripper $eed 3rum, B? ("* is cooled and partially condensed in the 6thane 8ecycle Baporiser, 6?(0", where recycle ethane from the 6thylene %tripper bottoms is vaporised. The partially condensed stream is further cooled by using ?(*C propylene refrigerant in the 3emethaniDer precooler :o.&, 6?(*&. This partially condensed stream is fed to the 3emethaniDer feed drum no. ", B?("", for separation of the vapour > li,uid streams. The vapour from the 3emethaniDer Prestripper Parallel feed drum is also cooled by using?(*C propylene refrigerant in the 3emethaniDer Parallel Precooler no.& This partially condensed stream is fed to the
SECTION
demethaniDer parallel feed drum no.", B?(") for separation of the vapour > li,uid streams. The li,uid streams from B?("" and B?(") contain methane and C#s, along with much of the remaining C& and heavier components. They are combined and fed to the 3emethaniDer Prestripper as the top feed. The vapour phase from B?("" is divided into two parallel streams, after which it is cooled further and partially condensed. The larger portion of this vapour stream is cooled by using the ?)"."C and ?2&.& C levels of ethylene refrigerant in the reminder is cooled by heat e7change with residue gas in demethaniDer core e7changer no.#, 6?("#. oth partially condensed streams are recombined and fed to the demethaniDer feed drum no.#, B?("#, where vapour and li,uid streams Are separated. The vapour phase from B?(") is also cooled using two levels of ethylene refrigerant ;?)"." C and ?2&.& C= in the 3emethaniDer parallel precooler no.(, 6?(##. The partially condensed stream is then fed to demethaniDer parallel feed drum no.#, B?("0, where vapour and li,uid streams are separated. The li,uid streams from B?("# and B?("0 are combined and fed to the 3emethaniser, C?(#*. The vapour streams from these drums ;mainly hydrogen, methane, and ethylene= are further cooled and partially condensed in an e7changer arrangement identical to that of the previous stage, e7cept for the use of ?"**.0 C ethylene refrigerant in the 3emethaniDer Precooler
SECTION
:o.0, 6?(*0, and 3emethaniDer Parallel Precooler :o.0, 6?(#(, respectively. The split stream from B?("# is cooled by heat e7change with residue gas in 3emethaniDer Core 67changer :o.&, 6?("&. A vapour > li,uid separation is repeated in the 3emethaniDer $eed 3rum :o.&, B?("&, and 3emethaniDer Parallel $eed 3rum :o.&, B?("2. The li,uid streams, consisting of ethylene , ethane, and methane, are combined and fed to the 3emethaniDer, C?(#*. The vapour streams are combined and cooled further and partially condensed in the 3emethaniDer core e7changer :o.(, 6?("(, prior to being fed into the 8esidue 9as 8ectifier, C?(&*, where the ethylene loss to fuel is minimised. The li,uid streams from the 3emethaniDer Prestripper $eed 3rum and 3emethaniDer Prestripper Parallel $eed 3rum, are combined and fed to the 3emethaniDer Prestripper, C?("*. A second feed to the Prestripper tower comes form the 3emethaniDer feed drum no." and the demethaniDer parallel feed rum no." The prestripper is reboiled with ,uench water in the demethaniDer prestripper reboiler, 6?("*. The stripper bottoms product is essentially methane free with roughly one third of the C# components and goes directly to the deethaniDer, C?((*, bypassing the demethaniDer, C?(#*. The prestripper overhead vapour is fed to the demethaniDer. The purpose of the demethaniDer is to make a sharp separation between methane and ethylene. 6ach feed enters the tower at
SECTION
different tray locations to gain the ma7imum benefit from the pre?fractionation produced by the fractional condensation. The heat input for the 3emethaniDer 8eboiler, 6?(#*, is supplied by condensing 2.# C propylene refrigerant vapour. The demethaniDer condenser, 6?(#), is cooled by evaporating ethylene refrigerant at ?"**.0C. The overhead product vapour stream is heated as it passes through the 3emethaniDer core e7changer no.& and is then directed to the Methane 67pander, ?(#". The 8esidue 9as 8ectifier recovers the ethylene contained in 3emethaniDer $eed 3rum :o.&, and 3emethaniDer Parallel $eed 3rum :o.&. The li,uid from the bottom of the 8esidue 9as 8ectifier is returned to the top of the 3emethaniDer, C?(#*. The 8esidue gas overhead is partially condensed in the 3emethaniDer core e7changer no.), 6?("), by gas which has been chilled by e7pansion in the cryogenic e7pansion turbine. The residue gas from the 8esidue gas rectifier reflu7 drum, B? (&0, is cooled an partially condensed through the .ydrogen core e7changer, 6?("5. The partially condensed stream is fed to the hydrogen drum B?(&", where 5) percent hydrogen vapour is separated from the li,uid. The ma7imum amount of 5) percent hydrogen vapour is sent to the pressure swing Adsorption +nit, P?(**, for the production of e7tra high purity hydrogen. The hydrogen vapour is heated through the demethaniDer core e7changer no." through ( and through the hydrogen core e7changer.
SECTION
The remainder of the .ydrogen 3rum vapour and the .ydrogen 3rum ottoms ;fuel gas= are flashed down to ".() kg>cm#g and are reheated in the following multi?pass e7changers. .ydrogen core e7changer, 6?("5, 3emethaniDer core e7changers :os. " through ). The fuel gas and the purge gas from the P%A unit are then directed to the $uel 9as Compressor, temperature of about &#*C. The 3emethaniDer net overhead vapour stream is heated through 3emethaniDer core e7changer no.& and is then sent to the Methane 67pander, ?(#". The e7pander outlet temperature is such that the re,uired amount of cooling is supplied to the overhead rectifier condenser. The e7pander effluent, which is at low pressure, is reheated in demethaniDer core e7changers nos. " through ). The heated gas regn. goes to the Methane 8ecompressor, ?(#*. The compressor is driven by the e7pander, usually, an integral construction. The gas leaves the compressor at a pressure of ).0 kg>cm#g, sufficient for regeneration re,uirements. The 3emethaniDer bottoms product goes to the 3eethaniDer after being heated by e7changer with cracked gas from precooler no." The Methane produce stream is obtained by removing a portion of the li,uid from the 3emethaniDer, 8eflu7 3rum, B?(#0, and
?5**, at a
SECTION
vaporising in an air vaporiser, 6?(#2, to about ) C. The vapour is then allowed to warm?up to ambient temperature by heat gain from the atmosphere in the pipeline before transfer to '% /I
'(1' PSA Unit The P%A unit, P?(**, provided piping by +'P, consists adsorber of a
prefabricated
valve
and
skid,
vessels,
molecular sieve type adsorbent control panel, instrumentation, and a tail gas surge tank. The unit is designed to permit outdoor unattended operation. It employs a pressure swing adosrpiton ;P%A= process to purify the 5) mol percent hydrogen stream supplied from the 3emethaniDer system. The P%A process uses a series of adsorbent beds to provide a continuous and constant hydrogen product flow. The adsorbers operate on an alternating cycle of adsorption and regeneration. 'ne adsorber is always in operation while the remaining are in various stages of regeneration. The unit produces a high purity hydrogen stream which fulfils the e7port product stream re,uirement, as well as the C#, C&, C( and 9asoline hydrogenation unit needs. The hydrogen stream has a
minimum composition of 55.5 mol percent

SECTION
hydrogen. The balance of the feed gas is purged to the fuel gas system. Constant hydrogen recovery can be maintained at flow rates as low as one?third of the design feed flow rate.
'(1, Deet aniBer The dual feed deethaniDer , C?((* separates the 3emethaniDer and 3emethaniDer Prestripper bottoms streams into a C# stream and a C& and heavier stream. The demethaniDer net bottoms is heated in the 3emethaniDer bottoms reheater, 6? (&4, and its parallel reheater, 6?(*4, before entering the tower as the top feed. The 3emethaniDer Prestripper 8eheater, 6?(&5 A> , and is the lower feed to the tower. The 3eethaniDer gross overhead, consisting primarily of C#Gs, is partially condensed in the 3eethaniDer condenser, 6?((), using ?#&.&*C propylene refrigerant. The vapour?li,uid mi7ture is separated in the 3eethaniDer reflu7 drum, B?((0. The li,uid is returned to the tower as reflu7 by the deethaniDer reflu7 pump, P?(() A> , and the net overhead vapour is directed to the c# acetylene hydrogenation system. The reboil heat to the tower is supplied by the deethaniDer reboiler, 6?((* A> , using ,uench water. The deethaniDer net ottoms
52 0 0 22/06/2012 BMK
SECTION
bottoms stream, which is composed of C&Gs and heavier components, is fed to the 3epropaniDer.
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SECTION
'(1. C' Acet0+ene $0drogenation S0steAcetylene ;C#.#= is produced in the cracking operation and as an impurity must be removed from the deethaniDer overhead stream by catalytic hydrogenation ;Palladium based catalyst=, so that the ethylene product contains less than # ppm of subse,uently separated in the ethylene acetylene. AcetyleneRs are hydrogenated into ethylene and ethane, which are fractionation system. The acetylene is removed in a three step hydrogenation process. Three identical adiabatic reactors are employed working in series. The first step is performed by the primary C# hydrogenation reactor, 8?()# A> which has its own spare. The second and third steps are performed by the C# hydrogenation reactors, 8?()" A> >C, which share a common spare. The deethaniDer net overhead vapour leaving the deethaniDer reflu7 drum, B?((0, is fed to the hydrogenation system on flow control. .ydrogen from the P%A unit is inLected, on ratio flow control, before it enters the C# hydrogenation feed > effluent e7changer, 6?()# A>3, and is steam heated by C# hydrogenation feed heater, 6?()*, where the inlet temperature to the $I8%T reactor is made in the first reactor. The reaction is controlled by adLusting the reaction temperature and by bleeding in raw hydrogen containing C' into the pure hydrogen stream from the P%A unit.
SECTION
The effluent from the first reactor passes through the C# hydrogenation adiabatic reactor Intercooler :o.", 6?()4, where the inlet temperature to the second reactor is controlled. A split range flow control system is provided such that part of the flow may be by?passed across 6?()4 for better temperature control. .ydrogen is inLected on ratio flow control, upstream of 6?()4. Appro7imately &)A of the conversion of the acetylene is made in the second reactor. The reaction is controlled by adLusting the reaction temperature and by bleeding in raw hydrogen containing C' into the pure hydrogen stream from the unit. The effluent from the second reactor is cooled in the C# .ydrogenation Adiabatic 8eactor Intercooler :o.#, 6?()), before passing to the third reactor. .ydrogen is again inLected on ratio control. In this reactor, the remaining acetylene is removed so that the reactor effluent contains less than ".2 ppm acetylene. The reaction is controlled by adLusting the reaction temperature and by bleeding in raw hydrogen containing C' into the pure hydrogen stream from the P%A unit. 6ffluent leaving the third reactor is water?cooled in C# hydrogenation Adiabatic 8eactor Afterooler, 6?()0 A> , prior to preheating the feed to the first reactor in the C# hydrogenation feed > effluent e7changer, 6?()# A>3. P%A
55 0 0 22/06/2012 BMK
SECTION
2
The reactor
beds
are
periodically
regenerated
using
regeneration gas supplied from the reactor treatment furnace, .?2"*, in the gasoline hydrogenation +nit. The three reactors, 8?()" A> >C are rotated such that the newly regenerated bed assumes the third reactor position. The effluent from 6?()# A>3 passes to the C# hydrogenation effluent separator, B?()), where condensed polymers are knocked out prior to the effluent being dried in the secondary dehydrators, B?()& A> . After drying, the effluent passes to the 6thylene rectifier, C?(2*. The secondary dehydrators are supplied for removal of any water formed in the acetylene hydrogenation reaction any polymers not removed in the C# .ydrogenation effluent separator. 1hile one dehydrator is operating, the second is either being reactivated or is in a standby operation. 8eactivation of the desiccant is accomplished by upward flow of reactivation gas through the beds. The reactivation gas is supplied from the same system employed by the cracked gas dehydrators, B?&2* A> . '(12 Et 0+ene )ractionation The C# acetylene hydrogenation system feeds the two?tower ethylene fractionation system. The feed stream consists essentially of ethylene and ethane with trace ,uantities of methane, hydrogen and propylene. This system fractionates the feed into an ethylene product stream and an ethane stream for recycle cracking in the furnaces.
SECTION
A pasteurising section is located at the top of the ethylene rectifier, C?(2*, above the ethylene product drawoff, to separate any lights from the gross overhead is ethylene product. The rectifier against ?(**C propylene condensed
refrigeration in the ethylene rectifier condenser, 6?(2). The condensed li,uid is collected in the ethylene 8ectifier 8eflu7 3rum, B?(20, then pumped back to the top pasteurising tray by the ethylene rectifier reflu7 pump, P?(2) A> . A vent is recycled from the drum to the C. 9. $ourth %tage %uction 3rum. elow the pasteurising section, the ethylene product is withdrawn as li,uid and fed under its own pressure to the intermediate storage spheres. The option also e7ists to either send the ethylene product to atmospheric storage via the ethylene product coolers no.",# C &, 6?(4*, 6?(4", 6?(4# respectively, or to vaporise the ethylene product and deliver it as a low pressure vapour to the battery limits via the ethylene product vaporiser, 6?(22, and ethylene product superheater, 6?(24 A>b. :ormally, the ethylene li,uid will be imported from the intermediate storage spheres after ,uality control and either fed as a low pressure li,uid to the ethylene product vaporiser, 6?(22, and ethylene product superheater, 6?(24 A> to produce a low pressure vapour for e7port or fed as a high pressure li,uid to the .P ethylene product heater no.", 6?(*, and .P ethylene
SECTION
product no.#, 6?(5", to produce a high pressure vapour for e7port. oth ethylene fractionation towers are e,uipped with reboilers. 3esuperheated ethylene refrigeration compressor discharge vapour is the reboiling medium for the ethylene rectifier reboiler, 6?(2*. Propylene refrigerant vapour at 2.#*C is the reboiling medium for the ethylene stripper reboiler, 6?(0*. The ethylene stripper, C?(0*, net bottoms supplies the ethane recycle. The ethane recycle is routed to the ethane recycle vaporiser, 6?(0", superheated furnace as feed for cracking. '(14 Depropaniser The dual?feed 3epropaniDer, C?)"*, is fed by the 3eethaniDer bottoms and condensate stripper bottoms. Propylene, propane, and any lighter components make up the tower overhead. This stream is totally condensed by vaporising 5.(*C propylene refrigerant in the 3epropaniDer condenser, 6?)"). The condensed li,uid is collected in the 3epropaniser 8eflu7 3rum, B?)"0. The li,uid is pumped to the tower as reflu7 by the 3epropaniDer 8eflu7 pump, P?)") A> . The net overhead stream is pumped by the C& hydrogenation feed pump, P?)"0 A>b, to the C& .ydrogenation system.
in
the
demethaniDer core
e7changer no.", 6?("", and then delivered to the +%C recycle
SECTION
The 3epropaniDer gross bottoms is reboiled against pan oil in the 3epropaniDer 8eboiler, 6?)"* A> . The net bottoms stream, composed mainly of C(Gs and heavier components, is sent to the 3ebutaniDer. '(1@ C, $0drogenation S0steThe C& .ydrogenation system, designed by Institut $rancais du Petrole ;I$P= is a one stage, li,uid?phase catalytic process. There are three installed reactors, 8?)&" A> >C. Two are normally operated in parallel while the third is on stand?by. Methyl acetylene ;MA and propadiene ;P3= in the 3epropaniDer net overhead are selectively converted to propylene and propane in the reactors. The condensed 3epropaniDer net overhead is pumped into the system by the C& .ydrogenation $eed Pump, P?)"0 A> . This stream first flows through the C& hydrogenation feed coalescer, B?)"5, which eliminates any free water. The coalescer outlet is split into two parallel passes, one for each operational reactor. 6ach pass is diluted with li,uid C& recycled from the C& hydrogenation recycle pump, P?)#* A> , and then mi7ed with make?up hydrogen from the P%A unit. The purpose of the li,uid recycle is to control inlet concentration of MAEP3 in the reactor feed. This avoids e7cessive vaporisation in the reactors due to the highly e7othermic reactions.
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SECTION
In the reactors, MA and P3 are selectively hydrogenated to propylene, propylene hydrogenation to propane is minimised. The heat of reaction induces partial vaporisation of the hydrocarbon stream. Purge to the C.9. $ourth %uction 3rum=. 3uring normal operation, the effluent is sub?cooled and no off?gas is purged. The drum bottoms are pumped out by the C& hydrogenation recycle pump, P?)#* A> , and divided into two streams @ li,uid recycle for reactor feed dilution and the product which feeds the secondary deethaniDer, C?)&*. The spare reactor allows catalyst reduction, reactivation or regeneration running. $or catalyst reduction or reactivation operations, hydrogen make?up gas is combined with fuel gas of the methane type to achieve mi7ed stream hydrogen content of #) molA. Alternately, nitrogen may be used instead of fuel gas. The mi7ed stream is then preheated to the re,uired temperature in the C& hydrogenation catalyst treatment e7changer, 6?)##. The off?gas, which is similar to the inlet gas, is sent to flare for disposal.
operations
with the
C& .ydrogenation
unit
SECTION
The reactors are regenerated, as re,uired, by regeneration gas supplied from the 9.+ first %tage 8eactor Treatment $urnace, .?2"*. %pent regeneration gas is returned to the 9.+ decoking drum, B?2"&, for disposal. The composition of the spent gas is similar to the fresh regeneration gas e7cept that it contains small amount of light hydrocarbons at the beginning of reactor sweeping and C'>C'#, during combustion steps. '(15 Secondar0 and Tertiar0 Deet aniBer %econdary and Tertiary 3eethaniDer,C )&* C C?)&), towers in series are designed to remove water and C# and lighter hydrocarbons from the propylene > propane stream prior to C& fractionation. The li,uid effluent from the C& hydrogenation system is fed to the secondary deethaniDer at tray number ##. The overhead vapour stream is condensed against cooling water in the secondary 3eethaniDer condenser, 6?)&). $ollowing the separation of water in the secondary 3eethaniDer reflu7 drum, B?)&0, the total hydrocarbon condensate phase is pumped back to the top of the tower by the secondary deethaniDer reflu7 pump, P?)&) A> . :oncondensables in the secondary deethaniDer overhead are normally vented to the cracked gas fourth stage suction drum. Any condensed water is removed
61 0 0 22/06/2012 BMK
SECTION
from the boot of the reflu7 drum and is sent to the oily?water sewer. The secondary deethaniDer reboiler, 6?)&*, is heated by ,uench water. The tower bottom stream flows to the Tertiary 3eethaniDer, C?)&) via the secondary deethaniDer bottoms pump, P?)&* A> . The Tertiary 3eethaniDer, C?)&), tower has been added to the system in series with the secondary deethaniDer to accommodate the increased e7pansion loads. It is designed to further remove water and C# and lighter hydrocarbons from the propylene > propane stream prior to C& fractionation to meet the re,uired product specifications. The %econdary 3eethaniDer ottoms Pump effluent is fed to the against cooling water in the 6?)&2. $ollowing the
Tertiary 3eethaniDer, C?)&), at tray number ##. The overhead vapour stream is condensed Tertiary 3eethaniDer Condenser,
separation of water in the Tertiary 3eethaniDer 8eflu7 3rum, B? )&2, the total hydrocarbon condensate phase is pumped back to the top of the tower by the Tertiary deethaniDer reflu7 pump, P?)&2 A> . :oncondensables in the Tertiary 3eethaniDer overhead are vented to the cracked gas $ourth %tage %uction 3rum. Any condensed water is removed from the boot of the 8eflu7 3rum and is sent to the oily?water sewer.
62 0 0 22/06/2012 BMK
SECTION
The Tertiary 3eethaniDer 8eboiler, 6?)&0, is heated by ,uench water. The tower bottom stream flows to the Propylene %tripper, c?)(*, via the Tertiary 3eethaniDer ottoms Pump, P?)&0 A> . '(1A Prop0+ene )ractionation The net bottoms stream from the secondary deethaniDer, containing propylene, propane, plus trace amounts of ethane and C(Gs , is fed to the propylene stripper, C?)(*. ecause of the large number of trays re,uired to make the separation, two towers are provided for the propylene > propane fractionation @ the Propylene %tripper, C?)(*, and the Propylene 8ectifier, C? ))*. 8eboil heat I supplied to the bottom of the stripper by circulating ,uench water in the Propylene Tower 8eboilers, 6? )(* A>3 and if necessary by the Propylene Tower Au7iliary 8eboilers, 6?)(" A> . The %tripper bottoms stream consists of propane recycle which is vaporised in the Propane 8ecycle Baporiser, 6?)(#, and is sent to the +%C 8ecycle $urnaces for cracking. 9reen oil formed in the C& hydrogenation reactor is continuously drained from 6?)(# and is sent back to the #nd stage suction drum B?&#*. Bapour from the top of the stripper flows to the bottom of the propylene rectifier. /i,uid from the bottom of the rectifier is pumped back to the top of the stripper via the propylene transfer pump, P?))* A> . 'verhead vapour from the rectifier is condensed using cooling water in the propylene tower condenser, 6?))) A>., and passes to the Propylene tower reflu7
SECTION
drum, B?))0. Condensate from the reflu7 drum is pumped to the top of the rectifier as reflu7 and to offsite propylene storage and uses by the propylene tower reflu7 > product pump, P?))) A> . A slip stream, located off the propylene product stream provides make up to the propylene refrigeration system, as needed. '('0 De:utaniBer The 3epropaniDer bottoms stream is fed to the debutaniDer, C? )0*. The tower gross overhead is condensed against cooling water in the debutaniDer condenser, 6?)0). The mi7ed C(Gs stream is pumped by the 3ebutaniDer 8eflu7 > Product Pump, P? )0) A>b, from the 3ebutaniDer reflu7 drum B?)00, to the C( hydrogenation unit > intermediate storage and back to the tower as reflu7. The 3ebutaniDer bottoms stream is reboiled against //P steam in the 3ebutaniDer 8eboiler, 6?)0* A> . The tower net bottoms, consisting of C)s and heavier, are sent to the 9asoline .ydrogenation +nit. '('1 C. $0drogenation S0ste- @ The raw C( cut is routed to the feed surge drum, B?4*" and then pumped under flow control by the feed pump, P?4*" A> . The vessel pressure is regulated at (.) kg>cm#g by a split range control which regulates the :# make up and release to flare.
SECTION
The flow rate of hydrogen make up is regulated by flow ratio control with the C( feed. This flow ratio set point is calculated in proportion to the butadiene content at reactor inlet ;feedErecycle=. The C( cut feed is mi7ed with li,uid recycle and hydrogen make up gas and flow to the top of the reactor 8?4*". The hydrogenation reaction is e7othermic and a cooled recycle stream is re,uired to be mi7ed with the C( feed and hydrogen in order to prevent e7cessive temperatures within the catalyst bed and in order to ensure a good hydraulic distribution through the catalyst bed. As the mi7ture flows down through the catalyst bed of the reactor 8?4*", the temperature rises due to the e7othermic reaction. The inlet temperature of the reactor 8?4*" is minimised ;in order to prolong the active life of the catalyst= consistent with achieving the re,uired conversion rate of diolefinic hydrocarbons. As the catalyst activity reduces, during the run life, the feed temperature is increased form about (&*C at start of run ;%'8=, to about 0**C at end of run ;6'8=. The reactor outlet temperature should not e7ceed "***C in order to prevent e7cessive damage to the catalyst. reaction rate is not sufficient to achieve conversion, even with fresh catalyst. elow (**C the the re,uired
65 0 0 22/06/2012 BMK
SECTION
%team preheating through the heater 6?4*" is necessary during start?up to reach the inlet 8?4*" temperature. The volume of the gaseous phase in the mi7ture reduces as hydrogen reacts with the diolefinic hydrocarbons but some of the C( hydrocarbons are vaporised as the temperature rises. The two phase mi7ture leaving the reactor 8?4*" flows directly to the .ot %eparator, B?4*#. Bapour from the .ot %eparator B? 4*# is cooled in the post?condenser, 6?4*&. The condensate which is formed, is separated in the post?condenser drum, B? 4*&, and is recycled to the separator B?4*# after mi7ing with reactor 8?4*" effluent. $irst reaction section pressure is controlled by purging B?4*& gas to the cracked gas compressor suction. The li,uid collected in the .ot %eparator is pumped by the 8ecycle Pump, P?4*# A> and cooled in the 8ecycle Cooler, 6? 4*#. Most of the cooled li,uid represents the 8?4*" recycle and the other part represents the first stage effluent. A separate bypass control around the cooler 6?4*# enables the regulation of 8?4*" inlet temperature. A second separate 6?4*# by?pass control enables the regulation of the 8?4*# inlet temperature. This stream is sent under flow control to the second stage hydrogenation reactor 8?4*#.
66 0 0 22/06/2012 BMK
SECTION
The .# make up to the finishing reactor 8?4*# is delivered under flow ratio control. the set point of this flow ratio is calculated in proportion to the butadiene content at 8?4*# inlet. 8?4*# effluent is cooled down to (&*C through the product cooler, 6?4*(, and flashed into the c( product flash drum, B?4*( at fuel gas network pressure to eliminate potential remains of hydrogen or other light components. the li,uid product is pumped to battery limit under level control by the C( product pump. An identical unit called as au7ilary hydrogenation is installed to operate in parallel to main unit for additional loads . '('' Et 0+ene Re;rigeration S0steThe 6thylene 8efrigerant Compressor, ?0**, is a three stage
single casing machine. The machine is designed to supply ethylene refrigerant at ?"**.0*C, and ?)"."*C, respectively. The compressor is driven by a steam turbine. The compressor third stage discharge vapour is desuperheated by using cooling water in in the the 6thylene 6thylene 8efrigerant 8efrigerant 3esuperheater :o.", 6?0(), then by using 2.# C and ?0.2 C propylene refrigerant 3esuperheaters :o.#, 6?0(0, and no.&, 6?0(2, respectively. The refrigerant vapour then flows through the ethylene refrigerant oil filter, D?0"* A> , for removal of compressor lube or seal oil.
SECTION
The takeoff for the minimum flow bypass line is downstream of the filter. :ormally, the desuperheated vapour is condensed in the ethylene rectifier reboiler, 6?(2* A> . $or start?up and upset conditions, the au7iliary ethylene refrigerant condenser, 6?0(5 condensing the desuperheated ethylene vapour as re,uired. The condensed ethylene refrigerant flows to the ethylene refrigerant surge drum, B?0(). The li,uid from the surge drum is sub cooled using ?(*.**C propylene refrigerant in a plate ? fin e7changer, the ethylene refrigerant subcooler, 6?0)*. The subcooled li,uid flows into the ethylene refrigerant third stage suction drum, B?0&*, via a level control valve. A slip stream of the subcooled li,uid flows to the ethylene product cooler no." refrigerant flash pot, B?(4* and demethaniDer parallel precooler no.( flash pot A, B?(##, which service ethylene product cooler no.", 6?(4* ;normally not in service= and demethaniDer parallel precooler no.(, 6?(##A, respectively=. The third stage suction drum pressure is maintained by the compressor, resulting in a refrigerant temperature of ?)"."*C. This drum serves as a thermossyphon drum for demethaniDer precooler no.(, 6?(*(. The flash vapour generated in this drum flow to the third stage suction noDDle of the compressor. A portion of the ?)"."*C li,uid flows into the ethylene product cooler no.# refrigerant flash pot, B?(4", servicing the ethylene
SECTION
product cooler no.#, 6?(4" and demethaniDer parallel precooler no.( flash pot , B?(#&, servicing the demethaniDer parallel precooler no.(, 6?(## . The balance of the li,uid from B?0&*, is fed into the ethylene refrigerant second stage suction drum, B? 0#*, via a level control valve. The second stage suction drum pressure is maintained at a corresponding li,uid temperature of ?2&.&*C. This drum serves as a thermosyphon drum for 3emethaniDer Precooler :o.), 6? (*). The vapour generated in this drum flows to the second stage suction noDDle of the compressor. A maLority of the ?2&.&*C li,uid satisfies four parallel process users@ the 3emethaniDer Precooler :o.0, 6?(*0N 6thylene Product Cooler no.&, 6?(4#N 3emethaniDer Condenser, 6?(#)N and 3emethaniDer Parallel precooler :o.0, 6?(#(. The ethylene vapour out of the associated flash pots of these users is sent to the ethylene 8efrigerant first stage suction drum, B?0"5, at ?"**.0*C. The entire first stage suction drum vapour is sent to the ethylene refrigerant compressor. Any accumulation of oil or li,uid in the first stage suction drum flows into the ethylene refrigerant drain drum, B?0(0. This drum is e,uipped with a propylene refrigerant heating coil, receiving propylene vapour upstream of propylene refrigerant condenser,
SECTION
6?055 A>., O>!, and discharging condensed propylene li,uid to the propylene refrigerant fourth stage flash drum, B?05*. Any ethylene refrigerant li,uid in the drain drum is evaporated, allowing the oil to accumulate and be periodically drained from the drum. Three minimum flow bypasses are provided into the
compressor suction drums to maintain the compressor in a stable flow regime. '(', Prop0+ene Re;rigeration S0steThe Propylene 8efrigerant Compressor, ?0)*, is a four stage
single ? casing machine, which is designed to supply propylene refrigeration at ?(**C, ?#&.&*C, ?0.2*C and 2.#*C, respectively. The compressor is driven by an e7traction condensing steam turbine. The compressor discharge vapour is desuperheated and condensed in the water cooled propylene refrigerant condenser , 6?055 A>., O>!. The minimum flow bypass is taken upstream of the propylene refrigerant condenser. As re,uired , this vapour goes to the propylene refrigerant first stage suction, second stage suction, third stage flash, and fourth stage flash drums.
0 0 0 22/06/2012 BMK
SECTION
The condensed propylene from 6?055 A>., O>!, flows into the propylene refrigerant surge drum, B?05). The drum pressure is maintained by saturated compressor discharge vapour. This is necessary to prevent Jstonewall operationK. The li,uid propylene at (*.0*C flows from the surge drum and divides into three separate streams. The propylene is subcooled in all three streams, acting as the heating medium for process streams. These services are @ 3emethaniDer core e7changer no.", 6?("". The subcooled propylene flows to propylene refrigerant second stage suction drum, B?02*. 6thylene product superheater, 6?(24 A> . The subcooled propylene flows to propylene refrigerant third stage flash drum, B?04*. .P ethylene product heater no.#, 6?(5". The subcooled propylene is divided into three parallel process services. 8eactivation gas feed chiller, 6?&2(, 3epropaniDer condenser, 6? )") and cracked gas rectifier overhead condenser, 6?&)). The vapour generated in these services and the balance of li,uid propylene refrigerant each flow to the propylene refrigerant fourth stage flash drum, B?05*.
1 0 0 22/06/2012 BMK
SECTION
The $ourth %tage flash drum vapour is used as the heat source in the ethylene stripper reboiler, 6?(0*, and demethaniDer reboiler, 6?(#*. The condensed propylene flows through the respective seal pots and is flashed into the propylene refrigerant third stage flash drum, B?04*. The fourth stage flash drum operates at 2.#*C. This drum serves as a thermosyphon drum for ethylene refrigerant desuperheater no.#, 6?0(0. %ome of the li,uid is vaporised in the demethaniDer precooler no.", 6?(*", and demethaniDer parallel precooler no.", 6?(*2. The balance of the li,uid is flashed directly to the third stage flash drum, B?04*. The third stage flash drum vapour, is condensed in the ethylene product vaporiser, 6?(22, and the .P 6thylene product heater no.", 6?(5*. The propylene condensed in these e7changer is collected in the respective seal pot, B?(22 and B?(5*, then flashed to the propylene refrigerant second stage suction drum, B?02*. The third stage flash drum operates at ?0.2*C. This drum serves as a thermosyphon the drum four for the ethylene Au7iliary refrigerant ethylene desuperheater :o.&, 6?0(2. The li,uid propylene from the drum supplies following services@ refrigerant condenser, 6?0(5 A> N 3eethaniDer condenser, 6?(() A>3N 3emethaniDer precooler :o.#, 6?(*#, and 3emethaniDer Parallel precooler no.#, 6?(*5. The vaporised propylene is sent
SECTION
to the propylene refrigerant second stage suction drum, B?02*. Additionally, the third stage flash drum li,uid is flashed into the second stage drum. All of the vapour from the second stage suction drum, at ?#&.&*C, is routed to the compressor. %ome of the li,uid satisfied three parallel process users @ 3emethaniser parallel precooler no.&, 6?(#"N 3emethaniDer Precooler no.&, 6?(*& and ethylene refrigerant subcooler, 6?)0*. The propylene vapour out of these services is sent to the propylene refrigerant first stage suction drum, B?00*. The balance of the li,uid is flashed into the first stage suction drum to satisfy the ethylene rectifier condenser, 6?(2), re,uirement. The first stage suction drum serves as a thermosyphon drum for the ethylene rectifier condenser. The entire first stage suction drum vapour is sent to the refrigerant compressor. Any e7cess li,uid in the first stage suction drum may be sent to the //P steam?traced propylene refrigerant drain drum, B?050. The vapour from the drain drum is returned to the first stage suction drum. '('. "aso+ine $0drogenation Unit The 9.+ consists of two stages. This process provided by Institut $rancais du Petrole ;I$P= produces a feedstock for downstream aromatic recovery by selectively hydrogenating
SECTION
the diolefins in the first stage and the olefins in the second stage. '('.(1 )irst stage reaction section The raw pyrolysis gasoline, mi7ed with the recycled wash oil, is fed to the feed surge drum, B?2*" under slight pressure, after being filtered through the P?2*# A> package. The filtration facility is mostly useful when some of the feed comes from the storage tanks. $ree water, if any, can be purged from B?2*" boot. The first stage feed pump, P?2*" A> raises the feed pressure
up to the reaction selection pressure. Part of the P?2*" discharge can be routed to storage under B?2*" level control. .# make up supply is introduced at the $irst stage feed pump discharge under pressure control. The pressure of both reaction sections, .3" and .3#, is controlled from the same point, at the top of the #nd stage separator drum, C?2(*. The fresh feed and .# make up are mi7ed with cooled reactor effluent to dilute the feed. The role of the dilution is to lower the feed reactivity and thus obtain a smooth control of temperature elevation in 8?2"* A> first catalyst bed. The mi7ed stream is charged to the reactor after heating through 6?2*", reactor feed effluent heat e7changer. 8?2"* A>
SECTION
reactor inlet temperature is controlled by by?passing part of the reactor effluent around 6?2*". 3uring start?up periods, the temperature is controlled by means of the steam preheater 6? 2*#. The reactions ;diolefins and alkenyl aromatics hydrogenation= occur in mi7ed phase ;mainly li,uid= in a fi7ed bed type reactor 8?2"* A> . The catalyst is divided into two beds. The overall temperature profile through the reactor is controlled by dilution of feed, as mentioned above, and by the inLection of ,uench under temperature flow control cascade ;TC at the inlet of second bed=. 8eactor 8?2"5 effluent, partly cooled through 6?2*", is flashed into the .ot %eparator, B?2"*. Part of the li,uids is recycled as ,uench and dilution via the $irst stage ,uench pump, P?2"* A> and $irst stage ,uench cooler, 6?2"". The remainder is sent under level flow control cascade etc. the depentaniDer, C?2#*. B?2"* vapour phase is cooled down through the hot %eparator Bapour Condenser , 6?2"# and flashed into cold separator B? 2"". B?2"" li,uid is fed to C?2#* under level control. B?2"" vapour feeds the second stage reaction section as hydrogen rich make?up.
5 0 0 22/06/2012 BMK
SECTION
3ecoking drum B?2"& collects the regeneration effluents of first and second stage reaction section, as well as C& and C( hydrogenation units. Depentaniser@ The first purpose of the depentaniDer C?2#* is to stabilise the first reactor product by eliminating the light components which have been dissolved under high pressure in B?2"* and B?2"". The second purpose is to split the C) cut from the C0E cut. %tabilisation is performed in the uppermost trays. The overhead vapours of C?2#* are condensed in the depentaniDer condenser, 6?2#) and the li,uid collected in reflu7 drum, B?2#0. 8eflu7 drum B?2#0 vapour phase is purged to flare or to cracked gas compressor under pressure control. The B?2#0 li,uid is pumped by the depentaniDer reflu7 pump, P? 2#) A> , as e7ternal reflu7 under flow control reset by level control. The C) cut is withdrawn in li,uid phase under temperature flow cascade control, and sent to battery limit after being water cooled through the C) product cooler, 6?2#0.
6 0 0 22/06/2012 BMK
SECTION
The depentaniDer reboiling is performed by the thermosyphon reboiler 6?2#*. C0 E Cut is fed to the deoctaniDer, C?2&*, under flow control reset by C?2#* bottom level control. Deoctoniser! The purpose of the 3eoctaniDer, C?2&* is to split the C0E cut into C0?C4 cut and C5E cut, and also to withdraw a C5?#***C wash oil cut. C?2&* is operated under slight vacuum in order to limit the bottom temperature to "2)*c and to allow the reboiling with saturated /MP steam. Bacuum is maintained by means of steam eLector P?2&0. The pressure is controlled at the top of C?2&* by recycling MP steam at P?2&0 outlet into the eLector together with the non condensable components issued from the column through post condenser, 6?2&0. The overhead vapours of reflu7 drum, B?2&0. The 3eoctaniDer 8eflu7 Pump, P?2&) A> , sends the e7ternal reflu7 to the column under flow control. The distillate feeds the second stage reaction section via the #nd stage feed pump, P? 2&0 A> , under flow control, reset by B?2&0 level control. C?2&* are condensed in the
deoctaniDer condenser, 6?2&), and the li,uid is collected in
0 0 22/06/2012 BMK
SECTION
The 3eoctaniDer reboiling is performed by the thermosyphon reboiler, 6?2&* A> which is controlled by temperature control of the bottom section of the tower. C5E cut is sent to battery limit via the deoctaniDer feed pump, P?2&* A> and water cooler, 6?2&#. The wash oil is withdrawn as a vapour phase & trays above the bottom of the column. It is condensed in water cooler, 6?2&", and collected in the wash oil holding drum, B?2&". It is sent to the battery limit via the wash oil transfer pump, P?2&" A> wash oil trim cooler, 6?2&2, under flow control. and
'('.(, Second Stage Reaction Section The feed to second stage reaction section is pumped via the #nd stage feed pump, P?2&0 A> under flow control reset by B? 2&0 level control. $luctuation in B?2&0 level can also be smoothed by the option of sending feed to storage. The feed is mi7ed with recycle and make up gas at the compressor ?2(* A> discharge, before being heated up through 6?2(* A> >C>3>6 feed effluent e7changer and feed
CHECKED BY N.S.P APPROVED BY B. DAS Process description and Utilities PAGE REV ISSUE DATE AUTHOR ! 0 0 22/06/2012 BMK
SECTION
2
heater .?2(*.
The second stage reactor inlet temperature is
controlled by the furnace .?2(*. The reactions ;hydrogenation of olefins and desulfuriDation= occur in vapour phase on a fi7ed bed type reactor 8?2(* filled with two types of catalysts @ /3 "() @ mainly hydrogenation .8&*0C @ mainly desulfurisation. The temperature profile through the reactor is kept under control by the inLection of ,uench between the two catalyst beds regulated by temperature control of the second bed. The effluent of 8?2(* is flashed in the second stage separator, B?2(*, after consecutive cooling in 6?2(* A> >C>3>6 and 6?2(" water cooler. B?2(* vapour phase is partly released to flare or to cracked gas compressor under flow control. The overall pressure control is ensured from B?2(* by action on .# make?up to the first reaction section. oth reaction section pressures are controlled through this pressure control. The remaining vapour phase is recycled to the #nd stage !.'. drum, B?2(", where it is mi7ed with first stage cold separator, B?2"", vapour, which is the h# rich make up to the second stage reaction section.
CHECKED BY N.S.P APPROVED BY B. DAS Process description and Utilities PAGE REV ISSUE DATE AUTHOR " 0 0 22/06/2012 BMK
SECTION
oth gases are sent under flow control back to the #nd stage reaction section via the recycle and make up compressor, ?2(* A> . The B?2(* net li,uid phase is fed to stripper section under level flow cascade control, while some li,uid is recycled as ,uench to the reaction section via the #nd stage ,uench pump, P?2(* A> . '('.(. Stripper Section The purpose of the stripper, C?2)*, is to eliminate .#% and light components dissolved at high pressure in the C0?C4 cut. efore being fed to the stripper, the C0?C4 cut is heated up against stripper bottom product through the feed > effluent e7changer, 6?2(5 A> . The stripper overhead vapours are partially condensed in the stripper Condenser, 6?2)) and collected in reflu7 drum B?2)0. The reflu7 is returned to the column by the reflu7 pump, P?2)) A> , under flow control reset by B?2)0 level control. B?2)0 vapour phase is purged to flare or to the cracked gas compressor under column overhead pressure control.
!0 0 0 22/06/2012 BMK
SECTION
The stripper reboiling is performed by the thermosyphon reboiler, 6?2)*, using /MP steam. The bottom product is pumped under level control to battery limit by the C0?C4 product pump, P?2)* A> through the feed > effluent e7changer, 6?2(5 A> and water cooler 6?2)". the pump, P?2)# is provided for the inLection of corrosion inhibitor into the stripper overhead. The $irst stage reactor treatment furnace, .?2"* is provided to service the $irst stage reactor 8?2"* A> , and the C#, C& and C( reactors during catalyst treatments. The purpose of the spent caustic o7idation unit is to o7idise the sodium sulphide in the spent caustic as completely as practicable to harmless sodium sulphate, to cool the resulting effluent, and sent it to the effluent treatment plant. %pent caustic is gasoline washed, de?oiled, stripped with steam, cooled and sent to the %C' feed surge drum, B?""#", which is nitrogen?blanketed and vented to the wet flare system. Alternatively, the spent caustic feed is pumped from holding tank T?""*" A> by P?""*" A> , and sent to B?""#".
!1 0 0 22/06/2012 BMK
SECTION
%pent caustic from B?""#" is pumped by reactor feed pump P? ""#" A> on flow control through feed > vent gas e7changer 6? ""## A> , where it is heated on temperature control. The heated spent caustic is sent to the bottom of 8?""##A, the first reactor in a series of three. The three reactors are fed with air compressor from reactor feed air
?""#" A> >C, by way of air surge drum B?""#&.
The air is sent under pressure control through feed air filter P? ""#" A> >C to two flow controllers on each reactor, supplying a special distributor at the bottom of each reaction Done. 6ach distributor is also fed with desuperheated steam on flow control. 6ach reactor operates nearly full of li,uid at "&**C, and is divided into two Dones by a valve tray. The spent caustic flows slowly upward in contact with a stream of fine air bubbles. The reactor pressures are individually controlled to allow the flow of spent caustic through each reactor, under level control. 'n the spent caustic stream from each reactor, a filter P?""#& A> >C is provided for removal of possible agglomerated polymer. The residence time in each reactor is appro7imately ( hours at the ma7imum design rate.
!2 0 0 22/06/2012 BMK
SECTION
The high reactor temperatures re,uired for good o7idation are maintained by adLustment of the steam inLection rates. The sulphide content is highest in 8?""##A, which therefore re,uires more air than the other reactors. .eat from the o7idation reactions is also highest in 8?""##A, causing its steam inLection rate to be the lowest. '7idised spent caustic from 8?""##C is filtered in P?""#&C, cooled in 6?""#" A> , and released on level control to effluent surge drum B?""##. The vent gases from the reactors are released by their pressure controls, and combined before flowing through feed > vent gas e7changer 6?""##A> and vent gas cooler 6?""#&A> to B?""##. Bent gas from B?""## is released on pressure control to atmosphere at (**C. It consists mainly of nitrogen and o7ygen, with a small amount of water vapour. The o7idised spent caustic from B?""## at (**C is pumped by the effluent transfer pump P? ""## A>b on level control to the T?""*" product tank. This spent caustic is further neutralised in CP+ pit to p. of 2.* and pumped to effluent treatment plant.
!3 0 0 22/06/2012 BMK
SECTION
UTILITIES
!4 0 0 22/06/2012 BMK
SECTION
,(1 Coo+ing *ater S0steThe cooling water in supplied by a dedicated cooling water tower at '% /. The cooling water ,uality supplied has the following specifications @ p. @ Chlorides %ilica $ree chlorine Turbidty Total viable count Total hardness as Caco& *.P*( T?P'( Total $C Pinc as Pn 5?"( &.* ma7. #.* ma7. 2.# to 2.4 Ma7. #** ppm as cl. Ma7. "** ppm as %"'# Ma7. *.) ppm Ma7. ") :TB Ma7. *.& million colonies per ml. )** ma7. 0.)?5.* ppm
Total 3issolved %olids Ma7. #)** ppm as caco&.
Corrosion monitoring system is provided at I% / at the inlet of 6?#&* e7changers. Cooling water supply temperature is &(*C. In order to keep the circumstances to an optimum low ,uantity. a two level system with some cooling services operating at an intermediate inlet temperature of &5*C which is known as cooling water tempered
CHECKED BY N.S.P APPROVED BY B. DAS Process description and Utilities PAGE REV ISSUE DATE AUTHOR !5 0 0 22/06/2012 BMK
SECTION
;C1T=. The ma7imum temperature rise through the entire circuit is 5*C. The typical return temperature will be (&*C. The cooling water supply pressure is ).* kg>cm#g with a return pressure of #.) kg>cm#g The cooling tower contains "0 cells and 4 main pumps and two stand by pumps which supply into the common C1% header of )(K siDe. Also C( one more #*K and parallel supply header complements the cooling water supply to tertiary deethaniDer. Au7iliary hydrogenation propylene fractionation overhead condensers. Total of )(*** m&>hr cooling water supply re,uirement is met by light pumps running continuously. The preselected three standby pumps cut in on auto In case of drop in header pressure to (.0 kg > cm#g. There are Lumpover from C1 supply to C1 tempered and C1 supply to C1 return to balance the header re,uirements. .owever, these Lump over valves are used only during start?up and remained closed during normal plant running. Apart from cooling water supply is provided to decoke pot scrubbing , furnace decoke header inLection and pump seal > hearing house cooling which are routed to '1% system. This is provided
to
convert
water
by
reducing
service
water
re,uirement and accomplishing cooling tower blowdown which

Process description and Utilities PAGE REV ISSUE DATE AUTHOR !6 0 0 22/06/2012 BMK
SECTION
otherwise it essential at holding tower to maintain circulating water ,uality.
! 0 0 22/06/2012 BMK
SECTION
3
Coo+ing *ater =a+ance
Coo+ing *ater User 6?&#* A?C 6?&&* A?C 6?&() A?3 A?"*" :ote " ?(#*>(#" T9?5** 6?5** 6?55* A> 6?0() T9?0** 6?50* 6?54* T9?0)* ?50) T9?&** 6?5&* 6?54" 6?54# 6?055 A?! 6?))) A?. 6?))0 6?)0) 6?2#) 6?2&0 6?2&2 6?2&4 ;:ote "= 6?2)" 6?2)) 6?5"* 6?5#* 6?2&) 6?#2& ?()4 6?()) 6?()0 A> 6?)#" 6?)&) 6?)00 6?2"" 6?2"# 6?2#0 6?2&# 6?2(" 6?2(# 6?4*# 6?4*& 6?4*( 6?#&* A?! 6?&2& 6?##* A?9 6?&2) 9?"*** ;:'T6 "= 6?""*# A> 6?5#" ;:'T6 "= 6?&(" P?5** A?C P?5*" A> P?545 A>
C*S $eader )+o? 9Cg# < ".")&.&&( ".""5.25" ".#"&.&#) ")5,"#* ##,)55 "*#,*0* "02,5*2 #),5)2 "05,"4* 0",05*
C*T $eader )+o? 9Cg# < In Out
C*R $eader )+o? 9Cg# < ".")&.&&( ".""5.25" ".#"&.&#) ")5,"#*
##,)55 "*#,*0* "02,5*2 #),5)2 "05,"4* 0",05* &,25*,"#5 "(2,0)( &,25*,"#5 "(2,0)( "*,0&&,4*# "*,0&&,4*# "#),)#4 &),()0
"*#,*0* 5#,544
"*#,*0* "*,0&&,4*# 5#,544 "*,0&&,4*# "#),)#4 &),()0
"",)0#,##) 4,00#,*** "*,)** 540,4** 40(,)** (,*** 4#,)** 0&.0(4 ")(,&&& 0&,"02 ##4,*** (&0,5#0 ",542,(** (0,*** ",*&&,0** ",*5*,0** ","#*,#** ((5,24& 0)*,*** )"&,(** )*2,002 "&,*** &*,002 00,)** (#*,&&& ),*** ",*##,4#( 0,0** 5(,50( (,"54,*** "##,50* &)),#"# 02#,*** "22,*** #0&,)(& &)),#"# &&,0)( 2"0 2"0
"",)0#,##) 4,00#,*** "*,)** 540,4** 40(,)** (,*** 4#,)** 0&,0(4 ")(,&&& 0&,"02 ##4,*** (&0,5#0 ",542,(** (0,*** ",*&&,0** ",*5*,0** ","#*,#** ((5,24& 0)*,*** )"&,(** )*2,002 "&,*** &*,002 00,)** (#*,&&& ),*** ",*##,4#( 0,0** 5(,50( (,"54,*** "##,50* 4,(&0,2)* &)),#"# 02#,*** "22,*** #0&,)(& &)),#"# &&,0)( 2"0 2"0 4,(&0,2)*
!! 0 0 22/06/2012 BMK
SECTION
3
6?&"* A?$ 6?#2( 6?)&2 %+ T'TA/ <PA%% T'TA/
",05&,20& &2,2** 2(2,)** (),##),"#( (),##),"#(
",05&,20& &2,2** 2(2,)** &5,4)*,2*) &5,4)*,2*)
&&,4*&,"#" 0,*(2,)4( &5,4)*,2*)
&5,"22,)(* 0,*(2,)4( (),##),"#(
!" 0 0 22/06/2012 BMK
SECTION
Coo+ing *ater =a+ance )or @00 KTA E3pansion Case ALL )LO*S ARE )RO/ LATEST ISSUE O) PROCESS DATA S$EETS D ,1 AU"(A. 9DESI"N )LO* i(e(NOR/AL OP"E DESI"N /AR"IN< PLUS A8AILA=LE 8ENDOR DATA
Coo+ing *ater User 6?&#* A?C 6?&&* A?C 6?&() A?3 A?"*" :ote " ?(#*>(#" T9?5** 6?5** 6?55* A> 6?0() T9?0** 6?50* 6?54* T9?0)* ?50) T9?&** 6?5&* 6?54" 6?54# 6?055 A?! 6?))) A?. 6?))0 6?)0) 6?2#) 6?2&0 6?2&2 6?2&4 ;:ote "= 6?2)" 6?2)) 6?5"* 6?5#* 6?2&) 6?#2& 6?()4 6?()) 6?()0 A> 6?)#" 6?)&) 6?)00 6?2"" 6?2"# 6?2#0 6?2&# 6?2(" 6?2(# 6?4*# 6?4*& 6?4*( 6?#&* A?! 6?&2& 6?##* A?9 6?&2) 9?"*** ;:'T6 "= 6?""*# A> 6?5#" ;:'T6 "= C*S $eader )+o? 9Cg# < ",#5",&42 ",#"5,#*& ",&&(,*02 ")5,"#* ##,)55 "*#,*0* "02,5*2 #),&2( #*&,5&( 0",05* C*T $eader )+o? 9Cg# < In Out C*R $eader )+o? 9Cg# < ",#5",&42 ",#"5,#*& ",&&(,*02 ")5,"#* ##,)55 "*#,*0* "02,5*2 #),&2( #*&,5&( 0",05* &,25*,"#5 "(2,0)( "*#,*0* 5#,544 "*#,*0* "*,0&&,4*# 5#,544 "*,0&&,4*# "#),)#4 &),()0 "&,#2&,0#5 5,50",&** "",))* ",*4),(4* ",*&2,(** (,(** 5*,2)* 0&,0(4 "05,200 2),&&( ##4,*** (4*,0"5 #,##),444 4&",#00 ","&0,50* ","55,00* ",#&#,##* (5(,20" 2(2,)** )0(,2(* 0*5,#** "(,&** &&,2&( 2&,")* (42,)40 ),*** ",#24,)&* "&,#** "&#,*** (,"54,*** "(2,))# )40,"** 02#,*** "22,*** #0&,)(& "&,#2&,0#5 5,50",&** "",))* ",*4),(4* ",*&2,(** (,(** 5*,2)* 0&,0(4 "05,200 2),&&( ##4,*** (4*,0"5 #,##),444 4&",#00 ","&0,50* ","55,00* ",#&#,##* (5(,20" 2(2,)** )0(,2(* 0*5,#** "(,&** &&,2&( 2&,")* (42,)40 ),*** ",#24,)&* "&,#** "&#,*** (,"54,*** "(2,))# "*,0*#,*** )40,"** 02#,*** "22,*** #0&,)(& "*,0*#,*** "*,0&&,4*# "#),)#4 &),()0 "*,0&&,4*# &,25*,"#5 "(2,0)(
"0 0 0 22/06/2012 BMK
SECTION
3
6?&(" P?5** A?C P?5*" A> P?545 A> 6?&"* A?$ 6?#2( 6?)&2 %+ T'TA/ <PA%% T'TA/
)0),"04 &&,0)( 2"0 2"0 ",4&0,((# (",(2* 2(2,)** )",0"&,4#" )",0"&,4#"
)0),"04 &&,0)( 2"0 2"0 ",4&0,((# (",(2* 2(2,)** (),2&4,)"0 (),2&4,)"0
&),504,&2" 5,22*,"(0 (),2&4,)"0
(",4(&,020 5,22*,"(0 )",0"&,4#"
Notes ! 1( Coo+ing *ater ;+o?s ;or E-@,5% "-1000% A-101 1 E-A'1 are :ased on Re+iance data( '( De+eted ,( Coo+ing *ater ;+o?s to ana+0sers% ana+0ser ouse and pu-p pedesta+s are not inc+uded 9-ini-a+% t0pica++0 1-4 +itres#-in<(
"1 0 0 22/06/2012 BMK
SECTION
3
,('
Stea- S0ste-
The steam system is based on well established principles developed by %C1. The following sections shall be read with reference to +tility flow diagram enclosed @ ,('(1 Stea- Le6e+s
Pressure Cg#c-'g Nor-a /in /a3( + "*) "*# "*2 (* &4 (# "2 ") "4 "# "".) "& &.) &.* (.) Te-perature Nor-a /in( + )"* (4* &2& &0* #)) #&) #0* #(* "42 "0)
0
$ive steam levels are employed with the I% /.

SteaLe6e+ %.P %team .P %team MP %team /MP %team //P %team C /a3(
)"**C (** #4 #2*
S$P Stea- 9S$< %.P %team is generated in the main and cracking recycle furnaces is utilised for driving C9 Compressor and propylene refrigeration compressor, along with import steam from '% /. %.P .eader float with '% / "*) kg level header. :ormally, %.P to M P let down remains closed and opens only during trip of any one of the two machines to satisfy .P steam demand. The import header is siDed for #&) TP..
"2 0 0 22/06/2012 BMK
SECTION
$P Stea- 9S/< .P %team is drawn as e7traction from propylene refrigeration turbine for I% / re,uirements. :ormally, no import or e7port of .P steam taken place. .owever, the header that with '% / header. The header is siDed for 0* TP.. Also .P to refrigeration compressor. /P Stea- 9S/P< MP %team is generated as e7tractor from cracked gas compressor turbine. This e7traction pressure is selected to float with '% /. e7isting pressure.> the header flats with '% / header. :ormally, any e7cess of MP %team letdown to /MP steam is e7ported to '% / network. .owever, import of steam takes place In case of C9 Compressor trip beyond the re,uirement of letdown from .P to /MP steam. The import e7port header is siDed for "** TP.. /P Stea-L 9SL/< /MP %team steam generated from the letdown of MP steam during normal operation ;or= from .P steam during emergencies > shutdown. There is nor /MP pressure level '% /. There is import > e7port facility for this steam. /MP letdown closed and opens only during trip of propylene
"3 0 0 22/06/2012 BMK
SECTION
3
LLP Stea- 9SL<
This steam is imported by letdown of ).) kg>cm#g pressure level at '% /. to e7tent of e7cess re,uirements of let down from /MP /evel. The import header is siDed for )* TP.. .owever, during start?up turndown and upsets two scenario is different depending on furnaces cracking and running of maLor turbine drives. ,(, Condensate and =oi+er ;eed ?ater s0ste$1 system after treatment. The
The cracker plant is self sufficient to handle and recycle all the steam condenste into the facility for condensate, e7port to '% / is also provided. $or the net ,uantity of steam that is reported as there are no facilities to import condensate, this loss is made up from the import of 3M water. The of oiler feed water is generated in deaerator from recycling clean condensate and by polishing of contaminated
condensate in condensate polishing units. 3M water imported form '% / is used to make up the loss of steam due to net e7port or otherwise and loss of condensate. This steam is heated and treated to meet boiler feed water for the generation of steam in furnace steam drums. Condensate Pressures @ .P Condensate @ &2 kg>cm# /MP Condensate @ "* kg>cm#
CHECKED BY N.S.P APPROVED BY B. DAS Process description and Utilities PAGE REV ISSUE DATE AUTHOR "4 0 0 22/06/2012 BMK
SECTION
//P Condensate @ #.) kg>cm# Condensate system is divided into two subsystems as clean condensate and support condensate. All high pressure .P, /MP from user e,uipment is condensate, flashed in flash drums to generate steam and the condensate is returned to deaerator directly as clean condensate. //P condensate from user e,uipments where process side pressure is higher than the steam pressure is routed to suspect condensate vessel and subse,uently sent to CP+ for polishing or to deaerator through activated carbon filter. All surface condensate from C9C,C#,C&8 turbines are sent to deaerator after polishing in condensate polishing unit. 3uring start?up and upset conditions, surface condensate can be e7ported to '% /, before polishing core after polishing. After deaeration and p. adLustment using ammonia, this is termed as au7iliary oiler, feed water. This dilution steam $1 is pumped to furnace systems and for steam drums for steam generation for make up in main and generation desuperheating in %.P to .P letdown system. Two motor driven and a turbine driven high pressure $1 pumps ate provided out of which two will be running normally and one motor driven pump as stand by on auto. In case of pressure drop in .P
CHECKED BY N.S.P APPROVED BY B. DAS Process description and Utilities PAGE REV ISSUE DATE AUTHOR
$1
"5 0 0 22/06/2012 BMK
SECTION
header, stand by pump takes auto start to maintain header pressure. 'ne /P boiler feed water pump is running to supply water to desuperheating stations and nominal ,uantity is e7ported to aromatics plant. ,(. )ue+ "as S0ste-! Cracker Plant is self sufficient of in fuel re,uirements. All fuel gas maLority methane from demethanise, residue gas from chilling train and purge gas from P%A unit is mi7ed in fuel gas mi7ing drum and is consumed in main, recycle and 9.+ furnaces at &.) kg>cm#g pressure. 67cess fuel gas during normal plant operation is e7ported at ).) kg>cm# g pressure level from the compressor. Provision of using C( raffinate from main and au7. C( hydrogenation units ;or= form '% / storage is provided as back up. Provision of using propane > off .spec propylene from '% / storage sphere. propane directly from propylene fracitonator is also provided. discharge off e7pander
"6 0 0 22/06/2012 BMK
SECTION
/P9 from '% / /P9 bullets can also be routed to fuel gas system through vaporisers in case of re,uirement. 3ue to various combination of full from methane during normal operation to C( raffinate during emergencies, homogeniser system is provided at the down stream of mi7ing drum to adLust density of fuel to furnaces. $uel gas is first superheated with //P steam and /MP steam is inLected superheated in the homogeniser based on the density of the fuel gas entering the homogeniser. $or initial start?up high pressure of fuel gas form '% / is provided as make up into the fuel gas mi7ing drum. 3esign specification of fuel gas MoleA C" C# C& C'# .#' .#% 5#.)A ".04A *."A ).2A *.*"A ( PPM mol>mol @ #2 kg>cm#g @ "&**C @ "2.5
Process description and Utilities PAGE REV ISSUE DATE AUTHOR " 0 0 22/06/2012 BMK
'perating pressure 3esign M1

'perating temperature
SECTION
,(2 Nitrogen Process Air% Instru-ent Air S0ste,(2(1 Nitrogen :itrogen is supplied to cracker at two pressure levels as .P :itrogen and /P :itrogen. This is supplied from air separation unit. ,(2(1(1 $P Nitrogen .P :itrogen is used during start?up as a sealing medium for compressor during start?up air run. 3uring normal operations. .P :itrogen is used in pump seals. Apart from '% / import, battery of .P nitrogen cylinders ;two sets= is provided to maintain I% / header pressure to PMP seals as back up in case of any drop in '% / header pressure. ,(2(1(' LP Nitrogen /P :itrogen is used for various services as tank blanketing, seal gas for ethylene refrigerator compressors and for hose stations with :8B to cannot to any e,uipment for purging etc. oth .P C /P :itrogen shall be oil free, dew point of ?"***C at atmospheric pressure and ma7. o7ygen gas content of "* ppm mol>mol.
CHECKED BY N.S.P APPROVED BY B. DAS Process description and Utilities PAGE REV ISSUE DATE AUTHOR "! 0 0 22/06/2012 BMK
SECTION
3
Pressure
:ormal .P :itrogen /P :itrogen ,(2(' &* 2
Min. #2 ?
Ma7. ? 4
Instru-ent Air
Instrument air is supplied form '% / by CPP which is compressed, dried and free of oil. Two parallel headers one at "*# : piperack and other at "*) : pipe rack maintain the re,uirement of IA throughout the plant. Pressure Cg#c-'g /in( Nor-a /a3( (.) + 2.* 2.) Te-perature 90C< /in( Nor-a /a3 &* + () )* 90C<
?(*
,(2(, P+ant Air Plant air is supplied from '% / by CPP which is compressed, saturated to moisture at the supply pressure. The oil content shall be ma7. *.) ppm wt>wt supply propane. The air is fed from the hose points to e,uipments which re,uired deinertisation etc. Pressure Nor-a+ 2.* Te-perature /in( Nor-a+ /a3( &* () )*
/in( 0.*
/a3( 4.*
"" 0 0 22/06/2012 BMK
SECTION
,(4 Ser6ice *ater S0ste%ervice water which is treated raw water is supplied by CPP to '% / which is used as service water at hose stations for washing etc. and an drinking water at control room, changerooms and yard toilet. Also this water is supplied to laboratory for cleaning, washing etc. Speci;ications ;or Ser6ice *ater p. @ Thurbidity @ Chloride @ %ulphate @ P?Alkalinity @ M?Alkalinity @ Total Anions @ Total .ardness @ Magnesium .ardness @ %odium @ Total Cations @ Total %ilica @ Collected silica @ Total iron @ Total 3issolved solids @ 2.4 # :TB &# ppm as cl. &) ppm as %'( :il "42 as Ca C'& ppm #05 as Ca C'& ppm "&( as Ca C'& ppm 0# as Ca C'& ppm "&) as Ca C'& ppm #05 as Ca C'& ppm "* as %i'# ppm *.# as %"'# ppm *.) as $6 ppm "2* ppm
100 0 0 22/06/2012 BMK
SECTION
,(@ D/ *ater s0ste3M water is imported from CPP at a ma7imum peak flow rate of #)* m&>hr during start?up and upsets. 3M water is received in 3M water storage tank and pumped to deaerator as make?ups. Also provision is provided for make up into ,uench water tower for make up. during upsets > start?up, 3M water consumption is minimised by recycling the condensate from various system. 3M water from '% / has the following specifications @ p. @ Total dissolved solids @ Total hardness @ Chlorides @ Iron @ 6lectricity conductivity @ Total silica @ %odium @ Colour @ :il Colourless :il :il .**) ppm as $6 *.# ms>cm *.*# as %i'# ppm 0.) to 2.* *.) ppm
101 0 0 22/06/2012 BMK
SECTION
,(5 )ire ?ater s0ste$ire water is received from the hydrant header surrounding the plant I% / from '% / fire water system. 6very area is provided with divide headed fire hydrant points with fire hose bo7 adLacent to them. 6ach hydrant point has an isolation valve and hydrant points ;single= on the structures has been provided with common isolation valve at grade. Apart from hydrant points, on line water monitors are provided at strategic locations. -uench fittings on main and recycle furnaces are provided with manual deluge system to be care of any fire emergency at this locations. .eaders in each area of the plant can be isolated by closing slice valves provided at both the ends of the network. ;8efer enclosed singe line sketch=.
102 0 0 22/06/2012 BMK
SECTION
,(A ELECTRIC PO*ER S7STE/ ! 6lectrical power at && !B, )* .D for start?up and normal operations shall be available from the '% / central electrical power handling facility at the battery limit. The electrical power system is characterised as follows @
Particu+ars
A $re,uency of all AC power supply 6lectrical Power 9eneration @ 6mergency 9enerator @ Type Boltage /evel Primary 3istribution in '% /@ Type Boltage /evel 3C Power supply system@ Boltage /evel a=
Speci;ication
)* .P S &A AC & phase (") B S 0A AC, & phase && !B S )A ##* B ?#*A E "*A,
Suggested Users
C 3
Critical lighting supply for breakers, annunciators.
control circuit alarm ;all in
b= ""* B ?#*A c= #( B 3C 6 a= b 'ther AC Power %upply %ystem @ Type Boltage /evel Type Boltage /evel Type Boltage /evel AC & phase 0.0 !B S 0A AC, & phase (") B S 0A AC " phase #(* B S 0A 8elay logic, switches, solenoid valves in I% /. Motor drives above "0* !1 Motor drives ;*."4 !1 to "0* !1, lighting, welding machine, overhead crane. Motor drives below *."4 !1 C control supply for (") B motor contactor, instrument cabinet lighting, hand lamp socket, portable tools, motor panel > space heater, plant communication, fire alarm, level gauge illumination. All instrument, 3C% PAGE REV ISSUE DATE AUTHOR 103 0 0 22/06/2012 BMK E "*A, %hutdown system solenoid valves= e7isting plant area.
Type Boltage /evel +P% based :on +P% CHECKED BY N.S.P APPROVED BY B. DAS
AC, " phase ""* B S #A ""* B S )A Process description and Utilities
SECTION
3
e Type Boltage /evel
AC, " phase #( B S 0A
$or handheld > portable lighting
UTILIT7 CONDITIONS AT =ATTER7 LI/IT

A// %T86AM P86%%+86 %.A//
S+( A Particu+ars %.P %team Pressure Temperature .P %team @ Pressure temperature .P %team ;Import=@ Pressure Temperature /MP %team ;67port=@ Pressure Temperature /P %team ;Import=@ Pressure Temperature //P %team ;67port=@ Pressure Temperature %team Condensate ;67port=@ Pressure ;note?&= Temperature Instrument Air @ Pressure Temperature Plant Air Pressure Temperature /P :itrogen 9as@ Pressure Temperature .P :itrogen 9as@ Pressure Temperature %ervice 1ater Pressure Temperature $ire 1ater@ Pressure Temperature Cooling 1ater %upply Pressure %upply Temperature
6 C':%I36863 A% AT 98A36 /6B6/ @

Unit kg>cm#g C kg>cm#g C kg>cm#g C kg>cm#g C kg>cm#g C kg>cm#g C kg>cm#g C kg>cm#g C kg>cm#g C kg>cm#g C kg>cm#g C kg>cm#g C kg>cm#g C kg>cm#g C (.* Ambient Operating Conditions /ini-uNor-a+ /a3i-u"*# (4) &4 &0* ") #&) "".) #(* ( "0* &.* "0) & AM ( &* ( &* 2 Ambient &* Ambient ( Ambient "*) )** (* &2& "2 #() "# #0* (.) "2* &.) "42 (.) AM 0.) () 2.* () 4 Ambient &# Ambient ).) Ambient "* Ambient ) &( 0 &( 2.) )* 2.) )* 5 && Ambient 2 Ambient "*2 )"* (# (** "4 #4* "& #2* ).) #** (.) ;(= Design ""# ;(= )"* (2 (#* ## &)* ") &** 4." #2* 0.) #)* "2.5 0) "*.) 0) "*.) 0) "*.) 0) (* 0) "* 0) "# 0) 4.* 0)
C 3 6 $ 9 . I O ! / M :
104 0 0 22/06/2012 BMK
SECTION
' P -
8eturn Pressure 8eturn Temperature 3emineraliDed ;3M= 1ater@ Pressure Temperature 3rinking 1ater Pressure Temperature /P oiler $eed 1ater@ Pressure Temperature
kg>cm#g C kg>cm#g C kg>cm#g C kg>cm#g C *.) Ambient
#.) (& ) Ambient " Ambient #".# "") 2.) Ambient &.*
4.* 0) "* 0) ).* 0) &&.) "2.*
105 0 0 22/06/2012 BMK
SECTION
E))LUENTS
106 0 0 22/06/2012 BMK
SECTION
.(0 P+ant e;;+uents and Disposa+ /et ods! 3ue to comple7 nature of operations, a variety of solid, gaseous and li,uid effluents are obtained form the gas cracker plant. This is intended that all operating personnel shall take all necessary measures to minimise effluents generation. .(1 So+id e;;+uents! CoCe! Coke is the solid waste product obtained during decoking operation from the decoke pots and during hydroLetting of +%M and collection headers. This is being disposed off to '% / as land fill. y the addition of 3M3% to the feed of cracking main and recycle furnaces, this coke formation is minimised. .('"aseous e;;+uents ! )+ue "ases ! There are produced in cracking furnaces and in 9.+ furnaces which are released to atmosphere continuous. The ,uality of this effluent from cracking furnace is continuously monitored by one line C' and '# analysers. Also, complete emission constituents are analysed by central environmental monitoring cell to ensure adherence to local statutory re,uirements.
"ases $0drocar:ons
10 0 0 22/06/2012 BMK
SECTION
3uring normal operation, no gases effluents are produced as most all of the vent gases are recycled into the process system for recovery. $ew discharges as 9.+ stripper vent and spent caustic o7idation stripper vents are routed into flare system where they are flared at ""* M high level. $or the completion of combustion, steam is inLected into the flare system. Also, hydrocarbon vent during unit upset is routed to flare stack for complete combustion and safe disposal. .(,LiFuid E;;+uents ! Stor- *ater ! 1ater during rains is collected in the I% / by means of catch pits and are routed to two storm water walls, located at north and south side of the plants with slice gate to stop flow into the storm water channel. 3uring normal season, the water collected into these walls from fire water drain, boiler drum C 3, decoke pot drain and steam condensate drains are pumped to effluent treatment plant for suitable treatment and disposal. 3uring monsoon, water collected in these walls overflow into the storm water channel and are disposed into Tapi 8iver entry.
Oi+0 ?ater se?er !

SECTION
1ater containing traces are hydrocarbon, seal cooling li,uid form pump seals, dil. steam generation blowdown, suspect condensate drain, and other process a,ueous plant drain are collected into '1% well via hubs connected to underground closed piping system. This is pumped to effluent treatment plant for suitable treatment and disposal. Spent Caustic E;;+uent ! %pent Caustic from Caustic Tower after treatment with gasoline and additives is pumped to spent caustic o7idation unit where C'3 and sulfur content is reduced to the great e7tent. Also, stripper provided at the upstream of spent caustic o7idation unit removes aromatic components. Thus this effluent is neutralised with hydrochloric acid to pit of 2.* and pumped to effluent treatment plant for disposal. CPU regeneration ?aste ! 8egeneration water effluent from condensate polishing unit is mi7ed along with %C' effluent and neutralised to p. 2.* and sent to 6TP for disposal. >uenc oi+ se?er ! All heavy oil drains in the prefractionation area is collected in a hubs which are connected to double pipe underground network to drain drum. $rom the drain drum it is recycle back into ,uench oil tower or can be sent to '% / storage tanks.
SECTION
E/ER"ENCIES
110 0 0 22/06/2012 BMK
SECTION
2(0 E-ergenc0 S utdo?n In all cases of emergency, the 'perator in charge shall e7ercise his discretion regarding shutdown, bearing in mind @ a= The safety of Personnel b= The safety of e,uipment $ailure of an individual pumping unit, where a standby unit is available for immediate serviceN individual instrument, failure, where bypass or direct manual control ;handLack= is available, and similar isolated or individual failures must not be treated as re,uiring emergency shutdown. Momentary failure of any utility should be treated as a temporary emergency and any tripped e,uipment or its standby unit must be commissioned, as ,uickly as possible. ,uench oil failure must not be treated as re,uiring emergency shutdown. -uenching of the furnace effluent is automatically continued by naphtha. Continue operation unit it is obvious that oil circulation canRt be restored and a planned shutdown is then carried out. %hutdown of the furnaces should be undertaken if the base li,uid level of the ,uench oil tower, C?#"*, approaches the transfer line inlet noDDle elevation and disposal of ,uench oil continues to be a problem. If ,uenching of the furnace effluent is insufficient for any reason, hydrocarbon feed should be taken out of the furnaces. If a compressor should trip due to
SECTION
an in?built safety system, the fault should be cleared before restartN trips must not be overridden. The e7tent to which the furnaces are kept on line during such an emergency will depend upon individual circumstances but there should be normally no necessity to use an emergency trip on the furnaces. The trip of any system, and in particular the reactor systems, must be thoroughly investigated before attempting to bring them back into operation. Again no emergency trip of any other e,uipment should be necessary in this case. 6mergency shutdowns will be carried out for the following events @ ". Total and sustained electric power failure #. Total and sustained cooling water failure. &. Total and sustained instrument air failure (. /oss of steam pressure ). +ncomfortable leakage of hydrocarbons 0. %erious and uncontrollable fire. The PCI diagrams show the maLor automatic alarm and shutdown systems included in the plant. %'P must be consulted as necessary for detailed operation.
E+ectric Po?er )ai+ure

SECTION
A sustained power failure is regarded as a remote possibility but would however result in the shutdown of @ ?furnaces, due to induced draft fan failure ;%3?# ?pumps and normal plant lighting Motor driven compressors Actions to be taken if Power is not Immediately 8estored@ a= lock off all hydrogen supply to the C# .ydrogenation 8eactors, depressurise the reactors and nitrogen and nitrogen purge. lock in regeneration air flow if any is being used. 8efer to the I$P 'perating Manuals for information on handling the C&,C( 9asoline .ydrogenation units. b= Close cracking furnace burner cocks, block in hydrocarbon fuel supply, close dampers to reduce rate of refractory cooling. Close decoking air if any was used. Try to maintain dilution steam to furnaces as long as is necessary to purge coils. c= If available, continue cooling water flows to all units. 8elease e7cessive pressures in e,uipments to the flare, using safety valve bypass valves, or depressuriDation control valves, in preference to allowing the safety valves to lift and possibly not reset. d= lock in cracked gas dehydrators, take note of regeneration status when blocking in regeneration lines. e= %hut off heating medium to fractionation tower reboilers at control valves and > or block valves.
SECTION
f= Isolate the various refrigeration stages by block valves to prevent pressure migration, if it is decided to shutdown the compressors. g= 8educe li,uid levels in towers and drums to near normal, by either pressuring to the ne7t process se,uence or to blowdown drums, In the choice being a dependent restart upon an circumstances. general, where after
emergency shutdown is anticipated fairly soon, levels should be maintained at the optimum to facilitate the restart. h= 6,uipment should be shutdown and shut in as far as possible by means of control room instruments, particular attention being paid to e,uipment pressures. Coo+ing *ater )ai+ure Cooling 1ater failure will automatically trip all +%C and 8ecycle furnaces to %3?# ?C9 Compressor ?C# .ydrogenation unit on offspec. Actions to be taken at a %ustained 1ater $ailure a= lock in furnaces as under 5.#.";b= block in. c= %top all heating media to reboilers. d= 8emove hydrogen from reactors and block in as under 5.#". ;a= b= %top electrically driven process compressors ; ?2(* A> = and
114 0 0 22/06/2012 BMK
SECTION
e= %top charge pumps, stop reflu7 pumps as reflu7 drum levels drop. f= 'n a system by system basis release e7cessive pressures in e,uipment to the flare only when re,uired, using safety valve bypass valves or drpressuriDation control valves, in preference to allowing the safety valves to lift and possibly not reset. 9reat care must be taken not to overload the flare relief system by dumping large relief loads simultaneously. g= 8educe li,uid levels in towers and drums to near normal by either pressuring to the ne7t process se,uence or to blowdown drums, In the choice being a dependent restart upon an circumstances. general, where after
emergency shutdown is anticipated fairly soon, levels should be maintained at the optimum, to facilitate the restart. h= 6,uipment should be shutdown and shut in as far as possible, by means of the control room instruments, particular attention being paid to e,uipment pressures. i= %top the pumping of fresh caustic solution to the caustic wash tower. L= %top the inLection of 3M3% to the $urnaces and shutdown all other process chemicals inLection systems. k= %top all product withdrawal Instru-ent Air )ai+ure Air failure would be result in the failure of activating air to control valves. the instrument design of the plant is such that
115 0 0 22/06/2012 BMK
SECTION
the valves move to put the plant in the safest possible condition under the circumstances. Action to be taken on a 9eneral Instrument Air $ailure All automatic valves will have gone to the fail?safe position, block valves on the following systems should also be closed to make doubly sure of safe conditions. a= lock off hydrogen to all reactors, proceed as under 5.#.";a=. b= %hutdown furnaces as under 5.#.";b=. c= block in compressors and refrigeration system. d= lock in cracked gas dehydrators as under 5.#.";d=. migration. f= lock off heating medium to reboilers, preheaters, etc. levels by use of control valve bypasses pressuring to the ne7t process se,uence or the blowdown drum, maintaining ade,uate levels to facilitate the starting operation. Loss o; stea- pressure 3ependent upon the steam main involved various emergencies could occur and the senior operator will need to e7ercise his discretion upon the appropriate action to be taken. I: all cases every effort must be made to continue dilution steam flows to the cracking furnaces until all hydrocarbon materials are purged out. g= 8educe li,uid levels in towers drums to normal working e= Isolate the various refrigeration stages to prevent pressure
116 0 0 22/06/2012 BMK
SECTION
5
Action to be taken
a= Conserve the dilution steam main pressure as long as possible, reducing higher pressure steam consumption wherever possible. b= Activate shutdown " on all furnaces. This will cut out furnace feed, add dilution steam to the hydrocarbon coils and cut 0*A of the heat input to the furnaces. c= If dilution steam failure is imminent, activate shutdown # on all furnaces. In addition to the %3?" trips, this will cut out all gas burners and after a short purge period, shut off the dilution steam flow. It is possible that furnaces which suffer dilution steam failure before the short purge period will re,uire decoking before the ne7t start?up. d= If the %?"*) steam supply pressure falls, stop the cracked gas compressor to maintain the 8efrigeration Compressors in service if re,uired depending on the steam demand at low levels. NOTE @ 1hen intending to shutdown furnaces or any other e,uipment in an emergency situation, do not proceed by an indirect route, i.e. making a process alteration which will in normal se,uence lead to the desired shutdown action.
11 0 0 22/06/2012 BMK
SECTION
If shutdown " or # on the furnaces is called, for, activate the switches provided, checking that all furnace conditions proceed thereby to the desired safe condition.
11! 0 0 22/06/2012 BMK
SECTION
Uncontro++a:+e LeaCage and )ire Actions to be taken at the occurrence of a large leakage or fire will obviously depend upon the location of the fire, the pro7imity of other inflammable materials and numerous other variables. Company standard fire drill procedures should be followed while the plant is being shutdown in as orderly a manner as possible, e7tinguishing all furnace burners as ,uickly as possible, stopping fans and closing furnace stack dampers, isolating the burning e,uipment and cutting off supplies of inflammable material to the source of the fire. Motor operated isolation valves are installed on the common suction lines to all hydrocarbon pumps and are also installed on the first stage suction, third stage discharge, and the fourth stage suction and discharge of the cracked gas compressor, and the suction and discharge of all stages of the propylene and ethylene refrigerant compressors, and also maLor product streams. All these valves are operable from the field so that easier isolation can be achieved. In the case of pumps, the pump motor is tripped when the remote isolation switch is activated. %nuffing steam purges to pump seals are provided with remote field valves. 3uring release any to plant the emergency and or normal shutdown, the
containment of gaseous and li,uid hydrocarbons with controlled flare blowdown must be enforced. Inflammable li,uids accidentally entering surface drainage
SECTION
systems and hydrocarbon vapours can lead to haDardous conditions or an increase in an e7isting conflagration.
120 0 0 22/06/2012 BMK
SECTION
E>UIP/ENT LIST
121 0 0 22/06/2012 BMK
SECTION
4(0 EFuip-ent List Section " # & ( ) 0 2 4 5 "* =UILDIN"S

ITE/ NO(
Tit+e +I/3I:9% 8'TATI:9 6-+IPM6:T% T'168% 6MC.A:968% 96:68A/ 6-+IPM6:T $+8:AC6% P+MP% 86ACT'8% TA:!% 38+M%
DESCRIPTION
A A A A A A A A A A A A A A
**& **( "*" "*) ""* "#* &*" (*" ("* ()* )"* 0*" 2*" 5*"
Mechanical 1orkshop>3ining 8oom .BAC Chilling +nit Compressor .ouse MCC C Control house 9as Turbine Control .ouse $urnace Analyser %helter :o." $urnace Analyser %helter :o.# Cracker 9as Compressor %helter Methane Compressor %helter Cold $ractionation Analyser %helter :o." Cold $ractionation Analyser :o.# 1arm $ractionation Analyser %helter 8efrigeration Compressor %helter 9...+. Compressor %helter $uel 9as Compressor %helter
122 0 0 22/06/2012 BMK
SECTION
ROTATIN" E>UIP/ENT
ITE/ NO( "** "*" A> "*# "*& ""* """ "#* "#" "&* "&" "(* ")* "0* "2* "4* "5* "5# "5( "50 &** (#* (#" 0** 0)* 2"* A> 2(* A> 5** 5") ""*" A> ""#" A> >C T "*# T &** T 0** T 0)* T 5** >T7( " # " " " " " " " " " " " " " " " " " " " " " " # # " " # & " " " " " DESCRIPTION 9as Turbine $3 $an ;Motor 3riven= $3 $an ;Motor 3riven= 9T $uel gas Compressor I3 $an ;+%C $urnace= I3 $an ;+%C 8ecycle $urnace= I3 $an ;+%C $urnace= I3 $an ;+%C 8ecycle $urnace= I3 $an ;+%C $urnace= I3 $an ;+%C 8ecycle $urnace= I3 $an ;+%C $urnace= I3 $an ;+%C $urnace= I3 $an ;+%C $urnace= I3 $an ;+%C $urnace= I3 $an ;+%C $urnace= I3 $an ;+%C $urnace= I3 $an ;+%C $urnace= I3 $an ;+%C $urnace= I3 $an ;+%C $urnace= Cracked 9as Compressor Methane 8ecompressor Methane 67pander 6thylene 8efrigerant Compressor Propylene 8efrigerant Compressor "st %tage Make?up and 8ecycle Compressor #nd %tage Make?up and 8ecycle Compressor $uel 9as Compressor Polisher Air lower .igh Pressure Air Compressors %C' 8eactor $eed Air Compressor $3 $an Turbine Cracked 9as Compressor Turbine 6thylene 8efrigerant Compressor Turbine Propylene 8efrigerant Compressor Turbine $uel 9as Compressor Turbine
123 0 0 22/06/2012 BMK
SECTION
*+1&.S
ITE/ NO( #"* ##* #&* #(* #)* #0* #2* #4* &(* &)* &0* ("* (#* (&* ((* (0* (2* )"* )&* )&) )(* ))* )0* 2#* 2&* 2)* ""*" >T7( " " " " " " " " " " " " " " " " " " " " " " " " " " " DESCRIPTION -uench 'il Tower -uench 1ater Tower .eavy $uel 'il %tripper /ight $uel 'il %tripper 3istillate %tripper /P 1ater %tripper 3ilution %team %tripper Au7iliary 3ilution %team %tripper Caustic Tower Cracked 9as 8ectifier Condensate %tripper 3emethaniDer Prestripper 3emethaniDer 8esidue 9as 8ectifier 3eethaniDer 6thylene %tripper 6thylene 8ectifier 3epropaniDer %econdary 3eethaniDer Tertiary 3eethaniDer Propylene %tripper Propylene 8ectifier 3ebutaniDer 3epentaniDer 3eoctaniDer %tripper %team %tripper
C C C C C C C C C C C C C C C C C C C C C C C C C C C
124 0 0 22/06/2012 BMK
SECTION
&2'0AN/&.S
ITE/ NO( 6*"" 6 *(" 6 *)" A> 6 *)# 6*)& 6 ""* A>., O>6 """ 6 "") A>3 6 "#* A>., O>6 "#" 6 "#) A>3 6 "&* A>., O>6 "&" 6 "&) A>3 6 "(* A>., O>6 "(" 6 ")* A>., O>6 ")" 6 "0*, A>., O>6 "0" 6 "2* A>., O>6 "2" 6 "4* A>., O>6"4" 6 "5* A>., O>6 "5" 6 "5# A>., O>6 "5& 6 "5( A>., O>6 "5) 6 "50 A>., O>6 "52 6 #"* A>C 6 #") A> 6 #"5 6 ##* A>9 6 #&* A>., O>! 6 #&5 >T7( " " # " " "0 " ( "0 " ( "0 " ( "0 " "0 " "0 " "0 " "0 " "0 " "0 " "0 " "0 " & # " 2 "* " DESCRIPTION 6thane>Propane 8ecycle .eater :aphtha $eed .eater A9' $eed .eater A9' $eed .eater :o.# A9' $eed .eater :o.& +%M 67changer ;+%C $resh $eed $urn.= T/M 67changer ;+%C $resh $eed $urn.= +%M 67changer ;+%C $resh $eed $urn.= +%M 67changer ;+%C $resh $eed $urn.= T/M 67changer ;+%C $resh $eed $urn.= +%M 67changer ;+%C $resh $eed $urn.= +%M 67changer ;+%C $resh $eed $urn.= T/M 67changer ;+%C $resh $eed $urn.= +%M 67changer ;+%C $resh $eed $urn.= +%M 67changer ;+%C $resh $eed $urn.= T/M 67changer ;+%C $resh $eed $urn.= +%M 67changer ;+%C $resh $eed $urn.= T/M 67changer ;+%C $resh $eed $urn.= +%M 67changer ;+%C $resh $eed $urn.= T/M 67changer ;+%C $resh $eed $urn.= +%M 67changer ;+%C $resh $eed $urn.= T/M 67changer ;+%C $resh $eed $urn.= +%M 67changer ;+%C $resh $eed $urn.= T/M 67changer ;+%C $resh $eed $urn.= +%M 67changer ;+%C $resh $eed $urn.= T/M 67changer ;+%C $resh $eed $urn.= +%M 67changer ;+%C $resh $eed $urn.= T/M 67changer ;+%C $resh $eed $urn.= +%M 67changer ;+%C $resh $eed $urn.= T/M 67changer ;+%C $resh $eed $urn.= +%M 67changer ;+%C $resh $eed $urn.= T/M 67changer ;+%C $resh $eed $urn.= $uel 'il Product Cooler -uench 1ater %team .eater Pan 'il Trim Cooler Primary ,uench water cooler %econdary ,uench water cooler /$' %tripping %team %uperheater
125 0 0 22/06/2012 BMK
SECTION
6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6
ITE/ NO( #)* #)4 #)5 #0) A> #05 #2* A>3 #2" A>. #2& #2( #25 #4* A>C &"* A>C &"* A>$ &#* A>C &&* A>C &(* &(" &() A>3 &)) &)5 &0* A> &2" &2# &2& &2( &2) (*" (*# (*& (*( (*) (*0 (*2 (*4 (*5 ("* ("" ("# ("& ("( (") ("5 (#* (#" (##
>T7( " " " # " ( 4 " " " & 0 & & " " ( " " # " " " " " " " " " " " " " " " " " " " " " " " " "
DESCRIPTION 3istillate %tripper 8eboiler 1ater %tripper $eed .eater 3%% d.>1ater %tripper $eed .eater 3%% $eed .eater :o." 3%% $eed .eater :o.# 3%% %team 8eboiler 3%% -.'. 8eboiler 3%% lowdown Cooler Au7iliary 3ilution %team %tripper lowdown Cooler Au7. 3ilution %team %tripper $eed .eater Au7. 3ilution %team %tripper 8eboiler C.9. $irst %tage Aftercooler C.9. %econd %tage Aftercooler C,9. Third %tage Aftercooler 1eak Caustic .eater 1ash 1ater Cooler C.9. $ourth %tage Aftercooler C.9. 8ectifier 'verhead Condenser Condensate %tripper $eed .eater Condensate %tripper 8eboiler Condensate %tripper 8eboiler 8eact. 9as $eed > 6ffluent 67changer 8eact. 9as $eed .eater 8eactivation 9as $eed Cooler 8eactivation 9as $eed Chiller 8eactivation 9as 6ffluent Cooler 3emethaniDer Precooler :o." 3emethaniDer Precooler :o.# 3emethaniDer Precooler :o.& 3emethaniDer Precooler :o.( 3emethaniDer Precooler :o.) 3emethaniDer Precooler :o.0 3emethaniDer Parallel Precooler :o." 3emethaniDer Parallel TM% 8eheater 3emethaniDer Parallel Precooler :o.# 3emethaniDer Prestripper 8eboiler 3emethaniDer Core 67changer :o." 3emethaniDer Core 67changer :o.# 3emethaniDer Core 67changer :o.& 3emethaniDer Core 67changer :o.( 3emethaniDer Core 67changer :o.) .ydrogen Core 67changer 3emethaniDer 8eboiler 3emethaniDer Parallel Precooler :o.& 3emethaniDer Parallel Precooler :o.(
126 0 0 22/06/2012 BMK
SECTION
&2'0AN/&.S
ITE/ NO( (#( (#) (#0 (#2 (&4 (&5 A> ((* A>C (() A>3 ()* ()# A>3 ()) ()0 A> ()4 (0* (0" (2* A> (2) A>3 (22 (24 (4* (4" (4# (5* (5" A> )"* A> )") A> )#" )## )&* )&) )&0 )&2 )(* A>3 )(" A> )(# ))) A>. ))0 )0* A> )0) )00 0() >T7( " " " " " # & ( " ( " # " " " # ( " " " " " " " # # " " " " " " ( # " 4 " # " " " DESCRIPTION 3emethaniDer Precooler :o.0 3emethaniDer Condenser Methane Product .eater Methane Product .eater 3emethaniDer ottoms 8eheater 3emethaniDer, Prestripper tms 8eheater 3eethaniDer 8eboiler 3eethaniDer Condenser C# .ydrog. $eed .eater C# .ydrog. $eed > 6ffluent 67changer C# .ydrog. Adia. 8ct. Intercooler :o.# C# .ydrog. Adia. 8ct. Aftercooler C# .ydrog. Adia. 8ct. Intercooler :o." 6thylene %tripper 8eboiler 6thylene 8ecycle Baporiser 6thylene 8ectifier 8eboiler 6thylene 8ectifier Condenser 6thylene Product Baporiser 6thylene Product %uperheater 6thylene Product Cooler :o." 6thylene Product Cooler :o.# 6thylene Product Cooler :o.& .P 6thylene Product .eater :o." .P 6thylene Product .eater :o.# 3epropaniDer 8eboiler 3epropaniDer Condenser Interstage Cooler Catalyst Treatment %econdary 3eethaniDer 8eboiler %econdary 3eethaniDer Condenser Tertiary 3eethaniDer 8eboiler Tertiary 3eethaniDer Condenser Propylene Tower 8eboiler Propylene Tower Au7. 8eboiler Propane 8ecycle Baporiser Propylene Tower Condenser Propylene Product Cooler 3ebutaniDer 8eboiler 3ebutaniDer Condenser Pyrolysis 9asoline Product Cooler C# 8efrigerant 3esuperheater :o."
6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6
12 0 0 22/06/2012 BMK
SECTION
&2'0AN/&.S
ITE/ NO( 0(0 0(2 0(5 A> 0)* 05) 055 A>., O>! 2*" 2*# 2"" 2"# 2"& 2#* 2#) 2#0 2&* A> 2&" 2&# 2&) 2&0 2&2 2&4 2(* A> 2(" 2(# 2(5 A> 2)* 2)" 2)) 4*" 4*# 4*& 4*( 4*) 4*0 4*2 4*4 5** 5*# 5*& 5*( 5*) 5*0 5*2 5*5 >T7( " " # " " "* " " " " " " " " # " " " " " " ) " " # " " " " " " " " " " " " " " " " " " " DESCRIPTION C# 8efrigerant 3esuperheater :o.# C# 8efrigerant 3esuperheater :o.& Au7. C# 8efrigerant Condenser C# 8efrigerant %ubcooler C& 8efrigerant 3esuperheater C& 8efrigerant Condenser "t %tage 8eactor $eed>6ffl. 67changer "st %tage 8eactor %tart?up .eater "st %tage -uench Cooler .ot %eparator Bapour Condenser "st %tage Compressor ypass Cooler 3epentaniDer Condenser 3epentaniDer Condenser C) Product Cooler 3eoctaniDer 8eboiler 1ash 'il Condenser 3eoctaniDer ottoms Cooler 3eoctaniDer Condenser 3ecoct Post Condenser Cooler 1ash 'il Trim Cooler 6Lector Condenser #nd stage $eed > 6ffluent 67changer #nd stage 8eactor 6ffluent Cooler #nd stage Compressor ypass Cooler %tripper $eed > 6ffluent 67changer %tripper 8eboiler C0?C4 Product Trim Cooler %tripper Condenser 8eactor start?up heater 8ecycle Cooler Post Condenser Product Cooler C(. %tartup .eater ;+nit?#= C(. 8ecycle Cooler ;+nit?#= C(. Postcondensor ;+nit?#= C(. Product Cooler ;+nit?#= $uel 9as Compressor 8ecycle Cooler Cold lowdown Baporiser C) $uel Baporiser %uspect Cond. 3rum vent Condenser C&>C( $uel Baporiser $uel gas %uperheater Methanol Baporiser Cold $lare %uperheater
6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6
12! 0 0 22/06/2012 BMK
SECTION
&2'0AN/&.S
ITE/ NO( 5"* 5#* 5#" 5## 5&* 5&4 50* 50" 50) 500 54* 54" 54# 55* A> ""*" ""*# A> ""*& ""*( ""*) ""#" ""## ""#& >T7( " " " " " " " " " " " " " # " " " " " " " " DESCRIPTION !nock?out 3rum %lops Cooler Contaminated Condensate Cooler Condensate Polisher Inlet Cooler CP+ 6ffluent .eat 67changer C.9. Comp. %team Turbine Condenser 6Lector Condenser C# 8efrig. Comp. %team Turb Condenser P?50* 6Lector Condenser C& 8efrig. Comp. %team Turb Condenser P?50) 6Lector Condenser C#>C& 8efrig. Compressor /ube>%eal 'il Cooler C9 Compressor /ube 'il Cooler Cg Compressor %eal 'il Cooler $uel 9as Compressor /ube > %eal 'il Cooler %team %tripper $eed Pre?heater %team %tripper 6ffluent Cooler Influent > 6ffluent .eat 67changer '7idation 8eactor 6ffluent Cooler %C' Treated 6ffluent Cooler %C' 6ffluent Cooler %C' $eed > Bent 9as 67changer %C' Bent 9as Cooler
6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6
12" 0 0 22/06/2012 BMK
SECTION
GENERAL E?UIPMENT@
ITE/ NO( 9 &** 9 0)* / &** / 0)* / 5** % &** T9 &** T9 0** T9 0)* T9 5** 9 "*" 9 2"" 9 2&0 9 2(# 9 2)# 9 54" 9 54# 9 540 9 542 9 544 9 "*** P ""* P """ P "#* P "#" P "&* P "&" P "(* P ")* P "0* P "2* P "4* P "5* P "5# P "5( P "50 P #"* A> >T7( " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " " Turning 9ear Motor C9 Compressor /ube 'il Console 6 0)* C 6 0** /'>%' Console $9 Compressor /'>%' Console C9 Compressor %eal 'il Console C9 Compressor 9land %tm 6Lector Pkg C# 8efrig. Comp. 9land %tm. 6Lector Pkg C& 8efrig Comp 9land %tm. 6Lector Pkg $uel 9as Comp 9land %tm 6Lector Pkg Main Control 8oom .BAC Package Polymerisation Inhibitor Package Including : T-711, Z-711, P-711 A-D 3eoctaniDer 6Lector %ystem 3M3% InLection Package Including: P-742 Corrosion Inhibitor InLection Package Including : T-752, Z-752, P-752 Phosphate InLection Package Including : T-981, Z-981, P-981 A/C .ydaDine InLection Package Including: T-982, Z-982, P-982 A/B 3M3% InLection Package Including : T-986, P-986 A/B, P-995 A/D Corrosion Inhibitor Package Including: T-987. Z-987, P-987 A/B 3efoaming @ T?542, P?542, P?542 A> Including : T-988, Z-988, P-988 A/B %pent Caustic '7idation +nit -uench $itting ;+%C $urnace= -uench $itting ;+%C 8ecycle $urnace= -uench $itting ;+%C $urnace= -uench $itting ;+%C 8ecycle $urnace= -uench $itting ;+%C 8ecycle $urnace= -uench $itting ;+%C $urnace= -uench $itting ;+%C $urnace= -uench $itting ;+%C $urnace= -uench $itting ;+%C $urnace= -uench $itting ;+%C $urnace= -uench $itting ;+%C $urnace= -uench $itting ;+%C $urnace= -uench $itting ;+%C $urnace= -uench $itting ;+%C $urnace= -uench $itting ;+%C $urnace= -uench 'il $ilters DESCRIPTION
130 0 0 22/06/2012 BMK
SECTION
/&N&.A, &3U(PM&N*
ITE/ NO( #&* A> #0" A> &** &*" &#* &&* &&) &(* &(" &(# &(& &(( (** (*" 0*" 0*# 0"* A> 0"" 00* 05* 2*" 2*# A> 2"" 2&0 2(* 2)# 5** 5*" A> 5*# A> 5*& A> 5*( A> 5*) 5*0 5"* 5"( 5&* 50* 50) 54" 54# 542 544 55* >T7( # # " " " " " " " " " " " " " " " " " " " # " " " " " # # # # " " " " " " " " " " " " DESCRIPTION .eavy $uel 'il $ilter 1ater %tripper feed $ilters 'il Purifier Cracked 9as Compressor %ervice Crane Bane %eparator for #nd stage suction drum Bane %eparator for &rd stage %uction 3rum Bane %eparator for &rd stage suction drum Bane separator for (th %tage %uction 3rum Caustic 3iluent Mi7er 1eek Caustic Circ. Pump %uction %trainer %pent Caustic > Aromatic 9asoline Mi7er Caustic Area %ump Pressure %wing Adsorption +nit Methane Comp. %ervice Crane Main Compressor %ervice Crane 6thylene Compressor %ervice Crane 6thylene 8efrigerant 'il $ilters Bane %eparator for C#8 "st %tage %uction 3rum Bane %eparator for C&8 "st %tage %uction 3rum Bane %eparator for C&8 (th %tage $lash 3rum 9.+ Compressor %ervice Crane 8P9 $eed $ilters Polymerisation Inhibitor Mi7er 3eoctaniDer 6Lector %ystem #nd stage eLector Corrosion Inhibitor Mi7er Condensate Polisher %(* 3esuperheater %"# 3esuperheater %&.) 3esuperheater %uspect Condensate $ilters 9.+ 8eboiler %team 3esuperheater %MP 67traction %team 3esuperheater $lare %ystem ;outside attery /imits of Cracker= Polisher Acid Tank Agitator C9 Compressor Turbine 6Lector Package C# refrig Compressor Turbine 6Lector Pkg C& refrig compressor Turbine 6Lector Pkg Phosphate tank Agitator .ydraDine Tank Agitator Corrosion Inhibitor Tank Agitator 3efoaming Agent Tank Agitator 6mergency Power generator
P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P
131 0 0 22/06/2012 BMK
SECTION
/&N&.A, &3U(PM&N*
ITE/ NO( 55) A> 550 ""*" ""*& ""*( ""#" ""## ""#& A> >C ""#( ""#) ""#0 ""#2 >T7( # " " " # " " & " " " " DESCRIPTION %torm %ewer Collection %ump '1% Collection %ump Bapour %crubber %C' %team 3esuperheater Carbon Canisters %C' $eed Air $ilter %C' 8eactor $eed $ilter %C' 8eactor 6ffluent $ilters %C' %/M %team 3esuperheater %C' 8eactor %parger Capsules ;" /ot= %C' $eed %team $ilter %C' Bent 9as %ilencer
P P P P P P P P P P P P
)U.NA'&S
ITE/ NO( ""* """ "#* "#" "&* "&" "(* ")* "0* "2* "4* "5* "5# "5( "50 2"* 2(* >T7( " " " " " " " " " " " " " " " " " DESCRIPTION +%C $resh $eed $urnace +%C 8ecycle $urnace +%C $resh $eed $urnace +%C 8ecycle $urnace +%C $resh $eed $urnace +%C 8ecycle $urnace +%C $resh $eed $urnace +%C $resh $eed $urnace +%C $resh $eed $urnace +%C $resh $eed $urnace +%C $resh $eed $urnace +%C $resh $eed $urnace +%C $resh $eed $urnace +%C $resh $eed $urnace +%C $resh $eed $urnace "st %tage 8eactor Treatment $urnace #nd %tage 8eactor $eed .eater > 8egeneration $urnace
. . . . . . . . . . . . . . . . .
132 0 0 22/06/2012 BMK
SECTION
PUMPS
ITE/ NO( #"* A>C #"" A> ##* A>C ##" A> ##) A>C #&* A> #(* A> #)* A> #0* A> #2* &** A> &"* A> &#* A> &(" A> &(# A> &(& A> &(( A> &() A> &(0 A> &(2 A> &(4 A> &(5 &)) A> &0* A> (** A> (*" (#) A> (() A> ()" A>C (2* A> (2) A> )") A> )"0 A> )#* A> )&* A> )&) A> )&0 A> )&2 A> ))* A> ))) A> )0) A> 2*" A> 2"* A> >T7( & # & # & # # # # " # # # # # # # # # # # " # # # " # # & # # # # # # # # # # # # # # DESCRIPTION -.'. Circulating Pump Pan 'il Circulating Pump -uench 1ater Circulating Pump -uench 'il Tower 8eflu7 Pump %econdary -uench 1ater Circ. Pump .eavy $uel 'il Product Pump /ight $uel 'il Product Pump 3istillate %tripper ottoms Pump 3ilution %team %tripper $eed Pump -' 3rain 3rum Pump 1ash 'il InLection Pump C.9. "st %tage Condensate Pump 3istillate %tripper $eed Pump Concentrated Caustic Pump 1eak Caustic Circulating Pump Medium Caustic Circulating Pump %trong Caustic Circulating Pump 1ash 1ater Circulating Pump Caustic Area %umTp Pump Aromatic 9asoline Circulating Pump %pent Caustic 3ischarge Pump Aromatic 9asoline InLection Pump Cracked 9as 8ectifier 8eflu7 Pump Condensate %tripper ottoms Pump Methanol Pump Methanol +nloading Pump 3emethaniDer 8eflu7 Pump 3eethaniDer 8eflu7 Pump C( Coolant Circ. Pump 6thylene 8ectifier ottoms Pump 6thylene 8ectifier 8eflu7 Pump 3epropaniDer 8eflu7 Pump C& .ydrogenation $eed Pump C& .ydrogenation 8ecycle Pump %econdary 3eethaniDer ottoms Pump %econdary 3eethaniDer 8eflu7 Pump Tertiary 3eethaniDer ottoms Pump Tertiary 3eethaniDer 8eflu7 Pump Propylene Transfer Pump Propylene Tower 8eflu7>Product Pump 3ebutaniDer 8eflu7>Product Pump "st %tage $eed Pump "st %tage -uench Pump
P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P
133 0 0 22/06/2012 BMK
SECTION
PUMPS
ITE/ NO( 2"" A> 2#) A>b 2&* A> 2&" A> 2&) A> 2&0 A> 2(* A> 2(# 2)* A> 2)# 2)) A> 4*" A> 4*# A> 4*& A> 5** A>C 5*" A> 5*# A> 5"* A>C 5"( 5") A> 5"0 A> 5"2 5&* A> 5&" A> 5&# A> 5(# A> 5)0 A> 50* A> 50" A> 50) A> 52" A> 52( A> 54" A>C 54# A> 54& A>C 54) A>3 540 A>C 542 A> 544 A> 545 A> 55* A> 55" A>C >T7( ( # # # # # # " # " # # # # & # # & " # # " # # # # # # # # # # & # & ( & # # # # & DESCRIPTION Polymerisation Inhibitor Pump 3epent aniDer 8eflu7 Pump 3eoctaniDer ottoms pump 1ash 'il Transfer Pump 3eoctaniDer 8eflu7 Pump #nd %tage $eed Pump #nd stage -uench Pump 3M3% InLection Pump C0?C4 Product Pump Corrosion Inhibitor Pump %tripper 8eflu7 Pump $eed Pump 8ecycle Pump C( Product Pump oiler $eed 1ater Pump /P oiler $eed 1ater Pump knock?out 3rum %lops Pump oiler $eedwater Make?up Pump CP+ $eed Pump Polisher Caustic Pump Polisher Acid Pump Polisher 6ffluent Pump C9 Compressor Turbine Condensate Pump Cracked 9as Compressor %eal 'il Pump Cracked 9as Compressor /ube 'il Pump Methane 67pander > 8comp. Condensate Pump 3ebutaniDer 8eboiler Condensate Pump C#8 Comp. Turbine Condensate Pump C#>C& 8efrig Comp. /ube > %eal 'il Pump C&8 Comp. Turbine Condensate Pump %>6 /' Pump ?2"* A> %>6 /' Pump ?2(* A> Phosphate InLection Pump .ydraDine InLection Pump Polymerisation Inhibitor InLection Pump $resh $eed $urnaces 3M3% InLection Pumps 3M3% InLection Pump Corrosion Inhibitor InLection Pump 3efoaming Agent InLection Pump %uspect Condensate Pump $uel 9as Compressor /ube > %eal 'il Pump oiler $eedwater /ube 'il Pump
P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P
134 0 0 22/06/2012 BMK
SECTION
PUMPS
ITE/ NO( 55# A> 55) A>3 550 A> 552 A> ""*" A> ""*# A> ""*& A> ""*( A> ""#" A> ""## A> >T7( # ( # # # # # # # # DESCRIPTION Au7. Corrosion Inhibitor InLection Pumps %torm %ewer Transfer Pump '1% Transfer Pump Portable 3ewatering Pump %pent Caustic $eed > 8ecycle Pump .igh Pressure $eed Pumps 6ffluent Transfer Pumps %team %tripper ottoms Pump %C' 8eactor $eed Pump %C' 6ffluent Transfer Pump
P P P P P P P P P P
135 0 0 22/06/2012 BMK
SECTION
.&A'*+.S
ITE/ NO( ()" A>C ()# A> )&" A )&" )&" C )&# 2"* A> 2(* 4*" 4*# 4*& 4*( ""*" ""## A> >C >T7( & # " " " " # " " " " " " & DESCRIPTION C# .ydrog. Adiabatic 8eactor Prim. C# .ydrog. Adiabatic 8eactor C& .ydrog. 8eactor S " C& .ydrog. 8eactor S # C& .ydrog. 8eactor S & C& .ydrog. %econd %tage 8eactor $irst %tage 8eactor %econd %tage 8eactor .ydrogenation 8eactor $inal .ydrogenation 8eactor C(. 8eactor ;+nit?#= C(. $inal .ydrog. 8eactor ;+nit?#= '7idation 8eactor %C' 8eactor
8 8 8 8 8 8 8 8 8 8 8 8 8 8
*ANKS
ITE/ NO( &** &(* (** 2"" 2)# 5** 5"* 5"( 5") 5"0 54" 54# 54& 540 542 544 ""*" A> >T7( " " " " " " " " " " " " " " " " " DESCRIPTION 1ash 'il Tank Concentrated Caustic Tank Methanol Tank Polymerisation Inhibitor Tank Corrosion Inhibitor Tank CP+ $eed %urge 3rum $1 Make?up %torage Tank Polisher Acid %torage Tank Polisher Caustic Tank Polisher Acid Tank Phosphate Mi7ing Tank .ydraDine Mi7ing Tank Polymerisation Inhibitor Tank 3M3% Tank Corrosion Inhibitor Mi7ing Tank 3efoaming Agent Mi7ing Tank %pent Caustic .olding Tank
T T T T T T T T T T T T T T T T T
136 0 0 22/06/2012 BMK
SECTION
D.UMS
ITE/ NO( *0" ""* """ "#* "#" "&* "&" "(* ")* "0* "2* "4* "5* "5# "5( "50 "54 "55 #0# A> #2* &"* &#* &&* &&) &(* &(# &(& &(0 &)5 &2* A> &2" (*& (*0 ("* ("" ("# ("& ("( (") ("0 ("2 >T7( " " " " " " " " " " " " " " " " " " # " " " " " " " " " " # " " " " " " " " " " " DESCRIPTION /P9>C( raffinate Baporiser $eed 3rum %team 3rum ;+%C $urnace= %team 3rum ;+%C 8ecycle $urnace= %team 3rum ;+%C $urnace= %team 3rum ;+%C 8ecycle $urnace= %team 3rum ;+%C $urnace= %team 3rum ;+%C 8ecycle $urnace= %team 3rum ;+%C 8ecycle $urnace= %team 3rum ;+%C 8ecycle $urnace= %team 3rum ;+%C 8ecycle $urnace= %team 3rum ;+%C 8ecycle $urnace= %team 3rum ;+%C 8ecycle $urnace= %team 3rum ;+%C 8ecycle $urnace= %team 3rum ;+%C 8ecycle $urnace= %team 3rum ;+%C 8ecycle $urnace= %team 3rum ;+%C 8ecycle $urnace= 3ecoke 3rum %eparator>%ilencer 3ecoke 3rum %eparator>%ilencer 1ater %tripper $eed Coalescer -uench 'il 3rain 3rum C9 $irst %tage %uction 3rum C9 %econd %tage %uction 3rum C9 Third %tage %uction 3rum C9 Third %tage 3ischarge 3rum C9 $ourth %tage %uction 3rum %pent Caustic 3eoiling 3rum %pent Caustic 3egassing 3rum Cracked 9as 8ectifier 8eflu7 3rum Condensate %tripper $eed Coalescer Cracked 9as 3ehydrators 8eactivation 9as %eparator 3emethaniDer Preclr. :o.& 8efrig. $lash Pot 3emethaniDer Preclr. :o.0 $lash Pot 3emethaniDer Prestripper $eed 3rum 3emethaniDer $eed 3rum :o." 3emethaniDer $eed 3rum :o.# 3emethaniDer $eed 3rum :o.& 3emethaniDer Prestripper Parallel $eed 3rum 3emethaniDer Parallel $eed 3rum :o." 3emethaniDer Parallel $eed 3rum :o.# 3emethaniDer Parallel $eed 3rum :o.&
B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B
13 0 0 22/06/2012 BMK
SECTION
D.UMS
ITE/ NO( ("4 ("5 (#* (## (#& (#( (#) (#0 (&" (&# (&0 (() ((0 ()& A> ()) (0* (20 (22 (4* (4" (4# (5* )"0 )"5 )#) )&0 )&2 ))0 )00 0"* 0#* 0&* 0() 0(0 0)* 00* 02* 04* 05* 05) 050 2*" 2"* >T7( " " " " " " " " " " " " " # " " " " " " " " " " " " " " " " " " " " " " " " " " " " " DESCRIPTION Methane 67pander #nd %tage %uction 3rum 6?("5 !nockout 3rum 3emethaniDer 8eboiler 8efrig. %eal Pot 3emethaniDer Parallel Precooler S ( $lash Pot A 3emethaniDer Parallel Precooler S ( $lash Pot 3emethaniDer Parallel Precooler S 0 $lash Pot 3emethaniDer Condenser 8efrig $lash Pot 3emethaniDer 8eflu7 3rum .ydrogen 3rum P%A +nit %urge 3rum 8esidue 9as 8ect. 8eflu7 3rum 3eethaniDer Condenser 8efrig. $lash pot 3eethaniDer 8eflu7 3rum %econdary 3ehydrators C# .ydrogenation 6ffluent %eparator 6thylene %tripper 8efrig. %eal Pot 6thylene 8ectifier 8eflu7 3rum 6thylene Prod. Baporiser 8efrig. %eal Pot 6thylene Product Cooler :o." 8efrig. $lash Pot 6thylene Product Cooler :o.# 8efrig. $lash Pot 6thylene Product Cooler :o.& 8efrig. $lash Pot .P 6thylene Product .eater :o." %eal Pot 3epropaniDer 8eflu7 3rum C& .ydrogenation $eed Coalescer C& .ydrogenation %eparator %econdary 3eethaniDer 8eflu7 3rum Tertiary 3eethaniDer 8eflu7 3rum Propylene 8ectifier 8eflu7 3rum 3ebutaniDer 8eflu7 3rum 6thylene 8efrig. "st %tage %uction 3rum 6thylene 8efrig. #nd %tage %uction 3rum 6thylene 8efrig. &rd %tage %uction 3rum 6thylene 8efrigerant %urge drum 6thylene 8efrigerant 3rain 3rum 6thylene 8efrigerant %ubcooler $lash pot Propylene 8efrig. "st %tage %uction 3rum Propylene 8efirg. #nd %tage %uction 3rum Propylene 8efrig. &rd %tage %uction 3rum Propylene 8efrig. (th %tage %uction 3rum Propylene 8efrigerant %urge 3rum Propylene 8efrigerant 3rain 3rum $eed %urge 3rum "st %tage .ot %eparator
B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B
13! 0 0 22/06/2012 BMK
SECTION
D.UMS
ITE/ NO( B 2"" B 2"# B 2"& B 2#0 B 2&" B 2&0 B 2&2 B 2(* B 2(" B 2)0 B 4*" B 4*# B 4*& B 4*( B 4*) B 0*0 B 4*2 B 4*4 B 5** B 5*" B 5*# B 5*( B 5*) B 5*0 B 5*2 B 5*4 B 5") A?C v 5"0 B 5"2 B 5#* B 5#0 B 5#2 A> B 5#4 B 5&* B 5&" B 5&# B 5&2 B 5(* B 5() B 5(0 B 5)( B 5)0 B 50" B 52# >T7( " " " " " " " " " " " " " " " " " " " " " " " " " " & " " " " " " " " " " " " " " " " " DESCRIPTION "st %tage Cold %eparator "st %tage !nock?out 3rum 3ecoking 3rum 3epentaniDer 8eflu7 3rum 1ash 'il .olding 3rum 3eoctaniDer 8eflu7 3rum P?2&0 'ily 1ater %eparator #nd %tage %eparator 3rum #nd %tage !nock?out 3rum %tripper 8eflu7 3rum $eed %urge 3rum .ot %eparator Cold %eparator C( Product $lash 3rum C(. $eed %urge 3rum ;+nit?#= C(. .ot %eparator ;+nit?#= C(. Cold %eparator ;+nit?#= C( Product $lash 3rum ;+nit?#= 3eaerator Cold $lare !nock?out 3rum .ot $lare !nock?out 3rum %&.) %uspect Condensate 3rum A9' $eed .eater :o.& Condensate Pot A9' $eed .eater :o.# Condensate Pot Methanol Baporiser :o." Condensate Pot Cold lowdown Baporiser Condnesate Pot Polisher Mi7ed eds Polisher 8egn Bessel Polisher 6ffluent Bessel %(* %team Condensate $lash 3rum 3%9 $eed .eater :o.# Condensate Pot 3%9 8eboiler Condensate Pots -uench 1ater %team .eater Condensate Pot %"# %team Condensate $lash 3rum Continuous lowdown 3rum Intermittent lowdown 3rum 8eactivation 9as .eater Condensate Pot $uel 9as Mi7ing 3rum C# .ydrog. $eed 1ater Condensate Pot C# .ydrog. Adia 8eactor $eed .tr Cond. Pot Propylene Tower 8eboiler Condensate Pot 3ebutaniDer 8eboiler Condensate Pot /P9>C( 8affinate Baporiser Cond Pot 3epentaniDer 8eboiler Condensate Pot
13" 0 0 22/06/2012 BMK
SECTION
*a4le 1
ITE/ NO( 52& 52) 54* 54" ""*" ""*# ""*& ""#" ""## ""#& >T7( " " " " " " " " " " DESCRIPTION 3eoctoniser 8eboiler Condensate Pot %tripper 8eboiler Condensate Pot C&>C( $uel Baporiser Condensate Pot $uel 9as %uperheater Condensate Pot %team %tripper $eed Preheater Condensate Pot 1ater !.'. 3rum %C' 8eactor $eed %urge 3rum %C' $eed %urge 3rum %C' 6ffluent %urge 3rum %C' Air %urge 3rum
B B B B B B B B B B
140 0 0 22/06/2012 BMK
)LARE S7STE/
141 0 0 22/06/2012 BMK
@(1 Pressure Re+ie;% =+o?do?n and ;+are s0ste@(1(1 Pressure Re+ie; 8a+6e $eader S0ste1ithin Cracker Plant, a relief valve .eader system is provided to collect hydrocarbon discharges @ ". The C# C lighter effluents which below ?()*C are collected in the cold flare header made of autenitic steel subLected to gravity separation in the cold flare knockout drum and steam superheated prior to being discharged to the hot flare header. #. Cold dry effluents ;basically C&= at temperatures from *C to ?()*C are collected in the intermediate flare header ;I$= which is ;/TC%= subLected to gravity separation in the same knock?out drum as the C# and lights effluents. &. .ot wet effluents above *C are collected in a carbon steel header and subLected to gravity separation in the horflare knockout drum. The gases from this drum Loined by the superheated effluent from the cold knockout drum and sent to '% / flare stack. (. Cold flare knock out drum vaporiser which vaporises any li,uid lighters and the outlet superheater is provided, heated by steam via an intermediate methanol loop as a heating medium.
@(1(' =+o?do?n S0steCHECKED BY N.S.P APPROVED BY B. DAS Process description and Utilities PAGE REV ISSUE DATE AUTHOR 142 0 0 22/06/2012 BMK
lowdown
%ystems
are
provided
to
remove
residual
hydrocarbon only during unit shut down or fire emergency. The drains of all hydrocarbons that will vaporise when opened to atmosphere are routed to the blowdown system. .ot blowdown is having C% piping ;above *C= and cold blown is provided with %% headers. These drain are collected in a common headers and terminate in their corresponding relief valve header !1 drums. Provision is made for vaporising any coalesced li,uids. In cold flare knockout drum, a steam heated indirect e7changer is used while in hot flare knock out drum a steam coil is used. Any accumulated li,uid from cold or hot flare knock out drum are pumped either to ,uench oil tower or to '% /. @(' )+are s0ste- at OS=L $lare from cracker I% /, Tank farm, M69 C Aromatics gaseous effluents are collected in the common header and are routed to '% / flea stack system. $lare stack system, corrosion of knock out drum where any li,uid is separated. Then gases are passed to li,uid drum where these gases bubbled through water seal and reach the flea stack. Then there gases pass through molecular seal at the stack top and are burnt at the flare tip.
( :o.s of burners continuously burn at the tip which is supplied by fuel gas separately. $lare front generator located at grade provides necessary ignition for putting pilots on these are designed remain on even during heavy wind with rain. 6ach pilot is provided with a thermocouple which sends any loss of flare and connected to alarm. %ystem both out the local panel and in 3C%. Also, one thermocouple provided at the centre of the tip gives warning incase of any burnback., Two stages of steam are provided one at the centre into the flare trip to cool the flea provides steam for complete combustion. Centre, steam is adLusted manually at controlled rate and the -% steam which is varied in accordance to the flow to obtain smokeless flare. $lare stack design parameters )+are "as! $low 8ate @ ",*)*,045 kg>hr Mot. 1t. @ &&.#0 Temp.@ 4**C
Pi+ot "as! Type @ $uel 9as

Pressure @ "**# kg>cm#g M1 @ "5.)2 Stea- ! Pressure @ 2.*& kg>cm#g U flare trip. $low ma7. @ &#,0)5 kg>hr -% manifold U 2.*& kg>cm#g $low @ (&* kg>hr. Cooling rate for -% manifold $low Ma7. @ &4)) kg>hr. through centre tip U 2.*& kg>cm#g $low @ ##) kg>cm#g cooling rate for center tip U 2.*& kg>cm# OPERATIN" INSTRUCITONS @ Pre-Start Up C ecC List efore starting up the flare, checks should be made for the following items @ ". Berify that all the flare components are installed in accordance with the reference drawings. #. If chromel?alumel Type ! thermocouples are used, the blue wire is negative ;?= and the brown wire is positive ;E=. &. All system lines should be dry and free of dirt and foreign material. (. Check that all drain and vent valves are closed and that all drain and vent plugs are tightly secured. A drain plug or valve is re,uired at each low point in each pilot ignition line. ). All manual valves in the pilot gas and waste gas systems should be closed. 0. Check that all set points are properly adLusted.
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2. The pilot ignition lines must be dry and unobstructed so that the flame front is not ,uenched or blocked. Start-Up and Operation Procedures ;or S-oCe+ess )+are S0ste- 9>S-C<! The 66$?-%?0*>00C flare uses ( 6nergy 6fficient Pilots as an ignition source. The flare is e,uipped with a 4K -% %team Manifold and steam inLectors capable of providing &#,0)5 kg>hr of saturated steam U 2.*& kg>cm#g. A &K Centre %team %parger is included which is capable of providing &,4)) kg>hr of saturated steam U 2.*&kg>cm#g. A continuous steam flow of &2) kg>hr should be maintained to the -% %team Manifold for cooling and to prevent cracking of the steam inLectors and manifold. The centre steam sparger re,uires ##) kg>hr of cooling steam. 1( Start up and operation! Lig t t e pi+ots! The method of lighting the ( pilots should be carried out using the flame front generator panel. ;refer to appendi7 JAK ? J'perating Instructions for $lame $ront 9eneratorK ? )(*"6 ;# pages=. c= Introduce the cooling steam flow to the Centre %team ;##) kg>h=. The Centre %team rate should be set manually. ulletin
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d= Introduce the cooling steam flow to the upper -% %team 8ing ;&2) kg>hr=. e= %tart the waste gas flow at a nominal vent rate ;)**?"*** kg>hr= f= 1ith the -% %team set at the cooling rate of &2) kg>hr, adLust the Centre %team until smokeless operation is achieved. It may be necessary to make this adLustment several times with the flea receiving gas at the nominal vent rate. 1hen the re,uired Centre %team rate is achieved, it should be changed. It is suggested that the Centre %team manual valve handle be removed. %ince one of the purposes of the Centre %team is to prevent burn?back inside the flare tip, it is advisable to observe the flare tip at night for a glow ;e7cessive heat= below the flare tip e7it. The above procedure should be followed for initial start?up. g= 3uring a flaring event, the steam flow to the -% %team Manifold should be adLusted to the point where smoke is not visible and the flame is a yellow orange colour. The amount of steam to achieve this is anticipated to be *.( kg steam per ".** kg. waste hydrocarbon. h= After cessation of a flaring event, the -% %team Manifold rate should be returned to a rate of &2) kg>h for cooling. 3o not readLust the centre steam rate as the flare will still be e7periencing a nominal vent rate of waste gas. '( S ut do?n
a= Close the steam supply valves to the -% %team Manifold on the flare trip. Close the steam supply to the Centre %team %parger. c= %hut 3own the purge gas flow @ d= 67tinguish the pilots by closing the pilot fuel gas block valve. e= Close all hand valves. f= Close all utility gas supply systems
OPERA TIN" INSTRUCITIONS )OR )LA/E )RONT "ENERATOR
Important @ A. All ignition lines must be one rich. . All low spots in ignition lines must be drained :ote @ %agging between supports is sufficient to cause low spots in the line which can hold li,uids and ,uench ignition flame. C. Confirm that all utilities are connected and operating properly per the Lob drawing. Ignition ! ". Purge flare system with nitrogen or fuel gas until all o7ygen has been replaced with purge gas. low down air and gas supply lines to flame front generator at blow down valves to remove condensate. 'pen all drains in the low spots of ignition lines. low down each ignition line, one at a time, through valves A,6 and C. Close all drains. Check each ignition line for blockage by opening valve 3 and at a time.
1hen valve 3 is closed, pressure should fall off rapidly on the pressure gauges. If pressure does not fall off rapidly, investigate and correct the blockage in the ignition line. &. Push switch F$K actuate Magiclite to check for spark at the sight port. (. 'pen valve JAG. Close valve J K and JCK to ignite pilot :o." ). 'pen valve J.K. This is the fuel for pilots. 0. 'pen valve J6K and set pressure gauge at "* psig. ;gas=. 2. 'pen valve J3K and set pressure gauge at "& psig. ;air=. 4. 1ait two to three minutes after opening valves 6 and 3. 5. Push and release ,uickly, switch J$K. At the same time observe through the sight port to see if air>gas mi7ture was ignited. ;If same is not observed, change either the air or gas slightly until flame is observed=. If the system uses Magiclite ignitor, actuate as if you were using switch J$K. "*. If pilot does not light, repeat steps 4 and 5. "". If repeating steps 4 and 5 two or three times does not ignite the pilot, change air or gas pressure slightly using valve J3K or valve J6K. 8epeat steps 4 and 5 until pilot is ignited. "#. Close valve JAK. 'pen valve J K to ignite Pilot :o.&. 8epeat steps 4 and 5 until the pilot is ignited. "(. 1hen all pilots are ignited, close valves F3K and J6K. "). 'n light or sunny days, if is difficult to observe pilot flame to verify ignition. To observe pilot flame, close valve J3K and open valve J6K fully for two or three minutes. If ignited, pilot flame
will become luminous. This can be repeated for each pilot by opening and closing valves A, , and C. "0. After all pilots are ignited and verified, the flea is ready for operation. 1aste gas can now be flared provided the remainder of each system is operational. ". If no spark is observed, check the electrical circuit and the spark gap ;">"0?">4 inch=. If a blue flash cannot be observed at the sight glass, check for gas and air delivery as follows @ A. 3isconnect the spark plug lead and remove sight glass. . Check for air delivery by opening valve J3K and check for gas delivery by opening valve J6K. C. If a noticeable hiss does not occur, break the piping union and check orifices at JIK ;air=. and JOK ;gas=. &. If the pilot will not light and the above have been confirmed. A. Check the piping between the flame front generator and the pilot to ensue no low points in the piping have filled with condensate. . 6nsure that pilot gas pressures is per Lob drawing. If a fuel gas other than that specified on the Lob drawing used, the orifices JIK and JOK must be resiDed. Please contact Oohn Pink in Tulsa for specific recommendations.
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SECTION
)(.& 5 /AS D&*&'*(+N S-S*&M
151 0 0 22/06/2012 BMK
SECTION
1.
(N*.+DU'*(+N
In'"(t#i%- !#o$e((e( in$#e%(in5- in.o-.e t)e "(e %n' m%n";%$t"#e o; )i5)- '%n5e#o"( ("<(t%n$e(8 !%#ti$"-%#- to6i$ %n' $om<"(ti<-e 5%(e(. Ine.it%<- 8 o$$%(ion%- e($%!e( o; 5%(e( o$$"# $#e%tin5 % !otenti%- )%A%#' to t)e in'"(t#i%- !-%nt8 it( em!-o ee( %n' !eo!-e -i.in5 ne%#< . In mo(t in'"(t#ie(8 one o; t)e &e !%#t( o; %n (%;et !-%n ;o# #e'"$in5 t)e #i(&( to !e#(onne- %n' !-%nt i( t)e e%#- ->%#nin5 'e.i$e ("$) %( /as Detectors . T)e(e $%n )e-! to !#o.i'e mo#e time in >)i$) to t%&e #eme'i%- o# !#ote$ti.e %$tion. T)e $%n %-(o <e "(e' %( !%#t o; tot%-8 inte5#%te' monito#in5 %n' (%;et ( (tem ;o# %n in'"(t#i%- !-%nt. T)i( #e!o#t i( inten'e' to o;;e# %n o.e#.ie> o; t)e 7i#e %n' G%( Dete$tion S (tem in N%!)t)% C#%$&e# !-%nt in RIL8 H%Ai#%. It !#o.i'e( % <#ie; e6!-%n%tion o; t)e !#in$i!-e( in.o-.e' in ("$) ( (tem( %n' t)e in(t#"ment%tion nee'e' ;o# (%ti(;%$to# !#ote$tion o; !e#(onne- %n' en.i#onment. Some o; t)e to!i$( #e-%te' to t)e 7i#e %n' G%( Dete$tion ( (tem %#e %-(o 'i($"((e'.
2.
'+MBUS*(B,& /AS&S
Com<"(tion i( <%(i$%-- % (im!-e $)emi$%- #e%$tion8 in >)i$) o6 5en $om<ine( #%!i'- >it) %not)e# ("<(t%n$e #e("-tin5 in t)e #e-e%(e o; ene#5 . T)i( ene#5 %!!e%#( m%in- %( )e%t - (ometime( in t)e ;o#m o; ;-%me(. T)e i5nitin5 ("<(t%n$e i( no#m%-- 8 <"t not %->% (8 %n o#5%ni$ o# ) '#o$%#<on $om!o"n'( %n' $%n <e % (o-i'8 -iB"i'8 .%!o# o# 5%(.
A(. )(.& )U&,
0&A*
T)e !#o$e(( o; $om<"(tion $%n <e #e!#e(ente' < t)e >e---&no>n ;i#e t#i%n5-e. A( $%n <e (een8 t)#ee ;%$to#( %#e %->% ( nee'e' i.e. % (o"#$e o; i5nition8 o6 5en %n' ;"e- in t)e ;o#m o; $om<"(ti<-e 5%( o# .%!o#. In %n ;i#e !#e.ention ( (tem8 t)e#e;o#e8 t)e %im i( %->% ( to #emo.e %t -e%(t one o; t)e(e !otenti%-- )%A%#'o"( item(.
3.
*+2(' /AS&S
T)o"5) t)e#e i( % -%#5e 5#o"! o; 5%(e(8 >)i$) %#e <ot) $om<"(ti<-e %n' to6i$8 t)e )%A%#'( %n' t)e #e5"-%tion( in.o-.e' %n' t)e t !e( o; (en(o# #eB"i#e' %#e 'i;;e#ent ;o# t)e t>o $%te5o#ie( o; t)e 5%(e(. Cit) to6i$ ("<(t%n$e(8 D%!%#t ;#om t)e o<.io"( en.i#onment%- !#o<-em(E t)e m%in $on$e#n i( t)e e;;e$t on >o#&e#( o; e6!o("#e to e.en .e# -o> $on$ent#%tion(8 >)i$) $o"-' <e in)%-e'8 in5e(te' o# %<(o#<e' t)#o"5) t)e (&in. It i( im!o#t%nt not on- to me%("#e t)e $on$ent#%tion o; 5%(8 <"t %-(o t)e tot%- time o; e6!o("#e8 (in$e %'.e#(e e;;e$t( $%n o;ten #e("-t ;#om %''iti.e8 -on5-te#m e6!o("#e. Sometime( t)e(e ("<(t%n$e( $%n inte#%$t %n' !#o'"$e % ;%# >o#(e e;;e$t >)en to5et)e# t)%n t)e (e!%#%te e;;e$t o; e%$) on it( o>n. Con$e#n %<o"t $on$ent#%tion( o; to6i$ ("<(t%n$e( in t)e >o#&!-%$e ;o$"( on <ot) o#5%ni$ %n' ino#5%ni$ $om!o"n'(8 in$-"'in5 t)e e;;e$t( t)e $o"-' )%.e on t)e )e%-t) %n' (%;et o; em!-o ee(8 t)e !o((i<-e CHECKED BY N.S.P APPROVED BY B. DAS PAGE REV ISSUE DATE AUTHOR 152 0 0 22/06/2012 BMK
SECTION
$ont%min%tion o; % m%n";%$t"#e' en' !#o'"$t Do# eB"i!ment "(e' in it( m%n";%$t"#eE %n' %-(o t)e ("<(eB"ent 'i(#"!tion o; no#m%- >o#&in5 %$ti.itie(. Con$ent#%tion( o; 5%( in %i# %#e e6!#e((e' %( !%#t( !e# mi--ion D!!mE8 >)i$) i( % me%("#e o; 5%( $on$ent#%tion < it( .o-"me.
4.
&2P,+S(6& ,(M(*S
T)e#e i( on- % -imite' <%n' o; 5%(,%i# $on$ent#%tion8 >)i$) >i-- !#o'"$e % $om<"(ti<-e mi6t"#e. T)i( <%n' i( (!e$i;i$ ;o# e%$) 5%( %n' .%!o# %n' <o"n'e# < %n "!!e# -e.e-8 &no>n %( t)e Upper &7plosi8e ,i9it :U&,; %n' % -o>e# -e.e-8 $%--e' t)e ,o<er &7plosi8e ,i9it :,&,;.
1 0 0 => a s 0 =a ir * + + . (' 0 U & , ) , A M M A B , & . A N / & , & , * + + , & A N
1 00 =a ir 0 => a s
At -e.e-( <e-o> t)e LEL8 t)e#e i( in(";;i$ient 5%( to !#o'"$e %n e6!-o(ion Di.e. t)e mi6t"#e i( too -e%nE8 >)i-(t %<o.e t)e UEL8 t)e mi6t"#e )%( in(";;i$ient o6 5en Di.e. t)e mi6t"#e i( too #i$)E. T)e ;-%mm%<-e #%n5e t)e#e;o#e ;%--( <et>een t)e -imit( o; t)e LEL %n' UEL ;o# e%$) in'i.i'"%- 5%( %#e mi6t"#e o; 5%(e(. O"t(i'e t)e(e -imit(8 t)e mi6t"#e i( not $%!%<-e o; $om<"(tion.
5.
0A?A.D ?+N&S
Not %-- %#e%( o; %n in'"(t#i%- !-%nt o# (ite %#e $on(i'e#e' to <e eB"%-- )%A%#'o"(. 7o# in(t%n$e8 %n "n'e#5#o"n' $o%- mine i( $on(i'e#e' %t %-- time( to <e %n %#e% o; m%6im"m #i(&8 <e$%"(e (ome met)%ne 5%( $%n %->% ( <e !#e(ent. On t)e ot)e# )%n'8 % ;%$to# >)e#e met)%ne i( o$$%(ion%-- &e!t on (ite in (to#%5e t%n&(8 >o"-' on- <e $on(i'e#e' !otenti%-- )%A%#'o"( in t)e %#e% ("##o"n'in5 t)e t%n&( o# %n $onne$tin5 !i!e >o#&. In t)i( $%(e8 it i( onne$e((%# to t%&e !#e$%"tion( in t)o(e %#e%( >)e#e -e%&%5e $o"-' #e%(on%<- <e e6!e$te' to o$$"#. In o#'e# to <#in5 (ome #e5"-%to# $ont#o- into t)e in'"(t# 8 t)e#e;o#e8 $e#t%in %#e%( )%.e <een $-%((i;ie' %( ;o--o>( @ ?+N& 0 ?+N& 1 CHECKED BY N.S.P APPROVED BY B. DAS in >)i$) %n e6!-o(i.e 5%(,%i# mi6t"#e i( $ontin"o"(- !#e(ent8 o# !#e(ent ;o# -on5 !e#io'(. in >)i$) %n e6!-o(i.e mi6t"#e i( -i&e- to o$$"# in t)e no#m%- o!e#%tion Process description and Utilities PAGE REV ISSUE DATE AUTHOR 153 0 0 22/06/2012 BMK
SECTION
o; t)e !-%nt. ?+N& 2 in >)i$) %n e6!-o(i.e mi6t"#e i( not -i&e- to o$$"# in no#m%- o!e#%tion.
6.
/AS D&*&'*(+N S-S*&MS AND /DA'S
7o# $ontin"o"(- monito#in5 %n in'"(t#i%- !-%nt ;o# -e%&%5e o; )%A%#'o"( 5%(e(8 % n"m<e# o; (en(o#( %#e !-%$e' %t (t#%te5i$ !oint( %#o"n' t)e !-%nt %t t)e !-%$e( >)e#e %n -e%&( %#e mo(t -i&e- to o$$"#. T)e(e %#e t)en $onne$te' to % m"-ti-$)%nne- $ont#o--e# -o$%te' (ome 'i(t%n$e %>% in % (%;e8 5%( ;#ee %#e% )%.in5 'i(!-% %n' %-%#m ;%$i-itie(8 #e$o#'in5 'e.i$e(8 et$. T)i( i( &no>n %( 7i6e' !oint ( (tem. It i( !e#m%nent- -o$%te' in t)e in'"(t#i%- !-%nt Di.e. oi- #e;ine# 8 $o-' (to#%5e8 et$.E %n' 5ene#%-- )%( % (t%n'%#' %n%-o5"e e-e$t#i$%- $i#$"it 'e(i5n. T)e $ont#o--e#( "(e' in t)e ;i6e' ( (tem( %#e no#m%-$ent#%-- -o$%te' in % $ont#o- !%ne-. T)e $ont#o- "nit( no#m%-- )%.e inte#n%- #e-% ( to $ont#o- ;"n$tion( ("$) %( %-%#m8 ;%"-t %n' ()"t 'o>n. T)e %-%#m $%n <e (et %t eit)e# one o# t>o -e.e-(8 'e!en'in5 on (t%t"to# #eB"i#ement( o# >o#&in5 !#%$ti$e( >it)in t)e in'"(t# . A-%#m in)i<it %n' #e(et8 o.e#-#%n5e in'i$%tion %n' %n %n%-o5"e 2-10 mA o"t!"t ;o# % '%t% -o55e# o# $om!"te# %#e (ome o; t)e "(e;"- ;e%t"#e( o; t)e $ont#o- "nit(. /DA'S (t%n'( ;o# G%( D%t% A$B"i(ition %n' Cont#o- S (tem. T)i( ( (tem "(e( t#%n(mitte#( to $on.e#t t)e 2-10 mA (i5n%- o; (t%n'%#' 5%( (en(o#( into 'i5it%-- $o'e' !"-(e(. It %-(o %--o>( t)e in;o#m%tion ;#om % n"m<e# o; ot)e# (o"#$e(8 tem!e#%t"#e o# !#e(("#e (en(o#(8 ;i#e 'ete$to#(8 et$. to <e inte#;%$e' to % t>o->i#e8 'i5it%- )i5)>% . Hi5)>% i( % (im!-e 'i5it%- $omm"ni$%tion $)%nne-. E%$) in!"t to t)e )i5)>% i( %--o$%te' % "niB"e %''#e(( $o'e %n' >)en % (en(o# i( Finte##o5%te'G < t)e )i5)>% $ont#o$%#'8 it t#%n(mit( (t%t"( in;o#m%tion <%$& to t)e $ont#o- #oom. T)e "(e o; t)e mi$#o!#o$e((o# te$)no-o5 en%<-e( t)e $om!en(%tion o; e6te#n%- en.i#onment%- in;-"en$e( ;o# 5#e%te# %$$"#%$ . B t>o->% $omm"ni$%tion >it) t)e (en(o#(8 t)e ( (tem $%n !#o.i'e o!e#%tion%- (t%t"( %n' 'i%5no(ti$ in;o#m%tion. T)e ( (tem $%n %$$e!t F(t%t"( (>it$)e(G on t)e )i5)>% in %''ition to %n%-o5"e 'e.i$e(. B "(in5 %''#e((%<-e o"t!"t %$t"%to#(8 it i( !o((i<-e to o!e#%te -o$%- %-%#m( o# ()"t 'o>n !#o$e'"#e( ;#om t)e )i5)>% it(e-;8 in(te%' o; >i#in5 %-- ;"n$tion( <%$& to t)e $ont#o--e#. T)e )i5)>% $ont#o- $%#'( 5i.e %n o"t!"t >it) 'et%i-e' (t%t"( in;o#m%tion ;#om t)e in!"t 'e.i$e( %n' t)e(e $%n <e !%((e' .i% % (e#i%- !o#t to % ("it%<-e )o(t $om!"te# %n' .i("%- 'i(!-% "nit.
,+'A*(+N +) S&NS+.S
T)e#e %#e t)#ee met)o'( o; -o$%tin5 (en(o#(@ Point Detection 8 >)e#e (en(o#( %#e -o$%te' ne%# t)e mo(t -i&e- (o"#$e( o; -e%&%5e8 Peri9eter Detection@ >)e#e (en(o#( $om!-ete- ("##o"n' t)e )%A%#'o"( %#e% D>)i$) $o"-' %-(o <e !oint 'ete$to#(E %n' +pen patA detectors D"(e( IR <e%m ;o# 'ete$tionE8 in >)i$) t)e 'ete$to#( $%n <e $onne$te' $o.e#in5 % 'i(t%n$e o; (e.e#%- )"n'#e' mete#(. Some o; t)e ;%$to#( to <e &e!t in min' >)i-e 'e$i'in5 t)e -o$%tion o; % (en(o# %#e 5i.en <e-o> @ 1. An (en(o# >)i$) i( to <e "(e' ;o# 'ete$tin5 % 5%( >it) .%!o# 'en(it 5#e%te# t)%n 1 D i.e. )e%.ie# t)%n %i#E8 e.5. B"t%ne8 LPG %n' H -em8 et$. ()o"-' <e -o$%te' ne%# 5#o"n' -e.e-. PAGE REV ISSUE DATE AUTHOR 154 0 0 22/06/2012 BMK
SECTION
1. Con.e#(e- 8 ;o# %n -i5)te#-t)%n-%i# 5%(e(8 ("$) %( ) '#o5en8 met)%ne8 %mmoni%8 et$. T)e (en(o# i(
to <e $onne$te' )i5)e#-"!.
*. In t)e o!en8 en.i#onment%- $on'ition( 5et mo#e im!o#t%n$e. Sen(o#( %#e to <e -o$%te' 'o>n(t#e%m
o; t)e !#e.%i-in5 >in'( %n' t)e >e%t)e# ()ie-'( %#e to <e ;itte' to !#ote$t %5%in(t #%in %n' (no>. Di;;"(ion-t !e (en(o#( >i-- no#m%-- <e mo"nte' (o t)%t t)e ;%$e 'o>n>%#'(8 !%#ti$"-%#- ;o# -i5)t 5%(e(. T)e -o$%tion o; IR (en(o#( ()o"-' <e ("$) t)%t8 t)e#e i( no !e#m%nent <-o$&%'e o; t)e IR <e%m. T)o"5) no#m%-- ("n-i5)t 'oe( not $%"(e %n !#o<-em8 it ()o"-' not ;%-- 'i#e$t- on t)e in(t#"ment >in'o>. T)e -o$%tion( mo(t- #eB"i#in5 !#ote$tion %#e %#o"n' 5%( <oi-e#(8 $om!#e((o#(8 !#e(("#iAe' (to#%5e t%n&(8 $ -in'e#( o# !i!e-ine(. V%-.e(8 5%"5e(8 ;-%n5e(8 T-Ioint(8 ;i--in5 o# '#%inin5 $onne$tion(8 et$. %#e mo(t ."-ne#%<-e. Sen(o#( ()o"-' <e !o(itione' % -itt-e >% <%$& ;#om %n )i5)-!#e(("#e !%#t( to %--o> 5%( $-o"'( to ;o#m. Ot)e#>i(e %n -e%&%5e o; 5%( i( -i&e- to !%(( < in % )i5)-(!ee' Iet %n' not <e 'ete$te' < t)e (en(o#.
2. 3.
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/&N&.A, +6&.6(&1 +) *0& )5/ S-S*&M (N NAP0*0A '.A'K&. P,AN*
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1. He%t 'ete$to#( *. IR 7-%me 'ete$to#( 2. M%n"%- A-%#m C%--!oint(.
T)e ( (tem $om!#i(e( ;i.e '"%- <% $%<inet( n%me- @ 1. 1. *. 2. 3. CHECKED BY N.S.P APPROVED BY B. DAS G%( $ont#o- $%<inet 7i#e $ont#o- $%<inet M%#()%--in5 $%<inet Cont#o- #oom mimi$ $%<inet 7i#e (t%tion mimi$ $%<inet. Process description and Utilities PAGE REV ISSUE DATE AUTHOR 155 0 0 22/06/2012 BMK
SECTION
Bot) t)e G%( %n' 7i#e 'ete$tion ( (tem( )%.e t>o )i5)>% ( e%$). Hi5)>% ( one : t>o %#e "(e' ;o# 5%( 'ete$tion ( (tem %n' Hi5)>% ( t)#ee : ;o"# %#e "(e' ;o# ;i#e 'ete$tion ( (tem. In'i.i'"%- 5%( (en(o# %n' ;i#e -oo! (t%t"( ;#om t)e GDACS i( 5i.en to % Data 'oncentrator . T)i( '%t% ;#om t)e D%t% Con$ent#%to# 5oe( to t)e D'S D Di(t#i<"te' Cont#o- S (temE .i% % Protocol 'on8erter . G%( %n' ;i#e %-%#m( on % ;i#e %#e%-5#o"!in5 <%(i( %#e %nn"n$i%te' .i% $ont#o- #oom %n' ;i#e (t%tion mimi$ !%ne-( %n' < (i#en,.i("%-,inte#n%- %"'i<-e( 'i#e$t- >it)in t)e ;i#e %#e%(. A-- ;ie-' 'ete$to# -oo!( %#e te#min%te' >it)in t)e m%#()%--in5 $%<inet8 >)i$) )o"(e( t)e int#in(i$ (%;et DI.S.E MTL i(o-%tion "nit( ;o# t)e(e $i#$"it(. G%( 'ete$tion t#%n(mitte# 12V DC ;ee'( %#e %-(o te#min%te' in t)i( $%<inet8 e%$) $i#$"it )%.in5 ;"(e,i(o-%tion te#min%-(.
156 0 0 22/06/2012 BMK
SECTION
)(/ %
)(.& 5 /AS D&*&'*(+N S-S*&M B,+'K D(A/.AM
". ".1
D&*&'*+.S
Gas Detectors %
15 0 0 22/06/2012 BMK
SECTION
T)e 5%( 'ete$to#( $om!#i(e t>o m%in "nit( - % t#%n(mitte# %n' % (en(o#. A-- "nit( "(e % >e%t)e# !#ote$tion %((em<- !#o.i'in5 !#ote$tion to t)e (en(o#-in!"t (inte# %5%in(t #%in>%te# (!-%() %n' )i5) %i# (!ee'(.
".1.1 'o94#sti4le /as Detectors %

Ne%#- %-- mo'e#n8 -o> $o(t8 co94#sti4le >as detection sensors %#e o; t)e electroDcatalBtic tBpe . T)e $on(i(t o; % .e# (m%-- (en(in5 e-ement $%--e' % F4eadE@ % FPellistorE o# % FSie>istorE . T)e %#e m%'e o; %n e-e$t#i$%-- )e%te' !-%tin"m >i#e $oi-. T)e $oi- i( $o.e#e' ;i#(t >it) % $e#%mi$ <%(e ("$) %( %-"min% %n' t)en >it) % ;in%- o"te# $o%tin5 o; !%--%'i"m o# #)o'i"m $%t%- (t 'i(!e#(e' in % ("<(t#%te o; t)o#i% %( ()o>n in t)e ;i5"#e <e-o>. C)en % $om<"(ti<-e 5%(,%i# mi6t"#e !%((e( o.e# t)e )ot $%t%- (t ("#;%$e8 $om<"(tion o$$"#( %n' t)e )e%t e.o-.e' in$#e%(e( t)e tem!e#%t"#e o; t)e F<e%'G. T)i( in t"#n %-te#( t)e #e(i(t%n$e o; t)e !-%tin"m $oi- %n' $%n <e me%("#e' < "(in5 t)e $oi- %( % tem!e#%t"#e t)e#momete# in % (t%n'%#' e-e$t#i$%- <#i'5e DC)et(tone( B#i'5eE $i#$"it. T)e #e(i(t%n$e $)%n5e i( t)en 'i#e$t- #e-%te' to t)e 5%( $on$ent#%tion in t)e ("##o"n'in5 %tmo(!)e#e %n' $%n <e 'i(!-% e' on % mete# o# (ome (imi-%# in'i$%tin5 'e.i$e. T)e $)%n5e
15! 0 0 22/06/2012 BMK
SECTION
in #e(i(t%n$e 5et( $on.e#te' to % 2-10 mA (i5n%- D< %m!-i;ie#E >)i$) $o##e(!on'( to 0-100J LEL.
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A '+MBUS*(B,& S&NS+.
15" 0 0 22/06/2012 BMK
SECTION
)(/ %
D(M&NS(+NS +) A '+MBUS*(B,& /AS D&*&'*+.
".1.2 *o7ic /as Detectors %

To6i$ 5%(e( %#e 5ene#%-- nee'e' to <e 'ete$te' %n' me%("#e' %t .e# -o> $on$ent#%tion(. T)e#e;o#e8 %-t)o"5) m%n to6i$ 5%(e( %#e %-(o $om<"(ti<-e( De.5. %mmoni%8 $%#<on mono6i'e o# met)%no-E8 it i( not !o((i<-e to "(e $om<"(ti<-e 5%( (en(o#( ;o# to6i$ 5%( me%("#ement( <e$%"(e t)e (en(iti.it nee'e' i( >e-<e-o> t)%t >)i$) $%n <e %$)ie.e' >it) % ;-%mm%<-e 5%( (en(o#. A to7ic >as detector "(e( %n electroDcAe9ical sensor. It i( %n e-e$t#o$)emi$%- $e--8 $on(i(tin5 o; t>o e-e$t#o'e( imme#(e' in % $ommon e-e$t#o- te me'i"m. T)i( $%n <e in t)e ;o#m o; eit)e# % -iB"i'8 % 5e--i&e ;-"i'8 o# %n im!#e5n%te'8 !o#o"( (o-i'. T)e e-e$t#o- te i( i(o-%te' ;#om o"t(i'e in;-"en$e( < me%n( o; % <%##ie#8 >)i$) m% <e in t)e ;o#m o; eit)e# % 5%( !e#me%<-e mem<#%ne8 % 'i;;"(ion me'i"m8 o# % $%!i--%# . T)e $e-- i( 'e(i5ne' ;o# m%6im"m (en(iti.it $om<ine' >it) m%6im"m inte#;e#en$e ;#om %n ot)e# 5%(e( !#e(ent. D"#in5 o!e#%tion8 % !o-%#iAin5 .o-t%5e i( %!!-ie' <et>een t)e e-e$t#o'e( %n' >)en 5%( !e#me%te( t)#o"5) t)e <%##ie# into t)e (en(o#8 %n o6i'%tion-#e'"$tion #e%$tion 5ene#%te( %n e-e$t#i$%- $"##ent t)%t i( -ine%#!#o!o#tion%- to t)e 5%( $on$ent#%tion.
160 0 0 22/06/2012 BMK
SECTION
)(/ %
A *+2(' S&NS+.
)(/ %
D(M&NS(+NS +) A *+2(' /AS D&*&'*+.
T)e Com<"(ti<-e %n' to6i$ 5%( 'ete$to#( %#e i'enti$%- in %!!e%#%n$e %$$e!t t)%t8 t)e t#%n(mitte# o; % to6i$ 5%( 'ete$to# i( (-i5)t- (m%--e# t)%n t)%t o; % $om<"(ti<-e 5%( 'ete$to# %( ()o>n in t)e ;i5"#e( %<o.e. CHECKED BY N.S.P APPROVED BY B. DAS PAGE REV ISSUE DATE AUTHOR 161 0 0 22/06/2012 BMK
SECTION
Tot%- 1!0 co94#sti4le >as detectors %#e in t)e !-%nt. Sin$e t)e $om<"(ti<-e 5%(e( )%.e % ten'en$ to 5o "!8 t)e(e 'ete$to#( %#e !-%$e' mo(t- %t t)e to!. E%$) o; 6 02S 5 '+ detectors %#e "(e' in t)e to! %n' 5#o"n' ;-oo#( o; t)e HVAC In-et %#e%.
)(/ % '+NN&'*(+N D(A/.AM +) A /D *+ /AS '+N*.+, 'AB(N&*
".2
Smoke Detectors %
O!ti$%- %n' IoniA%tion Smo&e Dete$to#( %#e t)e t>o mo(t $ommon t !e( o; !-"5-in (mo&e 'ete$to#(. IoniA%tion 'ete$to#( %#e e6$e--ent ;o# 'ete$tin5 t)e (m%--e# %e#o(o-( %((o$i%te' >it) $-e%n ;i#e(8 >)i$) #e("-t ;#om ;i<#o"( m%te#i%-(8 i.e. !%!e# o# >oo'. T)e#e;o#e t)i( 'ete$to# i( % 5oo' (e-e$tion ;o# o;;i$e %#e%(. T)e O!ti$%- 'ete$to#( !#o.i'e % <ette# #e(!on(e ;o# mi'-#%n5e #%n5e to )e%. o# -%#5e %e#o(o-( ("$) %( t)o(e !#o'"$e' < m%n ( nt)eti$ !#o'"$t(. T)e#e;o#e t)i( 'ete$to# i( % <ette# (e-e$tion ;o# !#ote$tin5 %#e%( >)e#e t)i( t !e o; m%te#i%- i( !#ominent8 i.e. e-e$t#i$%- (>it$) #oom(8 $%<-e (!#e%'e# #oom8 #%$& #oom8 >)e#e o.e#)e%te' $%<-e( %n' e-e$t#i$%- $om!onent( %#e t)e m%in #i(&. L%#5e (mo&e !%#ti$-e( $%n %-(o #e("-t ;#om (m%--e# %e#o(o-( $om<inin5 to5et)e#8 >)i$) "("%-- )%!!en( %( (mo&e t#%.e-( o.e# -on5e# 'i(t%n$e(8 i.e. %-on5 $o##i'o#(. T)%t i( >) 8 in t)e $ont#o- #oom <"i-'in5 %#e%8 <ot) t)e t !e( o; 'ete$to#( )%.e <een $onne$te' (i'e < (i'e.
162 0 0 22/06/2012 BMK
SECTION
)(/ %
S&NS(*(6(*- +) *0& D&*&'*+.S *+1A.DS SM+K& PA.*(',&S +) D())&.&N* S(?&S
".2.1 +ptical S9oGe Detector %

T)e inne# $)%m<e# o; %n o!ti$%- (mo&e 'ete$to# $on(i(t( o; t>o m%in !%#t( @ %n in;#%#e' LED %n' % !)oto-'io'e. T)e LED i( !o(itione' %t %n o<t"(e %n5-e to t)e !)oto 'io'e. T)e !)oto-'io'e )%( %n inte5#%- '% -i5)t ;i-te# ;o# !#ote$tion %5%in(t %m<ient -i5)t. T)e LED emit( % <"#(t o; $o--im%te' -i5)t e.e# 10 (e$on'. In $-e%# %i# $on'ition( t)e !)oto-'io'e 'oe( not #e$ei.e -i5)t !%#ti$-e( D!)oton(E '"e to t)e $o--im%tion o; t)e -i5)t %n' t)e %n5-e %t >)i$) t)e -i5)t t#%.e-( #e-%ti.e to t)e !)oto 'io'e. C)en (mo&e ente#( t)e $)%m<e#8 it e6$ite( t)e !)oto-'io'e < ($%tte#in5 !)oton( onto it. T)en t)e LED emit( t>o ;"#t)e# <"#(t( o; -i5)t %t %n inte#.%- o; t>o (e$on'(. D"e to t)e !#e(en$e o; (mo&e8 -i5)t i( ($%tte#e' on <ot) t)e(e !"-(e( o; t)e !)oto-'io'e $%"(in5 t)e 'ete$to# to 5o to t)e %-%#m (t%te. At t)e %-%#m (t%te8 % (i-i$on $ont#o--e' #e$ti;ie# on t)e !#inte' $i#$"it <o%#' i( (>it$)e' on %n' t)e $"##ent '#%>n < t)e 'ete$to# i( in$#e%(e' ;#om %n %.e#%5e o; 20 mA to % m%6im"m o; 91mA. To en("#e #e-i%<i-it 8 t)e LED emit( -i5)t mo'"-%te' %t %<o"t * KHA %n' t)e !)oto-'io'e #e%$t( on- on #e$ei.in5 -i5)t %t t)i( ;#eB"en$ .
".2.2 (oniHation S9oGe Detectors %

An IoniA%tion Smo&e 'ete$to# )%( %n inne# %n' %n o"te# $)%m<e#. T)e inne# : o"te# $)%m<e#( %#e $%--e' ioniA%tion Dinne# #e;e#en$e $)%m<e#E %n' (mo&e $)%m<e#( #e(!e$ti.e- . DT)e (mo&e $)%m<e# )%( (mo&e in-et %!!%#%t"( ;itte' >it) %n in(e$t #e(i(t%nt me().E A #%'io%$ti.e (o"#$e )o-'e# %n' t)e (mo&e $)%m<e# %$t( %( !o(iti.e %n' ne5%ti.e e-e$t#o'e( #e(!e$ti.e- . T)e #%'io%$ti.e (o"#$e i( in(i'e t)e CHECKED BY PAGE 163 N.S.P Process description and Utilities REV 0 ISSUE 0 APPROVED BY DATE 22/06/2012 B. DAS AUTHOR BMK
SECTION
ioniA%tion $)%m<e#. T)i( #%'io%$ti.e (o"#$e i##%'i%te( t)e %i# in <ot) t)e $)%m<e#( to !#o'"$e !o(iti.e %n' ne5%ti.e ion(. On %!!- in5 % .o-t%5e %$#o(( t)e e-e$t#o'e(8 %n e-e$t#i$ ;ie-' i( ;o#me'. T)e ion( %#e %tt#%$te' to t)e e-e$t#o'e( o; o!!o(ite (i5n(8 (ome ion( $o--i'e %n' #e$om<ine8 <"t % (m%-- net e-e$t#i$ $"##ent ;-o>( <et>een t)e e-e$t#o'e(. A (en(in5 e-e$t#o'e <et>een t)e t>o $)%m<e#( $on.e#t( .%#i%tion( in t)e $)%m<e# $"##ent( into % .o-t%5e. C)en (mo&e !%#ti$-e( ente# t)e ioniA%tion $)%m<e#8 ion( <e$ome %tt%$)e' to t)em %n' #e'"$e t)e $"##ent ;-o>in5 t)#o"5) t)e ioniA%tion $)%m<e#. T)e $"##ent in t)e (mo&e $)%m<e# #e'"$e( ;%# mo#e t)%n t)%t o; ioniA%tion. T)i( im<%-%n$e $%"(e( t)e (en(in5 e-e$t#o'e to 5o mo#e !o(iti.e. T)e (en(o# e-e$t#oni$( monito#( t)e .o-t%5e on t)e (en(in5 e-e$t#o'e %n' !#o'"$e( % (i5n%- >)en % !#e(et t)#e()o-' -e.e- i( #e%$)e' %n' $%"(e( t)e 'ete$to# to 5o to t)e %-%#m (t%te. T)e tot%- n"m<e# o; (mo&e 'ete$to#( "(e' in t)i( !-%nt i( 133 %n' t)e(e )%.e <een ("!!-ie' < A!o--o 7i#e Dete$to#( Limite'. T)e 'ete$to#( %#e "(e' in(i'e t)e $ont#o- #oom <"i-'in5 %#e%. T)e(e %#e mo"nte' on t)e $ei-in58 %<o.e $ei-in5 %n' <e-o> ;%-(e ;-oo#in5. Remote in'i$%to#( %#e %-(o !#o.i'e' ;o# 5i.in5 in'i$%tion o; %n %$t"%tion %<o.e $ei-in5. T)e IoniA%tion : O!ti$%- Smo&e 'ete$to#( %#e i'enti$%- in %!!e%#%n$e. T)e 'i;;e#en$e i( t)%t8 t)e $o-o# o; t)e LED( on t)e IoniA%tion %n' O!ti$%- Smo&e 'ete$to#( %#e #e' %n' >)ite #e(!e$ti.e- . B"t >)en t)e 5et %$t"%te'8 <ot) emit #e' -i5)t. T)e tot%- n"m<e# o; s9oGe detectors "(e' in t)e $ont#o- #oom <"i-'in5 %#e% i( 155 .
".3
Heat detectors %
He%t 'ete$to#( %#e <%(i$%-- tem!e#%t"#e-(en(in5 'e.i$e(. T)e m%in ;"n$tion o; t)e )e%t 'ete$to#( i( to !#o.i'e ;i#e 'ete$tion >)e#e (!ee' o; #e(!on(e i( not (o $#iti$%-8 o# ;o# t)e %#e%( >)e#e "n>%nte' t#i55e#in5 o; (mo&e 'ete$to#( i( -i&e- to o$$"#8 i.e. &it$)en %n' >o#&()o! %#e%(. He%t 'ete$to#( %#e %.%i-%<-e in t)#ee <%(i$ ;o#m( --- 7i6e' Tem!e#%t"#e8 R%te o; Ri(e (en(o#( %n' R%te Com!en(%te' (en(o#(. 7i6e' Tem!e#%t"#e t !e 'ete$to#( %#e "(e' in t)i( !-%nt. T)e(e )e%t 'ete$to#( m% <e o; <i-met%- (>it$) 'e(i5n o# o; (in5-e ;i6e' e-e$t#oni$ t)e#m%- (en(o# 'e(i5n. T)e(e %#e 'e(i5ne' >it) % !#e-(et ;i6e' tem!e#%t"#e t#i! !oint e.5. 908 +3 o# K00C. I; t)e !#e(et tem!e#%t"#e .%-"e i( e6$ee'e'8 $ont%$t( o; t)e (>it$) $)%n5e( %n' 5ene#%te( %-%#m (i5n%-. T)e 'ete$to# $ont%$t $-o(e( %t o!e#%tin5 tem!e#%t"#e. T)e $ont%$t i( (e-;-#e(ettin5. T)e 'ete$to# tem!e#%t"#e (ettin5 i( t)e ("m o; %m<ient tem!e#%t"#e %n' 10007. He#e8 %m<ient tem!e#%t"#e )%( <een t%&en %( 2007. T)e#e;o#e t)e (et !oint o; t)e )e%t 'ete$to#( i( 12007 o# 900C. T)e 'ete$to# >i-- 5i.e % -o>--e.e- %-%#m i; t)e tem!e#%t"#e in$#e%(e( to 13J o; it( !#e(et .%-"e. In $#%$&e# !-%nt on- 13 0eat detectors %#e in "(e. Mo(t o; t)em %#e "(e' in t)e t#%n(;o#me# %#' %n' Die(e- Gene#%to# #oom.
".4
IR Flame Detectors %
T)e IR 7-%me Dete$to#( !#o.i'e e%#- >%#nin5 o; ) '#o$%#<on ;-%me(. T)e 'ete$to#( %#e "(e' ;o# t)e !#ote$tion o; )i5) #i(& %#e%( ;#om ;i#e D!#o'"$in5 CO1 E $%"(e' < t)e %$$i'ent%- <"#nin5 o; m%te#i%-(8 -i&e ;-%mm%<-e -iB"i'( : 5%(e(8 !%!e#8 >oo'8 !-%(ti$(8 et$. T)e 'ete$to# "(e( in;#%#e' (en(o#(8 ;i-te#( %n' mi$#o!#o$e((o# t)%t !#o.i'e imm"nit to F<-%$& <o' G ;%-(e %-%#m (o"#$e(. T)e 'ete$to#( )%.e % .e# ;%(t (!ee' o; #e(!on(e -- t !i$%-- 1 to * (e$on'(.
164 0 0 22/06/2012 BMK
SECTION
T>o (i5n%-( D>%.e;o#m(E %#e 'e#i.e' ;#om t)e 2.* Vm >%.e-en5t)8 >)i$) $o##e(!on'( to )ot CO1 emi((ion( o; % ) '#o$%#<on ;i#e. T)e mi$#o!#o$e((o# %n%- (e( t)i( (i5n%- %n' %not)e# one t%&en ;#om t)e *./Vm >%.e-en5t) < me%n( o; % !%#ente' $o##e-%tion te$)niB"e to 'ete#mine t)e !#e(en$e o; ;i#e. T)e 'ete$to#( $%n (ee ) '#o$%#<on ;-%me( t)#o"5) (mo&e %n' )i5) 'en(itie( o; (o-.ent .%!o#(. T)e(e %#e <-in' to>%#'( ("n#% (. T)e#e %#e 16 (. )la9e Detectors in t)e !-%nt. T)e(e )%.e <een ("!!-ie' < T)o#n Se$"#it Limite'. T)e 'ete$to#( %#e "(e' mo(t- in t)e C#%$& G%( Com!#e((o# DCGCE B"i-'in58 Re;#i5e#%tion Com!#e((o#8 Met)%ne Com!#e((o# S)e-te#8 Re$ $-e Com!#e((o# %n' 7"e- G%( Com!#e((o# %#e%.
".5
Manual Call Points %
T)e MAC i( t)e (im!-e(t o; %-- t)e ot)e# 'ete$to#( "(e' in t)e 7i#e %n' G%( 'ete$tion S (tem. T)i( i( % m%n"%-- o!e#%te' 'e.i$e. T)e MAC "(e' in t)i( !-%nt i( o; FB#e%&-5-%((G t !e. T)e "nit i( o!e#%te' < %!!- in5 t)"m< !#e(("#e to % !#e-($o#e' 5-%(( !-%te8 #e-e%(in5 % mi$#o-(>it$)8 >)i$) i( no#m%-- )e-' o!en8 < t)e e'5e o; t)e 5-%(( !-%te %n' %-%#m i( 5ene#%te'. T)e 5-%(( i( $o.e#e' < % $-e%# ;i-m to !#ote$t t)e o!e#%to# ;#om (";;e#in5 5-%(( $"t( o# (!-inte#( '"#in5 o!e#%tion. D"#in5 o!e#%tion8 t)e LED in t)e ;#ont (i'e %-(o 5-o>(. T)e n"m<e# o; MAC( "(e' in t)e >)o-e !-%nt i( "0.
)(/ %
'+NN&'*(+N D(A/.AM +) MA' 5 SD ).+M )(&,D *+ /AS PAN&,
165 0 0 22/06/2012 BMK
SECTION
T)e#e %#e t>o -e.e- %-%#m( ;o# 5%( 'ete$tion ( (tem @ 7o# 0-100J LEL 'ete$to#(8 I(t D-o>e#E -e.e- %-%#m i( %t 10J LEL %n' 1n' D)i5)e#E -e.e- %-%#m i( %t 90J LEL 7o# 0-300 !!m CO 'ete$to#(8 I(t -e.e- %-%#m i( %t 10J i.e. 30 !!m %n' 1n' -e.e- %-%#m i( %t 90J i.e. *00 !!m. 7o# 0-30 !!m H1S 'ete$to#(8 I(t -e.e- %-%#m i( %t 10J i.e. 10 !!m %n' 1n' -e.e- %-%#m i( %t 30J i.e. 13 !!m.
10.
AUD(B,& AND 6(SUA, A,A.MS
7o# >%#nin5 t)e !e#(on( >o#&in5 in t)e !-%nt o; 5%( -e%&%5e o# ;i#e8 E-e$t#oni$ So"n'e#( %#e "(e'. T)e tone o; t)e (o"n'e# i( .e# !ie#$in5 D300 - 1000 HAE. T)e (o"n' 5ene#%te' $%n <e mo'"-%te' in % n"m<e# o; >% ( D!"-(e8 >%#<-e8 m"-ti tone8 et$.E >)i$) m%&e( t)e (o"n' (t%n' o"t ;#om ot)e# %m<ient noi(e(. In %#e%( >)e#e t)e %m<ient noi(e i( !%#ti$"-%#- )i5) to t)e !oint >)e#e t)e o$$"!%nt( %#e #eB"i#e' to "(e e%# 'e;en'e#(8 F;-%()in5 -i5)tG %-%#m 'e.i$e( %#e %-(o "(e' %( % .i("%- <%$&"! >%#nin5 to t)e o$$"!%nt(.
11. 11.1
S-S*&M D&S'.(P*(+N
Gas Control Cabinet %
T)e (i5n%-( ;#om %-- t)e 5%( 'ete$to#( $ome to t)i( $%<inet .i% t)e M%#()%--in5 $%<inet %n' %#e te#min%te' in t)e ;o"# $)%nne- Sa$e Area 3#ad (np#t :SA3(; $%#'(. T)e(e (i5n%-( %$t %( t)e in!"t to t)e 0i>A<aB 'ontrol 'ards :0'';. T)e G%( Cont#o- C%<inet )%( ;o"# !%i#( o; HCC(8 ;"n$tionin5 in % m%in %n' (t%n'< $on;i5"#%tion. T)e#e %#e t>o Hi5)>% ( in e%$) HCC @ P#im%# %n' Se$on'%# . T)e P#im%# Hi5)>% i( no#m%-- %$ti.e. T)e Se$on'%# Hi5)>% i( %"tom%ti$%-- "(e' i; ;%i-"#e o; t)e P#im%# Hi5)>% i( 'ete$te' < t)e HCC. Comm"ni$%tion t%&e( !-%$e in one Hi5)>% %t % time. E%$) !%i# o; HCCG( )%( <ot) % '"%- !o>e# ("!!- $%#' %n' % )i5)>% <"( m%n%5e# mo'"-e. T)e <"( m%n%5e# mo'"-e $ont#o-( t)e (>it$)in5 ;#om t)e m%in to (t%n'< HCC >)ene.e# t)e '"%- !o>e# ("!!- $%#' ;%i-(. D"%- 0i>A<aB 6otin> 'ards :06'; %#e inte#;%$e' to e%$) o; t)e ;o"# )i5)>% ( to !#o.i'e .ote' %-%#m(. HVC t%&e( (i5n%-( ;#om t)e HCC %n' .ote( %( !e# "(e# -o5i$8 >)i$) i( $on;i5"#e' in HVC %n' 5ene#%te( o"t!"t. T)e(e o"t!"t( %#e "(e' to in'i$%te %-%#m(8 (i#en(8 et$. T)e .otin5 o; t)e 7i#e A#e% i( e6!-%ine' >it) t)e )e-! o; t)e .otin5 -o5i$ %n' t)e $%"(e %n' e;;e$t 'i%5#%m( in t)e ne6t !%5e.
166 0 0 22/06/2012 BMK
SECTION
)(/ % 6+*(N/ ,+/(' )+. *0& D&*&'*+.S (N *0& )AD3
)A D 3 D G ROOM CAUSE EFFECTS
6+*(N/ 1 OUT O7 1 1 OUT O7 *
MA(N '+N*.+, PAN&, AUDIBLE ALM VISUAL ALARM
/.AP0(' M(M(' PAN&,S AUD. ALMS 7IRE GAS AUD ALMD7S ONLYE 7IRE : GAS VISUAL ALMS 7IRE,7LAME GAS
DETECTION
CCT
HEAT DPOINTE HEAT DPOINTE
1ST 1ND H
H H
H H
H H
H H
H H
H H
GAS-7LAM 10J GAS-7LAM 90J GAS-7LAM 90J 1ST 1ND H
H H H
H H H
H H H H H H H
MANUAL
)(/ % 'AUS& 5 &))&'* D(A/.AM )+. *0& )AD3 Hi5)>% ( one %n' t>o )%.e t>ent -ei5)t SA?I $%#'( e%$). Tot%- (i6teen no o; 19 $)%nne- in!"t $%#'( %#e "(e' in )i5)>% ( t)#ee %n' ;o"#. A SA?I $%#' )%( ;o"# $)%nne-( >)i-(t % 19 $)%nne- I,P $%#' )%( (i6teen $)%nne-( %( t)e n%me ("55e(t(. T)e >)o-e !-%nt )%( <een 'i.i'e' into 'i;;e#ent ;i#e %#e%(. A-- t)e 5%(8 )e%t %n' IR ;-%me 'ete$to#( )%.e "niB"e %''#e((e( %n' t)e %#e $onne$te' in'i.i'"%-- to t)e )i5)>% (. In (ome $%(e(8 MAC %n' (mo&e 'ete$to#( o; (ome ;i#e %#e%( )%.e <een $onne$te' in -oo!( %n' t)e(e -oo!( )%.e <een %((i5ne' "niB"e %''#e((e(. T)e ( (tem <ein5 %n An%-o5"e A''#e((%<-e S (tem $%nnot $)e$& t)e (t%t"( o; e%$) o; t)e 'ete$to#( in t)e -oo!. CHECKED BY N.S.P APPROVED BY B. DAS Process description and Utilities PAGE REV ISSUE DATE AUTHOR 16 0 0 22/06/2012 BMK
SECTION
T)e in$omin5 '%t% o; 5%( $on$ent#%tion %n' ;%"-t in;o#m%tion i( 5%t)e#e' on )i5)>% ( one %n' t>o %n' ;i#e %-%#m,;%"-t (>it$) in!"t( %#e 5%t)e#e' on )i5)>% ( t)#ee %n' ;o"#. T)e 2-10 mA %n%-o5"e -oo! (i5n%-( ;#om t)e 5%( 'ete$to#( $ome to t)e SA?I $%#'(8 >)i$) $on.e#t t)em to 'i5it%- ;o#m%t. T)e o"t!"t( o; t)e SA?I $%#'( %#e t)e in!"t( to )i5)>% one %n' t>o. T)e (i5n%-( ;#om (mo&e8 )e%t8 IR ;-%me 'ete$to#( %n' MAC $ome to 19 $)%nne- I,P $%#'( D.i% 1 $)%nne- %n' 9 $)%nne- 7i#e $%#'(E. T)e o"t!"t o; t)e(e $%#'( i( 5i.en to )i5)>% ( t)#ee %n' ;o"#. T)e m%in ;"n$tion o; HCC in !o--in5 mo'e i( to #eB"e(t '%t% ;#om e%$) %''#e(( -oo!. T)e '%t% $o--e$te' i( $)e$&e' %5%in(t t)e $on;i5"#%tion '%t% in t)e EPROM in t)e HCC. T)e $on;i5"#%tion '%t% $ont%in( %-%#m (ettin5( %n' #e-% '#i.e# $)%nne- %--o$%tion( ;o# e%$) Hi5)>% 'e.i$e %''#e((. I; %n %-%#m -e.e-8 ;%"-t o# >%#nin5 $o'e i( !#e(ent in t)e #e$ei.e' me((%5e ;#om %n %''#e((e' 'e.i$e8 % t#%n(i(to# #e-% '#i.e# $)%nne- m% <e %$ti.%te'. In (ome (!e$i;i$ %#e%(8 (ome <"t not %-- 'ete$to#( %#e .ote' ;o# ;in%- o"t!"t8 e.5. T>o o"t o; t)#ee 'ete$to#( %#e .ote' i.e. i; %n t>o 'ete$to#( o"t o; t)e t)#ee 5et %$t"%te' t)en on- %n o"t!"t >i-- <e 5ene#%te'. T)e Hi5)>% ( o; %-- t)e ;o"# HCC( %#e $onne$te' to % Data 'oncentrator >)i$) %$t( %( % m"-ti!-e6e#. T)e D%t% Con$ent#%to# $%n time 'i.i(ion m"-ti!-e6 "!to / HCC(. T)e D%t% Con$ent#%to# $on.e#t( t)e RS 211 '%t% ;#om t)e HCC to RS 1*1 %n' 5i.e( it to t)e Protocol 'on8erter . T)e P#oto$o- Con.e#te# D<%(e' on Inte- /01/9 $om!%ti<-e (in5-e <o%#' $om!"te#E inte#n%-- <"i-'( % t%<-e o; GDACS 5%( #e%'in5(8 (en(o# (t%t"(e(8 t !e( %n' #%n5e(. It t)en $omm"ni$%te( t)e(e .%-"e( in % ("it%<-e ;o#m%t .i% % (e$on' (e#i%- !o#t to t)e DCS ( (tem. T)e P#oto$o- Con.e#te# $on.e#t( GDACS !#oto$o- to MODBUS !#oto$o-8 >)i$) i( %$$e!t%<-e ;o# ABB DCS.
11.2
Fire control cabinet %
T)e (i5n%-( ;#om t)e 'ete$to#( "(e' ;o# ;i#e 'ete$tion $ome to t)i( $%<inet .i% t)e M%#()%--in5 $%<inet %n' %#e te#min%te' in t)e 16 cAannel (/P cards . T)e (i5n%-( t)en 5o to t)e HCC( in t)e G%( $ont#o$%<inet. T>o t !e( o; $%#'( %#e "(e' ;o# ;i#e 'ete$tion $ont#o-. *<in ?one )ire card monito#( t)e (mo&e 'ete$tion -oo!( %n' Si7 'Aannel S<itcA (np#t $%#'( monito#( t)e MAC -oo!(. Be-o> t)e 7i#e C%#'(8 t)e#e i( % ("< !%ne- ;o# !#o.i'in5 %nn"n$i%tion %n' o!e#%tion ;"n$tion(. T)e(e %#e %( ;o--o>( @ SBste9 AealtAB DG#een LEDE SBste9 $a#lts DAm<e# LED(E 06A'/Plant Stat#s DAm<e# LED(E Alar9 reset Accept ,a9p *est A#di4le alar9 T)e S (tem He%-t) in'i$%to# in t)e !%ne- 5oe( o;; >)ene.e# t)e#e i( %n ;%"-t in t)e ( (tem. T)e T>in Lone 7i#e Mo'"-e monito#( t)e 'ete$to# -oo! $"##ent ;o# o!en %n' ()o#t $i#$"it( %n' %-(o !%((e( % nomin%- B"ie($ent $"##ent o; 2 mA t)#o"5) t)e -oo! ;o# monito#in5. An HARDCARE e##o# $on'ition i( %nn"n$i%te' < .i("%- %n' %"'i<-e %-%#m( >it)in t)e $ont#o- #oom ;o# initi%- %ttention (ee&in5. T)e %"'i<-e %-%#m )%( t>o tone(8 contin#o#s to 'e;ine ;i#e o# 5%( %-%#m %n' inter9ittent to 'e;ine % ;%"-t $on'ition. CHECKED BY N.S.P APPROVED BY B. DAS PAGE REV ISSUE DATE AUTHOR 16! 0 0 22/06/2012 BMK
SECTION
11.3
Marshalling cabinet %
T)e '"%- <% m%#()%--in5 $%<inet !#o.i'e( t)e m%in te#min%tion ;%$i-it <et>een ;ie-' %n' $ont#oe-e$t#oni$(. T)e !%ne- $ont%in( %-- int#in(i$ (%;et i(o-%tin5 mo'"-e( ;o# in!"t %n' o"t!"t -oo!(.
T !e,mo'e- %n' -oo! t !e@ MTL *021 MTL *02* G%( Dete$tion 7i#e Dete$tion 2,10 mA -oo!( 1,20 mA -oo!(
Conne$tion( into t)e ot)e# ( (tem !%ne-( %#e <ein5 te#min%te' in ELCO (o$&et(.
11.4
Control room mimic cabinet %
T)e $ont#o- #oom mimi$ !%ne- i( $on(i'e#e' t)e m%(te# mimi$. It )o"(e( LED 'i(!-% 8 5#%!)i$%-#e!#e(entin5 ;i#e %n' 5%( Aon%- %-%#m (t%t"(. LED $o-o#(@ .ed A94er Bl#e D;i#e 'ete$tionE D$om<"(ti<-e 5%( 'ete$tionE DTo6i$ 5%( 'ete$tionE
S#pplB on SBste9 Alert DHVAC (t%t"( $)%n5eE SBste9 $a#lt ,a9p test D(>it$)E At t)e no#m%- $on'ition8 %-- t)e LED( %n' t)e -%m!( on t)e mimi$ !%ne- %#e o;;. T)e FS (tem A-e#tG %n' FS (tem 7%"-tG 5-o> on- >)en t)e#e i( %n ;%"-t in t)e ( (tem. T)e FL%m! Te(tG (>it$) i( "(e' ;o# $)e$&in5 t)e >o#&in5 $on'ition o; t)e LED( on t)e !%ne-. T)e LED( on % 7i#e A#e% 5-o> >)en %n 5%( -e%&%5e o# ;i#e i( 'ete$te' in t)%t !%#ti$"-%# %#e%. A '#%;t o; t)e $%<inet i( 5i.en on t)e ne6t !%5e.
M%(te#,;"n$tion,in'i$%tion(@
11.5
Fire station mimic cabinet %
T)e ;i#e (t%tion mimi$ $%<inet i( (imi-%# to t)e $ont#o- #oom in #e(!e$t to t)e 'i(!-% .
12.
S(&/&. 'A,(B.A*(+N 5 '+MMUN('A*(+N S+)*1A.& PA'KA/&@ 'A,'+M
T)e o!e#%tion o; t)e G.D.A.C.S. i( ;"-- monito#e' %n' $ont#o--e' >it) t)e )e-! o; (o;t>%#e8 >)i$) i( &no>n %( 'A,'+M. A PC )%.in5 CALCOM $%n <e $onne$te' to t)e RS 1*1C (e#i%- inte#;%$e on % Bidico9. T)e Bi'i$om i( % <i-'i#e$tion%- $omm"ni$%to#8 >)i$) $%n $on.e#t <ot) RS 211 : RS 2/3 into RS 1*1 $omm"ni$%tion( ("it%<-e ;o# $onne$tion into % (e#i%- !o#t o; % $om!"te#. C)ene.e# t)e#e i( no .i("%- in'i$%tion 'e;inin5 %n )%#'>%#e ;%i-"#e8 % (o;t>%#e 'i%5no(i( $%n <e 'one t)#o"5) CALCOM. T)e o!e#%to# $%n inte##o5%te % )i5)>% %n' it( #e(!e$ti.e 'e.i$e %''#e(( e-e$t#oni$( CHECKED BY PAGE 16" N.S.P Process description and Utilities REV 0 ISSUE 0 APPROVED BY DATE 22/06/2012 B. DAS AUTHOR BMK
SECTION
%(&in5 ;o# #e(!on(e( to t)e $ont#o- $omm%n'(. T)e #e(!on(e( $ont%in mo#e 'et%i-e' '%t% on o$$"##en$e o; % ;%"-t. CALCOM i( %-(o "(e' ;o# $%-i<#%tin5 t)e 5%( 'ete$to#(.
13. 'A,(B.A*(+N D&*&'*+.S
P.+'&DU.&
+)
/AS
Sm%-- !%#ti$-e(8 $o##o(ion8 >%te# m% <-o$& t)e (inte# o; % $om<"(ti<-e (en(o# t)e#e< $%"(in5 it( ;%i-"#e. E6!o("#e to $e#t%in F!oi(on(G $%n %-(o 'e5#%'e t)e !e#;o#m%n$e o; % (en(o#. T)e#e;o#e it i( e((enti%- t)%t %n 5%( monito#in5 ( (tem ()o"-' <e $%-i<#%te' %t t)e time o; in(t%--%tion %( >e-- %( $)e$&e' #e5"-%#%n' #e-$%-i<#%te' %( ne$e((%# . An %$$"#%te- $%-i<#%te' standard 5%( mi6t"#e ()o"-' <e "(e' ;o# $)e$&in58 (o t)%t t)e FAe#oG %n' F(!%nG -e.e-( $%n <e (et $o##e$t- on t)e t#%n(mitte#. He#e >e %#e "(in5 1.3J met)%ne in %i# %( t)e $%-i<#%tion 5%(. To $%-i<#%te8 one )%( to e6!o(e t)e (en(o# to % ;-o> o; 5%( %n' t)e ot)e# to $)e$& t)e #e%'in5 ()o>n on t)e ($%-e o; it( $ont#o- "nit DPCE. A'I"(tment( %#e t)en m%'e to t)e FAe#oG %n' F(!%nG !otentiomete#( "nti- t)e #e%'in5 e6%$t- m%t$)e( t)%t o; t)e 5%( mi6t"#e $on$ent#%tion. T)e $%-i<#%tion !#o$e'"#e ;o# <ot) t)e $om<"(ti<-e %n' to6i$ 5%( 'ete$to#( i( (%me. C%-i<#%tion $%n <e 'one in (it" o# #emote ;#om t)e t#%n(mitte#. Sen(o#( $%n <e !#e-$%-i<#%te' %n' t)en !-"55e' in. T)e t#%n(mitte# i( ;%$to# (et %n' 'oe( not #eB"i#e $%-i<#%tion. I; #eB"i#e'8 t)e t#%n(mitte# $%n <e $%-i<#%te' "(in5 % D#99B Sensor. T)e (en(o#( %#e $%-i<#%te' #emote ;#om t)e t#%n(mitte# #sin> tAe 'ali4ration #nit %( ;o--o>( @ 1. 1. *. 2. 3. 9. +. Po>e# i( %!!-ie' %n' >%ite' ;o# 3 min"te( ;o# (t%<i-iA%tion. T)e $%-i<#%tion $o.e# %<o.e t)e %'I"(tment !otentiomete#( %#e -oo(en %n' (-i'e' "!. T)e 'i(!-% on t)e $%-i<#%tion "nit >i-- ()o> FCALG. Le#o !otentiomete# DMLE i( %'I"(te' to o<t%in Ae#o #e%'in5 on t)e 'i(!-% . Te(t 5%( %t t)e #%te o; 1-1 -ite#(,min i( %!!-ie' %n' >%ite' ;o# 3 min"te( to (t%<i-iAe. S!%n !otentiomete# i( %'I"(te' "nti- 'i(!-% in'i$%te( 30J LEL o; t)e te(t 5%(. Te(t 5%( i( #emo.e' %n' Ae#o i( #e-$)e$&e'. T)e $%-i<#%tion $o.e# i( ti5)tene' D()o"-' not <e o.e# ti5)tene'E. T)e 'i(!-% ()o"-' #e%' Ae#o %n' t)e FCALG ;#om t)e 'i(!-% ()o"-' 'i(%!!e%#.
T)e %<o.e !#o$e'"#e i( #e!e%te' i; ne$e((%# . T)e d#99B sensor i( "(e' to inIe$t eit)e# % Le#o o# % .%#i%<-e (i5n%- into t)e t#%n(mitte#. T)e !#o$e'"#e i( %( ;o--o>( @ 1. T)e (en(o# i( #emo.e' ;#om t)e t#%n(mitte# to <e $%-i<#%te' %n' t)e '"mm (en(o# i( ;itte' in it( !-%$e. 1. T)e t#%n(mitte# -o$%- 'i(!-% ()o"-' ()o> F7%"-tG %n' no 5%( #e%'in5. *. T)e t#%n(mitte# ()o"-' ()o> Ae#o #e%'in5 >)en t)e (>it$) on t)e '"mm i( in Ae#o !o(ition. I; not8 it ()o"-' <e m%'e Ae#o < %'I"(tin5 t)e (i5n%- -e.e- &no< "nti- Ae#o i( 'i(!-% e'. Le#o $%-i<#%tion $omm%n' i( 5i.en ;#om t)e CALCOM Dt)#o"5) t)e PCE $onne$te' to t)e D%t% Con$ent#%to# o; t)e ( (tem. 2. T)e (>it$) o; t)e '"mm (en(o# i( $)%n5e' to t)e S!%n !o(ition. T)en t)e (i5n%- -e.e&no< i( t"#ne' to inIe$t % (im"-%te' F5%( (i5n%-G into t)e t#%n(mitte#. T)e 'i(!-% on t)e t#%n(mitte# ()o"-' ()o> 30J LEL. 30J S!%n $%-i<#%tion $omm%n' ;#om CALCOM i( 5i.en. 3. T)e t#%n(mitte# ()o"-' in'i$%te Ae#o >)en t)e (>it$) on t)e '"mm (en(o# i( &e!t in Ae#o !o(ition. T)e t#%n(mitte# ()o"-' %-(o in'i$%te t)e $o##e$t .%-"e >)en t)e (>it$) i( &e!t on t)e (!%n !o(ition. 9. A;te# $om!-etin5 t)e te(t(8 t)e '"mm (en(o# i( #emo.e' %n' t)e $o##e$t (en(o# i( #e;itte' to t)e t#%n(mitte#. CHECKED BY N.S.P APPROVED BY B. DAS Process description and Utilities PAGE REV ISSUE DATE AUTHOR 1 0 0 0 22/06/2012 BMK
SECTION
T)e !#o$e'"#e i( #e!e%te' i; #eB"i#e'.
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Heat Detectors %
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14.3
IR Flame Detectors %
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14.4
MAC %
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1 1 0 0 22/06/2012 BMK
SECTION
An +8er8ie< screen !#o.i'e( t)e o$$"##en$e o; %-%#m in %n Aone. It i( in'i$%te' < t)e $)%n5e o; <o#'e# $o-o# o; t)%t !%#ti$"-%# Aone. T)e Men# 4ar %t t)e <ottom #i5)t $o#ne# in t)e o.e#.ie> ($#een )%( 'i;;e#ent ;"n$tion &e (8 e.5. Alar9@ 0istorB@ &n>ineer@ et$. C)en A-%#m ($#een i( o!ene'8 % ($#een Men" %!!e%#( %t t)e #i5)t )%n' (i'e o; t)e A-%#m S$#een >it) o!tion(@ Alar9 ,o> )iles : ,o> )iles . T)e A-%#m Lo5 7i-e en%<-e( t)e "(e# to .ie> t)e %-%#m -o5 ;i-e( -i(te' in t)e '%te o#'e#. Lo5 ;i-e o!tion $%n <e "(e' to (ee t)e -o5 on,o;; e.ent( %n' (e$"#it .io-%tion(. A-%#m Hi(to# 5i.e( t)e -i(t o; %-- t)e %-%#m( in t)e <";;e#. T)e En5inee#in5 ($#een -i(t( %-- t)e t%5(8 t)ei# 'e($#i!tion(8 $"##ent .%-"e(8 $"##ent (t%t"(8 %n' GDACS %''#e((e( ;o# %-- t)e (en(o#( in e%$) Aone. No#m%-iA%tion %n' C%-i<#%tion o; t)e 5%( (en(o#( $%n <e $%##ie' o"t ;#om t)e En5inee#in5 ($#een Men". T)e 7i#e %#e% (e-e$t Men" on t)e to! #i5)t $o#ne# o; t)e O.e#.ie> ($#een en%<-e( t)e "(e# to .ie> %n !%#ti$"-%# ;i#e %#e%. A #e' ("##o"n'in5 o; % ;i#e %#e% <"tton in'i$%te( t)e o$$"##en$e o; %n %-%#m. T)e 'ete$to#( on t)e ($#een %( >e-- %( t)e %-%#m me((%5e %!!e%#in5 in t)e Alar9 S#99arB $ield %t t)e <ottom o; t)e ($#een $)%n5e( t)ei# $o-o# $o##e(!on'in5 to t)e t !e o; %-%#m8 e.5. % 5%( 'ete$to#8 >)i$) )%( <een ()o>n %( G#een %t no#m%- (t%te8 >i-- <e$ome O#%n5e to in'i$%te % Hi5) %-%#m8 Re' to in'i$%te HiHi %-%#m %n' Ye--o> to in'i$%te % ;%"-t. T)i( )e-!( t)e o!e#%to# to $)e$& >)et)e# %$t"%- ;i#e o# 5%( -e%& )%( t%&en !-%$e o# not. T>o <"tton( -- FA$$e!tG %n' FA-%#m Re(etG %#e "(e' ;o# %$$e!tin5 %n' #e(ettin5 %n %-%#m. A SBste9 screen $%n <e .ie>e' >it) t)e )e-! o; t)e FS (temG <"tton %t t)e #i5)t (i'e o; t)e O.e#.ie> ($#een. B 'o"<-e $-i$&in5 %t % (en(o# t)e "(e# $%n .ie> t)e *rend /rapAs . T)e t#en' -o5( #e$o#' *0 '% ( o; '%t% %t 1-min"te inte#.%-(. T)e t#en' 5#%!)( o; t)e 5%( 'ete$to#( $%n <e "(e;"- ;o# #e-%tin5 o# $om!%#in5 t)e 5%( -e.e-( o; t)e !-%nt %#e% %t 'i;;e#ent time(.
1 2 0 0 22/06/2012 BMK

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SECTION RELIANCE INDUSTRIES LIMITED

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PROCESS DESCRIPTION AND UTILITIES

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Process description and Utilities

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SECTION RELIANCE INDUSTRIES LIMITED

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Process description and Utilities

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SECTION RELIANCE INDUSTRIES LIMITED

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Process description and Utilities

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Process description and Utilities

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DESI"N SPECI)ICATION O) N"L )EEDSTOCK!

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Process description and Utilities

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SPECI)ICATION O) $7DRO"EN PRODUCT!

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