You are on page 1of 324

Vendor Document No.

TPC-DQR-002-TRM-OPS-015

ARAMIS Development Ltd

Rev.
A

Page
1 of 323

TRAINING MODULE

RESIDUE FLUID CATALYTIC CRACKER (RFCC)


UNIT: 15

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY (DQR) PROJECT
DUNG QUAT, VIETNAM

Requisition Number:

8474L-000-CFB-XXXX-0001

Purchase Order Number:

8474L-000-CS01-17061

Equipment / Item Tag:

Not Applicable

Equipment / Item Description:

Not Applicable

TPC Document Number:

8474L-015-A5016-0000-001-005

Document Class:

06-DEC-07

Rev

Date
DD-MMM-YY

Stamp

Comment given in this document does not relieve vendor of his/her responsibility for the
correct engineering design and fabrication. This equipment or product shall be made as per
the codes, requisition, specification, project procedures, and international standards.

Issue for review

Benoit Rabaud

Paul Walsh

JB Guillemin

Status

Written By
(name & visa)

Check By
(name & visa)

Approved By
(name & visa)

Pages changed in this revision:


Sections changed in last revision are identified by a vertical line in the margin
DOCUMENT REVISIONS

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

TRAINING MODULE

RESIDUE FLUID CATALYTIC CRACKER (RFCC)


UNIT: 15

A
06/12/07
REV
DATE
TRAINING DURATION

Benoit Rabaud
Paul Walsh
PREPARED BY
CHECKED BY
VENUE

JB Guillemin
APPROVED BY

ATTENDANCE
ATTENDEES REQUIREMENTS
MODULE OBJECTIVES

INSTRUCTORS NAME/POSITION
SUMMARY/AGENDA

Page 2 of 323

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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

IMPORTANT

THIS TRAINING MODULE HAS BEEN PREPARED BY ARAMIS FOR THE DUNG QUAT
REFINERY.
THIS MODULE MUST BE RECOGNIZED AS A TOOL AND GUIDE ONLY. IT WOULD BE
IMPOSSIBLE TO ANTICIPATE AND PRESENT ALL POTENTIAL VARIABLES AND
PROCESS CONDITIONS THAT OPERATIONAL PERSONNEL MIGHT BE EXPOSED TO.
IT IS IMPERATIVE THAT THE READER ALWAYS AS CERTAIN THAT REFERENCE
MATERIALS UTILIZED, WHILE PERFORMING OPERATIONAL DUTIES, CONFORM AT A
MINIMUM TO THE LATEST ISSUE OF STANDARD OPERATING PROCEDURES, SAFETY
CODES, ENGINEERING STANDARDS, AND GOVERNMENT REGULATIONS.
SOME DESIGN FIGURES MIGHT NOT BE IN LINE DURING THE START-UP OF THE
REFINERY.

Page 3 of 323

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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

TABLE OF CONTENT
SECTION 1 : GENERAL description ........................................................................................... 14
1.1.

Purpose of the Unit ................................................................................................ 17

1.2.

Basis of Design ...................................................................................................... 24


1.2.1. Duty of Plant ............................................................................................... 24
1.2.2. Feed Characteristics ................................................................................... 25
1.2.2.1. Atmospheric Residue Properties................................................... 25
1.2.2.2. CDU Stabilizer Off Gas ................................................................. 25
1.2.2.3. NHT Stripper off gas to RFCC....................................................... 26
1.2.2.4. CDU LPG Rich Stream.................................................................. 27
1.2.2.5. Slops feed to RFCC ...................................................................... 27
1.2.3. Product Specifications ................................................................................ 27
1.2.3.1. Distillation Specifications............................................................... 27
1.2.3.2. Gas Recovery Targets .................................................................. 28
1.2.3.3. Flue Gas Specifications................................................................. 28
1.2.3.4. Fuel Gas Specification .................................................................. 28
1.2.3.5. Decant Oil Specification (after Slurry Separation) ........................ 28
1.2.3.6. Estimated Product Properties........................................................ 29
1.2.3.7. LPG Composition .......................................................................... 32
1.2.4. Utility/Power/Chemicals/Catalyst consumption .......................................... 33
1.2.4.1. Utility Consumption ....................................................................... 33
1.2.4.2. Catalysts & Chemicals .................................................................. 43

1.3.

Glossary of terms and Acronyms........................................................................... 47


1.3.1. Acronyms .................................................................................................... 47
1.3.2. Glossary ...................................................................................................... 50

SECTION 2 : Process Flow Description ...................................................................................... 52


2.1.

Feed Section .......................................................................................................... 52

2.2.

Reaction Section .................................................................................................... 53


2.2.1. Feed Injection Zone .................................................................................... 53
2.2.2. Riser/Reactor .............................................................................................. 54
2.2.3. Stripper........................................................................................................ 55
2.2.4. Spent Catalyst Transfer .............................................................................. 56

2.3.

Catalyst Regeneration Section .............................................................................. 56


2.3.1. Air blower and air heaters........................................................................... 57

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REV: A

DATE: 06/12/07

2.3.2. First stage regenerator ............................................................................... 57


2.3.3. Second stage regenerator .......................................................................... 58
2.3.4. Combustion Air Rings ................................................................................. 59
2.3.5. Regenerated catalyst transfer..................................................................... 59
2.3.6. Catalyst handling ........................................................................................ 59
2.4.

Flue gas treatment ................................................................................................. 61


2.4.1. Phosphate injection .................................................................................... 65

2.5.

Fractionation Section ............................................................................................. 66


2.5.1. Fractionator bottom section ........................................................................ 66
2.5.2. HCO section................................................................................................ 67
2.5.3. LCO section ................................................................................................ 68
2.5.4. MTC and heavy naphtha section ................................................................ 69
2.5.5. Top section ................................................................................................. 70
2.5.6. Fractionator overhead section .................................................................... 70

2.6.

Gas Recovery section ............................................................................................ 71


2.6.1. Wet gas compressor and HP condenser.................................................... 71
2.6.2. Stripper condenser and high pressure separator drum.............................. 71
2.6.3. Primary absorber T-1551............................................................................ 72
2.6.4. Stripper........................................................................................................ 72
2.6.5. Secondary absorber T-1553 ....................................................................... 73
2.6.6. Fuel gas absorber ....................................................................................... 73
2.6.7. Debutanizer................................................................................................. 74
2.6.8. LPG amine absorber T-1556 ...................................................................... 75

SECTION 3 : Process control ...................................................................................................... 77


3.1.

Control narrative & operating parameters.............................................................. 77


3.1.1. Feed Oil Temperature Control .................................................................... 77
3.1.2. UC-001 Feed Injector ................................................................................. 79
3.1.3. UC-028 MTC INJECTOR............................................................................ 81
3.1.4. Riser Outlet Temperature Control .............................................................. 83
3.1.5. Catalyst Stripper Level Control ................................................................... 86
3.1.6. Catalyst Regenerators Level Control.......................................................... 87
3.1.7. Catalyst Regenerators Pressure Control.................................................... 89
3.1.8. Disengager Pressure Control ..................................................................... 91
3.1.9. Catalyst Regeneration Air and Total Flue gas to Stack Control................. 91
3.1.10. Catalyst Draw-Off Control ......................................................................... 94
3.1.11. Slurry Pumparound Return Control........................................................... 96
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REV: A

DATE: 06/12/07

3.1.12. Feed Pumps Automatic Start-up............................................................... 98


3.1.13. UY-405, Slurry Pumparound (PA) Return Control .................................... 98
3.1.14. UC-414, E-1505 Slurry PA flow balance control..................................... 100
3.1.15. UC-413, E-1503 Slurry PA flow balance control..................................... 102
3.1.16. Steam Generation 3 Elements Control ................................................... 104
3.1.17. Split Range Control of Surge Drum ........................................................ 105
3.1.18. Main Fractionator Pressure Control ........................................................ 107
3.1.19. HCO Pumparound Heat Removal Control.............................................. 107
3.1.20. HCO Recycle and HCO Recycle MP steam generator E-1508.............. 108
3.1.21. HCO LP Steam Generator E-1510 Controls........................................... 108
3.1.22. HCO Flushing Oil Pumps Auto-start Control .......................................... 109
3.1.23. LCO and Heavy Naphta Pumparound Heat Removal Control ............... 111
3.1.24. Heavy Naphta Product Draw-Off and T-1501 Overheads Temperature
Control 111
3.1.25. Water Draw Off and Recirculation .......................................................... 112
3.1.26. Wet Gas Compressor Control................................................................. 112
3.1.27. First Stage KO Drum D-1551 Level Control ........................................... 112
3.1.28. Stripper.................................................................................................... 113
3.1.29. Debutanizer ............................................................................................. 114
3.1.30. LPG Amine Absorber .............................................................................. 114
3.1.31. Control Narrative for the Slurry Separator Package X-1504 .................. 114
3.1.32. Tempered Water for E-1507 A-D ............................................................ 116
3.1.33. Amine Closed Drain Recovery Drum Pump P-1564............................... 117
3.1.34. RFCC lift station No.1 & No.2 Pits Pumps Control ................................. 118
3.1.35. Inter-Unit Controls & Interfaces............................................................... 118
3.1.35.1. RFCC Feed Control ................................................................... 118
3.1.35.2. Temperature of Lean Amine from the ARU............................... 120
3.1.36. Operating Parameters............................................................................. 122
3.2.

Instrument List...................................................................................................... 122

3.3.

Main Equipment ................................................................................................... 123


3.3.1. Reactor Riser, Stripper, Disengager and Catalyst Stand Pipe................. 123
3.3.1.1. Riser Outlet Separation System .................................................. 126
3.3.1.2. Catalyst Stripper .......................................................................... 129
3.3.2. 1st Stage Regenerator D-1502.................................................................. 131
3.3.3. 2nd Stage Regenerator D-1503................................................................. 133
3.3.4. Aeration and Fluidization Systems ........................................................... 137
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DATE: 06/12/07

3.3.5. Special Valves .......................................................................................... 138


3.3.6. Air Heaters ................................................................................................ 142
3.3.7. CO Boiler / Waste Heat Boiler Package H-1503 ...................................... 144
3.3.8. Electrostatic Precipitator X-1507 .............................................................. 151
3.3.9. Main Fractionator ...................................................................................... 153
3.3.10. Stripper T-1552 & Primary Absorber T-1551 .......................................... 155
3.3.11. Debutanizer T-1554 ................................................................................ 159
3.3.12. LPG Amine Absorber .............................................................................. 161
3.3.13. Secondary Absorber T-1553................................................................... 163
3.3.14. Fuel Gas Absorber T-1555...................................................................... 165
3.3.15. Slurry Separator ...................................................................................... 167
3.3.16. Air Blower, C-1501 .................................................................................. 168
3.3.17. Wet Gas Compressor C-1551................................................................. 171
SECTION 4 : Safeguarding devices .......................................................................................... 175
4.1.

Alarms and Trips .................................................................................................. 175

4.2.

Safeguarding Description..................................................................................... 175


4.2.1. Logic UX-001 Reaction Stop ................................................................. 175
4.2.2. Logic UX-002: Catalyst Circulation Stops................................................. 178
4.2.3. Logic UX-003: First Regenerator Air Heater Trip ..................................... 179
4.2.4. Logic UX-004: Second Regenerator Air Heater Trip ................................ 180
4.2.5. Logic UX-005: Air Blower Protection ........................................................ 181
4.2.6. Logic UX-008: COB/WHB 1st Regenerator Flue Gas Bypass Operation . 182
4.2.7. Logic UX-009: Steam Drum D-1512 overfilling protection ....................... 183
4.2.8. Logic UX-010: COB/WHB 2nd Regenerator Flue Gas Bypass Operation 184
4.2.9. Logic UX-013: Economizer Bypass Cooling............................................. 185
4.2.10. Logic UX-421: Feed Surge Drum D-1513 overfilling protection ............. 186
4.2.11. Logic UX-422: Feed Pumps P-1501 A/B Protection ............................... 186
4.2.12. Logic UX-423: T-1501 & P-1507 A/B inventory isolation........................ 187
4.2.13. Logic UX-424: T-1501 & P-1508 A/B inventory isolation........................ 188
4.2.14. Logic UX-425: Slurry pumps P-1519 A/B/C protection........................... 189
4.2.15. Logic UX-426: T-1501 & P-1519 inventory isolation............................... 190
4.2.16. Logic UX-427: T-1504 & P-1509 A/B inventory isolation........................ 192
4.2.17. Logic UX-428: Heavy Naphta Product Pumps P-1515 A/B protection ... 194
4.2.18. Logic UX-429: LCO Stripper Pumps P-1511 A/B protection .................. 194
4.2.19. Logic UX-430: D-1514, P-1516 A/B & P-1518 A/B inventory isolation... 195
4.2.20. Logic UX-431: D-1524, P-1517 A/B inventory isolation.......................... 196
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DATE: 06/12/07

4.2.21. Logic UX-432: D-1515 overfilling protection ........................................... 197


4.2.22. Logic UX-433: Slurry Product Pumps P-1504 A/B protection................. 198
4.2.23. Logic UX-434: Backflush Oil Recycle Pumps P-1506 A/B protection .... 198
4.2.24. Logic UX-435: D-1517 overfilling protection ........................................... 198
4.2.25. Logic UX-436: Backflush Oil Pumps P-1505 A/B protection .................. 199
4.2.26. Logic UX-437: D-1516 overfilling protection ........................................... 199
4.2.27. Logic UX-438: HCO Flushing Oil Pumps P-1521 A/B protection ........... 200
4.2.28. Logic UX-439: LCO Flushing Oil Pumps P-1522 A/B protection ............ 201
4.2.29. Logic UX-440: D-1522 overfilling protection ........................................... 201
4.2.30. Logic UX-441: Light Slops Pumps P-1526 A/B protection...................... 201
4.2.31. Logic UX-442: D-1523 overfilling protection ........................................... 202
4.2.32. Logic UX-443: Heavy Slops Pumps P-1527 A/B protection ................... 202
4.2.33. Logic UX-444: Tempered Water Pumps P-1528 A/B Protection ............ 203
4.2.34. Logic UX-705: C-1551 Isolation and Protection...................................... 203
4.2.35. Logic UX-706: Interstage drum pump P-1551 A/B Protection ................ 204
4.2.36. Logic UX-707: HP separator drum D-1553 Interface Isolation ............... 205
4.2.37. Logic UX-708: HP separator drum D-1553 Inventory Isolation .............. 205
4.2.38. Logic UX-709: Lean Oil Coalescer Interface Isolation............................ 206
4.2.39. Logic UX-710: T-1555 Interface Isolation ............................................... 207
4.2.40. Logic UX-712: Debutanizer T-1554 Inventory Isolation .......................... 207
4.2.41. Logic UX-713: D-1554 Interface Isolation............................................... 208
4.2.42. Logic UX-714: Debutanizer Reflux Drum D-1554 Inventory Isolation .... 209
4.2.43. Logic UX-715: T-1556 Interface Isolation ............................................... 210
4.2.44. Logic UX-716: LPG amine coalescer D-1555 Interface Isolation ........... 210
4.2.45. Logic UX-717: LPG amine absorber T-1556 depressurization............... 211
4.2.46. Logic UX-718: Fuel Gas Absorber Outlet KO Drum D-1559 Interface
Isolation ................................................................................................................ 211
4.2.47. Logic UX-719: D-1553 depressurization ................................................. 212
4.2.48. Logic UX-861 Wet Gas Compressor C-1551 Protection ........................ 212
4.3.

Safeguarding Equipment ..................................................................................... 214


4.3.1. Pressure Safety Devices .......................................................................... 214

SECTION 5 : Fire & Gas Systems............................................................................................. 225


5.1.

Fire & Gas detection ............................................................................................ 225

5.2.

Fire Protection...................................................................................................... 225

SECTION 6 : Quality control...................................................................................................... 227


6.1.

Sampling Analysis................................................................................................ 227


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DATE: 06/12/07

6.1.1. Feed Oil .................................................................................................... 227


6.1.2. Catalyst ..................................................................................................... 227
6.1.3. Light Cycle Oil........................................................................................... 228
6.1.4. Heavy Cycle Oil ........................................................................................ 228
6.1.5. Clarified Oil ............................................................................................... 228
6.1.6. Slurry......................................................................................................... 229
6.1.7. Absorber Gas............................................................................................ 229
6.1.8. Heavy Naphta ........................................................................................... 229
6.1.9. LPG ........................................................................................................... 229
6.1.10. Sour Water .............................................................................................. 230
6.1.11. Sampling Connections ............................................................................ 230
6.2.

On-line analyzers ................................................................................................. 233

SECTION 7 : Causes and effect................................................................................................ 237


7.1.

Cause & Effect Matrix: ......................................................................................... 237


7.1.1. Example from Cause and Effect Chart ..................................................... 237
7.1.1.1. Sheet 18: UX-426: T-1501 & P-1519 inventory isolation ............ 237

SECTION 8 : Operating practices.............................................................................................. 243


8.1.

Normal Operation................................................................................................. 243


8.1.1. Operating conditions................................................................................. 243
8.1.2. Operating Parameters .............................................................................. 271

8.2.

Start-up Procedure............................................................................................... 271


8.2.1. Pre-commissioning Activities .................................................................... 272
8.2.2. Initial Start-up............................................................................................ 272
8.2.2.1. Status of the Unit prior to first start-up ........................................ 272
8.2.2.2. Chronology of first Start-up ......................................................... 273
8.2.3. Initial & Normal Start-Up ........................................................................... 274
8.2.3.1. Start-up summary of the Reaction Section ................................. 274
8.2.3.2. Start-up summary of the Fractionation & Gas Recovery Sections
279

8.3.

Shutdown Procedures.......................................................................................... 284


8.3.1. Normal Shutdown ..................................................................................... 284
8.3.1.1. Normal Shutdown Summary of Reactor & Regenerator............. 284
8.3.1.2. Normal Shutdown Summary of Fractionation and Gas Recovery
Section 288

8.4.

Emergency Shutdown .......................................................................................... 290


8.4.1. General emergency shutdown.................................................................. 290
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8.4.2. Power failure ............................................................................................. 290


8.4.3. Instrument air failure ................................................................................. 291
8.4.4. Fluidization / Aeration / Purge Air and FG failure ..................................... 292
8.4.5. Steam failure............................................................................................. 293
8.4.6. Boiler feed water failure ............................................................................ 294
8.4.7. Cooling water failure ................................................................................. 295
8.4.8. Sea water failure ....................................................................................... 295
8.4.9. Air blower failure ....................................................................................... 295
8.4.10. Feed pump failure ................................................................................... 297
8.4.11. Other pump failure .................................................................................. 297
8.4.12. Fuel gas failure........................................................................................ 297
8.4.13. Wet gas compressor failure .................................................................... 298
8.4.14. Catalyst slide valve / plug valve failure ................................................... 299
8.4.15. Loss of regenerators pressure control (flue gas slide valve failure) ....... 299
8.4.16. Control system failure ............................................................................. 300
8.4.17. Oil reversal .............................................................................................. 300
8.4.18. Low riser outlet temperature (ROT) ........................................................ 300
8.4.19. Plugged catalyst circulation .................................................................... 301
8.4.20. Downstream unit failure .......................................................................... 301
8.4.21. Fire emergency ....................................................................................... 301
8.4.22. Emergency shutdown of Fractionator and Gas Recovery Section - General
302
8.4.23. Steam failure for the Fractionation/Gas Recovery Section..................... 302
8.4.24. Instrument air failure for the Fractionation/Gas Recovery Section......... 302
8.4.25. Boiler feed water failure for the Fractionation/Gas Recovery Section.... 303
8.4.26. Fuel gas failure for the Fractionation/Gas Recovery Section ................. 303
8.4.27. Electrical power failure for the Fractionation/Gas Recovery Section ..... 303
8.4.28. Cooling water failure for the Fractionation/Gas Recovery Section......... 304
8.4.29. Sea water failure for the Fractionation/Gas Recovery Section............... 304
8.4.30. Wet gas compressor failure for the Fractionation/Gas Recovery Section
304
SECTION 9 : HSE...................................................................................................................... 306
9.1.

Hazardous Areas ................................................................................................. 306

9.2.

Safety Equipment................................................................................................. 306

9.3.

Specific PPE ........................................................................................................ 306


9.3.1. Catalyst ..................................................................................................... 306
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9.3.2. Flue gas .................................................................................................... 307


9.3.2.1. Carbon Monoxide ........................................................................ 307
9.3.3. H2S ........................................................................................................... 307
9.3.4. Nickel passivator NALCO NICKEL PASSIVATION PLUS EC9192 ...... 308
9.3.5. Corrosion Inhibitor - CHIMEC 1430.......................................................... 308
9.3.6. Antifoam CHIMEC 8045 ........................................................................... 309
9.3.7. Phosphate NALCO 7208 .......................................................................... 309
9.4.

Chemical Hazards................................................................................................ 309


9.4.1. Hazardous Properties of Catalyst............................................................. 310
9.4.2. Flue gas .................................................................................................... 310
9.4.2.1. Hazardous properties of carbon monoxide (CO) ........................ 310
9.4.3. Hazardous Properties of Cracked hydrocarbons ..................................... 311
9.4.4. Hazardous Properties of Hydrogen Sulfide Toxicity................................. 311
9.4.4.1. Acute Hydrogen Sulfide Poisoning.............................................. 312
9.4.4.2. Subacute Hydrogen sulfide Poisoning ........................................ 313
9.4.5. Hazardous Properties of NALCO NICKEL PASSIVATION PLUS EC9192
313
9.4.6. Hazardous Properties of Corrosion Inhibitor - CHIMEC 1430.................. 314
9.4.7. Hazardous Properties of Antifoam CHIMEC 8045 ................................... 314
9.4.8. Hazardous Properties of Phosphate NALCO 7208 .................................. 315

SECTION 10 : Reference documents index.............................................................................. 317


10.1. Operating Manual/ Licensor Documentation ....................................................... 317
10.2. Arrangement Drawings, Layouts and Plot Plans ................................................. 317
10.3. Process Flow Diagrams ....................................................................................... 317
10.4. Piping and Instrumentation Diagrams.................................................................. 317
10.5. Equipment list....................................................................................................... 320
10.6. Main Equipment Data Sheet ................................................................................ 320
10.7. Instrument List...................................................................................................... 321
10.8. Cause & Effect Matrix .......................................................................................... 321
10.9. Safety Logic diagram ........................................................................................... 321
10.10.

Fire & Gas Cause & Effect Chart .............................................................. 321

10.11.

Fire & Gas Detectors Layout..................................................................... 321

10.12.

Fire Protection Layout ............................................................................... 321

10.13.

Hazardous Area Classification.................................................................. 322

10.14.

MSDS ........................................................................................................ 322

10.15.

Vendors Documentation............................................................................ 322


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TRAINING MODULE

RESIDUE FLUID CATALYTIC CRACKER (RFCC)


UNIT: 15

Course Content:
Section 1 - General Description

Section 2 - Process Flow Description


Section 3 - Process Control
Section 4 - Safeguarding Devices
Section 5 - Fire & Gas Systems
Section 6 - Quality Control
Section 7 - Cause & Effects
Section 8 - Operating Procedures
Section 9 - HSE
Section 10 - Reference Document Index

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SECTION 1 : GENERAL DESCRIPTION


The Residue Fluid Catalytic Cracking (RFCC) converts various residues from CDU to lower
boiling, high value products: Naphtha sent to NTU (unit 17), Light Cycle Oil sent to LCO HDT
(unit 24) and intermediate storage and LPG sent to the LTU (unit 16).
As by-products of the reaction, fuel gas, slurry oil, and coke are also generated in the reactorriser. The resulting Decanted Cycle Oil from these by-products will then be incorporated in the
Fuel oil Blend.
The majority of the RFCC reaction section equipment handles catalyst / vapour product
separation and removal of the coke from the catalyst, while only a small portion of the system is
directly used for the cracking reaction.
The RFCC is also provided with a Fractionation Section to distillate the vapour product from the
reaction section, as well as a Gas recovery Section which process the overhead of the
Fractionation Section

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Figure 1: 2D Refinery Plot Plan


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Figure 2: 3D Refinery Plot Plan


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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

1.1. Purpose of the Unit


The purpose of the Residue Fluid Catalytic Cracker (RFCC) R2R process is to convert
various reduced crudes to lower boiling, high value products, primarily C3-C4 LPG,
gasoline and light cycle oil.
This is achieved using vapour phase chemical reactions in the presence of specialized
FCC cracking catalyst during which the long molecular chain of the reduced crude is
cracked into shorter chain molecules. Heat for the cracking process is supplied by the hot
regenerated catalyst which vaporizes the finely atomized oil feed and sets the stage for
the rapid and selective cracking process. The vaporization and cracking reactions occur
in the reactor riser in about 2 seconds.
As by-product of the reaction, fuel gas, slurry oil, and coke are also generated in the
reactor riser.
The RFCC has been designed by AXENS to offer maximum flexibility. The reaction
section of this unit particularly includes a 2-stage catalyst regeneration system, a unique
feed injection system, mixed temperature control, an efficient riser termination system
and effective air/steam distribution devices.
The Fractionation section of the RFCC fractionates the vapour product from the reaction
section into clarified oil, LOC and heavy naphta. The fractionator overhead vapour and
liquid streams are further processed in the Gas Recovery section, which produces light
gasoline, amine treated fuel gas and amine treated LPG.
For the Maximum Gasoline Operation, the heavy naphta is combined with the light
gasoline from the Gas Recovery Section. For the maximum Distillate Operation, the
heavy naphta combined with LCO products.

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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Figure 3: Refinery Plot Plan


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REV: A

DATE: 06/12/07

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CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

North East View


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CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

North West View


Page 21 of 323

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CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

South East
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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

South West
Figure 4: RFCC 3D Drawings
Page 23 of 323

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CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

1.2. Basis of Design


1.2.1. Duty of Plant
The Residue Fluid Catalytic Cracking (RFCC) is designed for 2 atmospheric
residues from Bach Ho and Bach Ho/Dubai crudes mixture:

The RFCC design capacity is 3,256,000 tones per annum of Bach Ho


370+C crude distillation residue (from unit 11), which is equivalent to a
volumetric flowrate of 69,700 BPSD, based on the RFCC operation of 8 000
hours operation per year.

The RFCC is also designed to process a residue based on the CDU (from
unit 11) processing a sour crude blend in the ratio of 1.0 million tones of
Dubai crude to 5.5 million tones of Bach Ho crude. The sour residue blend
capacity is also 3,256,000 tones per annum, which is equivalent to a
volumetric flowrate of 69,700 BPSD, based on 8 000 hours operation per
year.

The RFCC is also designed to process both the Bach Ho and sour crude mix
residues in2 modes of operation:

Maximize RFCC Naphtha (Max Gasoline)

Maximize LCO (Max Distillate)

NOTE:
The product guarantees are based on RFCC operating in the maximum distillate
mode of operation.
The RFCC is designed to process 100% hot feed direct from the Crude Distillation
Unit and is capable of processing up to 100% cold feed from storage.
In addition to the above, the RFCC Gas Plant can process the following streams:

CDU Stabilizer Off-gas

CDU LPG rich stream

The RFCC shall also treat the off-gas stream from the Naphtha hydrotreater
(NHT).

Page 24 of 323

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CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

1.2.2. Feed Characteristics


1.2.2.1. Atmospheric Residue Properties
Crude (Sour)
Blend

100% (Sweet)
Bach Ho

Cut Range, TPB (C)

370+

370+

Vol% on Crude

46.6

47.3

Wt% on Crude

50.0

50.1

API Gravity

2695

28.9

Specific Gravity at 15/4C

0.893

0.882

Nitrogen (wt ppm)

1800

1300

Sulphur (wt%)

0.55

0.05

D-1266

Conradson Carbon (wt%)

2.66

1.57

D189

Vanadium (wt ppm)

10.5

D2787

Sodium (wt ppm)

1.6

1.6

D2788

Viscosity at 50C (cSt)

43.4

43.4

D445

Viscosity at 100C (cSt)

8.8

Pour Point (C)

50

52

D97

Asphaltenes (wt%)

2.0

1.0

D128

Wax Content (wt%)

N/A

41

Hydrogen (wt%)

12.7

12.84

D1018

Neutralization No. (mg KOH/gm)

0.05

0.05

D3242

Characterization K Factor

12.58

12.78

IBP

263

262

10%

379

379

30%

435

437

50%

475

480

Vol% above 550C

32.4

32.5

Property

Nickel (wt ppm)

ASTM Test
Method

ASTM Distillation (C)


D-1160 at 760
mmHg

1.2.2.2. CDU Stabilizer Off Gas


The following gas stream is fed from the CDU Stabilizer, directly to the
suction of the wet-gas compressor in the RFCC Gas Plant:
Page 25 of 323

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CRACKER (RFCC)

Property

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Crude (Sour) Blend [1]

100% (Sweet) Bach Ho

339.0

291.0

N2 (mol%)

H2S (mol%)

C1 (mol%)

0.7

C2 (mol%)

6.3

4.8

C3 (mol%)

37.0

22.7

iC4 (mol%)

14.3

16.0

nC4 (mol%)

40.6

53.5

iC5 (mol%)

0.4

0.4

nC5 (mol%)

C6+ (mol%)

H2O (mol%)

1.4

1.9

Total (mol%)

100.0

100.0

Molecular Weight

50.6

52.6

Flowrate (kg/hr)
Composition

Note:
[1]: Sour Crude Blend data based on 100% Dubai Crude.

1.2.2.3. NHT Stripper off gas to RFCC


Component

Content

H2O (kg mol/h)

0.13

H2S (kg mol/h)

0.32

NH3 (kg mol/h)

Trace

H2 (kg mol/h)

13.17

C1 (kg mol/h)

1.69

C2 (kg mol/h)

1.37

C3 (kg mol/h)

0.83

iC4 (kg mol/h)

0.06

nC4 (kg mol/h)

0.40

IC5 (kg mol/h)

0.10

C6+ (kg mol/h)

0.63

Total (kg mol/h)

18.84

Total (kg/h)

243
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CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

1.2.2.4. CDU LPG Rich Stream


Property

Crude (Sour) Blend [1]

100% (Sweet) Bach Ho

Flowrate (kg/hr)

6206

2071

Specific Gravity at 15C

0.565

0.572

1.2

0.8

Propene (mol%)

Propane (mol%)

19.3

10.7

iC4 (mol%)

16.5

16.1

nC4 (mol%)

61.7

71.0

iC5+ (mol%)

1.3

1.4

Total (mol%)

100.0

100.0

Composition
Ethylene (mol%)
Ethane (mol%)

Butene (mol%)

1.2.2.5. Slops feed to RFCC


Provision is made to allow the re-running of slops through the RFCC main
fractionator.
Heavy slops:

5000 BPSD

Light slops:

5000 BPSD

1.2.3. Product Specifications


1.2.3.1. Distillation Specifications
Product
Gasoline
LCO
Slurry

Property

Max. Gasoline

Max. Distillate

TBP cut points

C5 - 205C

C5 - 165C

RVP (kPa)
TBP cut point

60 max.
205 360C

Flash Point
TBP cut point
Flash Point

165 390C
65C min.

360+C

390+C
100C min.

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CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

1.2.3.2. Gas Recovery Targets


Component

Value

C3 overall recovery

95% min.

C4 overall recovery

96% min.

C5+ content in LPG

0.7% wt max.

H2S content in LPG

25 ppm wt max.

1.2.3.3. Flue Gas Specifications


The following describes the flue gas properties downstream of the
electrostatic precipitator and the DeSOx unit:
Component

Value

NOx

1000 mg/Nm3 max

SOx

500 mg/Nm3 max

Catalyst fines

50m/Nm3 max

CO content

300 mg/Nm3 max

NOTE:
DeSOx unit will be provided in the future.
Indeed, the unit will be initially operated with Bach Ho Crude only, thus
producing SO2 content smaller than 500 mg/Nm3.

1.2.3.4. Fuel Gas Specification


H2S content: 50 wt ppm MAX.

1.2.3.5. Decant Oil Specification (after Slurry Separation)


Catalyst content: 100 wt ppm MAX.

Page 28 of 323

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CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

1.2.3.6. Estimated Product Properties


Mixed
MG

Bach Ho
MG

Mixed
MD

Bach Ho
MD

LPG
Specific Gravity 15/15

0.565

0.566

.565

0.565

Mercaptans (wt ppm)

78

7.1

78

1.7

COS (wt ppm)

5.0

5.0

5.0

5.0

Total Sulphur (wt ppm)

3786

332

4260

383

Butadiene (wt ppm)

3012

1647

1358

1063

Sulphur (wt ppm)

230

10

RON clear

92.0

91.7

MON clear

79.5

79.2

True Vapour Pressure (g/cm2)

498

531

Reid Vapour Pressure (kPa)

48

51

Specific Gravity (15/15)

00.719

0.715

IBP

35

34

43

42

10

47

46

30

60

58

50

72

70

70

89

90

129

129

95

144

143

EBP

159

156

43

45

Gasoline (C5 165C)

D-86

Olefins (wt %)
Gasoline (C5 205C)
Sulphur (wt ppm)

340

10

RON clear

92.1

91.8

79.9

79.6

True Vapour Pressure (g/cm )

337

363

Reid Vapour Pressure (kPa)

32

34

Specific Gravity (15/15)

0.736

0.732

MON clear
2

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CRACKER (RFCC)

Mixed
MG

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Bach Ho
MG

Mixed
MD

Bach Ho
MD

D-86
IBP

39

39

50

49

10

55

54

30

71

70

50

90

87

70

116

113

90

160

159

95

176

175

EBP

197

197

34

35

Olefins (wt %)
Light Cycle Oil (165 390C)
Sulphur (wt %)

0.45

0.04

Cetane Number

33.9

38.4

Cloud Point (C)

-1.8

-0.9

Viscosity at 100C (cSt)

1.02

1.02

Viscosity at 50C (cSt)

2.05

2.04

Pour Point (C)

-17.3

-18.9

Flash Point (C)

67

67

Specific Gravity 15/15

0.881

0.864

IBP

189

189

203

204

10

212

212

30

239

239

50

263

264

70

291

292

90

333

334

95

349

350

EBP

373

374

D-86

Light Cycle Oil (205 360C)


Sulphur (wt %)

0.619

0.055

Cetane Number

24.4

28.1

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CRACKER (RFCC)

Mixed
MG

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

Bach Ho
MG

Cloud Point (C)

-6.1

-5.3

Viscosity at 100C (cSt)

0.99

0.97

Viscosity at 50C (cSt)

1.92

1.88

Pour Point (C)

-12.8

-14.0

Flash Point (C)

76

74

Specific Gravity 15/15

0.926

0.911

IBP

188

180

221

220

10

230

230

30

24

245

50

263

262

70

287

286

90

323

322

95

336

335

EBP

353

353

DATE: 06/12/07

Mixed
MD

Bach Ho
MD

D-86

Slurry (390+C)
Specific Gravity 15/15

0.994

0.960

Sulphur (wt %)

0.835

0.07

Conradson Carbon (wt %)

12.5

9.5

Viscosity at 100C (cSt)

8.94

6.09

Viscosity at 50C (cSt)

110

45

Pour Point (C)

15-20

15-20

Slurry (390+C)
Specific Gravity 15/15

1.092

1.043

Sulphur (wt %)

1.03

0.10

Conradson Carbon (wt %)

15.7

12.7

Viscosity at 100C (cSt)

14.5

11.1

Viscosity at 50C (cSt)

160

140

Pour Point (C)

15-20

15-20

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CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

1.2.3.7. LPG Composition

Component

Mixed MG

Bach Ho MG

Mixed MD

Bach Ho MD

LPG Rate
(kg/h)

LPG Rate
(kg/h)

LPG Rate
(kg/h)

LPG Rate
(kg/h)

H2 S

H2

C1

C2

449

333

444

349

Ethylene

C3

6124

5179

6627

5793

Propylene

20251

14145

19626

14621

iC4

14681

11273

13689

10839

nC4

5801

4221

7858

6560

Isobutylene

6579

4679

6758

5170

1-Butene

6317

4706

5922

4653

Cis-2-Butene

6482

4751

5909

4592

Trans-2-Butene

9862

7245

8964

6975

Butadiene

106

50

184

64

20-50

541

399

540

424

TOTAL:

77203

56988

76530

60049

Component

LPG (kmol/h)

LPG (kmol/h)

LPG (kmol/h)

LPG (kmol/h)

H2 S

0.04

0.03

0.04

0.06

H2

0.00

0.00

0.00

0.00

C1

0.00

0.00

0.00

0.00

C2

14.94

11.07

14.77

11.62

Ethylene

0.31

0.21

0.32

0.24

C3

138.87

117.44

150.28

131.37

Propylene

481.23

336.14

466.37

347.44

iC4

252.58

193.94

235.51

186.49

nC4

99.81

72.63

135.20

112.86

Isobutylene

117.26

83.39

120.45

92.15

1-Butene

112.59

83.88

105.54

82.93

Page 32 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

Mixed MG

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

Bach Ho MG

DATE: 06/12/07

Mixed MD

Bach Ho MD

Cis-2-Butene

115.53

84.68

105.32

81.84

Trans-2-Butene

175.76

129.12

159.76

124.31

Butadiene

1.96

0.93

3.41

1.18

20-50

8.07

6.10

8.00

6.47

TOTAL:

1518.96

1119.56

1504.96

1178.96

Mercaptans (wt ppm)

78

78

COS (wt ppm)

Temperature (C)

40

40

40

40

Pressure (kg/cm2g)

18

18

18

18

Density (P; T)

530.2

530.1

529.8

529.8

Density (15C)

563.3

563

562.8

562.7

Note: Dry Liquid.

1.2.4. Utility/Power/Chemicals/Catalyst consumption


1.2.4.1. Utility Consumption
The following describes the utility consumption of the RFCC based on the
Estimated Utility Consumption Documents:
8474L-015-CN-0003-511

Bach Ho Max Gasoline Normal case

8474L-015-CN-0003-512

Bach Ho Max Distillate Normal case

8474L-023-CN-0003-513

Mixed Crude Max Gasoline Normal


case

8474L-023-CN-0003-514

Mixed Crude Max Distillate Normal


case

8474L-015-CN-0003-521

Bach Ho Max Gasoline Design case

8474L-015-CN-0003-522

Bach Ho Max Distillate Design case

8474L-023-CN-0003-523

Mixed Crude Max Gasoline Design


case

8474L-023-CN-0003-524

Mixed Crude Max Distillate Design


case

Page 33 of 323

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CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Only the Bach Ho Max Distillate Normal case is described in the


following. For the other cases, refer to the abovementioned documents.
Note:
In the following subsections:
( ): Intermittent Producer/Consumer
+: Indicates Quantity Produced
-: Indicates Quantity Consumed
1.2.4.1.1. Electrical Power
Electric Power, kW
Mech.
Running
Load

Elec.
Oper.
Load

-0.3

-0.3

1230

-683.0

-697.0

Air Blower

-3.0

-3.0

P-1529A

C-1501 Turbine Condensate Pump

55

-39.0

-43.3

P-1529B

C-1501 Turbine Condensate Pump

55

(-39.0)

(-43.3)

C-1501 Lube oil Pump (Main)

37

-18.5

-20.6

Turbine Gear Motor

15

-15.0

-15.0

C-1551

Wet Gas Compressor

-1.5

-1.5

P-1559A

C-1551 Turbine Condensate Pump

18.5

-13.9

-14.8

P-1559B

C-1551 Turbine Condensate Pump

18.5

(-13.9)

(-14.8)

C-1551 Lube Oil Pump (Main)

30

-16.0

-17.8

P-1501A

Feed Pump

600

-476.0

-500.5

P-1501B

Feed Pump

600

(-476.0)

(-500.5)

P-1504A

Slurry Product Pump

55

-42.7

-45.1

P-1504B

Slurry Product Pump

55

(-42.7)

(-45.1)

P-1505A

Backflush Oil Pump

22

-15.0

-16.5

P-1505B

Backflush Oil Pump

22

(-15.0)

(-16.5)

P-1506A

Backflush Oil Recycle Pump

11

-7.4

-8.4

P-1506B

Backflush Oil Recycle Pump

11

(-7.4)

(-8.4)

P-1507A

HCO Recycle Pump

150

-128.0

-142.2

P-1508B

HCO Recycle Pump

150

(-128.0)

(-142.2)

P-1508A

HCO Pumparound Pump

220

-179.4

-188,4

P-1508B

HCO Pumparound Pump

220

(-179.4)

(-188.4)

Item No.

Description

H-1503

COB/WHB package

C-1502A

Forced Draft Air Fan

C-1501

Motor
Load/
Rating

Page 34 of 323

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CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Electric Power, kW
Motor
Load/
Rating

Mech.
Running
Load

Elec.
Oper.
Load

HCO Product Pump

15

-9.1

-10.1

P-1509B

HCO Product Pump

15

(-9.1)

(-10.1)

P-1510A

LCO Pumparound Pump

335

-303.0

-316.0

P-1510B

LCO Pumparound Pump

335

(-303.0)

(-316.0)

P-1511A

LCO Stripper Pump

90

-73.4

-76.9

P-1511B

LCO Stripper Pump

90

(-73.4)

(-76.9)

P-1512A

MTC Recycle Pump

75

0.0

0.0

P-1512B

MTC Recycle Pump

75

(0.0)

(0.0)

P-1513A

Lean Oil Pump

75

-55.0

-58.1

P-1513B

Lean Oil Pump

75

(-55.0)

(-58.1)

P-1514A

Naphta Pumparound Pump

225

-203.0

-213.9

P-1514B

Naphta Pumparound Pump

225

(-203.0)

(-213.9)

P-1515A

Heavy Naphta Product Pump

55

-39.4

-41.6

P-1515B

Heavy Naphta Product Pump

55

(-39.4)

(-41.6)

P-1516A

Fractionator Reflux Pump

110

-96.0

-101.3

P-1516B

Fractionator Reflux Pump

110

(-96.0)

(-101.3)

P-1517A

Overhead Sour Water Pump

30

-25.5

-27.6

P-1517B

Overhead Sour Water Pump

30

(-25.5)

-(27.6)

P-1518A

Overhead Liquid Pump

250

-206.0

-228.9

P-1518B

Overhead Liquid Pump

250

(-206.0)

(-228.9)

P-1521B

HCO Flushing Oil Pump

110

(-80.9)

(-84.4)

P-1522A

LCO Flushing Oil Pump

30

-18.4

-19.9

P-1522B

LCO Flushing Oil Pump

30

(-18.4)

(-19.9)

P-1526A

Light Slops Pump

37

-16.1

-27.9

P-1526B

Light Slops Pump

37

(-16.1)

(-27.9)

P-1527A

Heavy Slops Pump

37

-27.9

-29.8

P-1527B

Heavy Slops Pump

37

(-27.9)

(-29.8)

P-1528A

Tempered Water Pump

15

-10.5

-11.7

P-1528B

Tempered Water Pump

15

(-10.5)

(-11.7)

P-1551A

Interstage Drum Pump

150

-134.0

-142.3

P-1551B

Interstage Drum Pump

150

(-134.0)

(-142.3)

Item No.

Description

P-1509A

Page 35 of 323

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DATE: 06/12/07

Electric Power, kW
Mech.
Running
Load

Elec.
Oper.
Load

-1.2

-1.4

KO Drum Liquid Pump

(-1.2)

(-1.4)

P-1553A

Stripper Feed Pump

132

-112.0

-117.9

P-1553B

Stripper Feed Pump

132

(-112.0)

(-117.9)

P-1554A

Gasoline Recycle Pump

55

-44.0

-47.7

P-1554B

Gasoline Recycle Pump

55

(-44.0)

(-47.7)

P-1556A

Debutanizer Overhead Pump

225

-185.0

-194.9

P-1556B

Debutanizer Overhead Pump

225

(-185.0)

(-194.9)

P-1560A

RFCC Closed Drain Pump

22

(-16.5)

(-18.1)

P-1560B

RFCC Closed Drain Pump

22

(-16.5)

(-18.1)

P-1561

RFCC Lift Station No.1 Sump Pump

7.5

(-4.9)

(-5.4)

P-1562

RFCC Lift Station No.2 Sump Pump

7.5

(-4.9)

(-5.4)

P-1563

Oily Water Lift Pump Common Spare

7.5

(-4.9)

(-5.4)

P-1564

Amine Closed Drain Pump

15

(-10.8)

(-12.0)

E-1514

LCO Air Cooler

120

-97.6

-106.2

E-1517

Heavy Naphta Air Cooler

33

-20.4

-23.1

E-1519

Overhead Air Condenser

960

-736.0

-800.9

E-1521

Heavy Naphta Pumparound Air Cooler

120

-99.6

-108.4

E-1530

Tempered Water Air Cooler

22.5

-15.0

-17.8

E-1551

Wet Gas Compressor Intercooler

240

-190.4

-207.2

E-1553

HP Condenser

180

-134.4

-146.2

E-1558

Gasoline Air Cooler

120

-92.8

-101.0

X-1504

Slurry Separator

-230.0

-230.0

X-1505

Corrosion Inhibitor Injection Package

P-1520

Corrosion Inhibitor Pump

0.55

-0.40

-0.44

X-1507

Electrostatic Precipitator

491

-379.0

-379.0

Intermittent Users in X-1507

88

(-53)

(-53)

(-270.0)

(300.0)

Item No.

Description

P-1552A

KO Drum Liquid Pump

P-1552B

Motor
Load/
Rating

X-1508

DeSOx Unit (Future)

X-1509

Metal Passivation Injection Package

P-1502A

Metal Passivation Pump

0.55

0.00

0.00

P-1502B

Metal Passivation Pump

0.55

(0.00)

(0.00)
Page 36 of 323

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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Electric Power, kW
Mech.
Running
Load

Elec.
Oper.
Load

6.05

-4.36

-4.84

Anti-Foaming Pump

0.55

(-0.40)

(-0.44)

P-1558

Anti-Foaming Pump

0.55

(-0.40)

(-0.44)

EJ-1501

Catalyst Hoppers Steam Ejector

SV-1501

Regenerated Catalyst Slide Valve

4.0

-3.0

-3.3

SV-1502

Spent Catalyst Slide Valve

4.0

-3.0

-3.3

SV-1503

1st Regenerator Flue Gas Slide Valve

4.0

-3.0

-3.3

SV-1504

2nd Regenerator Flue Gas Slide Valve

4.0

-3.0

-3.3

PV-1501

Plug Valve

4.0

-3.0

-3.3

Oil Mist Generator

3.0

-3.0

-3.0

TOTAL(excluded Future DeSOx): 10066

-5225.9

-5526.7

TOTAL(included Future DeSOx): 10066

-5495.9

-5836.7

Item No.

Description

X-1510

Phosphate Injection Package

X-1551

Antifoam Injection Package

P-1557

Motor
Load/
Rating

Page 37 of 323

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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

1.2.4.1.2. Steam, Condensate & Boiler Feed Water


Steam (T/h)
Item No.

Description

HP
STM

H-1503

COB/WHB Package (with


Economizer)

219.3

C-1502B

Forced Draft Air Fan

(-21.0)

C-1502B Hot Standby

-1.7

MP
STM

Condensate (T/h)
LP
STM

HP
COND

MP
COND

LP
COND

BFW (T/h)
COLD
COND

0.7

HP
BFW
-225.5

LP
BFW
-0.7

Cold
BFW

Losses
(T/h)
6.2

(21.0)

E-1534

BFW Heater

-7.0

C-1501

Air Blower

-68.7

C-1501 Lube Oil Pump (Spare)

(-2.6)

C-1551

Wet Gas Compressor

-30.4

C-1551 Lube Oil Pump (Spare)

(-2.1)

D-1501

Disengager / Stripper

COB/WHB LP Blowdown Drum

0.5

-0.5

D-1527

LP Blowdown Drum

0.2

-0.2

T-1503

LCO Stripper

-3.0

3.0

T-1504

HCO Stripper

-0.5

0.5

P-1519A

Slurry Pumparound Pump

-10.3

10.3

P-1519B

Slurry Pumparound Pump

-10.3

10.3

P-1519C

Slurry Pumparound Pump

(-10.3)

(10.3)

P-1519C Hot Standby

-0.8

-0.3

7.0
-0.1

0.0

68.7

0.3

30.4

0.4

(2.6)
-0.4
(2.1)
-34.7

34.7

0.8
Page 38 of 323

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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Steam (T/h)

Condensate (T/h)

BFW (T/h)

Item No.

Description

HP
STM

P-121A

HCO Flushing Oil Pump

-3.7

E-1503

Slurry HP Steam Generator

0.0

0.0

E-1504

Slurry HP Steam Generator

18.0

-18.5

E-1505

Slurry MP Steam Generator

E-1506

Slurry LP Steam Generator

E-1508

HCO Recycle MP Steam


Generator

E-1510

HCO LP Steam Generator

E-1513

LCO Product LP Steam


Generator

E-1522

MP steam Feed Heater [1]

-6.5

E-1523

HCO Pumparound MP Steam


Generator

7.3

E-1524

HP Steam Feed Heater [2]


st

MP
STM

LP
STM

HP
COND

MP
COND

LP
COND

COLD
COND

HP
BFW

LP
BFW

Cold
BFW

Losses
(T/h)

3.7

13.8
1.3
6.5
2.9
8.6

-11.3

0.5
-14.2

0.4

-1.4

0.1

-6.7

0.2

-3.0

0.1

-8.9

0.3

-7.5

0.2

6.5

11.3

SPR1501

1 Regenerator Torch Oil


Sprayer

(-0.3)

(0.3)

SPR1502

2nd Regenerator Torch Oil


Sprayer

(-0.3)

(0.3)

SPR1503

Water Spray for D-1502 Flue


Gas Bypass

(-1.5)

(-22.8)

(-24.3)

SPR1504

Water Spray for D-1503 Flue


Gas Bypass

(-1.5)

(-14.0)

(-15.5)

Page 39 of 323

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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Steam (T/h)
Item No.

Description

SPR1505

Water Spray for Economizer

X-1507

Electrostatic Precipitator

EJ-1501

Catalyst Hoppers Steam Ejector

HP
STM

MP
STM

Condensate (T/h)
LP
STM

MP
COND

LP
COND

COLD
COND

HP
BFW

(-1.5)

LP
BFW

Cold
BFW

(-5.2)

0.3

(-0.9)

(0.9)

SV-1503

1 Regenerator Flue Gas Slide


Valve

-0.1

Steam Trace

-2.0
100.1

-20.6

Losses
(T/h)

(-6.7)

-0.3

st

TOTAL:

HP
COND

BFW (T/h)

31.8

0.1
2.0
11.3

13.5

2.1

99.1

-244.0

-42.4

0.0

49.1

Notes:
[1]: Cold Feed Case: -16.4 T/h MPS
[2]: Cold Feed Case: -20.7 Y/h HPS

Page 40 of 323

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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

1.2.4.1.3. Cooling water & Seawater

Item no.

Description

Cooling Water
T (C)

m3/hr

E-1518

Heavy Naphta Trim Cooler

6.0

-20

E-1520 A-H

Overhead Trim Condenser

8.0

-1743

E-1531

Surface Condenser

E-1532

Blowdown Cooler

13.0

-15

E-1533

Blowdown Cooler

15.0

-24

E-1552 A/B

Wet gas Compressor Trim


Cooler

8.0

-225

E-1554 A-D

Stripper Condenser

6.0

-650

E-1559

Gasoline Cooler

6.0

-138

E-1561 A/B

Debutanizer Condenser

12.0

-1159

E-1562

LPG Cooler

6.0

-49

E-1564

Lean Oil Cooler

6.0

-196

E-1565

Fuel Gas Cooler

6.0

-6

E-1566

Lean Amine Cooler

6.0

-53

E-1567

Turbine Condenser
Pump / Compressor
Cooling

T (C)

m3/hr

8.8

-7285

8.8

-2300

-95

H-1503

COB/WHB Package

C-1501 Gland Condenser

-76

C-1501 Oil Cooler

-32

C-1501 Main Oil Cooler

6.0

-60

C-1501 Gland Condenser

6.0

-50

TOTAL

Seawater

15.0

-3

-4594

-9585

Note:
[1]: Peak consumption of 12.9 Nm3/hr with temperature rise of
13C

Page 41 of 323

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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

1.2.4.1.4. Instrument & Plant Air


Plant Air (Nm3/h)

Item No.

Description

Instrument
Air (Nm3/h)

Continuous Intermittent

H-1503

COB/WHB Package

-120

-50

(-125)

X-1507

Electrostatic Precipitator

-26

-8

(-85)

X-1504

Slurry Separator

-1

Oil Mist Generator

-165

X-1502

Fresh Catalyst Feeder

-3

-60

(-40)

X-1503

Auxiliary Catalyst Feeder

(-3)

(-60)

(-40)

C-1501

Air Blower

-22

C-1551

Wet Gas Compressor

PV-1501

Plug Valve

-611

SV-1504

nd

2 Regenerator Catalyst Slide


Valve

-134

Primary Plant Air for Regeneration


Section (form instrument air
header)

-4230

Secondary Plant Air for


Regeneration Section

(-2320)

Miscellaneous Users

-340
TOTAL: -5658

-118

1.2.4.1.5. Nitrogen
Item No.

Description

Nitrogen Nm3/h
Continuous

C-1551

Wet Gas Compressor

-71

SV-1501

Regenerated Catalyst Slide Valve

-84

SV-1502

Spent Catalyst Slide Valve

-36

Miscellaneous Users

-160
TOTAL: -351

Intermittent
(-280)

(-560)
0

Page 42 of 323

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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

1.2.4.1.6. Furnaces & Boilers


Item No.

Description

Fuel Fired

H-1501

1st Regenerator Air Heater Start-Up

Approx. 4.5 T/h

H-1502

2nd Regenerator Air Heater Start-Up

Approx. 4.5 T/h

H-1503

COB/WHB Package

-110 MW

1.2.4.2. Catalysts & Chemicals


1.2.4.2.1. Catalysts
The proper selection of catalyst is very important for successful
residue cracking operations. Several catalyst properties should
be examined for a particular feed.
The Axens recommendation for use in R2R residue cracking unit
is low sodium, Ultra-Stable Hydrogen Y type (USHY) zeolite.
For detailed information on the catalyst properties and
recommendations, refer to the licensor operating manual doc.
No. 8474L-015-ML-001.
Catalyst Inventory and Addition Rate:
Catalyst Inventory: 675 tons
Fresh Catalyst Addition Rate:

Mixed Crude:

Bach Ho Crude: 5.2 Tons/day (dry basis)

15.2 Tons/day (dry basis)

Fresh Catalyst Selection


The fresh catalyst will be specifically designed to maximize
middle distillate (LCO) and metal resistance. The target for the
MAT activity associated with the corresponding delta coke is
given hereafter and linked to the metal concentration to be
sustained.
Mixed

Mixed

Bach Ho

Bach Ho

Max. Gasoline Max. Distillate Max. Gasoline Max. Distillate


Ni Content (ppm)

3213

1776

V Content (ppm)

6748

Page 43 of 323

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Mixed

Mixed

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Bach Ho

Bach Ho

Max. Gasoline Max. Distillate Max. Gasoline Max. Distillate


Equilibrium Catalyst
MAT Activity (wt %)

68

55

75

60

Delta Coke (Wt %)

1.22

0.99

0.94

0.91

2 catalyst lines fit appropriately with the operation objectives:

Albemarle (Former Akzo), COBRA RMR DQ1

GRACE Davison, GDC-1825

The final guarantee catalyst will be selected by AXENS after


evaluation of the best candidates proposed by Vendors.

1.2.4.2.2. Antimony (Nickel passivator, only in Mixed Crude Case)


Metal Passivator is injected into the fresh feed just ahead of the
feed nozzles from the Metal Passivator Injection Package X-1509
acts to inhibit the undesirable effects of nickel on the catalyst in
the feed. It is required for Mixed Crude Feed case only.
Used in:

RFCC Feed Section

Type:

NALCO EC9192A or equivalent

Antimony content:

23%

Injection rate:

ratio Sb/Ni in feed: 0.5

Normal consumption:

109 kg/day Mixed Case


0 kg/day Bach Ho Case

Maximum consumption:

15 kg/h

1.2.4.2.3. Corrosion inhibitor


Used in:

Fractionator overhead

Type:

CHIMEC 1430

Normal consumption:

60 kg/day

Maximum consumption:

120 kg/day

Page 44 of 323

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CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

1.2.4.2.4. Amine antifoaming agent


Antifoaming agent is injected batch wise in either the fuel gas
absorber T-1551 or the LPG amine absorber T-1556 of when
foaming is experienced.
Once foaming is settled, stop injection to avoid over-dosing of
chemical. It should be noted that injection of antifoaming agent is
the last resolution.
Used in:

Gas recovery Section in LPG / Fuel


gas amine absorber

Type:

CHIMEC 8045

Normal consumption:

10 kg/day:

Maximum consumption:

20 kg/day

1.2.4.2.5. Amine (outside battery limit)


Lean amine if supplied from the ARU (unit 19) to absorb H2S
contained in both the fuel gas and the LPG recovered in the Gas
Recovery Section of the RFCC. Lean amine if fed to the Fuel Gas
Absorber T-1555 and the LPG Amine Absorber T-1556. The rich
amine leaving these 2 towers is then returned to the ARU for
regeneration.
Type DEA:

20% wt di-ethanolamine

H2S content:

0.022 mole/mole DEA

Lean Amine Flowrate:

Bach Ho: 50382 kg/hr


Mixed Crude: 77623 kg/hr

Rich Amine Flowrate:

Bach Ho: 50926 kg/hr


Mixed Crude: 78145 kg/hr

During amine absorber operation, lean amine temperature should


be always 15C higher than feed gas to avoid condensation of
hydrocarbon inside of the fuel gas absorber.

1.2.4.2.6. Phosphate for Steam Generation


Phosphate is injected to buffer the water in order to minimize pH
fluctuation. It also precipitates calcium or magnesium into a soft
deposit rather than a hard scale. Additionally, it helps to promote
the protective layer on steam generators metal surfaces.
The following phosphate quantities will be used for steam
generation:
Page 45 of 323

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CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

RFCC HPS and MPS Generation

7.0 kg/day

RFCC Waste Heat Boiler

24.0 kg/day

Total

31.0 kg/day

Phosphate injection rate depends on blow down flow rate and


phosphate level in the steam drum or generator.
The above rate is based on 1.0 % of blow down from the steam
generation system, and marinating 30 wt ppm of phosphate
concentration.
For LPS steam generation, it is not required to operate blow
down operation, and thus phosphate injection is also not
required.

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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

1.3. Glossary of terms and Acronyms


1.3.1. Acronyms
COMPANIES/ORGANISATIONS
DQR
DQIZMB
EVN
FW
MOC
MOSTE
MPI
SRV
TPC

Dung Quat Refinery


Dung Quat Industrial Zone
Management Board
Electricity Authority of Vietnam
Foster Wheeler Energy Limited
Ministry of Construction
Ministry of Science, Technology
and Environment
Ministry of Planning and
Investment
Socialist Republic of Vietnam
Technip Consortium

OTHERS
ACE
ADP
AER

Application Control Environment


Analyser Data Acquisition
System
Alarm Display Panel
Application Engineers Room

AI

Analyser Indicator

AIT

Auto Ignition Temperature

MCC
MCR
MCS
MOV
Control
System
MDF

AMS

Asset Management System

MIS

ANSI

American National Standards


institute

MMS

APC

Advanced Process Control

MMT

API
ARU
ASC

American Petroleum Institute


Amine Regeneration Unit
Analyser Speciality Contractor
American Society of
Mechanical Engineers

MOC
MOM
MOV

Minimum Maintained
Temperature
Madrid Operating Center
Minutes of Meeting
Motor Operated Valve

MP

Medium Pressure

Analyser Systems Package

MPT

Minimum Pressurization
Temperature

MR

Material Requisition

MRR
MSD
MSDS
MTBF
MTTR

Marshalling Rack Room


Material Selection Diagram
Material Safety Data Sheet
Mean Time Between Failures
Mean Time To Repair

ADAS

ASME
ASP
ASTM
ATM
BCS
BEDD
BFD
BFW

American Society of Testing


and Materials
Asynchronous Transfer Mode
Blending Control System
Basic Engineering Design Data
Block Flow Diagram
Boiler Feed Water

MC

Marshalling Cabinet

MCB

Main Control Building


Motor Control Center
Main Control Room
MOV Control System
Main Distribution Frame
Management Information
System
Machine Monitoring System

Page 47 of 323

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REV: A

DATE: 06/12/07

BL
BOM

Battery Unit
Bill of Materials

MTO
MTPA

BPC

Blending Properties Control

MVIP

BPCD

Barrels per Calendar Day

NACE

BPSD
BRC

Barrels per Stream Day


Blending Ratio Control

NCR
NDE

CAD

Computer Aid Design

NFPA

CALM
CBT

NHT
NIR
NPSH

Net Positive Suction Head

CCC
CCR
CCTV
CD

Catenary Anchor Leg Mooring


Commercial Bid Tabulation
Control Complex Auxiliary
Room
Central Control Complex
Continuous Catalytic Reformer
Closed Circuit Television
Chart Datum

Material Take-Off
Metric Tonnes per Annum
Multi Vendor Interface
Program (Honeywell)
National Association of
Corrosion Engineers
Non Conformance Report
Non Destructive Examination
National Fire Protection
Association
Naphtha Hydrotreater (Unit)
Near Infrared Spectroscopy

NPV
NTU
OAS
OJT

CDU

Crude Distillation Unit

OM&S

OSBL

Net Present Value


Naphtha Treater Unit
Oil Accounting System
On Job Training
Oil Movement and Storage
Control System
Oil Movement and Storage
automation
Operation Override Switch
Operations Planning and
Scheduling System
Outside Battery Limit

OTS

Operator Training Simulator

CCAR

CENELEC
CFC
CFR
C&I
CMMS
CNU

European Committee for


Electrotechnical Standardization
Chlorofluorocarbons
Cooperative Fuel Research
(Engine)
Control and Instrumentation
Computerized Maintenance
Management System
(Spent) Caustic Neutralization
Unit

OMSA
OOS
OPSS

PABX

CPI

Corrugated Plate Interceptor

PAGA

CSI
DAF
DAU
DCS

Control Systems Integrator


Dissolved Air Flotation
Data Acquisition Unit
Distributed Control System

PCB
PFD
PFM
PDB

DEA

Diethanolamine

PGC

Private Automatic Branch


Exchange
Public Address / General
Alarm
Printed Circuit Board
Process Flow Diagram
Path Find Module
Project Documents Base
Process Gas Chromatograph
(Analysers)

PHD

Plant History Database

DMDS
DMS

Detailed Environmental Impact


Assessment
Dimethyldisulfide
Document Management System

PI
PIB

DNV

Det Nork Veritas

PID

Plant Air
Process Interface Building
Piping and Instrument
Diagram
Project Implementation
Manual
Process Knowledge System
(Honeywell DCS)
Pipeline End Manifold
Planning
Project Management

DEIA

DPTD
DQMIS
DQRP
DVM
DWT

Design, Pressure, Temperature


Diagram
Dung Quat Management
Information System
Dung Quat Refinery Project
Digital Video Manager
Dead Weight Tonnes

PIM
PKS
PLEM
PLG
PMC

Page 48 of 323

TRAINING MODULE
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CRACKER (RFCC)

EL
EOR

ERP
ES
ESD
ETP
ETS
EWS
FDC
FAP

Equipment List
End of Run
Electronic Document
Management System
Electromagnetic Compatibility
Engineering Procurement,
Construction and
Commissioning
Enterprise Resource Planning
Ethernet Switch
Emergency Shut Down
Effluent Treatment Plant
Effluent Treatment System
Engineering Work Station
Feed Development Contract
Fire Alarm Panel

FAT

Factory Acceptance Test

FEL

Front End Loading

F&G
FIU
FIC

Fire and Gas System


Field Interface Unit
Flow Indicating Controller

FM

Factory Mutual (Approval body)

FOTC

Fibre Optic Termination Cabinet

EDMS
EMC
EPC

FTE
GC
GFT

Fail Safe Controller (Honeywell


ESD)
Fault Tolerant Ethernet
Gas Chromatograph
Ground Fault

HAZAN

Hazard Analysis Study

HAZOP

Hazard and Operability Study

HDT

Hydrotreater

HEI

Heat Exchange Institution

HHP
HGO
HIC
HP
HSE

High High Pressure (Steam)


Heavy Gas Oil
Hydrogen Induced Cracking
High Pressure
Health, Safety and Environment
Heating Ventilation Air
Conditioning
Instrument Air
International Civil Aviation
Organisation
Instrument Clean Earth

FSC

HVAC
IA
ICAO
ICE

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PMI
PMT

Consultant
Positive Material Identification
Project Management Team

PO

Purchase Order

POC

Paris Operating Center

PP

Project Procedure

PPB
PPM
PRU
PWHT
QA
QC
RA
R&D

Parts per Billion


Parts per Million
Propylene Recovery Unit
Post Weld Heat Treatment
Quality Assurance
Quality Control
Risk Analysis
Research and Development
Real Time Database
RDBMS
Management System
Residue Fluid Catalytic
RFCC
Cracking
RFSU
Ready for Start-Up
RLU
Remote Line Unit
ROW
Right of Way
Refinery Performance
RPMS
Management System
Resistance Temperature
RTD
Detector
Real Time Data Base
RTDB
(System)
RTU
Remote Terminal Unit
SAT
Site Acceptance Test
SBT
Segregated Ballast Tanks
Software Bypass Management
SBMS
System
Supervisory Control and Data
SCADA
Acquisition
SCC
Satellite Control Complex
Simulation Control
SCE
Environment
SCR
Satellite Control Room
SDH
Synchronous Digital Hierarchy
SE
Safety Earth
S&E
Safety & Environmental
SGS
Safeguarding System
SOE

Sequence of Events

SOR

Start of Run

SOW

Scope of Work

SP

Specification
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ICS

Integrated Control System

SPIR

IIP
I/O
IP

SPM
SR
SRU
STC

Construction Standard

IRP
IRR

Initial Interface Plan


Input/Output
Institute of Petroleum
Instrumented Protective
System
Interposing Relay Panel
Internal Rate of Return

Spare Parts and


interchangeability Record
Single Point Mooring
Scope of Supply
Sulphur Recovery Unit

STD
STEL

IS

Intrinsically Safe

SVAC

ISA
ISE
ISBL
ISOM

Instrument Society of America


Intrinsically Safe Earth
Inside Battery Limit
Isomerisation Unit

SWS
TAS
TBT

ITB

Invitation to Bid

TCF

ITP

Inspection and Test Plan

TCM

JB

Junction Box

TEMA

JCC

Jetty Control Complex

TGIF

JCR
JSD
JSS

Jetty Control Room


Job Specification for Design
Job Specification for Supply

TLCR
TLCS
TN

JVD

Joint Venture Directorate

TPS

KLOC
KTU
LAN
LCO
LCOHDT

Kuala Lumpur Operating Center


Kerosene Treatment Unit
Local Area Network
Light Cycle Oil
LCO Hydrotreater

TQM
TS
TWA
UFD
U/G

LDE

Lead Discipline Engineer

UL

Design Standard
Short Term Exposure Limit
Shelter Ventilation and Air
Conditioning
System (Analyser houses)
Sour Water Stripping (Unit)
Terminal Automation System
Technical Bid Tabulation
Temporary Construction
Facilities
Task Control Module
Tubular Exchanger
Manufacturers' Association
Temperature Gauge Indication
Facilities (Tankage)
Truck Loading Control Room
Truck Loading Control System
Transmittal Note
Total Plant Solution
(Honeywell)
Total Quality Management
Terminal Server
Time Weighted Average
Utility Flow diagram
Underground
Underwriter Laboratories
(Approval body)

IPS

LEL
LGO
LIMS

Lower Exposition Limit (F&G,


Analysers)
Light Gas Oil
Laboratory Information
Management System

UPS

Uninterruptible Power Supply

VDU

Visual Display Unit

VPU

Vendor Package Unit

LIS

Laboratory Information System

WABT

LLU
LP
LPG
LTU LPG

Local Line Unit


Low Pressure
Liquefied Petroleum Gas
Treater Unit

WBS
WHB
YOC

Weight Average Bed


Temperature
Wash Breakdown Structure
Waste Heat Boiler
Yokohama Operating Center

1.3.2. Glossary
Refer to separate glossary.

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TRAINING MODULE

RESIDUE FLUID CATALYTIC CRACKER (RFCC)


UNIT: 15

Course Content:
Section 1 - General Description
Section 2 - Process Flow Description

Section 3 - Process Control


Section 4 - Safeguarding Devices
Section 5 - Fire & Gas Systems
Section 6 - Quality Control
Section 7 - Cause & Effects
Section 8 - Operating Procedures
Section 9 - HSE
Section 10 - Reference Document Index

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SECTION 2 : PROCESS FLOW DESCRIPTION


Drawing to be inserted here
Figure 5: RFCC Block Flow Diagram
Drawing to be inserted here
Figure 6: RFCC Process Flow Scheme
2.1. Feed Section
Drawing to be inserted here
Figure 7: RFCC Feed Section
Long residue is normally fed directly to the unit from the Crude Unit (CDU) at 115C.
Alternatively part, or all, of the feed can be fed from storage at 70C. Indeed, the preheat
system of the feed is also designed to process 100% cold feed.
Hot feed straight from the CDU and cold feed from storage enters the battery limits and
flows to the Feed Surge Drum D-1513 on level control by LIC-042 with a split range level
control signal to the controller inside the CDU or to the flow controller on the cold feed
from storage. The pressure in the Feed Surge Drum is maintained at 1 kg/cm2g by either
admitting Fuel Gas or venting excess off gas to the Flare header. In D-1513, water
contained in the feed is separated and sent to the OWS.
The feed is then pumped from the feed Surge Drum by the Feed Pumps P-1501 A/B to
the feed preheat train, in which the way feed is preheated depends on the type of crude
used:

Bach Ho Case:
Feed is 1st pumped to the LCO Pumparound Feed Preheat Exchangers E-1512 AD, in which the feed is preheated against LCO pumparound pumped by the LCO
Pumparound Pumps P-1510 A/B from the tray #25 of the main fractionator T1501.
Then the feed is further heated against MP steam first in the MP Steam Feed
Heater E-1522 and secondly against HP steam in the HP steam Feed Heater E1524.
The Residue Feed is finally heated against Slurry in the 1st Feed Preheat Slurry
Exchangers E-1502 A/B/C and the 2nd Feed Preheat Slurry Exchangers E-1501
A/B, from where feed exits at the temperature of 290C. Slurry is feed to the tube
sides of the 1st and 2nd feed preheat slurry exchangers by means of the Slurry
Pumparound Pumps P-1519 A/B/C from the bottom of the Main Fractionator T1501.

Mixed Crude Case


In the case of Mixed Crude feed, the feed is pumped by the Feed Pumps P-1501
A/B to E-1512 A/B/C/D where it is preheated to the required temperature of 170C
by the LCO pumparound when 100% of the feed to the surge drum is hot.
Additionally, the feed is heated against MP steam downstream of the LCO
Pumparound Preheat Exchangers only when the feed is all or partly cold. This is
required to obtain the required temperature of 170C.
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Downstream of the preheat train, preheat feed is mixed with HCO recycle from above the
Bed #4 of the main fractionator. Before being mixed with the feed, HCO recycle is cooled
against Boiler Feed Water in the HCO Recycle MP steam Generator E-1508.
Depending upon the operating case, a different quality of recycle to feed is used.
In Mixed Crude Max Gasoline (MG) operation, a heavy naphtha recycle is used in order
to adjust the feed viscosity and further improve the feed atomization. An additional effect
is to decrease the heavy oil partial pressure leading to a better vaporization. In MD
operation, a HCO recycle is used in order to improve the bottom (HCO and heavier)
conversion.
The combined feed is then sent to the reaction section via the Feed Line Static Mixer M1501.
The LCO pumparound used in E-1512 A/B/C/D is then returned to the main fractionator
above the Bed #2.
The Slurry used in the 2nd Feed Preheat Slurry Exchangers is returned to the main
fractionator above the Bed #5 and so is part of the slurry used in the 1st Feed Preheat
Slurry Exchangers. The remaining part of the Slurry used in E-1501 A/B is sent back to
the quench zone of T-1501.
NOTE:
When processing mixed crude feed, the slurry preheat exchangers are not required.
These exchangers should have the slurry flushed out of them to avoid settling of catalyst
fines and because of the high viscosity and high pour point of the slurry.
2.2. Reaction Section
Drawing to be inserted here
Figure 8: RFCC Reaction Section
2.2.1. Feed Injection Zone
The specially designed feed injection system insures the reaction is carried out
efficiently to minimize the production of coke, gas and slurry oil.
Oil feed to the riser is preheated before entering the reaction system. Preheat
temperature along with regenerated catalyst temperature is controlled to result in
an optimum catalyst to oil ratio.
The preheated feed mixture is sent to the base of the riser D-1501 and divided into
equal flows by the flow controllers FIC-003 A-F to each of the six feed nozzles I1501 A-F.
Metal Passivator is injected into the fresh feed just ahead of the feed nozzles from
the Metal Passivator Injection Package X-1509 by means of the Metal Passivation
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Pumps P-1502 A/B and acts to inhibit the undesirable effects of nickel on the
catalyst in the feed. It is required for Mixed Crude Feed case only.
Shutdown valves will stop the flow of feed to the riser and divert it back to the feed
surge drum D-1513 in case of certain emergencies.
Dispersion steam is supplied to each of the six feed nozzles to promote
atomization and vaporization of the feed. The flow of MP steam to each of the feed
nozzles is adjusted by flow controllers FIC-005 A-F.
Heavy FCC naphta is injected to the riser above the feed injection zone through
the MTC (Mix Temperature Control) injectors I-1502 A-D, where it is mixed with
medium pressure dispersion steam.
MTC plays an important role in the heat balance control and heavy feed
vaporization. The key is to achieve a higher temperature in the fresh feed mixing
zone. The MTC is designed to face the two main challenges encountered when
processing very heavy, highly contaminated feeds:

Achieve a satisfactory vaporization of the feed so as to eliminate the


unnecessary coke production resulting from an incomplete vaporization

To keep the desired heat balance while maintaining the conversion at the
optimum level

MTC flow and dispersion steam flow to each of the four injectors are adjusted by
flow controllers FIC-010 A-D and FIC-011 A-D respectively.
Upstream the feed injection, stabilization steam is injected in the riser, through the
four stabilization steam injectors I-1503 A-D, in order to promote a smooth and
homogeneous catalyst flow at the feed injection point. The flow to each of the
injectors is adjusted by flow controllers FIC-007 A-D.
Upon emergency shutdown the steam flow control valves on all injectors
automatically open to clear the riser of oil and catalyst with steam.
Finally Backflush oil is pumped by the backflush oil recycle pumps P-1506 A/B
from the backflush oil receiver in the fractionation a section to the riser,
downstream of the MTC injectors.
Backflush oil is injected into the riser and mixed with MP dispersion steam via the
backflush oil injector I-1504. The flow of backflush oil and dispersion steam to the
injector is controlled by FIC-012 and FIC-013 respectively.

2.2.2. Riser/Reactor
The sensible heat, heat of vaporization and heat of reaction required by the feed is
supplied by the hot regenerated catalyst. From the withdrawal well, hot
regenerated catalyst flows to the riser wye, to be mixed with the feed, via the
regenerated catalyst slide valve SV-1501. The riser outlet temperature is
controlled by the amount of regenerated catalyst admitted to the riser through SV1501.
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In the wye section at the base of the riser, steam is injected via a steam ring to
keep the regenerated catalyst in a fluid state at all times.
The small droplets of feed contact hot regenerated catalyst in a counter current
way and vaporize immediately. The vaporized oil intimately mixes with the catalyst
particles and cracks into lighter, more valuable products along with slurry oil, coke
and gas.
The cracking reactions take place during the 2 seconds residence time in the riser
as the reaction mixture (composed of the products and the catalyst) accelerates
toward the Riser Outlet Separator System (ROSS) at the top of the riser.
To prevent the continuation of reactions which produce gas at the expense of
gasoline the catalyst is quickly separated from the hydrocarbon/steam vapors in
the ROSS separator located at the end of the riser. This system drastically
reduces the post riser catalyst/vapors contact time.
After exiting the ROSS separator, the vapors pass through high efficiency single
stage Disengager Cyclones CY-1501 A/B/C/D/E/F to complete the separation of
catalyst from vapors, thus minimizing the amount of catalyst lost into the product.
The ROSS separator and disengager cyclones CY-1501A-F separate the product
vapors from spent catalyst and return the catalyst to the stripper bed.
The reactor product vapors, containing a small amount of inerts, catalyst and
steam, flow to the quench zone of the main fractionator T-1501. The small amount
of catalyst contained in the product vapors is carried away from the fractionator in
the bottom slurry product.
The reactor pressure "floats on" the main fractionator pressure and as such is not
directly controlled at the reaction section: A pressure control at the main
fractionator reflux drum D-1514 allows achieving a steady operating pressure in
the reaction system.

2.2.3. Stripper
Catalyst exiting the ROSS separator is pre-stripped with MP steam from a steam
ring located immediately at the exit of the separator diplegs. This is an important
feature for reducing coke yield.
The catalyst is further stripped by steam from the main steam ring as the catalyst
flows down the Disengager/stripper D-1501. 2 additional rings are also provided in
addition to the main ring:

The upper ring, above the main ring, achieves a second stage of prestripping of the catalyst before it enters the stripper.

The lower ring is located in the bottom head of the stripper to achieve a
stable fluidization at the inlet of the spent catalyst standpipe.
The steam rate for this ring is part of the total steam required for good
stripping but its prime function is to aerate the catalyst entering the spent
catalyst standpipe. This is important for adequate head build-up to maintain
an adequate slide valve differential pressure for controlling the stripper
level.
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The total steam flow is designed to provide about 6 kg of steam per ton of catalyst
circulated.
The contact between catalyst and steam is enhanced by the presence of fluidized
bed packing permitting cross and counter current flow of steam and catalyst. The
fluidized bed packing is located between the main ring and the lower ring.
It allows efficient contact between the catalyst and steam to displace the volatile
hydrocarbons contained on and in the catalyst particles before they enter the 1st
stage regenerator D-1502, where coke will be burnt off.

2.2.4. Spent Catalyst Transfer


Downstream of the main ring, stripped catalyst flows down the spent catalyst
standpipe where the spent catalyst is aerated by means of fuel gas from the fuel
gas header (or Nitrogen) to maintain proper density and fluid characteristics of the
spent catalyst. Aeration gas injectors are distributed al along the spent catalyst
stand pipe.
While aerated, the catalyst flows down through the spent catalyst line expansion
joint EX-1501 and then the spent catalyst slide valve SV-1502, which regulates the
level of the stripper by regulating the flow of catalyst leaving it.
Then the spent catalyst flows into the 1st stage regenerator D-1502 through a
distributor which ensures that the entering coke-laden catalyst is spread across
the regenerator bed.
2.3. Catalyst Regeneration Section
The first stage regenerator D-1502 burns 50 to 80% of the coke and the remainder is
burned in the second stage regenerator D-1503. This two stage approach to regeneration
adds considerable flexibility to the process as potential heat is rejected in the first stage
regenerator in the form of CO. When running heavy feeds, the need for heat rejection is
higher; the amount of coke burned in the first stage regenerator is increased, thereby
lowering the final temperature of the regenerated catalyst. When running lighter feeds the
amount of coke burned in the first stage regenerator D-1502 is reduced, thus increasing
the regenerated catalyst temperature. The amount of coke burned in the first stage can
be varied by adjusting the air flowrate in order to achieve operating flexibility on the unit
for different feedstocks.
The heat of combustion released by the combustion of coke is transferred to the catalyst
which will later supply the heat required to the reactor D-1501. The heat balance of the
unit is much more flexible than in single stage regeneration systems because potential
energy in the form of carbon monoxide from the first stage regenerator D-1502 can be
adjusted while complete regeneration of the catalyst is accomplished in the second
stage.

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2.3.1. Air blower and air heaters


The combustion air required for the combustion reactions in the 1st and 2nd
catalyst regenerators D-1502 and D-1503 is supplied by the steam turbine driven
air blower C-1501.
Atmospheric air is introduced to the air blower C-1501 through an intake filter and
silencer F-1501. At C-1501 discharge, the blower air is distributed to a header
system providing combustion air to the downstream equipment as follow:

Combustion air is supplied to the inner air rings and outer air rings at the
bottom of the 1st Catalyst Regenerator D-1502 via the 1st regenerator air
heater H-1501 which heats the blower to the required temperature. The
outer air ring and inner air ring are designed to handle about 70% and 30%
of the combustion air to the first stage regenerator D-1502 respectively.

Combustion air is supplied on flow control to the unique air ring located at
the bottom of the 2nd regenerator D-1503 via the 2nd regenerator air heater
H-1502, which also heats the blower to the required temperature for coke
burning in D-1503.

Blower air is also used as lift air and is supplied on flow control to the
bottom of the lift line of the 1st regenerator in order to transfer partly
regenerated catalyst from D-1502 to D-1503. Air is injected through the
hollow stem of the plug valve PV-1501 which regulates the amount of
catalyst transferred to the 2nd stage regenerator.

Blower air is also injected in the catalyst loading line at the bottom of each
regenerator as fluidizing medium.

Finally blower air is supplied in the withdrawal ring of the withdrawal well
downstream of the point where the hot regenerated catalyst is discharged
to the well, also as fluidizing medium.

C-1501 surging is prevented by venting air using a sophisticated anti-surge


controller. Also, power assisted check valves at the blower discharge prevent
back-flow of catalyst in the event of blower shutdown.
The air heaters are working on propane and are used during start-up to heat-up
the equipment including dry out of refractory.
Instrumentation is provided to prevent overheating the equipment during air heater
operation and a flame safety package is included to prevent unsafe conditions
during burner operation.
2.3.2. First stage regenerator
Spent catalyst containing roughly 1 to 1.5 wt % coke flows from the spent catalyst
distributor and is spread across the bed in the first stage regenerator D-1502. Part
of the coke is burned by combustion air supplied from the outer and inner air rings.
This regenerator operates in a counter current (air inlet at bottom and spent
catalyst inlet at top) to prevent catalyst overheating.

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In order to limit hydrothermal deactivation of the catalyst, the regeneration


conditions are mild: 1st stage regenerator total combustion air is controlled to limit
the temperature in this 1st stage to maximum 730C.
The partially regenerated catalyst flows down through the first stage regenerator
bed to the entrance of the air lift. Aeration by a fluffing ring is supplied in the
vicinity of the air lift to ensure smooth flow of catalyst to the lift. A hollow stem plug
valve PV-1501 regulates the flow of catalyst to the lift line and is controlled by the
level in the first stage regenerator D-1502 via LIC-004. Blower air injected through
the hollow stem of the plug valve into the air lift is flow controlled at a rate
sufficient to lift the catalyst in a dilute phase up to the second stage regenerator D1503. Emergency air is provided through blast connections to clear the lift in the
event of plugging.
2 stage cyclones (CY-1502A-F / CY-1503A-F) separate entrained catalyst from
the flue gas exiting the 1st stage regenerator D-1502 towards the CO Incinerator
H-1503 where the incineration of the CO in the flue gas is then accomplished.
At the exit of the regenerator, the flue gas pressure is reduced through a double
disc flue gas slide valve SV-1503 controlling the regenerator pressure.
During the start-up, torch oil is used to heat the regeneration process to its
operating temperature. Oil and steam on flow control (FIC-069/077A-C) are
directed to three nozzles SPR-1501A-C which spray into the bed of air preheated
catalyst.
A continuous catalyst withdrawal is necessary to maintain the unit catalyst
inventory in the normal operating region. Equilibrium catalyst is continuously
withdrawn from D-1502 through the Catalyst Draw-Off System X-1501 and is sent
either to the spent catalyst hopper D-1506 or the Auxiliary Catalyst Hopper D1507.

2.3.3. Second stage regenerator


The partially regenerated catalyst flows up the lift line through the expansion joints
between the regenerators EX-1502 and enters the 2nd stage regenerator D-1503
below the air ring. A distributor at the end of the lift provides for efficient
distribution of catalyst and air from the lift.
Catalyst is then completely regenerated to less than about 0.05% carbon through
combustion at more severe conditions than in the first stage regenerator D-1502.
Very little carbon monoxide is produced in the 2nd stage and excess oxygen is
regulated by flow control of the combustion air from C-1501 (FIC-164) for efficient
and complete combustion.
Because most of the hydrogen in coke was removed in the 1st stage, very little
water vapor is produced in the second stage. This limits hydrothermal deactivation
of the catalyst as higher regeneration temperatures are experienced.
External refractory lined cyclones CY-1504A-D are used on the 2nd stage flue gas
outlet to remove entrained catalyst. The cyclone dip legs are external to the
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regenerator. Catalyst recovered in the cyclones is returned to the regenerator bed


below the normal operating level by way of the diplegs.
Aeration is supplied to the diplegs to maintain a smooth fluidized catalyst flow and
the diplegs outlets are equipped with flapper (trickle) valves to prevent catalyst
and gas backflow into the cyclones.
Flue gas from the 2nd stage regenerator then flows to the Waste Heat Boiler H1503 through the 2nd Regenerator Flue gas Slide Valve SV-1504 and the 2nd
Regenerator Flue gas Block Valve BV-1502 A.
The second stage regenerator pressure is controlled by the flue gas double disc
slide valve SV-1504, through differential pressure between the first and second
stage regenerators PDIC-172.
2.3.4. Combustion Air Rings
The combustion air rings distribute the combustion air evenly across the bed in the
regenerators. A well distributed source of combustion air is essential for good,
evenly distributed catalyst regeneration without after burn. The rings are designed
to operate satisfactorily at the minimum turndown design for the unit.
The pressure drop across the ring is kept above 0.07 bar at turndown to maintain
adequate distribution and prevent intrusion of catalyst into the ring and avoid
associated erosion.
2.3.5. Regenerated catalyst transfer
The hot regenerated catalyst flows from the 2nd stage regenerator D-1503 through
a lateral into the withdrawal well. In the withdrawal well a stable bed is established
at proper standpipe density by introduction of a controlled amount of fluidizing air
from the withdrawal well ring.
A smooth stable flow of catalyst down the standpipe is provided by injection of
aeration Plant Air at several elevations on the regenerated catalyst standpipe. As
the head pressure increases down the standpipe and the fluidized catalyst is
compressed, these aeration points are used to replace the lost volume to ensure a
continuity of fluid catalyst flow properties.
At the bottom of the regenerated catalyst standpipe the regenerated catalyst slide
valve SV-1501 controls the flow of hot catalyst. The Riser Outlet Temperature sets
the position of the slide valve which regulates the flow of hot regenerated catalyst.
The regenerated catalyst passes to the wye section at the base of the riser D1501 where a steam ring fluidizes the catalyst. The wye steam and fluidization
points in the wye section ensure that the catalyst flow to the feed injection point is
stable and smooth in order for the feed injection system to perform at its optimum.

2.3.6. Catalyst handling


The catalyst handling system includes hoppers for storage of fresh catalyst and
spent catalyst, loading devices for catalyst addition and a draw-off device for
continuous equilibrium catalyst withdrawal.
Three hoppers are installed:

The fresh catalyst hopper D-1505,


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The spent catalyst hopper D-1506

The auxiliary catalyst hopper D-1507, which provides flexibility in the


operation for different options:
o Storage of imported equilibrium catalyst reused as part of the makeup catalyst,
o Storage of excess spent catalyst,
o Storage of a 2nd grade of fresh catalyst for make-up.

The spent and fresh catalyst hoppers are sized to contain the entire unit inventory.
Each hopper is provided with one cyclone and with aerations in the bottom cone to
assist the catalyst circulation to the transfer lines.
Hoppers loading and unloading
Fresh catalyst or equilibrium catalyst, delivered in trucks, are loaded into the fresh
catalyst hopper D-1505 for fresh catalyst, and spent catalyst hopper for equilibrium
catalyst, using either the truck compressor or the steam ejector EJ-1501 supplied
for reducing the hopper pressure.
Spent catalyst is unloaded from the spent catalyst hopper D-1506 to the flexible
bag by hopper pressurizing with plant air.
Unit loading and unloading
Before start-up, equilibrium catalyst is loaded into the spent catalyst hopper D1506 as described above.
When the unit warm-up is completed, the catalyst is loaded into the unit through
the first regenerator D-1502. The hopper is pressurized with plant air. Air from the
blower C-1501 is injected into the catalyst addition line to D-1502 to act as motive
fluid to transport the catalyst.
After shutdown, the spent catalyst is unloaded from the unit into the spent catalyst
hopper by reducing the pressure in the hopper using the steam ejector EJ-1501.
Catalyst addition and withdrawal
To maintain the catalyst inventory during normal operation, fresh catalyst is
automatically added (batchwise) at the desired rate into the unit through the 1st
regenerator D-1502 by means of either of the batch catalyst feeders: X-1502 for
the fresh catalyst hopper D-1505 or X-1503 for the auxiliary Catalyst Hopper D1507. Each batch catalyst feeder can be adjusted for batch size and frequency of
additions.
As most of the time, catalyst addition is higher than the catalyst losses from the
unit, catalyst must be withdrawn to keep the unit inventory constant. This
operation is achieved by a catalyst draw-off system X-1501 provided on the first
regenerator D-1502: Hot catalyst is withdrawn, cooled down through a finned tube
and sent to the spent catalyst hopper D-1506 at a temperature below 400C.

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2.4. Flue gas treatment


Drawing to be inserted here
Figure 9a: Flue Gas Treatment Section

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Figure 9b: COB/WHB Package Flow Scheme


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The flue gas coming from the first regenerator contains CO and some unburned
products. It is sent to the CO incinerator H-1503, via flue gas slide valve SV-1503
for combustion completion.
The incinerator burner is supplied with combustion air via the duty motor driven
forced draft air fans C-1502 A/B. The CO Boiler is provided with burners for fuel
gas and also fuel oil in order to obtain a complete combustion of CO into CO2.
The flue gas from the CO Boiler is routed to the Waste Heat Boiler H-1503 for HP
steam regeneration.
The flue gas coming from the second regenerator D-1503 is sent straight to the
waste heat boiler H-1503 via the second regenerator flue gas slide valve and SV1504 and the COB/WHB 2nd regenerator flue gas block valve BV-1502 A.
The flue gas exiting the waste heat boiler H-1503 is sent to an electrostatic
precipitator X-1507 before flowing through the economizer E-1525 section of the
CON/WHB package, and DeSOx unit (X-1508, for future), and then to a stack SK1501.
Heat released in WHB H-1503 is used for HP steam generation:
HP boiler feed water is fed from the battery limits to the heavy naphta boiler feed
water heater E-1516 where HP BFW is heated in the tube side against heavy
naphta product (in the shell side) pumped by the heavy naphta product pumps P1515 A/B.
The heated BFW is then sent to the LCO Pumparound BFW heater E-1511 where
the BFW (tube side) is heated against LCO pumparound (shell side) drawn off
from the main fractionator and pumped by the LCO Pumparound Pumps P-1510
A/B.
The preheated HP BFW leaving E-1511 is then split into 2 streams:

Part of the preheated BFW is fed to:


o The Slurry HP Steam Generators E-1503 A/B/C in which preheated
HP steam is generated against slurry pumparound pumped by P1519 A/B/C from the bottom of the main fractionator.
o The slurry HP Steam Generators E-1504 A/B in which HP steam is
generated against slurry pumparound pumped by P-1519 A/B/C from
the bottom of the main fractionator
The HP Steam leaving E-1503 A/B/C and E-1504 A/B is then recombined
before being fed to the HP steam superheater of the waste heat boiler.

The other part of the preheated BFW is sent to the economiser section of
the COB/WHB Package H-1503. Preheated HP BFW is then heated (tube
side) against MP steam (Shell side) in the BFW Preheater E-1534. before
being fed to the economizer E-1525. In the economizer, the flue gas
coming from the electrostatic precipitator X-1507 is used as heating
medium. The steam leaving the economizer is then fed to the Steam Drum
D-1512

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Phosphate is also injected into the Steam Drum D-1512 by means of either of the
Phosphate injection Pumps A-1502-P-01-A/B from the Phosphate Tank A-1502TK-01.
Phosphate is injected to buffer the water in order to minimize pH fluctuation. It also
precipitates calcium or magnesium into a soft deposit rather than a hard scale.
Additionally, it helps to promote the protective layer on boiler metal surfaces.
However, phosphate forms sludge as it reacts with hardness; So blowdown or
other procedures need be established to remove the sludge during a routine boiler
shutdown.
Boiler water then exits the bottom of the steam drum via 3 lines, the inlet of each
being equipped with a vortex breaker, and flows to the 4 Evaporator Coil Banks of
the WHB H-1503. In each of the Evaporator Coil Banks, steam is generated (tube
side) by means of the flue gas exiting the HP superheater of the WHB H-1503.
The mixture of steam and boiler water at the outlet of each evaporator coil bank is
then routed back to the steam drum via 4 dedicated lines.
Boiler water from the steam drum is also fed to the Screen Steam Generator
upstream the HP steam Superheater in the Waste Heat Boiler. The steam/boiler
water stream generated by the flue gas exiting the CO Combustion exits the
Screen Steam Generator and is routed back to the Steam Drum D-1512.
Saturated steam from D-1512 is sent to the HP Steam Superheater after being
mixed with HP steam from the E-1503 A/B/C and E-1504 A/B. In the Superheater,
flue gas exiting the Screen Steam Generator generates Superheated HP steam
(tube side). The superheated HP steam generated is then de-superheated by
means of HP BFW prior to being sent to the Superheated HP steam header. Part
this HP steam is also sent to the turbine of the standby forced draft fan C-1502 B.
A continuous blowdown from the steam drum is sent to the continous blowdown
drum D-1531. The LP steam recovered in D-1531 is sent to the LP steam header
while the water collected is sent to the intermittent blowdown drum D-1532. The
water in D-1532 is cooled down against cooling water in the Blowdown Cooler E1533 before being sent to the oily water sewer.
Superheated MP steam is also generated in the WHB:
LP Boiler Feed Water is fed to the following MP steam generators in parallel:

HCO recycle MP steam generator E-1508 where LP BFW is heated (shell


side against HCO recycle drawn-off from the main fractionator and pumped
by the HCO recycle pumps P-1507 A/B.

HCO Pumparound MP steam generator E-1523 where LP BFW is heated


(shell side) against HCO pumparound drawn off from the main fractionator
and pumped by the HCO Pumparound pumps P-1508 A/B.

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Slurry MP steam generators E-1505 A/B where LP Boiler Feed Water is


heated (shell side) against slurry from the HP steam generators E-1504 A/B

The MP steam streams leaving in the above exchangers are then recombined and
the MP steam stream is fed to the MP steam superheater downstream of the 4th
Evaporator Coil Bank. There, the MP steam is superheated against the flue gas
leaving the evaporator. Superheated MP steam is then de-superheated against LP
BFW prior to being discharged to the MP steam header.
The flue gas leaving the WHB H-1503 is then routed to the Electrostatic
Precipitator X-1507 where the content of catalyst dust contained in the flue gas
leaving the COB/WHB package is decreased to meet the environmental
specification. The dust fine content at precipitator outlet shall not exceed 50
mg/Nm3 dry basis.
The principle of operation is to provide high voltage electric for collection of dust
by corona effect. (Refer to the section 4 of the present document for more
information on X-1507 package.)
In case of trip of the COB/WHB package, the flue gas from the 1st and 2nd
regenerators is sent directly to the electrostatic precipitator package X-1507
through the bypass valves BV-1501B (1st regenerator flue gas) and BV-1502B (2nd
regenerator flue gas). In such an event, H-1503 is isolated by closure of the
associated block valves BV-1501A (1st regenerator flue gas) and BV-1502A (2nd
regenerator flue gas).
The flue gas leaving the electrostatic precipitator is then fed to the Economizer E1525 before being finally sent to the stack. In the future, the flue gas leaving the
Economizer will undergo another stage of processing with the DeSOx unit before
running to the stack.
2.4.1. Phosphate injection
For the same reasons than for the phosphate injection in the steam drum D-1512
(see previous paragraph), phosphate solution, from the tank TK-1510 in the
phosphate injection package X-1510, is injected to the BFW fed to the following
steam generators:

Slurry HP steam generators E-1503 A/B/C by means of the metering


pumps P-1531A/B/C respectively;

Slurry HP steam generators E-1504 A/B by means of the phosphate


injection pumps P-1531 D/E respectively;

Slurry MP steam generators E-1505 A/B by means of the phosphate


injection pumps P-1532 A/B respectively;

HCO LP steam generator E-1510, also from the discharge of the phosphate
injection pump P-1532B

HCO pump pumparound MP steam generator E-1523, Slurry LP steam


generators E-1506 A/B and LCO product LP steam generator E-1513 by
means of the phosphate injection pump P-1532C
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HCO recycle MP steam generator E-1508 by means of the phosphate


injection pump P-1532D

2.5. Fractionation Section


Drawing to be inserted here
Figure 10: Fractionation Section
2.5.1. Fractionator bottom section
The reactor effluent from the disengager of the reaction section is sent to the
bottom of the main fractionator T-1501 below the Bed #5.
The bottom slurry pumparound is circulated by Slurry Pumparound Pumps P1519A/B/C to the downstream equipment depending on the operating case:

In the case of Bach Ho feed, a large proportion of the bottom pumparound


duty is used to preheat the feed in the 1st & 2nd Feed Preheat Slurry
Exchangers E-1502 A/B/C and E-1501 A/B.
The remaining duty is used to generate HP steam in HP steam generators
E-1504 A/B and then MP steam in MP steam generators E-1505 A/B, prior
to being sent back to T-1501 in the Quench Zone on flow control reset by
the bottoms temperature controller (TIC-439) at the suction of the slurry
pumparound pumps P-1519 A/B/C. Part of the slurry from E-1505 A/B is
also sent back to T-1501 above the Bed #5 on flow control reset by the
temperature controller TIC-443 above Bed #4.
Meanwhile, the slurry used to preheat the feed in E-1502 A/B/C and part of
the slurry exiting E-1502 A/B/C are then sent back to T-1501 in the grid
section (Bed #5) after being mixed with the portion of Slurry Pumparound
bypassing all the exchangers and steam generators. The remaining part of
the slurry leaving E-1502A/B/C is sent to the Quench Zone of T-1501 on
flow control reset by the bottoms temperature controller (TIC-439) at the
suction of the slurry pumparound pumps P-1519 A/B/C. This quench is
used to maintain the bottoms temperature to around 349C in order to
minimize coking

For the Mixed Crude feed case, E-1501A/B and E-1502 A/B/C are not in
service. In this case the slurry pumped by P-1519 A/B/C is sent to the
Slurry HP steam generators E-1503 A/B/C, where HP steam is generated
shell side with BFW fed from E-1511.
The main part of this cooled slurry pumparound is returned to the grid
section (Bed #5) on flowrate control (FIC-425) reset by the temperature
controller TIC-443 below the HCO draw-off tray.
In the Grid Section of the Main Fractionator the reactor effluent is
desuperheated and the bottom slurry product is condensed.
Part of the cooled slurry is returned to the bottom of the column to quench
the bottoms temperature TIC-439 to around 340C to minimize coking. The
remaining quench is taken from the discharge of the MP steam generator
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on flow control reset by the bottoms temperature controller as described for


the Bach Ho case.

A constant total flowrate (controlled by FIC-426) to the grid is maintained by


by-passing hot slurry from the discharge of the slurry pumparound pumps.

The slurry product is taken from the discharge of the MP steam generators E-1505
A/B on flow control reset by T-1501 bottoms level controller (LIC-448) and flows to
slurry draw-off drum D-1515. The pressure in D-1515 is maintained constant by
either admitting fuel gas inside the vessel or venting excess off gas to the flare.
The slurry product is pumped by the Slurry Product Pumps P-1504 A/B and is
cooled in the Slurry LP Steam Generator E-1506 A/B, in which BFW is feed to
generated LP steam shell side. Downstream of E-1506 A/B, the cooled slurry
flows to the Slurry Separator X-1504 where catalyst fines are removed. The
clarified oil leaving the slurry separator is finally cooled in tempered water coolers
E-1507 A/B/C/D before going to storage on flow control reset by the level
controller of the slurry draw off drum D-1515.
The slurry separator X-1504 consists of 10 modules. These are automatically and
sequentially taken out of service for back-flushing while the others remain in
service. The modules are back-flushed by P-1505 A/B with Backflush Oil (HCO)
from the Backflush Oil Draw Off Drum D-1516.
The flush oil from the separator, containing a high concentration of catalyst fines,
goes to back-flush oil receiver D-1517 after being mixed with HCO. The pressure
in D-1517 is maintained constant by either admitting fuel gas inside the vessel or
venting excess off gas to the flare.
From D-1517, the back-flush oil is returned to the reactor riser at constant rate by
the Backflush oil recycle pumps P-1506 A/B.

2.5.2. HCO section


Heat is removed at high level in the HCO pumparound section. HCO flushing oil
and HCO recycle are also taken from this section.
HCO products and pumparound are taken from the draw off tray above the Bed #4
of the main fractionator T-1501.
HCO pumparound is circulated by the HCO Pumparounds Pumps P-1508 A/B to
the following equipment in parallel:

The tube side of the Debutanizer Reboilers E-1560 A/B

The shell side of the Heavy Naphtha Stripper Reboiler E-1509

The tube side of MP Steam Generator E-1523

The cooled HCO leaving E-1560 A/B, E-1509 and E-1523 is then recombined
before being returned to the main fractionator above the Bed #3.
The total pumparound flow is maintained constant by controlling the flow of HCO
by-passing the above equipments with (FIC-419) at P-1508 A/B discharge. Heat
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removal in the pumparound circuit is controlled by the flow controller at the outlet
of E-1523 reset by the temperature controller TIC-446 on the recombined
pumparound return line to T-1501.
HCO for flushing oil is also taken from the draw off tray above the Bed #4 and is
then stripped in the HCO stripper T-1504 by LP steam on flow control. The stripper
vapour is returned to T-1501 above the pumparound return, Bed #3. The stripped
HCO is pumped from T-1504 bottom by the HCO products pumps P-1509 A/B to
the tube side of the LP Steam Generator E-1510 where it is used as heating
medium to generate LP Steam from BFW in the shell side. The cooling of the HCO
is controlled with TIC-474 on the HCO outlet by resetting the pressure controller of
the LP steam generated to adjust the quantity of LP steam leaving E-1510.
Part of the HCO goes to Backflush Oil Receiver D-1516 on flow control by FIC-469
reset by D-1516 level controller LIC-464. The pressure in D-1516 is maintained
constant by either admitting fuel gas inside the vessel or venting excess off gas to
the flare.
The remaining part goes to:

The HCO flushing oil system for flushing of slurry pump seals and for
instrument flushing.

The Backflush Oil Receiver D-1517, on flow control reset by the level
controller in D-1517, after being mixed with flush oil from the slurry
separator X-1504.

For maximum distillate mode operation, HCO is recycled to the reactor feed. The
HCO recycle is taken from the draw off tray above the Bed #4 and is pumped by
P-1507 A/B to the tube side of the MP Steam Generator E-1508 where it is used
as heating medium to produce MP steam from BFW in the shell side. The cooling
of the HCO in E-1508 is controlled by TIC-425 on the HCO recycle line to the feed
section by adjusting the amount of HCO bypassing the MP Steam Generator.
HCO is then mixed with the feed upstream of the feed temperature control point,
as described previously.

2.5.3. LCO section


This section of T-1501 consists of six fractionating trays, trays 25 to 30, and a
packed pumparound bed, Bed #2.
LCO product and LCO pumparound are drawn off from the pumparound draw-off
tray below the bed#2 of T-1501. LCO pumparound is circulated by the LCO
pumparound pumps P-1510 A/B to the following equipment in parallel:

Shell Side of the Stripper 2nd Reboiler E-1557,

Tube Side of the LCO pumparound Feed Preheat Exchangers E-1512


A/B/C/D,

Shell Side of the LCO pumparound BFW Heater E-1511.

The cooled LCO leaving E-1557, E-1512 A/B/C/D and E-1511 is then recombined
before being returned to the main fractionator above the Bed #2.

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The total pumparound flow is maintained constant by controlling the flow of LCO
by-passing the above equipments with (FIC-411) at P-1510 A/B discharge. Heat
removal in the pumparound circuit is controlled by the flow controller at the outlet
of E-1511 reset by the temperature controller TIC-452 on the recombined LCO
pumparound return line to T-1501.
LCO product is taken as a slip stream at the suction of the LCO pumparound
pumps P-1510 A/B and is sent to the LCO stripper T-1503 on level controller of
the stripper bottoms by LIC-436. The LCO is stripped by LP stream on flow control
(FIC-452).
The stripper vapor is returned to T-1501 above the pumparound, Bed #2. Stripped
LCO is pumped by the LCO Stripper Pumps P-1511 A/B and is cooled on
temperature control in LCO Product LP Steam Generator E-1513 and the air
cooler E-1514 before going to the LCO Hydrotreater unit or to storage.
For maximum gasoline operation this is the total LCO product. For maximum LCO
operation (maximum distillate operation), heavy naphtha from the Heavy Naphta
Trim Cooler E-1516 is mixed with this stream before being sent to the LCO
Hydrotreater unit.
In case of LCO Hydrotreater shut down, the LCO is sent directly to storage.

2.5.4. MTC and heavy naphtha section


This section consists of 14 fractionating trays, trays 11 to 24, and heavy naphtha
pumparound bed, Bed #1.
MTC is drawn off from tray 19. The MTC (Mix Temperature Control) has a
composition between the light end of the LCO and the heavy end of the heavy
naphtha. This cut is recycled to the riser in the Mixed Crude Maximum Gasoline
case. The MTC is pumped by the MTC Recycle Pumps P-1512 A/B to the riser
injection nozzle on flow control.
Heavy naphtha pumparound and heavy naphta product are drawn off from the tray
below the bed #1. Heavy naphta pumparound is circulated by the naphta
pumparound pumps P-1514 A/B to the following equipment in parallel:

Tube side of the Stripper Feed Preheater E-1555,

Heavy Naphtha Pumparound air cooler E-1521

E-2107 & E-2108 in the Propylene Recovery Unit (PRU) for reboiling
purpose.

The air cooler E-1521 is designed for the case when the PRU is not in operation.
The cooled heavy naphta leaving E-1555, E-1521 and the PRU is then
recombined before being returned to the main fractionator above the Bed #1.

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The total pumparound flow is maintained constant by controlling the flow of heavy
naphta by-passing the above equipments with (FIC-412) at P-15114 A/B
discharge. Heat removal in the pumparound circuit is controlled by the flow
controller at the outlet of E-1521 reset by the temperature controller TIC-430 on
the recombined heavy naphta pumparound return line to T-1501.
Heavy naphta product is taken as a slip stream of the pumparound draw-off at the
suction of the P-1514 A/B and is sent to the heavy naphta stripper T-1502 on level
controller of the stripper bottoms by LIC-439. The heavy naphta stripper bottoms is
reboiled in the reboiler E-1509, using HCO pumparound as heating medium. The
stripper vapor is returned to T-1501 above the pumparound bed, Bed #1.
Stripped heavy naphtha is pumped by the Heavy Naphta Product Pumps P-1515
A/B. It is first cooled by preheating HP boiler feed water in E-1516 and is then
cooled in air cooler E-1517 and trim water cooler E-1518.
For maximum LCO case, the heavy naphtha is mixed with LCO and for maximum
gasoline case it is mixed with debutanized gasoline in the Gas Recovery Section.
Heavy naphtha is also drawn off at the suction of P-1514 A/B as lean oil for the
secondary absorber in the Gas recovery Section. The lean oil is pumped by P1513 A/B on flow control FIC-718 in the Gas Recovery Section where it is first
cooled in Lean Oil / Rich Oil Exchanger E-1563 before cooling in Lean Oil Cooler
E-1564.

2.5.5. Top section


This section of T-1501 consists of 10 fractionation trays, trays 1 to 10.
Rich oil from the bottom of the secondary absorber in the Gas Recovery Section is
fed to tray 9. A partial draw-off accumulator tray is provided below the top tray.
The accumulator tray is designed to separate water and hydrocarbon. Any water is
drawn-off under interface level control LIC-416 and flows by gravity to the inlet of
overhead condenser E-1519.

2.5.6. Fractionator overhead section


The overhead vapor from T-1501 is partially condensed in the overhead air
condenser E-1519 and cooling water exchanger E-1520A-H before flowing to the
fractionator reflux drum where the liquid hydrocarbon, water and vapor phases are
separated.
Off-gas streams from CDU and NHT Units are also fed to D-1514.
Part of the liquid hydrocarbon is sent back to the tray #1 of the main fractionator
as a reflux by means of the Fractionator Reflux Pumps P-1516 A/B. The overhead
naphtha cut point is controlled by the overhead temperature controller TIC-461
resetting this reflux rate.
Part of the wash water is recycled from the fractionator reflux drum D-1514 boot to
the inlet of the overhead condenser E-1519 by means f the overhead sour water
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pumps P-1517 A/B on flow control (FIC-459) in order to minimize corrosion in the
condenser. From the discharge of P-1517 A/B, the remaining water is sent to:

The SWS (unit 18) on flow control reset by the interface level controller LIC446 of the D-1514 boot;

To the wet gas compressor inter cooler on flow control (FIC-703) to be used
as wash water.

Corrosion inhibitor is also injected into the overhead line of T-1501, upstream of
the overhead condensers E-1519, from the corrosion inhibitor tank TK-15101 by
means of either of the corrosion inhibitor pumps P-1520 A/B.
The net overhead liquid product is pumped by the Overhead Liquid Pumps P-1518
A/B, under flow control FIC-455 reset by the level controller of the Main
Fractionator Reflux Drum LIC-443, to the primary absorber in the Gas Recovery
Section.
The overhead vapor from D-1514 flows to the first stage KO drum of the wet gas
compressor D-1551, while excess off gas is vented to flare on pressure control.
2.6. Gas Recovery section
Drawing to be inserted here
Figure 11: Gas Recovery Section
2.6.1. Wet gas compressor and HP condenser
Wet gas from the Main Fractionator Reflux Drum D-1514 flows to the wet gas
compressor first stage knock-out drum D-1551 where entrained and condensed
liquids are separated. The liquid collected in D-1551 is pumped by the KO drum
liquid pumps P-1552 A/B back to the fractionator reflux drum D-1514.
The gas from D-1551 is compressed in the 1st stage of the compressor C-1551
and is then cooled in wet gas compressor intercooler E-1551 and trim cooler E1552 A/B. Sour water from the Fractionation Section is injected at the inlet of E1551 to minimize corrosion.
The cooled vapor and condensed liquid from E-1552 are separated in the
interstage KO drum D-1552. The vapor from D-1552 is compressed in the 2nd
stage of compressor C-1551.
The liquid phase in D-1552, hydrocarbon and water, is pumped by P-1551 A/B
and is re-contacted with the compressor discharge vapor. This combined stream is
partially condensed in HP air condenser E-1553 before being fed to the Stripper
Condensers E-1554 A/B/C/D.
A slip stream of this combined stream is recycled back to the inlet of the wet gas
compressor intercooler E-1551.

2.6.2. Stripper condenser and high pressure separator drum


The outlet from E-1553, the primary absorber T-1551 bottom liquid and the
stripper T-1552 overhead vapour are combined before entering stripper water

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condensers E-1554A/B. An LPG stream from the CDU is also fed to the inlet of E1554 A/B.
The mixed phase outlet from E-1554A/B is separated into water and hydrocarbon
liquid phases and a vapor phase in HP separator drum D-1553. The sour water is
sent on D-1553 boot interface level control to the sour water stripper (unit 18).
The hydrocarbon liquid phase is pumped by the stripper feed pumps P-1553 A/B
and after preheating in E-1555 by heavy naphta pumparound is fed to the top of
stripper T-1552.
The vapor phase from D-1553 is fed to the primary absorber T-1551, below the
bottom tray.

2.6.3. Primary absorber T-1551


The primary absorber T-1551 recovers most of the C3 and C4 from D-1553 vapor.
The overhead liquid from the Fractionation Section is fed to the top tray of T-1551.
For other than Bach Ho Max Gasoline case, gasoline is also recycled from the
bottom of the debutanizer T-1554:
After being cooled in the stripper first reboiler E-1556, the gasoline air cooler E1558 and the gasoline cooler E-1559, recycle gasoline is pumped by the Recycle
Gasoline Pumps P-1554 A/B to be mixed with the overhead liquid from the
fractionation section and is fed to the to tray of T-1551.
This Gasoline recycle enables required recovery of C3 and C4.
The absorber bottom rich oil flows to the inlet of E-1554 under level control.

2.6.4. Stripper
The LPG and gasoline mixture is fed from HP separator drum D-1553 to the top
tray of the stripper by means of the stripper feed pumps P-1553 A/B and after
cooling in the stripper feed preheater E-1555 against heavy naphta pumparound.
The purpose of the stripper is to remove H2S, C2 and lighter from The LPG and
gasoline mixture.
The stripper feed temperature is controlled by the temperature of the stripper at
the outlet of E-1555 with TIC-723 adjusting the flowrate of heavy naphta
pumparound leaving E-1555.
The necessary heat to perform the stripping operation is supplied by two reboilers
in series:

In the 1st stripper reboiler E-1556, the stripper bottoms are heated against
debutanizer bottoms.

In the 2nd stripper reboiler E-1557, the stripper bottoms leaving E-1556 are
heating by LCO pumparound from the Fractionation Section.

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The heat input to E-1557 is controlled by the stripper overhead vapor rate FIC709. This rate, and hence the reboiler duty, is set to meet the C2 specification in
the debutanizer overheads.
The overhead vapor leaving the stripper is returned to and condensed in E-1554.
The bottom liquid of the stripper is fed to the debutanizer T-1554 on flow control
FIC-714 reset by the stripper bottoms level controller LIC-712.
2.6.5. Secondary absorber T-1553
The secondary absorber T-1553 recovers gasoline light fractions contained in the
overhead gas from primary absorber T-1551, by means of stripping with a heavy
naphta stream from the fractionation section. The overhead gas from the primary
absorber is sent straight to the secondary absorber T-1553 where it enters below
the tray #20.
The lean oil used for the absorption is a heavy naphtha stream is drawn off from
the main fractionator T-1501 and pumped by P-1513 A/B to the lean oil/rich oil
exchanger E-1563, where the lean oil is cooled by exchange with the bottoms of
T-1553. Lean oil is then further cooled in the lean oil water cooler E-1564. The
cooled liquid flows through lean oil coalescer D-1556 to remove entrained water
before it is fed to the top tray of T-1553 on flow control FIC-718.
Sour water collected in the boot of the lean oil coalescer D-1556 is sent to the
SWS (unit 18) on boot interface level control.
The rich oil from the bottom of the secondary absorber T-1553 flows under level
control of T-1553 bottoms (by LIC-720) to the lean oil/rich oil exchanger E-1563
where it recovers heat before being recycle to the tray #9 of the Main Fractionator
T-1501.
The stripped overhead gas leaving T-1553 is cooled in the fuel gas water cooler E1565 and flows to fuel gas absorber K.O. drum D-1557.

2.6.6. Fuel gas absorber


The fuel gas absorber T-1555 removes H2S and CO2 from the gas leaving the
secondary absorber by contact with lean amine (DEA) fed from the ARU (unit 19).
The small amount of liquid in the effluent from E-1565 is separated in the K.O.
drum D-1557. The liquid is sent to mixing with rich oil at the inlet of the lean oil/rich
oil exchanger E-1563 on level control of the absorber feed KO drum (LIC-726).
The overhead gas of the FG absorber feed KO drum is fed to the bottom of the
Fuel Gas Absorber T-1555, while the lean amine is fed to the top tray on flow
control.
In order to avoid hydrocarbon condensation, the temperature of the lean amine is
controlled by TDIC-746 to maintain the lean amine at a fixed temperature
difference above the inlet gas.
Once treated by the lean amine, the overhead gas is sent to the Fuel Gas
Absorber Outlet K.O. drum D-1559, where entrained and condensed liquid are
separated before the treated fuel gas is sent to the fuel gas system. The gas

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leaving D-1559 is sent to the fuel gas system on pressure control of the secondary
absorber overheads by PIC-733.
The rich amine leaving the bottom of the fuel gas absorber is sent to the amine
regeneration unit (ARU) under T-1555 level control by LIC-730. Any amine
accumulated in K.O. drum D1559 also goes to the ARU on level control of D1559 by LIC-733.

2.6.7. Debutanizer
The debutanizer separates LPG from gasoline.
The bottom of the stripper T-1552 is fed to the tray #22 of the debutanizer T-1554.
The heat required to perform the separation is provided by the debutanizer
reboilers E-1560 A/B in which the debutanizer bottoms are heated by HCO
pumparound. The reboilers duty is controlled by adjusting the flow of HCO leaving
the reboilers with FIC-722 and is set to ensure that the C4 specification in the
gasoline is met.
The overhead vapor leaving the debutanizer is totally condensed in the
debutanizer condensers E-1561 A/B. The pressure in T-1554 is controlled with
PIC-745 by bypassing part of the overhead vapor around E-1561 A/B to the reflux
drum D-1554. The condensed liquid is pumped from D-1554 by P-1556 A/B:

Part of the liquid from the debutanizer KO drum is sent to the tray #1 of the
debutanizer as a reflux. The reflux rate is flow controlled by FIC-721 reset
by the temperature controller TIC-754 on the sensitive tray (tray #8) in the
top section of the column. This control loop determines the C5 specification
in the overhead product.

The remaining overhead liquid, LPG product, is sent to the LPG Amine
Absorber T-1556 after being cooled against cooling water in the LPG
Cooler E-1562. The flow of LPG product being sent to T-1556 from the
discharge of the Debutanizer Overheads Pumps P-1556 A/B is controlled
by FIC-723 located downstream of the water cooler and reset by the level
controller of the Debutanizer Reflux Drum LIC-742.

The water collected in the boot of the debutanizer reflux drum is sent to the SWS
on interface level control.
The gasoline product from the bottom of the debutanizer column is first cooled in
stripper reboiler E-1556, then in air cooler E-1558 and finally in gasoline water
cooler E-1559, before being split into 2 streams:
Part of the cooled gasoline is pumped on flow control by the gasoline recycle
pumps P-1554 A/B to the primary absorber as supplementary lean oil when
required.
The net gasoline product is sent to the Gasoline Treating Unit on flow control by
FIC-715 reset by the debutanizer level controller LIC-736. For maximum Gasoline
operation the heavy naphtha from the Fractionation section is combined with this
stream.

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2.6.8. LPG amine absorber T-1556


The LPG amine absorber T-1556 removes H2S by contact with lean amine (DEA)
from the ARU (unit 19).
T-1556 is a packed column. The LPG enters at the bottom and flows up through
the amine. Lean amine from the ARU is fed to the LPG amine absorber after being
cooled against cooling water in E-1566.
The LPG amine interface level control LIC-746 above the top packed section is
maintained by controlling rich amine flow leaving the bottom of the absorber. The
overhead LPG liquid flows to the LPG amine coalescer D-1555, where amine
carry-over is separated:

The amine collected in the boot of the LPC amine coalescer is sent to the
rich amine stream from the absorber bottom on boot interface level control
by LIC-749.

The overhead LPG from the drum goes to the LPG Treating Unit.

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TRAINING MODULE

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UNIT: 15

Course Content:
Section 1 - General Description
Section 2 - Process Flow Description
Section 3 - Process Control

Section 4 - Safeguarding Devices


Section 5 - Fire & Gas Systems
Section 6 - Quality Control
Section 7 - Cause & Effects
Section 8 - Operating Procedures
Section 9 - HSE
Section 10 - Reference Document Index

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SECTION 3 : PROCESS CONTROL


The following is a description of the main control loops of the RFCC unit. For a detailed
description of the control loops and the controllers, refer to the process control narrative, 8474L015-SP-1511-001.
3.1. Control narrative & operating parameters
3.1.1. Feed Oil Temperature Control
The feed oil temperature control is the prime process parameter for the reactor
riser temperature after the Riser Outlet Temperature Control.
In the Bach Ho case preheating of feed is by the LCO pumparound, MP and HP
steam exchangers and finally by slurry to obtain the feed temperature of 290C. In
the case of Mixed Crude feed, the feed is preheated to the required temperature of
170C by the LCO pumparound when 100% of the feed to the surge drum is hot.
Additionally, MP steam heating is required when the feed is all or partly cold.
The temperature is controlled by TIC-002 at the outlet of the preheat train,
downstream of the point where the feed is mixed with HCO Recycle. The output of
TIC-002 is sent to the selector switch HS-002 which is used to select between the
different modes of operation:

Position 1: Bach Ho Crude:


The output from TIC-002 is routed to TV-002 which regulates the flow of
feed bypassing the 1st and 2nd feed preheat slurry exchangers E-1502 A-C
and E-1501 A/B respectively. This way TIC-002 controls the final
temperature of the feed.
The preheat duty in LCO Pumparound Feed Exchanger in E-1512A/B/C/D
is set by flow control of the total LCO pumparound via FIC-417, which acts
on FV-417: Flow of LCO pumparound bypass.
The duty of E-1522 is set by flow control of the MP Steam via FIC-410
acting on FV-410.
The Duty of E-1524 is set by flow control of the HP Steam via FIC-411 reset
by the temperature of the feed directly at the outlet of this exchanger (TIC411).

Position 2: Mixed Crude-1 (Hot Feed)


The output from TIC-002 is used to reset the flow controller FIC-409 at the
LCO pumparound outlet of E-1512 A/B/C/D. FIC-409 adjusts the duty of the
LCO Pumparound Feed Preheat Exchangers by acting on FV-409: LCO
Pumparound return to main fractionator.

Position 3: mixed Crude-2 (Cold Feed)


The output from TIC-002 is used to reset the flow controller FIC-410 which
controls the duty of the MP steam supply to E-1522 by acting on FV-410: E1522 MP steam inlet.

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Figure 12: Feed Oil Temperature Control


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A constant pressure is maintained on the feed to the reactor feed control valves by
the pressure control valve PV-410 upstream of E-1502A/B/C with PIC-410 located
upstream of the point where the recombined feed is mixed with HCO recycle. This
pressure control ensures that the HCO recycle can enter the feed line. The
location of the pressure control valve also facilitates the by-pass temperature
control.

3.1.2. UC-001 Feed Injector


The feed injection control system provides even distribution of the total feed flow
(feed + recycle) to the 6 distributor nozzles I-1501 A/B/C/D/E/F.
The total feed flow to each of the 6 feed nozzles I-1501 A-F is respectively
controlled by FIC-003 A-F acting on FV-003 A-F at the nozzles inlet.
Flowrate of the different feed sources, raw oil flow controller FIC-001 and HCO
Recycle Oil flow controller FIC-002 are sent to the master controller UC-024 which
sums the contributions from FIC-001 and FIC-002 and divides the total set flow by
the number of feed injectors (6). UC-024 then provides this new set point (Total
set flow/6) to each feed nozzle flow controller FIC-003 A-F which adjust the
position of their feed nozzle flow valve accordingly.
The process variable of UC-024 is the output from UY-020. UY-020 calculates the
total measured feed flowrate to the riser with outputs from the 6 feed nozzles flow
controllers FIC-003 A-F
Total set flow = FIC-001 + FIC-002
Set value to FIC-003A= (Total set flow)/6
Set value to FIC-003B= (Total set flow)/6
Set value to FIC-003C= (Total set flow)/6
Set value to FIC-003D= (Total set flow)/6
Set value to FIC-003E= (Total set flow)/6
Set value to FIC-003F= (Total set flow)/6
Total measure flow= FIC-003A + FIC-003B + FIC-003C + FIC-003D + FIC-003E +
FIC-003F
Each flow controller FIC-003 A-F is temperature compensated with TI-003.
HS-013 is provided for selection of signal from FIC-001 to FV-001, which is used
for start-up operation of RFCC, when feed oil is circulating to the feed surge drum.
During normal operation, HS-013 is selected to set flow rate of FIC-001 to UC024.

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Figure 13: Feed Injector Distribution Control


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The feed dispersion steam injected at each of the feed nozzles I-1501
A/B/C/D/E/F to mix with the feed is flow controlled by 6 controllers FIC-005
A/B/C/D/E/F (1 per feed nozzle) acting on their respective steam inlet valve FV005 A/B/C/D/E/F. The total flow of MP steam supplied to the feed injectors is
computed and displayed via FI-005.

3.1.3. UC-028 MTC INJECTOR


MTC (Mix Temperature Control) injectors I-1502A-D are provided above the feed
injection zone to inject recycled heavy FCC naphtha. MTC plays an important role
in the heat balance control and heavy feed vaporization. The key is to achieve a
higher temperature in the fresh feed mixing zone.
MTC injection is required for Maximum Gasoline Mode of Mixed Crude. MTC
flowrate is set to maintain the desired temperature at the fresh feed injection point.
A thermocouple located upstream of the MTC injectors measure the catalyst/vapor
mixture temperature.
The MTC Recycle flow to the 4 injectors I-1502 A/B/C/D is evenly distributed and
controlled by the flow controllers FIC-010 A/B/C/D:
A signal representing the flow of MTC recycle to the riser is sent by FI-009 to UC028, the late being the master controller for each individual controllers FIC-010 AD. UC-028 divides the flowrate signal from FI-009 by the number of MTC injectors
(4) and sends the resulting value to each of the 4 flow controllers FIC-010 A/B/C/D
as their new setpoint. Then FIC-010 A/B/C/D adjust the flow of MTC recycle to
their respective injector by acting on FV-010 A/B/C/D respectively.
The process variable of UC-028 is the output from UY-014. UY-014 calculates the
total measured MTC flowrate to the riser with outputs from the 4 MTC injectors
flow controllers FIC-010 A-D.
Total measured flow= FIC-010A+FIC-010B+FIC-010C+FIC-010D
Set value to FIC-010A= (Total measured flow by FI-009)/4
Set value to FIC-010B= (Total measured flow by FI-009)/4
Set value to FIC-010C= (Total measured flow by FI-009)/4
Set value to FIC-010D= (Total measured flow by FI-009)/4

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Figure 14: MTC Injector Distribution Control


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The MTC dispersion steam injected at each of the MTC injectors I-1502 A/B/C/D
to mix with the MTC is flow controlled by 4 controllers FIC-005 A/B/C/D (1 per feed
nozzle) acting on their respective MP steam inlet valve FV-005 A/B/C/D.

3.1.4. Riser Outlet Temperature Control


The most critical control loop on the Reactor and Regenerator is the Riser Outlet
Temperature Control TIC-010. The temperature should be controlled within 1C
of the setpoint. A thermocouple located near the outlet of the riser measures the
reaction temperature. Since the temperature is a function of the amount of catalyst
admitted to the riser by the Regenerated Catalyst Slide Valve SV-1501, the Riser
Outlet Temperature controls the regenerated catalyst slide valve in order to
provide sufficient flow of hot catalyst to maintain the riser at the desired
temperature. Reaction temperature is basic to conversion of RFCC feedstocks.
At the bottom of the regenerated catalyst standpipe the regenerated catalyst slide
valve controls the flow of hot catalyst to the wye section at the base of the riser D1501. The Riser Outlet Temperature sets the position of the slide valve which
regulates the flow of catalyst.
The Regenerated Catalyst Slide Valve position can be set by either of the
following temperature controllers:

Riser Outlet Temperature Controller TIC-020

TIC-015 located above the Upper Steam Stripping Ring above the fluidized
bed packing in the stripper section of the riser

The operator selects between these controllers via HS-004. In normal operation,
the output of TIC-020 is selected.
The output of the temperature controller TIC-020 is then sent to the low switch
selector UY-020 which selects between this input and the output of the differential
pressure controller PDIC-247. The later receives the measure of the differential
pressure across SV-1501 by PDT-247.
In the event the differential pressure across the slide valve falls to 0.1 bar then the
signal from PDIC-247 will be selected by UY-020 in order to re-adjust the slide
valve differential to its normal value (0.3 to 0.5 bar). Normal valve differential is
essential to provide safe operation as well as stable control. Negative differentials
should never happen.
Note:
In the event that PDIC-015 is less than 0.15 barg, then the output of PDIC-247 will
be 0% to close SV-1501.
The operator enables the low selector switch by means of HS-015 which has 2
positions: Enable/Disable. When HS-015 selects Disable, Low Selector Switch
UY-012 will exclusively select the output of HS-004.

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The output of UY-012 is then sent to the software switch HS-028 which is used to
select between this input and the output of the Software Hand Controller HIC-029
(which can be tuned in the range 0-100%). Software switch HS-028 has 2
positions: Auto & Manual:

When AUTO is selected, then the output of HS-028, UY-017, is the signal
from the low selector UY-017 and is sent to the PLC of the Regenerated
Catalyst Slide Valve (Signal to UV-017).

In the case MANUAL is selected then the output of HS-028, UY-017, is the
signal from the software hand controller HIC-029 and is sent to the PLC of
the Regenerated Catalyst Slide Valve (Signal to UV-017).

HS-008 is used to activate the standby mode of the accumulator.

Figure 15: SV-1501

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A Riser Outlet Temperature (ROT) is chosen based on the type of feedstock


processed and the type of yields distribution desired. The heat of reaction, the
coke make, catalyst circulation rate, and the regenerator temperature change as
the Riser Outlet Temperature is varied. The feed preheat temperature, MTC oil
flow rate, can be manipulated to control these operating parameters within their
optimum ranges.
The optimum ROT operation varies with feedstock and operational goals.
If the feed temperature is reduced, more hot regenerated catalyst will be required
to heat the reaction mixture. The regenerated catalyst slide valve will open and the
catalyst to oil ratio will increase. Coke make will increase because of the increased
catalyst to oil ratio. The lower heat input into the RFCC, from the feed preheat
exchangers will be made up by burning the extra coke. As the regenerator
temperature increases the catalyst/oil ratio will find a new equilibrium. Thus, feed
temperature can be adjusted to affect conversion at the expense of coke make.
If the feed quality changes such that coke make begins to increase the
regenerator temperature will rise and the regenerated catalyst slide valve will
close slightly as it senses the increasing temperature of the riser outlet. The
catalyst-to-oil ratio then decreases, conversion decreases, and coke make
decreases. Although the unit is now in a new, stable, equilibrium operating point,
an adjustment of some other operating variable may be necessary to maintain the
desired product distribution at the new heat balanced level.
If the percentage of residue in the feedstock gets too high there may be no
remaining flexibility for the heat balance. In this case, coke make due to the nature
of the feed becomes the predominant source of coke and changes in catalyst-tooil ratio have a smaller effect on overall coke make. In this case, an increase in the
feed preheat may cause very high regenerator temperatures as the coke level
builds up on the catalyst and significantly reduces the catalyst-to-oil ratio.
Unacceptably poor conversion will result.
If the MTC oil rate is increased, the Riser Outlet Temperature begins to decrease
and the regenerated catalyst slide valve will open slightly as it senses the lower
ROT. The catalyst-to-oil ratio then increases, mix zone temperature increases,
conversion increases, and coke / slurry oil production decreases.
When the set point of the riser outlet temperature is changed, the regenerated
catalyst slide valve will immediately vary the catalyst-to-oil ratio to satisfy the new
riser heat demand. Before the system reaches steady state and the regenerator
equilibrates at a new temperature, the system will go through a transition stage
due to the large catalyst inventory. During the transition, operating signals can be
confusing. For example, a higher riser outlet temperature demands a higher
catalyst circulation rate and a higher coke make. But the catalyst takes time to
travel through the riser, disengager, stripper and the spent catalyst transfer line to
reach the regenerator. The temperature in the regenerator will decline initially
because of the immediate extra heat demand in the riser. Eventually, the unit will
heat balance by producing more coke, and the regenerator temperature will rise.
This higher temperature will cause the catalyst circulation rate to decrease. The
system can eventually be returned to the optimal catalyst to oil ratio if the feed
preheat temperature is adjusted to offset the additional riser heat demand.

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3.1.5. Catalyst Stripper Level Control


The spent catalyst slide valve controls the catalyst stripper level by modulating the
flow of spent catalyst from the catalyst stripper to the first stage regenerator. The
catalyst level in the stripper is measured by differential pressure instruments and
sends a signal to the controller which sets the position of the slide valve. A
minimum level is required in the catalyst stripper to ensure good stripping of
hydrocarbons from the catalyst and a seal at the diplegs outlet of the Riser Outlet
Separation System.

Figure 16: SV-1502

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The selector HS-005 is provided to select between either of the level controller of
the catalyst stripper LIC-002 and LIC-003. The Level controller output selected is
then sent to the low signal selector UY-011 which selects between this input and
the output from PDIC-103. The later receives the differential pressure across SV1502 as measured by PDT-103 as input. In the event the differential pressure
across the slide valve falls to 0.1 bar then the signal from PDIC-103 will be
selected by UY-011 in order to re-adjust the slide valve differential to its normal
value (0.3 to 0.5 bar). Normal valve differential is essential to provide safe
operation as well as stable control. Negative differentials should never happen.
The software switch HS-014 is provided to enable or disable the low selector
switch. HS-014 has only 2 positions: Enable and Disable. When HS-014 selects
Disable, Low Selector Switch UY-011 will exclusively select the output of HS005.
The output of UY-011, (in normal operating conditions: either of the level
controllers of the catalyst stripper) is sent to the software switch HS-025 which is
used to select between UY-011 output and the manual control of the slide valve
via software hand controller HIC-025.
Software switch HS-025 has only 2 positions, Auto & Manual:

When AUTO is selected, then the output of HS-024, UY-015, is the signal
from the low selector UY-011 and is sent to the PLC of the Spent Catalyst
Slide Valve (Signal to UV-015).
This way, in normal operation, the position of the spent catalyst slide valve
is controlled by either of the level controller of the catalyst stripper.

In the case MANUAL is selected then the output of HS-024, UY-015, is the
signal from the software hand controller HIC-025 and is sent to the PLC of
the Spent Catalyst Slide Valve (Signal to UV-015).

HS-003 is used to activate the standby mode of the accumulator.

3.1.6. Catalyst Regenerators Level Control


The level in the first stage regenerator is measured by a differential pressure
instrument LT-004 and is sent to the level controller of the 1st stage regenerator
LIC-004 which resets the position of the air lift plug valve PV-1501.
The plug valve modulates the flow of catalyst from the first stage regenerator into
the lift to the second stage regenerator.
A minimum level must be maintained in the first stage regenerator to ensure good
regeneration and to seal the cyclone diplegs. A low level in the regenerator may
unseal the diplegs which could result in backflow of flue gas up the diplegs and
loss of catalyst fines with the flue gas.
A high level in the first stage regenerator can also result in catalyst carryover from
the cyclones because of higher entrainment from the bed and re-entrainment from
the cyclone dust bowls.

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During normal operation, the second stage regenerator level LIC-007 is not
controlled, but follows the unit inventory. This level is monitored and adjusted by
continuous withdrawal as the level builds through catalyst addition. The level in the
second stage regenerator must be held within certain limits for the same reasons
as stated above for the first stage regenerator.

Figure 17: Air Lift Plug Valve PV-1501 Control


In normal operation, the air lift plug valve is controlled by LIC-004, however, HS004 is provided to select between LIC-004 and LIC-007. The output of HS-006,
(=output of LIC-004 in normal operation) is then sent to the software switch HS026 which is used to select between this input and the manual operation of the
plug valve PV-1501 via HIC-027.
Software switch HS-027 has only 2 positions, Auto & Manual:
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When AUTO is selected (=normal operation), then the output of HS-026,


UY-016, is the signal from the low selector UY-006 and is sent to the PLC
of the Air Lift Plug Valve (Signal to UV-016).
This way, in normal operation, the position of the spent catalyst slide valve
is controlled by either of the level controller of the catalyst stripper.

In the case MANUAL is selected then the output of HS-026, UY-016, is the
signal from the software hand controller HIC-027 and is sent to the PLC of
the Air Lift Plug Valve (Signal to UV-016).

HS-007 is used to activate the standby mode of the accumulator.

3.1.7. Catalyst Regenerators Pressure Control


The regenerators pressures are controlled by flue gas slide valves SV-1503/1504
which throttle the flow of flue gas from the vessels.
The pressure of the first stage regenerator is directly controlled by the first
regenerator flue gas slide valve SV-1503 with PIC-146.

Figure 18: First Regenerator Flue Gas Slide Valve SV-1503 Control
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The output of the pressure controller PIC-146 located at the top of the 1st
regenerator D-1502 is sent to the software switch HS-030 which is used to select
between this input and the manual operation of the slide valve via HIC-031. In
normal operation, PIC-146 controls the operation of the slide valve SV-1503 and
its output is sent to UY-018, which forwards 2 identical signals, UY-018 A and UY018 B and identical to the selected signal in HS-030, to the PLC of the double disc
slide valve (UY-018A is sent to UV-018A and UY-018B is sent to UV-018B). This
way PIC-146 commands both discs of the slide valve SV-1503.
Software switches HS-040 A and B are provided to activate the standby mode of
the valve accumulator A & B respectively.
The differential pressure PDIC-172 between the first stage and second stage
regenerators is controlled by the second regenerator flue gas slide valve SV-1504.
This differential pressure is set to provide adequate pressure drop across the plug
valve PV-1501 for stable control of the regenerators levels.

Figure 19: 2nd Regenerator Flue Gas Slide Valve SV-1504 Control
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PDIC-172 measures and controls the differential pressure between the top of the
1st regenerator and the bottom of the 2nd regenerator.
The output of PDIC-172 is sent to the software switch HS-032 which is used to
select between this input and the manual operation of the slide valve via HIC-033.
In normal operation, PDIC-172 controls the operation of the 2nd regenerator slide
valve SV-1504 and so its output is sent to UY-019. The later forwards 2 identical
signals, UY-019 A and UY-019 B and identical to the selected signal in HS-032, to
the PLC of the double disc slide valve (UY-019A is sent to UV-019A and UY-019B
is sent to UV-019B). This way PDIC-172 commands both discs of the slide valve
SV-1504.

3.1.8. Disengager Pressure Control


The disengager pressure rides on the main fractionator pressure which is
controlled at the main fractionator overhead receiver D-1514. The objective in
operation is usually to set the main fractionator pressure to a base level for
efficient operation and the regenerator vessel pressures to result in approximately
equal differentials across the catalyst slide valves.

3.1.9. Catalyst Regeneration Air and Total Flue gas to Stack Control
The pressure of blower air to the 1st Regeneration Air Heater H-1501 is controlled
by PIC-311 located at the blower discharge and acting on the pressure valve PV311 on the blower air line to H-1501, upstream of the 1st regenerator air ring
assisted check valve CV-1501.
The flow of air to H-1501 is monitored by FIC-161 (Venturi Tube) just upstream of
PIC-311. The output of FIC-161 is sent to the air blower C-1501 speed controller
SC-803 via the selector unit HS-827.
The flow of blower air to the 2nd regeneration air heater H-1502 is controlled by
FIC-164 (Venturi Tube) with FV-164 on the air blower line to H-1502, upstream of
the 2nd regenerator air ring assisted check valve CV-1502.
The flow of blower air to the air lift plug valve PV-1501 of the first regenerator D1502 is controlled by FIC-166 (Venturi Tube) with FV-166 on the air blower line to
PV-1501, upstream of the air lift assisted check valve CV-1503.
The flow of blower air to the withdrawal well is controlled by FIC-169 with FV-169
on the blower air line to the withdrawal well.
All above mentioned flow controllers are pressure and temperature compensated
by PIC-311 and TI-821 respectively.
The total Regeneration Air Flow is calculated by FI-162 which receives the signals
from FIC-161, FIC-164, FIC-166 and FIC-169 as inputs:
FI-162 (PV) = FIC-161(PV) + FIC-164(PV) + FIC-166(PV) + FIC-169(PV)

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The total flue gas to RFCC stack is calculated by the summing device UY-110 in
order to monitor the emissions.
The Total Flue Gas from COB H-1503 is calculated as per the following:
[Flue Gas from COB] = FI-902(PV) + FI-920(PV) + FI-923(PV) + FI-908(PV) [kg/h]

FI-902: Total combustion air to COB (kg/hr)

FI-920: Total fuel gas used for COB combustion (kg/hr)

FI-923: Total fuel oil used for COB combustion (kg/hr)

FI-908: Total MP Steam used for atomising COB combustion (kg/hr)

The total Regeneration air is calculated from FI-162 by multiplying with a factor to
take into account air to the flue gas from the regeneration section as coke burning
in the regenerators, and by converting from Nm3/h to kg/h.
UY-110 calculates the total flue gas flow by summing the total regeneration air
flow and the flow of flue gas from H-1503. The total flue gas flow is then displayed
by FI-110 which converts the results from kg/h to Nm3/h.

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Figure 20: Regeneration Air and Total Flue Gas to Stack

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3.1.10. Catalyst Draw-Off Control


The catalyst draw-off system allows the transfer of equilibrium catalyst from the 1st
regenerator to the spent catalyst hopper. The hot catalyst is withdrawn through
ON/OFF valve UV-021 actuated by timer and cooled down through a finned pipe.
The catalyst flow rate is set by a Restriction Orifice RO-161.
For catalyst conveying and line cleaning, plant air is injected into the catalyst line
downstream of the restriction orifice by another ON/OFF valve UV-023 actuated
by timer. The total amount of catalyst withdrawal is adjusted by the timer setting
taking into account the operation requirement for overall catalyst balance.
One cycle of catalyst draw off is fixed at 60min.
The total daily amount of catalyst withdrawal is adjusted by timer HIC-018 setting
taking into account the operation requirements for the overall catalyst balance.

Figure 21: Catalyst Draw Off Control

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HIC-018: Set Point of Opening Time (Range: 0 30 min/cycle). This setting


value is used for timer set point of T-2 and T-4 (see DCS sequence below).

HIC-042: Set Point of Frequency (Range: 3 24 cycle/day (Integer number


only to be used)) .This setting value is used for timer set point of T-5 (see
DCS sequence here after).

The sequence can be stopped locally with HS-043 or remotely with the DCS
software switch HS-044.
The flow of catalyst to the catalyst hopper is monitored via TI-029. In the event of
high temperature alarm from TI-029, then the drawoff sequence will also be
stopped.
DCS Draw-Off Sequence:
(1) Sequence Start
Sequence shall be started by activation of HS-043 at local panel.
(2) Timer Setting
T-1: Timer of Cleaning (UV-021: Close, UV-022: Open, UV-023: Open)
T-1 = 5min
This timer is started when HS-043 is activated or T-5 is up.
When timer T-1 is up, T-2 will start.
T-2: Timer of Conveying (UV-021: Open, UV-022: Open, UV-023: Open)
T-2 = HIC-018 (Set Point) [min]
When timer T-2 is up, T-3 will start.
T-3: Timer of Cleaning (UV-021: Close, UV-022: Open, UV-023: Open)
T-3 = 5min
When timer T-3 is up, T-4 will start.
T-4: Timer of Free of Catalyst
T-4 = 60 (T-1) (T-3) - HIC-018 (SP) [min]
When timer T-4 is up, T-5 will start.
T-5: Timer of Interval
T-5 = {{24 HIC-024(SP)} x 60} / HIC-024(SP) [min]
When this timer is up, T-1 will start.
(3) Sequence in Progress
Total time of conveying will be shown on DCS graphic, when sequence is in
progress. This total time will reset at the end of the day.
HIC-018 and HIC-042 can be changed during sequence in progress. New setting
will be applied to the next cycle.
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(4) Sequence Stop


The causes of sequence stop can be:

HS-044: Normal Stop

TAH-029: Temperature High

Valve Discrepancy Alarm (UV-021/022/023)

When sequence is stopped by any of the above events, the sequence goes to
cleaning mode (UV-021: Close, UV-022: Open, UV-023: Open) for 5min, then, all
valves (UV-021/022/023) will be in the closed position and sequence will stop,
then skip to the end (T0).
The sequence will start, only when HS-043 is activated.

3.1.11. Slurry Pumparound Return Control


The purpose of this control is to maintain a constant total flowrate of hot slurry
pumparound bypass to the grid of Bed #5 of the main fractionator.
It is essential to have an adequate flow to the grid of No.5 bed to ensure good
distribution, and maintain liquid flow on the bed to minimize coking-up of the
packing bed. The hot by-pass flow by FIC-426 and HIC-427 allow for this constant
flow to the grid whistle permitting changes in heat removal from the heat
exchangers.

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Figure 22: Catalyst Draw Off Sequence


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3.1.12. Feed Pumps Automatic Start-up


The feed pump P-1501 A or B on standby is automatically started when Low low
flow alarm FALL-404 at the pumps discharge is activated.
HS-401 is provided for the duty/standby selection.

3.1.13. UY-405, Slurry Pumparound (PA) Return Control


The purpose of this controller is to maintain the total flow rate of Slurry PA return
to Bed No.5 of the main Fractionator. It is essential to have adequate flow to the
grid of No.5 bed to ensure good distribution, and maintain liquid flow on the bed to
minimize coking-up of the packing bed.
The hot by-pass flow by FIC-426 and HIC-427 allow for constant flow to the grid
whistle permitting changes in heat removal from the heat exchangers.
The total flowrate of Slurry PA is set by the operator via the software hand
controller HIC-427. This value is sent to UY-405 which also receives the following
signals:

FI-539 output: Total flowrate of slurry pumparound from the 2nd feed
preheat slurry exchangers E-1501 A/B returned to the grid. The flowrate of
slurry pumparound leaving E-1501 A is controlled by FIC-406 with FV-406
on the slurry returned line to the PA return header. Meanwhile, the flowrate
of LCO pumparound leaving E-1501 B is controlled by FIC-501 with FV-501
on the slurry returned line to the PA return header. The output of FIC-406
and FIC-501 are summed in UY-539 and the result is sent to FI-539, which
in turns forward the total slurry PA return flowrate to UY-405.

FIC-408 output: FIC-408 controls the flow of slurry pumparound leaving the
last feed preheat slurry exchanger E-1501 A with FV-408 on the slurry PA
return line to the PA header.

FIC-425 output: FIC-425 controls the flow of slurry pumparound flowing


through the HP steam generators E-1503 A/B/C with FV-425 located on the
return line to the pumparound header.

FIC-440 output: FIC-440 controls the flow of slurry pumparound leaving the
MP steam generators E-1505 A/B and flowing through the slurry
pumparound header back to the bed #5 of the main fractiontator.

The output of FI-539, FIC-408, FIC-425 and FIC-440 are summed in UX-405. The
result of this summation is substracted to the total pumparound flowrate value set
via HIC-427, which gives the setpoint of the hot bypass flow controller FIC-426.
The later adjusts the position of FV-426 on the hot bypass line accordingly.

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Figure 23: Slurry Pumparound (PA) Return Control

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3.1.14. UC-414, E-1505 Slurry PA flow balance control


The function of this controller is to balance evenly the slurry pumparound flow
through the 2 branches of the steam generators:

Branch A: E-1504A and E-1505A

Branch B: E-1505 adnd E-1505B

The basic function is that UC-414 selects the highest valve opening request. One
of the flow control valves should then be fully opened by manual. The other valve
will be then throttled as required to maintain equal flow through each exchanger
train.
The intent of the design is not to maintain a particular flow through the exchangers
but to balance the flows through the exchangers. If there is an increase/decrease
in flows downstream of these control valves then the flow rate through all
exchangers will increase/decrease and the flow balancing will act to open to
maximum one valve and throttle the others. As one valve is always fully open, the
pressure drop through these control valves is always minimized. The operation of
these valves should, therefore, not interfere with the downstream control.

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Figure 24: E-1505 Slurry PA flow balance control


The flow of slurry leaving the MP steam generator E1505A is controlled by FIC438 with FV-438. The output of FIC-438 is sent to both the flow control valve FV438 and the summing device UY-410.

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The flow of slurry leaving the MP steam generator E1505b is controlled by FIC43y with FV-437. The output of FIC-437 is sent to both the flow control valve FV437 and the summing device UY-410.
The controllers 015-FIC-437 and 015-FIC-438 can not be in Auto mode
simultaneously: One of them must be in manual mode with its control valve fully
open.
UY-410 sums the flowrate of slurry pumparound through each of the 2 branches of
E-1504 A/B and E-1505 A/B. The total flowrate obtained is then sent to the master
controller UC-414 which divides it by the number of heat exchangers (2), to get the
new setpoint of the flow controllers. The output of UC-414 is sent to FIC-438 or
FIC-437 whichever is in auto mode. The flow controller in AUTO mode will in turn
adjust the flow of slurry through its branch of the exchangers to half of the total
flow measured, by means of its control valve.
The slurry pumparound leaving the MP steam exchangers E-1505 A/B is then
divided into 3 streams:

Part of the slurry is sent to the slurry draw-off drum D-1515 on flow control
by FIC-462 with FV-462 on the slurry draw-off line to D-1515 inlet. To
maintain the normal level in the bottom of T-1501, the setpoint of FIC-462
is reset by the main fractionator bottoms level controller LIC-411.

Another part of the slurry leaving the MP steam generators E-1505 A/B
flows to the quench zone of the main fractionator. The flow of slurry from
E-1505 A/B sent to the quench zone is controlled by FIC-439 which is
reset by the temperature controller TIC-439 of the main fractionator
bottoms via software switch HS-426.
HS-426 is provided to select either the flow control of the slurry PA to the
quench from E-1505 A/B (FIC-439) or the flow control of the slurry PA to
the quench from E-1503 A/B/C (FIC-424).

The last part of the slurry PA from the MP steam generators E-1505 A/B is
sent back to the Bed #5 of the main fractionator via the PA return header.
This slurry PA return flow is controlled by FIC-440 reset by the
temperature controller TIC-443 on the Bed #4 of the main fractionator, via
software switch HS-471.
HS-471 is provided to select either the flow control of the slurry PA to the
PA return from E-1505 A/B (FIC-440) or the flow control of the slurry PA to
the PA return from E-1503 A/B/C (FIC-425).

3.1.15. UC-413, E-1503 Slurry PA flow balance control


The function of this controller is to balance evenly the slurry pumparound flow
through the 3 steam generators E-1503 A, B and C.
The basic function is that UC-413 selects the highest valve opening request. One
of the three flow control valves should then be fully opened by manual control. The
other valves are then throttled as required to maintain equal flow through each
exchanger train.
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The intent of the design is not to maintain a particular flow through the exchangers
but to balance the flows through the exchangers. If there is an increase/decrease
in flows downstream of these control valves then the flow rates through all
exchangers will increase/decrease and the flow balancing will act to open to
maximum one valve and throttle the others. As one valve is always fully open the
pressure drop through these control valves is always minimized. The operation of
these valves should, therefore, not interfere with the downstream control.

Figure 25: E-1503 Slurry PA flow balance control

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The flow of slurry leaving the slurry HP steam exchanger E-1503A is controlled by
FIC-428 with FV-428 on the discharge line back to T-1501. The output of FIC-428
is sent both to its flow control valve and to the summing function UY-409.
The flow of slurry leaving the slurry HP steam exchanger E-1503B is controlled by
FIC-429 with FV-429 on the discharge line back to T-1501. The output of FIC-429
is sent both to its flow control valve and to the summing function UY-409.
The flow of slurry leaving the slurry HP steam exchanger E-1503A is controlled by
FIC-430 with FV-430 on the discharge line back to T-1501. The output of FIC-430
is sent both to its flow control valve and to the summing function UY-409.
The controllers FIC-428, FIC-429 and FIC-430 can not be in Auto mode
simultaneously: One of them must be in manual mode with its control valve fully
open.
UY-409 sums the flowrate of slurry pumparound through each HP steam
generator. The total flowrate obtained is then sent to the master controller UC-413
which divides it by the number of heat exchangers (3), to get the new setpoint of
each of the flow controllers. The output of UC-413 is sent to FIC-428, FIC-429
and/or FIC-430, whichever is in auto mode, as the new setpoint. The flow
controller in AUTO mode will in turn adjust the flow of slurry through its HP steam
generator to 1/3 of the total flow measured, by means of its control valve.
Downstream of the slurry HP steam generators, the flow of slurry returned to the
main fractionator is divided in 2 streams:

Part of the slurry leaving the HP steam generators E-1503 A/B/C flows to
the quench zone of the main fractionator on flow control by FIC-424. The
later is reset by the temperature controller TIC-439 of the main fractionator
bottoms via software switch HS-426.
HS-426 is provided to select either the flow control of the slurry PA to the
quench from E-1505 A/B (FIC-439) or the flow control of the slurry PA to
the quench from E-1503 A/B/C (FIC-424).

Another part of the slurry leaving the HP steam generators E-1503 A/B/C
is sent back to the Bed #5 of the main fractionator via the PA return
header. This slurry PA return flow is controlled by FIC-425 reset by the
temperature controller TIC-443 on the Bed #4 of the main fractionator, via
software switch HS-471.
HS-471 is provided to select either the flow control of the slurry PA to the
PA return from E-1505 A/B (FIC-440) or the flow control of the slurry PA to
the PA return from E-1503 A/B/C (FIC-425).

3.1.16. Steam Generation 3 Elements Control


Three element controls are provided for the kettle type steam generators E-1503
A/B/C and E-1503 A/B. This scheme has the objective to control the level on the
kettle steam generator at a constant set point, based on the high-pressure steam
flow rate as major disturbance, like a feedfoward variable, that impact the level.

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Since the flow rate of steam increases, the level decreases, with the consequent
action to increase the boiler feed water flow rate.

Figure 26: Steam Generation 3 Elements Control


The summing function receives the linearized steam flowrate signal and adds or
subtracts from the steam signal a signal which is the difference between the steam
drum level controller output and a bias signal (the level setpoint) set at 50% signal.
The resultant output signal from the summing function is the setpoint signal to the
boiler feed water flow controller.
The system is designed so that for every weight unit of steam make a weight unit
of feed water is introduced and the level controller signal is only used to
compensate for blowdown and error in steam to water ratio.

3.1.17. Split Range Control of Surge Drum


The pressure of the following surge drums is maintained constant by means of
split range pressure controller PIC-XXX with 2 control valves: One to admit fuel
gas in the surge drum and the other one to vent off gas from the surge drum to the
flare
If the pressure inside the feed surge drum is lower than the setpoint of the
pressure controller, Then the pressure controller will send an output in the low
range (0-50%). In that case the control valve for fuel gas in will open while the
control valve to flare will remain closed. The opening of control valve for fuel gas
will increase when the output of the pressure controller decreases in the 0-50%
range.

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If the pressure inside the feed surge drum is higher than the setpoint, then the
pressure controller will send an output in the high range (50-100%). In this case,
the control valve for fuel gas in will remain closed while the control valve to flare
will open. The opening of the later will increase when the output of the controller
increases (and so the pressure) in the 50-100% range.

Figure 27: Feed Surge Drum Pressure Control


The above pressure control scheme is valid for the following drums:
Drum Tag No.

Controller Tag No.

PV for Fuel Gas In

PV to Flare

D-1513

PIC-403

PV-403A

PV-403B

D-1515

PIC-468

PV-468A

PV-468B

D-1516

PIC-479

PV-479A

PV-479B

D-1517

PIC-475

PV-475A

PV-475B

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Drum Tag No.

Controller Tag No.

PV for Fuel Gas In

PV to Flare

D-1518

PIC-483

PV-483A

PV-483B

D-1519

PIC-489

PV-489A

PV-489B

D-1522

PIC-505

PV-505A

PV-505B

D-1523

PIC-510

PV-510A

PV-510B

3.1.18. Main Fractionator Pressure Control


The main fractionator pressure is controlled at the reflux drum D-1514 via PIC-456
by speed control of the wet gas compressor C-1551 in the gas recovery section.
A signal proportional to the pressure in the Main Fractionator Reflux Drum D-1514
is sent by the pressure controller PIC-456 to the software selector HS-702 which is
used to select between this input and the output of the pressure controller PIC-068
at the Disengager section of the riser D-1501. In normal operation, the signal from
PIC-456 is selected. HS-702 then forwards the selected signal to the speed
controller SIC-861 of the wet gas compressor C-1551 in the gas recovery section.
SIC-861 then adjusts the speed of C-1551 accordingly to maintain the adequate
pressure in D-1514.
Pressure is not a process variable from an operation point of view and is not
adjusted to correct product specifications.
The unit has been designed to operate with a pressure of 0.4 kg/cmg in the
fractionator reflux drum. This pressure sets the pressure in the reactor, where low
pressure is desirable to achieve good feed vaporization.
The output of the software selector switch is also routed to the low selector switch
UY-701 which selects the lowest signal between this input and the output of the
pressure controller PIC-707 at the gas outlet of the interstage KO drum D-1552 to
the 2nd stage compressor. The lowest signal is then routed to the compressor antisurge control UC-861

3.1.19. HCO Pumparound Heat Removal Control


The HCO pumparound provides heat to the debutanizer reboiler E-1560A/B and
heavy naphtha stripper reboiler E-1509. Constant heat removal in the pumparound
is controlled by controlling these 2 variables:

Total pumparound flow with FIC-419 at the discharge of P-1508 A/B,


which adjusts the HCO pumparound bypass flow by acting on FV-419 on
the bypass line. This HCO pumparound bypass flow is routed directly to
the PA return from the discharge of the HCO pumparound pumps.

Return pumparound temperature with TIC-446 located on the HCO PA


return line to the Bed #3. The output of the temperature controller TIC-446
is used to reset the flow controller FIC-420, which controls the flow of HCO
pumparound leaving the HCO Pumparound MP Steam Generator E-1523
with FV-420. The flow of HCO PA exiting E-1523 is measured and
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transmitted to FIC-420 by FT-420A in the high range and FT-420B in the


low range.

3.1.20. HCO Recycle and HCO Recycle MP steam generator E-1508


For maximum distillate mode operation, HCO is recycled to the reactor feed after
being cooled in the HCO recycle MP steam generator E-1508.
The temperature of the cooled HCO is controlled via TIC-425 on the HCO outlet of
E-1508 by adjusting the amount of HCO bypassing E-1508 with TV-425 on the
bypass line.
The differential pressure between the LCO inlet and outlet of the heat exchanger
is controlled by PDIC-420 with PDV-420 on the LCO inlet line.
The level in the MP steam generator is controlled and maintained constant by LIC408 cascaded on the flow controller FIC-415 of the BFW supply to the heat
exchanger.

Figure 28: HCO Steam Generator Controls

3.1.21. HCO LP Steam Generator E-1510 Controls


The temperature of the HCO leaving the LP steam generator E-1510 is controlled
by TIC-474, at the HCO outlet of E-1510, cascaded on the pressure controller
PIC-447 on the steam side of the HCO LPS generator E-1510. When the HCO
temperature at TIC-474 is above the setpoint, then the setpoint of PIC-447 will be
decreased to command the opening of the pressure valve PV-447
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The level in E-1510 is controlled by LIC-435 cascaded on the flow controller FIC450, which adjust the flow of BFW fed to the LPS generator with FV-450.

Figure 28: HCO Steam Generator Controls

3.1.22. HCO Flushing Oil Pumps Auto-start Control


HCO flushing oil is sent from the LCO HP steam generator E-1510 to the HCO
flushing oil drum D-1518. From D-1518, HCO is pumped by the HCO flushing oil
pumps P-1521 A/B to the HP flush oil header after being filtered in either of the
HCO flushing oil filters F-1502 A/B.
There are 2 HCO flushing oils pumps:

P-1521 A is HP-LP steam backpressure turbine driven

P-1521 B is motor driven

The selection between these pumps is made via the software switch HS-404.
The flow to the HCO flushing oil filters is controlled at the pumps discharge by
means of FIC-461 which regulates the flow of HCO recycled back to the HCO
flushing oil drum D-1518 with FV-461 on the spillback line.

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The minimum pressure at the pumps discharge is controlled by PIA-487: In case


the pressure at the pumps discharge falls to the low pressure setting PAL-487,
then the standby pump is automatically started.
The turbine driven pump P-1521A is provided with 3 position switch (XHSO468/XHSC-468-XHSM-468) to have a similar function as HOA (Hand-Off-Auto)
switch of motor. This function is configured as part of the ESD function UX-438
(see section 4) acting on the valve XV-468. Indeed, since this pump is steam
turbine driven, the opening/closing of valve XV-468 in the steam inlet line drive this
pump:

When XHSO-468 is selected, then the valve will open, allowing the steam
to flow through the turbine and so the pump starts.

When XHSC-468 is selected, then the valve XV-468 will close, thereby
stopping the pump by cutting off the steam supply.

WhenXHSM-468 is selected, then the pump P-1561A will start remotely \.

The ESD trip logic UX-438 will take precedence over any manual valve open or
remote (auto start) command.

Figure 29: HCO Flushing Oil Pumps Auto-Start

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3.1.23. LCO and Heavy Naphta Pumparound Heat Removal Control


In a similar manner than the HCO PA heat removal, constant heat removal in the
LCO pumparound is controlled by controlling these 2 variables:

Total pumparound flow with FIC-417 at the discharge of P-1510 A/B, which
adjusts the LCO pumparound bypass flow by acting on FV-417 on the
bypass line.

Return pumparound temperature with TIC-452 (located on the LCO PA


return line to the Bed #2) cascaded on the flow controller FIC-418 which
controls the flow of LCO PA leaving the LCO PA BFW Heater E-1511.

In the same way, constant heat removal in the heavy naphta pumparound is
controlled by controlling:

The total pumparound flow with FIC-412 at the discharge of P-1514 A/B,
which adjusts the LCO pumparound bypass flow by acting on FV-412 on
the PA bypass line back to T-1501 Bed #1.

The return pumparound temperature with TIC-430 (located on the Heavy


Naphta PA return line to the Bed #1) cascaded on the flow controller FIC414 controlling the flow of heavy naphta PA leaving the Heavy Napht
Pumparound Cooler E-1521.

3.1.24. Heavy Naphta Product Draw-Off and T-1501 Overheads Temperature Control
Heavy naphtha product is also drawn off with the heavy naphtha pumparound.
The cut point between LCO and heavy naphtha is controlled by the temperature
controller TIC-454 below the heavy naphtha draw tray. TIC-454 resets the heavy
naphtha flow controller FIC-453 (via software switch HS-428) which controls the
flow of heavy naphta leaving the unit with FV-453 downstream of the heavy
naphta trim cooler E-1518.
The cut point between heavy naphtha and overhead distillate is controlled by
fractionator overhead temperature controller TIC-461 resetting reflux flow
controller FIC-427 (via software switch HS-429) with FV-427 downstream of the
Fractionator Reflux Pumps P-1516 A/B.
HS-428 is provided to forward the output of TIC-454 either to FIC-453 (normal
condition) or HS-429. HS-429 is provided to select between the output of TIC-461
(normal condition) and the one from HS-428. So alternatively, the heavy naphtha
draw rate can be fixed on flow control and the temperature controller below Bed 1
can be switched to reset reflux flow via HS-428 and HS-429.
For Maximum Distillate operation the overhead cut point is critical to ensure that
the combined LCO flash point specification is met. Even with maximum reboiling
of the heavy naphtha stripper T-1502, the flash point specification will not be met if
the overhead cut point is too low. This temperature should be adjusted based on
operating experience, in order to maximize total LCO product while meeting the
flash point specification.
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3.1.25. Water Draw Off and Recirculation


A water draw-off tray is provided below the top tray. In normal operation, water is
continuously drawn off from the main fractionator. The flow of water draw-off is
controlled by the software hand controller HIC-418 acting on the control valve LV416 located on the wash water line to E-1519.
The normal overhead temperature is approximately 15C to 20C above the water
dew point. If the column is operated at or near the overhead water dew point,
water will condense (risk of corrosion). This can occur during start-up with the unit
at turndown as the steam rates are not reduced proportionately to feed rate. In
that case, water is drawn off under interface level control by LIC-416 acting on LV416.
Software switch HS-417 is provided to select between the output of LIC-416 or the
output of HIC-418 to control the opening of LV-416.
Part of the wash water is recirculated from the boot of D-1514 back to the inlet of
E-1519 on flow control by FIC-459 at the overhead sour water pumps P-1517 A/B
discharge.
Another part of the sour water from D-1514 boot is sent to the inlet of the wet gas
compressor intercooler E-1551 on flow control by FIC-703, while the remaining
sour water is sent to the SWS on flow control by FIC-456 at P-1517 discharge
FIC-456 is reset by the interface level controller LIC-446 of D-1514.

3.1.26. Wet Gas Compressor Control


The wet gas compressor operation is controlled by the pressure controller on the
fractionator reflux drum, as described in the section 3.1.18 of this document.
This pressure sets the operating pressure on the reaction section. The pressure
controller is set at the normal value. It is not an operating variable for the gas plant
and is not normally adjusted.
The primary control on the compressor is speed control of the steam turbine within
the operating speed range: In normal operation, the compressor speed is
controlled by the pressure controller PIC-456 of the fractionator reflux drum D1514 which is cascaded on the compressor speed controller SIC-861 via HS-702.
The secondary control is the spill-back control on the two compressor stages by
UV-702 (controlled by the anti-surge controller UC-862) on the spillback line from
the 2nd stage compressor back to the inlet of the wet gas intercooler E-1551.
The compressor is protected from surge by the compressor anti-surge control
system UC-861/862.

3.1.27. First Stage KO Drum D-1551 Level Control


The liquid level on the drum D-1551 is controlled by starting/stopping the KO drum
liquid pump P-1552 A/B based on the level controller LIA-701 of the KO drum:

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Figure 30: D-1551 Level Control


The duty pump will be automatically started when LAH-701 is activated and
stopped when LAL-701 is activated. HS-701 is provided for duty / stand-by
selection.

3.1.28. Stripper
The level in the HP separator Drum D-1553 is controlled by LIC-717, the output of
which is used to reset the flow controller FIC-711 controlling the flow of stripper
feed downstream of P-1553 A/B with FV-711.
Correct operation of the stripper T-1552 is critical to the operation of the gas
recovery section. The feed preheat temperature is controlled by TIC-723 on the
feed outlet of the stripper feed preheater E-1555. TIC-723 controls the duty of E1555 by regulating the flow of heavy naphta leaving E-1555 with TV-723: If the
feed temperature at the outlet of E-1555 is higher than the setpoint then TIC-723
will command the closing of TV-723.
If the feed temperature is too low, there may be water condensation in the stripper.
If it is too high it can reduce C3 recovery.
The duty of the 2nd stripper reboiler E-1557 is controlled by the stripper overhead
flow controller FIC-709 on the overhead line back to the stripper condensers E1554 A-D. FIC-709 reset the flow controller FIC-710 on the LCO pumparound inlet
of E-1557, which adjust the flow of LCO entering the 2nd stripper reboiler with FV710 accordingly: In case the flow of stripper overheads is higher than the setpoint,

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then FIC-709 will decrease the setpoint of FIC-709 which will in turn reduce the
opening of FV-710 to reduce the duty of the 2nd reboiler.
If the reboil rate is too high, and hence the stripping rate, the primary absorber can
be overloaded, resulting in reduced C3/C4 recovery. If the reboil rate is too low,
the C2 and H2S rates going to the debutanizer will be too high. The set point of
the stripper overhead flowrate should be adjusted to optimize C3 recovery, while
maintaining acceptable H2S and C2 concentrations in the debutanizer overheads.
As an alternative to controlling reboiler rate by the overhead flowrate, the reboiler
duty can be fixed based on operating experience.

3.1.29. Debutanizer
The debutanizer is designed to separate the LPG from gasoline. The two
specifications to be met are the vapor pressure of the gasoline and the C5 content
of the LPG. Additionally, there is an overall C4 recovery specification. Generally, if
this recovery specification is met, the gasoline RVP specification will also be met.
The column operating variables are the reflux rate FIC-721 and the reboiler duty:

The overhead C5 specification is controlled by the temperature controller


TIC-745 in the top section of the column (tray #8). The output of TIC-745 is
used to reset FIC-721 which controls the reflux flow from P-1556 A/B with
FV-721. Decreasing the temperature controller set point decreases C5
concentration in the LPG.

The reboilers duty is controlled by FIC-722 located on the HCO PA inlet of


E-1560 A/B. FIC-722 maintains the duty of the reboilers by keep the flow of
HCO PA constant with FV-722 on the HCO PA return line to the main
fractionator. The reboilers duty should be set manually to obtain the
gasoline RVP specification and/or the overall C4 recovery.

3.1.30. LPG Amine Absorber


The LPG amine absorber removes H2S from the LPG prior to LPG treatment for
the removal of mercaptans.
The LPG-amine interface level above the top packed section is maintained by the
interface level controller LIC-746 regulating the flow of rich amine leaving the
absorber to the ARU.
The lean amine flow entering the absorber is controlled by FIC-724 with FV-724
downstream of the lean amine cooler E-1566 to meet the H2S specification and
also to maintain a maximum H2S to DEA mole ratio of 0.4 in the rich DEA.

3.1.31. Control Narrative for the Slurry Separator Package X-1504


The slurry separator is a system with 10 cylindrical modules. Special glass beads
fill each module. High voltage is pressured to the internal of module. When slurry
oil containing catalyst passes through the module, the catalyst particles are
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separated into positive/negative charge and transfer to the oil. Then the charges
are absorbed by the glass beads (dielectric migration) while the slurry oil passes
through the glass beads with minor pressure drop.
This system is provided with a backflushing sequence using LCO. The control of
the slurry separator system is as follow:
1. The system is ready to operate when 400 VAC power is applied to both local
panels and 230 VAC is applied to the Unit Control Panel from either UPS #1 or
UPS #2, or both.
2. The operator uses the Panelview Display Unit to input commands. Operator
commands are:
a) System Run
b) System Stop
c) Unit Bypass Select [1, 2, 3, 4, 5, 6, 7, 8, 9, 10]
d) Alarm reset
e) Overload Acknowledge
The operator ca also set the Backflush Time, the High Voltage Delay Time and
Pause Time.
3. When the operator issues a System Run Command, if there is no PLC fault
alarm, then the PLC generates a Start Permissive Signal, and the Start
Permissive Lights on both local panels are turned on. The system is now ready
for automatic operation. The automatic operation is initiated by placing the
Stop/Start switch in the Start Position at the local Panel.
4. When the Stop/Start Switch is placed in the Stop position, the system is
inactive; all solenoids are de-energized and all high voltage power supplies are
off.
5. When the Stop/Start switch is placed in the Start Position, after the Start
Permissive is received, automatic operation of the system starts and will
continue until stopped by one of the following:
a) A system Stop command
b) The Stop/Start Switch being placed in the Stop Position
c) Loss of the Start Permissive Signal
6. With the system in automatic operation, each unit (module) is selected in
sequence for an operational cycle. Each cycle proceeds as follow:
a) For the unit selected, the high voltage is off and the feed solenoid and
backflush solenoid are energized. Backflushing takes place until the
backflush time expires.
b) When the backflushing time expires, separation begins. The feed
solenoid and the backflushing solenoid are de-energized and the high
voltage delay time starts. Also, the unit count advances and the next
unit in the sequence is selected. If any unit is bypassed, the system will
advance to the next unit. Units are selected by the system in numerical
order, with unit 1 following unit 10.
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c) As soon as the count advances, Pause Time starts. When Pause Time
is complete the unit that was just selected will begin backflushing,
thereby starting a new cycle. The process continues until stopped as
described above.
Whenever the Start/Stop Switch is in the Start position, all high voltage power
supplies are monitored. If any of the power supplies indicates a high temperature,
high pressure or overload, an alarm will be generated and the high voltage power
supply for that module will not be allowed to turn on. In the case of an overload, an
overload latch is set for that unit. The overload latch will reset when the overload is
cleared, the unit is selected, the system is backflushing, and the operator issues
an overload acknowledge command.

3.1.32. Tempered Water for E-1507 A-D


Tempered water is provided from the tempered water surge drum D-1524 to the
slurry clarified oil coolers E-1507 A-D, where it is used as cooling medium, by
means of the tempered water pumps P-1528 A/B. Tempered water leaving E-1507
A-D is then cooled down in the tempered water air cooler E-1530 on temperature
control of the water leaving E-1530 by TIC-525 acting the flow of water bypassing
the cooler with TV-525 on the bypass line. The differential pressure across the
cooler is controlled by PDIC-514 acting on PDV-514 in the water inlet line.
Cooled tempered water is then recycled back to E-1507 A-D by means of P-1528
A/B.
The flow of tempered water pumped to the slurry clarified oil coolers is controlled
by FIC-487 which adjusts the amount of tempered water sent from the discharge
of P-1528 A/B back to the pumps suction line with FV-487.
The duty pump is selected by means of HS-488. In case of low low flow (FALL488) activated then the standby pump will automatically kick-in.

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Figure 31: Tempered Water Pumps Control


RFCC Closed Drain Pumps P-1560 A/B
Closed drain hydrocarbon liquid is collected in the RFCC closed drain vessel D1560, which is equipped with 2 vertical pumps P-1560 A/B (one on duty and one
on standby) to empty the closed drain drum by pumping the slop oil to storage.
Software switch HS-601 is provided to for standby/duty selection. Each pump P1560 A/B can be selected in manual or auto operation by means of MHS-601B
and MHS-602B respectively.
In AUTO mode, the standby pump will be automatically started when the high level
alarm of the closed drain drum LAH-601 is activated and stopped when the low
level alarm LAL-601 of the drum level controller LIC-602 is activated.
Both pumps will be automatically stopped when the low low level alarm LALL-603
in the closed drain drum is activated.

3.1.33. Amine Closed Drain Recovery Drum Pump P-1564


The amine recovery closed drain drum D-1561 recovers amine from several
locations in the gas recovery section of the RFCC through the closed drain amine
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header. The amine recovered in D-1561 is then pumped to the ARU for
regeneration by means of the pump P-1564 and on level control of the drum:
P-1564 will automatically start when the high level alarm LAH-769 of the amine
closed drain drum D-1560 is activated. Likewise, the pump will automatically stop
when the low level alarm LAL-769 of the drum is activated.
Also the pump will automatically stop in case the low low level trip LALL-774 is
activated.

3.1.34. RFCC lift station No.1 & No.2 Pits Pumps Control
Oily water from west area is collected in the No.1 Pit XP-1501 while oily water
from east area is collected in the No.2 Pit XP-1502. The oily water is pumped from
the pits XP-1501 and XP-1502 to the Effluent Treatment Plant (ETP) by means of
P-1561 and P-1562 respectively. The pumps operated on level control of their
sump just like for the amine closed drain drum D-1560:
P-1561 starts automatically when the high level alarm of XP-1501 LAH-770 is
activated and stops when the level in the sump has reached the low level setting
of the level controller LIC-770, that is when LAL-770 is activated. The pump will
stop in case the low low level alarm of the sump LALL-770 is activated
Likewise, P-1562 starts automatically when the high level alarm of XP-1502 LAH772 is activated and stops when the level in the sump has reached the low level
setting of the level controller LIC-772, that is when LAL-772 is activated. The
pump will stop in case the low low level alarm of the sump LALL-772 is activated

3.1.35. Inter-Unit Controls & Interfaces


3.1.35.1. RFCC Feed Control
The objective of the control of the atmospheric residue from the CDU to
the RFCC to control the level in the bottom of the Main Fractionator of the
CDU and route as much of the outgoing atmospheric residue to the
RFCC as required.

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Figure 32: RFCC Feed Control


The level in the Main Fractionator, T-1101 is controlled by a 3 way split
range level controller 011-LIC-007 (direct acting):

In the low range (0 -33%) the signal from 011-LIC-007 goes to 011LY-082, then to low selector 011-LY-007B, which selects between
011-LIC-007 and the feed requirement of the RFCC (015-LIC-402)
to control the flow to the RFCC.
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In the mid range (33-67%) 011-LIC-007 resets the setpoint of


011-FQIC-026.

In the high range (67-100%) 011-LIC-007 resets the setpoint of


011-FQIC-027.

011-FQIC-026 and 011-FQIC-027 are parallel controllers used to regulate


the flow of residue to storage. 011-FV-026 is a smaller valve than 011-FV027 and will normally be sufficient to control the amount of residue to
storage whilst the RFCC is on-line. In the event that the RFCC is off-line
then 011-FQIC-026 will be fully open and 011-FQIC-027 will control the
flow to storage. The sum of flow of atmospheric residue to storage and
RFCC is indicated to operator by signal 011-FI-065. The total flow of
atmospheric residue is indicated to operator by signal 011-FI-167.
The RFCC feed is controlled by a split range level controller 015-LIC-402,
which takes flow preferentially from the CDU by cascading onto 011FQIC-029 via 011-LY-007B (low range output of the feed surge drum
level controller). If there is not enough flow coming from the CDU (high
range output of the feed surge drum level controller) then flow is taken
from storage by acting on 015-FIC-402, flow controller in the line from
storage.

3.1.35.2. Temperature of Lean Amine from the ARU


The temperature of the lean amine fed from the Amine Regeneration Unit
to the RFCC (and LCO HDT) is controlled such that there is a fixed
minimum temperature differential between the fuel gas and lean amine in
the Fuel Gas Absorbers T-1555 in the RFCC Unit (and T-2402 in the LCO
HDT Unit).

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Figure 33: Temperature Control of Lean Amine from the ARU


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The T between the temperature of the fuel gas entering the fuel gas
absorber T-1555 from the FG Absorber Feed KO Drum D-1557 and the
temperature of the lean amine fed to the top of the Fuel Gas Absorber is
controlled by 015-TDIC-746.
This T is controlled by TDIC-087 in the LCO HDT.
Signals from both 015-TDIC-746 in RFCC and 024-TDIC-087 in LCO
HDT are directed to a low signal selector 019-TDY-019D in the ARU, in
order to ensure that the lean amine temperature is always controlled at
5C above the higher fuel gas temperature, to prevent hydrocarbon
condensation.
The lowest signal simultaneously acts on the control valves around the
Amine Air-Cooler E-1904 via -019-TDY-019 A/B/C (direct acting for amine
flow to aircooler and reverse acting for air-cooler by-pass valve so that
one valve will close when the other opens). This arrangement will allow
adjusting the required temperature difference with minimum flow/pressure
variation of the lean amine supplied to the Refinery users.

3.1.36. Operating Parameters


For the operating conditions of the RFCC refer to the following Process Flow
Diagrams:
8474L-015-PFD-0010-101

Reactor / Regeneration Section Case: Bach Ho

8474L-015-PFD-0010-102

Flue Gas Treatment Section Case: Bach Ho

8474L-015-PFD-0010-103

Feed Section Case: Bach Ho

8474L-015-PFD-0010-104

Fractionation Section Case: Bach Ho

8474L-015-PFD-0010-105

Gas Recovery Section Case: Bach Ho

8474L-015-PFD-0010-106

Material Balance Table Case: Bach Ho MG

8474L-015-PFD-0010-107

Material Balance Table Case: Bach Ho MD

8474L-015-PFD-0010-111

Reactor / Regeneration Section Case: Mixed Crude

8474L-015-PFD-0010-112

Flue Gas Treatment Section Case: Mixed Crude

8474L-015-PFD-0010-113

Feed Section Case: Mixed Crude

8474L-015-PFD-0010-114

Fractionation Section Case: Mixed Crude

8474L-015-PFD-0010-115

Gas Recovery Section Case: Mixed Crude

8474L-015-PFD-0010-116

Material Balance Table Case: Mixed Crude MG

8474L-015-PFD-0010-117

Material Balance Table Case: Mixed Crude MD

3.2. Instrument List


Refer to attached extracted instrument list: Unit 015 extracted instrument list.xls

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3.3. Main Equipment


3.3.1. Reactor Riser, Stripper, Disengager and Catalyst Stand Pipe
The cracking reactions between the feed mixture and the catalyst take place in the
riser, within the 2 sec. residence time.
The riser is provided with (from bottom to top)

Riser wye where the hot regenerated catalyst is injected from the
withdrawal well

Riser Bottom Ring where MP steam is injected to fluidize the catalyst

4x Stabilization MP Steam injectors I-1503 A-D to promote smooth and


homogeneous catalyst flow at the feed injection point.

6x Feed Injectors I-1501 A-F where the feed is finely atomized and mixed
with dispersion steam

4x MTC injectors I-1502 A-D to inject recycled heavy naphta. The MTC
plays an important role in the heat balance control and heavy feed
vaporization.
It is the key to achieve a higher temperature in the fresh feed mixing zone:
With MTC, it is possible to raise the mix temperature while maintaining the
Riser Outlet Temperature or even lowering it. Thus the optimum catalyst
temperature, the target catalyst circulation, and the desired catalytic
cracking reactions can be adjusted separately.
The MTC technology offers the possibility of operating the feed injection
zone at a higher temperature thereby promoting vaporization without
reaching over-cracking conditions in the riser whose outlet is maintained at
a lower temperature. MTC provides additional heat removal. Cooling is
carried out by vaporization of the liquid hydrocarbons introduced at the
MTC level.

Backflush Oil injector I-1504 for the slurry recycle

Riser Outlet Separator System (ROSS), located at the outlet of the riser,
where the catalyst is quickly separated from the hydrocarbon / steam
vapour.

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Riser
Position

Vertical

Normal/MAX. Operating Temperature (C)

772 / 815

Normal/MAX. Operating Pressure (kg/cm2g)

2.2 / 2.6

Design Conditions:
Shell

350C and 5.2 kg/cm2g

Internals

Normal/Max. Temperature (C): 560 / 840

Insulation

Refractory Lining

Materials:
Shell / Heads:

CS A516 Cr 70

Internals

Stainless Steel

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Figure 34: Reactor Riser


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Figure 35: injectors Arrangement

3.3.1.1. Riser Outlet Separation System


The principle of the patented AXENS Riser Outlet Separation System
(ROSS) is a symmetrical structure of separation chambers and collecting
chambers alternatively arranged around the top of the riser.
The separation chambers are connected in their upper section to the riser
and the vapor + catalyst mixture follows a 45 turn downwards around an
inlet baffle. The vapor outlets to the collecting chambers are located
underneath the inlet baffle in the perpendicular direction of the incoming
stream. This geometry provides simultaneously both the centrifugal effect
and the inertial effect which are key factors for catalyst separation.
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The catalyst separated is collected in a hopper prolonged by a dip leg


which achieves the necessary seal between the riser and the stripper
vessel. The vapor exiting the separation chamber is then mixed in the
collecting chamber with the steam evolved from the stripper vessel. The
collecting chambers are then connected to a center pipe collector which
distributes the vapor to the disengager cyclones for final catalyst
separation.
This system achieves in a single device an extra-short time of vapor
disengagement of about 1 second (45 turn, no vortex) and an efficient
catalyst separation in two chambers arranged in series. The main
chamber which is the separation chamber itself and the secondary
chamber which is the vapor collecting chamber providing an additional
safety buffer volume for further catalyst disengagement in case of catalyst
carry-over.

Figure 36: Cyclones Orientation

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Figure 37: Separator Arrangement

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3.3.1.2. Catalyst Stripper


The purpose of this section of D-1501 is to strip the catalyst exiting the
ROSS with steam to reduce coke yield.
In order to provide an efficient stripping, the stripper is provided with the
following steam rings:

Pre-stripping steam ring (I1 on the figure) located immediately at


the exit of the separator diplegs

Upper Stripping Ring (I2 on the figure) located just upstream of the
fluidized bed packing

Stripper Main Ring (I3 on the figure) located just downstream of the
fluidized bed packing

Lower Stripping Ring (I4 on the figure) located at the bottom of the
stripper to achieve a stable fluidization at the inlet of the spent
catalyst standpipe.

The steam rate for this ring is part of the total steam required for
good stripping but its prime function is to aerate the catalyst
entering the spent catalyst standpipe. This is important for
adequate head build-up to maintain an adequate slide valve
differential pressure for controlling the stripper level.

The stripper is also provided with a fluidized bed packing allowing for
cross and counter current flow of steam and catalyst and enhancing the
contact between the catalyst and the steam.
Stripper
Position

Vertical

Normal/MAX. Operating Temperature (C)

525 / 545

Normal/MAX. Operating Pressure (kg/cm2g)

2.2 / 2.6

Design Conditions:
Shell

350C and 5.2 kg/cm2g

Internals

Normal/Max. Temperature (C): 560 / 650

Insulation

Refractory Lining

Materials:
Shell / Heads:

CS A516 Cr 70

Internals

CS A516 Cr 70

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Figure 38: Stripper Arrangement


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3.3.2. 1st Stage Regenerator D-1502


The purpose of the 1st stage regenerator is to burn part of the coke by combustion
air from the air rings provided at the bottom of the vessel. Combustion air to the
first stage regenerator D-1502 is split between two air rings: The outer air ring and
inner air ring, which are designed to handle about 70% and 30% of the
combustion air to the first stage regenerator D-1502 respectively.
This regenerator operates in a counter current (air in at bottom and spent catalyst
in at top) mode which helps prevent catalyst overheating. The regeneration
conditions are mild to limit hydrothermal deactivation of the catalyst. First stage
regenerator total combustion air is controlled to limit the temperature in the first
stage to maximum 730C.
The first regenerator D-1502 is equipped with an air lift to transfer the catalyst from
the bottom of D-1502 to the 2nd regenerator D-1503. The flow of catalyst transfer
is regulated by means of the air lift plug valve PV-1501 (see special valves)
A set of 6 two-stage cyclones is provided at the top of the first stage regenerator to
separate entrained catalyst from the flue gas leaving D-1502. A double-disc flue
gas slide valve (SV-1503) is provided at the outlet of the 1st stage regenerator to
reduce the pressure of the flue gas upstream of the CO Combustor H-1503.
1st Stage Regenerator D-1502
Position

Vertical

Normal/MAX. Operating Temperature (C)

678 / 730

Normal/MAX. Operating Pressure (kg/cm2g)

2.28 / 2.68

Design Conditions:
Shell

350C and 5.2 kg/cm2g

Internals

Normal/Max. Temperature (C): 760 / 840

Insulation

Refractory Lining

Materials:
Shell / Heads:

CS A516 Cr 70

Internals

SS A240-304H

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Figure 39: 1st Stage Regenerator


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Figure 40: 1st Stage Regenerator Two-Stage Cyclones Arrangement

3.3.3. 2nd Stage Regenerator D-1503


In the 2nd stage regenerator, the partly regenerated catalyst from D-1502 is
completely regenerated to less than about 0.05% by means of combustion air and
at more severe conditions than in D-1502. The combustion air is provided at the
bottom head of the regenerator.
A set of 4 external refractory lined cyclones CY-1504 A-D are provided to remove
entrained catalyst from the 2nd stage flue gas. This design expands the operating
envelope for regenerator temperatures. The cyclone dip legs are external to the
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regenerator. Catalyst recovered in the cyclones is returned to the regenerator bed


below the normal operating level by way of the diplegs.
Aeration is supplied to the diplegs to provide for smooth fluidized catalyst flow and
the diplegs outlets are equipped with flapper (trickle) valves to prevent catalyst
and gas backflow into the cyclones.
At the flue gas outlet of the 2nd stage regenerator is provided a flue gas double
disc slide valve SV-1504 to control the pressure of the flue gas flowing to the
waste heat boiler H-1503.
2nd Stage Regenerator D-1503
Position

Vertical

Normal/MAX. Operating Temperature (C)

772 / 815

Normal/MAX. Operating Pressure (kg/cm2g)

1.30 / 1.70

Design Conditions:
Shell

350C and 5.2 kg/cm2g

Internals

Normal/Max. Temperature (C): 760 / 840

Insulation

Refractory Lining

Materials:
Shell / Heads:

CS A516 Cr 70

Internals

SS ASTM A240-304H

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Figure 41: 2nd Stage Regenerator


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Figure 42: 2nd Stage Regenerator Cyclones

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Figure 43: 2nd Stage Regenerator Cyclones Arrangement

3.3.4. Aeration and Fluidization Systems


The catalyst fluidization and aeration systems play a vital role in the stability of
catalyst circulation.
The standpipe aeration systems on the unit are designed to handle a wide range
of conditions and still provide the smooth, stable, catalyst flow required for proper
operation. This is essential for stable and adequate catalyst slide valve
differentials.
The system includes aeration points located along the vertical portions of the
standpipes with a rotor meter or flow orifice provided for each tap. The flows to the
taps are initially set equally to replace the volume of interstitial gas compressed by
head pressure.
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It is important to note the difference between aeration and fluidization systems:

Aeration is the process of replacing, with the injection of gas, the volume
lost to compression by head pressure in a column of fluidized catalyst.
Aeration medium is necessary to keep the catalyst from becoming non
fluidized and developing unstable flow characteristics. The taps on
standpipes are located such that there are twice the numbers required for
an adequate aeration. If one becomes plugged the neighboring tap will
continue to ensure stable operation.

Fluidization taps are employed when the direction of catalyst flow changes.
In the R2R unit, 45 angle changes are used to redirect catalyst flow
whenever possible. As the catalyst flows into a 45 line the fluidization
media is injected to assist in the turn. On the other hand, when catalyst
flows from a 45 line, the fluidization media is added to smooth the turn and
to penetrate the denser catalyst layer at the wall to allow easier entrance. A
smooth, stable flow of catalyst into vertical standpipes is very important.
Therefore, fluidization taps are either doublets or triplets

Two locations merit special notice:

The regenerated catalyst standpipe handles catalyst without any coke and
is at high temperatures. Catalyst at these conditions is inherently more
difficult to maintain fluidized.

The second location to note is the second stage cyclone dip leg aeration.
Instrument purges provide a large part of the required aeration. The
fluidization in the slanted portions of the diplegs is very important. The
penetration of the dense catalyst layer near the regenerator wall is
necessary to ensure smooth flow of fines returning to the regenerator.
Without proper aeration in the diplegs the cyclones may flood and catalyst
losses will increase.

3.3.5. Special Valves


Two types of valves are used in the R2R process: catalyst slide valves and plug
valve. Slide valves are carefully designed with abrasion resistant protection for
improving the valves reliability. Internal insulation allows to use carbon steel for
the body of the valves.
The valves are provided with appropriate purges, on the stem and body, to clear
catalyst particles from the valves. Internal inlet shapes are designed to provide
smooth operation.
The plug valve design includes a stuffing box, an insulation sleeve and an air
purge which provides efficient protection against catalyst blockage. Thrust limiter
and seat and plug angles have been optimized to overcome the thermal
expansion of the air lift.
All valves are provided with independent hydraulic oil system to ensure a reliable
and stable operation.

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Regenerated Catalyst Slide Valve SV-1501


Location

Bottom of withdrawal well

Fluid

FCC Catalyst

Purpose

To regulate the amount of hot regenerated catalyst flowing from the


withdrawal well to the reactor riser, thereby controlling the reactor
outlet temperature.

Direction of Flow

Vertical Down

Inlet Pressure (kg/cm2g) Normal: 2.66 / Max.: 3.06


Pressure Drop (kg/cm2g) 0.48
Fluid Temperature (C)

Normal: 712 / Max.: 815


Spent Catalyst Slide Valve SV-1502

Location

Bottom of spent catalyst stand pipe

Fluid

FCC Catalyst

Purpose

To control the level in the stripper D-1501 by regulating the flow of


spent catalyst flowing from the bottom of the stripper to the 1st stage
regenerator D-1502 via the spent catalyst stand-pipe.

Direction of Flow

Vertical Down

Inlet Pressure (kg/cm2g) Normal: 2.69 / Max.: 3.09


Pressure Drop (kg/cm2g) 0.41
Fluid Temperature (C)

Normal: 545 (650C for 6 hours during start-up) / Max.: 511


Flue Gas Double Disc Slide Valve SV-1503

Location

Flue Gas outlet of 1st regenerator

Fluid

1st Regenerator Flue Gas

Purpose

To reduce the pressure of the flue gas leaving the 1st stage
regenerator to the CO combustor H-1503, thereby controlling
the pressure in D-1502.

Direction of Flow

Vertical Down

Operating Temperature (C)

678 / 730

Inlet Pressure (kg/cm2g)

Normal: 2.13 / Max.: 2.53

Outlet Pressure (kg/cm2g)

0.085

Valve Pressure Drop (kg/cm2g)

1.28 / 1.57

Variable Orifice Pressure Drop 0.765 / 0.875


(kg/cm2g)
Total Pressure Drop (kg/cm2g)

2.045 / 2.445

Flowrate wet basis (kg/h)

Normal: 282,084 / Min.: 178,544


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Flue Gas Double Disc Slide Valve SV-1504


Location

Flue Gas outlet of 2nd regenerator

Fluid

2nd Regenerator Flue Gas

Purpose

To control the 2nd stage regenerator pressure (and


maintaining the adequate P across the 2 regenerators) by
regulating the flow of flue gas leaving D-1503 to the waste
heat boiler H-1503.

Direction of Flow

Vertical Down

Operating Temperature (C)

Normal: 772 / Max.: 840

Inlet Pressure (kg/cm2g)

Normal: 1.24 / Max.: 1.64

Outlet Pressure (kg/cm2g)

0.085

Valve Pressure Drop (kg/cm2g)

0.68 / 0.95

Variable Orifice Pressure Drop 0.475 / 0.605


(kg/cm2g)
Total Pressure Drop (kg/cm2g)

1.155 / 1.555

Flowrate wet basis (kg/h)

Normal: 138,674 / Min.: 86,941


Air Lift Plug Valve PV-1501

Location

Bottom head of the 1st regenerator

Fluid

Combustion air from blower

Purpose

To control the catalyst level in the first regenerator by allowing


the transfer of catalyst from the 1st regenerator to the 2nd
regenerator.

Regenerator Pressure at valve Normal: 2.56 / Max.: 2.92


(kg/cm2g)
Catalyst Flow (Ton/min)

Normal: 43.61

Pressure Drop (Catalyst Side) 0.35


(kg/cm2g)
Catalyst Temperature (C)

Normal: 646

Air temperature (C)

Normal: 216 / Max.: 238

Air Flowrate (kg/hr)

47,832

Inlet Air Pressure (kg/cm2)

2.46

COB/WHB 1st Regenerator Flue Gas Block Valve and Bypass Valve BV-1501 A/B
Fluid

Flue gas from the 1st regenerator

Service

This system of 2 valves is installed on the flue gas line


coming from the first regenerator. It allows to isolate the
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COB/WHB 1st Regenerator Flue Gas Block Valve and Bypass Valve BV-1501 A/B
COB/WHB and bypass the flue gas to the Electrostatic
Precipitator in case of trip
Operating conditions for Design Case (Mixed Crude Max Gasoline)
Operating Temperature (C)

Normal: 678 / Max.: 730

Inlet Pressure (kg/cm2g)

0.085

Outlet Pressure (kg/cm2g)

0.055

Valves Pressure Profile

Block Valve (A)

Block Valve (B)

Normal Situation (kg/cm2):

Nil

0.03

Trip Situation (kg/cm2g):

2.68

2.68

Flowrate wet basis (kg/hr)

282084

Catalyst Concentration in Flue 446.4


Gas (mg/Nm3)
COB/WHB 2nd Regenerator Flue Gas Block Valve and Bypass Valve BV-1502 A/B
Fluid

Flue gas from the 2nd regenerator

Service

This system of 2 valves is installed on the flue gas line


coming from the second regenerator. It allows to isolate the
COB/WHB and bypass the flue gas to the Electrostatic
Precipitator in case of trip

Operating conditions for Design Case (Mixed Crude Max Gasoline)


Operating Temperature (C)

Normal: 772 / Max.: 840

Inlet Pressure (kg/cm2g)

0.085

Outlet Pressure (kg/cm2g)

0.055

Valves Pressure Profile

Block Valve (A)

Block Valve (B)

Normal Situation (kg/cm2):

Nil

0.03

Trip Situation (kg/cm2g):

1.7

1.7

Flowrate wet basis (kg/hr)

138,674

Catalyst Concentration in Flue 665.5


Gas (mg/Nm3)

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3.3.6. Air Heaters


2 air heaters H-1501 and H-1502 are provided downstream of the air blower C1501. The purpose of H-1501 and H-1502 is to preheat the combustion air
supplied to the air rings of 1st regenerator and the 2nd regenerator respectively. In
order to burn the coke off the spent catalyst.
These heaters are also used during start-up of the plant to dry-out the
regenerators as well as to heat-up the catalyst.
H-1501
Heater Data
Type

Air Heater Horzontal

Type of Fuel Gas

Propane (LPG)

Air Allowable Pressure Drop (kg/cm2g)

0.05

Chamber External Diameter (mm)

2624

Chamber Length (mm)

6950

Internal Design Pressure (kg/cm2)

5.2

Internal Operating Pressure (kg/cm2g)

2.98

Design Temperature (C)

350

Operating Temperature (C)

BH MG

BH MG

MC MG

MC MD

Inlet

238

232

216

223

Outlet

651

636

683

646

Air Flowrate (kg/hr)

180946

166001

261266

214783

Burner Data
Number of Burners

Burner Type

Low NOx Forced Draft

Firing Position

Horizontal Fired

Connection to heater

Flanged

Design Burner Duty (MW)

46.57

Normal Burner Duty (MW)

44.36

MIN. Burner Duty (MW)

4.65

Excess Air at Design Capacity

20%

Max Flame Dimension (mm)

Length: 5500

Diameter: 1800

Pilot/Ignition Data
Type

Forced draft with compressed air

Pilot Liberation (kW)

30

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H-1501
Fuel Gas Pressure Required (kg/cm2g)

0.5

Compressed air pressure required (kg/cm2g)

Ignition Method

High tension, by electric spark rod

Emission Levels
NOx (mg/Nm3)

140

CO (mg/Nm3)

30

H-1502
Heater Data
Type

Air Heater Horzontal

Type of Fuel Gas

Propane (LPG)

Air Allowable Pressure Drop (kg/cm2g)

0.05

Chamber External Diameter (mm)

2000

Chamber Length (mm)

7800

Internal Design Pressure (kg/cm2)

5.2

Internal Operating Pressure (kg/cm2g)

2.03

Design Temperature (C)

350

Operating Temperature (C)

BH MG

BH MG

MC MG

MC MD

Inlet

232

238

216

223

Outlet

713

695

762

712

Air Flowrate (kg/hr)

38773

31685

79610

57261

Burner Data
Number of Burners

Burner Type

Low NOx Forced Draft

Firing Position

Horizontal Fired

Connection to heater

Flanged

Design Burner Duty (MW)

14.22

Normal Burner Duty (MW)

13.55

MIN. Burner Duty (MW)

1.42

Excess Air at Design Capacity

20%

Max Flame Dimension (mm)

Length: 3500

Diameter: 1200

Pilot/Ignition Data
Type

Forced draft with compressed air


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H-1502
Pilot Liberation (kW)

30

Fuel Gas Pressure Required (kg/cm2g)

0.5

Compressed air pressure required (kg/cm2g)

Ignition Method

High tension, by electric spark rod

Emission Levels
NOx (mg/Nm3)

140

CO (mg/Nm3)

30

3.3.7. CO Boiler / Waste Heat Boiler Package H-1503


The purpose of the CO Boiler is:

To completely convert as efficiently as possible the CO of the 1st


regenerator into CO2. This conversion will be accomplished by firing
auxiliary fuel gas in order to achieve the SOX emission specification.

To recover a maximum of heat from the resultant products of combustion,


for the following services:
o Preheating of the boiler feed water fed to the Economizer
o Steam Generation of the CO Boiler itself
o Superheating of the different steam production of the main
fractionator section as required.

In case of emergency, the CO boiler can be bypassed while the unit is still
operating at full capacity.
H-1503 consists of the following elements:
1) CO incinerator with forced draft fans, where the CO contained in the flue gas
fed from the 1st regenerator is converted into CO2
2) Waste Heat Boiler, where the flue gas from the CO incinerator is routed along
with the flue gas from the 2nd regenerator. The Waste Heat Boiler recovers the
heat of these flue gas streams to produce superheated HP and MP steam
through the following elements:
a. HP Superheater and HP de-superheater
b. MP Superheater and MP de-superheater
c. HP Generator
d. Economizer
e. Steam Drum D-1512
f. HP BFW Preheater E-1534

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The following elements are also provided in H-1503 package:

Phosphate dosing package A-1502 comprising of the Phosphate tank A1502-TK-01 and the Phosphate injection pumps A-1502-P-01 A/B

Continuous and intermittent blowdown drums D-1531 and D-1532


respectively.

Stack

Water Sprayers

Flue Gas Block valves:


o COB/WHB 1st regenerator flue gas block valve BV-1501 A
o COB/WHB 2nd regenerator flue gas block valve BV-1501 B

Flue Gas Bypass valves


o COB/WHB 1st regenerator flue gas bypass valve BV-1502 A
o COB/WHB 2nd regenerator flue gas bypass valve BV-1502 B

The auxiliary burners and forced draft fans provided with H-1503 are designed for
the production of 250 ton/hr of superheated steam under normal operation.
One is motor driven for normal operation. The second one, in standby, is HP-LP
back pressure turbine driven. Both blowers are equipped with auto-start device.
Part of the generated superheated HP steam from H-1503 is supplied to the
turbine driver of the forced draft fan.

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Design

DATE: 06/12/07

Normal

Start-up (Fres

CO Max

CO Min

Bach HO MG

Bach Ho MD

Mix Crude MG

Mix Crude MD

LPG/H2 rich fu
gas firing only

Flowrate 9kg/h)

310292

310292

194650

178544

383084

231506

Temperature (C)

730

730

641

631

678

646

Combustion Air (kg/h)

146,168

96674

224520

235302

140077

178120

315000 / 21116

Fuel / Normal Gas (kg/h)

703

1560

7621

8346

3788

5987

8072 / 3044

Heat Release (kW)

9260

20560

100100

109960

49900

78880

102300 / 70000

Total Flowrate (kg/h)

457163

408527

426790

439192

425948

415613

323073 / 21421

Temperature (C)

1183

100

1178

1173

1130

1197

1000 / 1000

Residence Time (sec.)

0.9

1.1

1.0

1.0

1.0

1.0

CO content (mg/Nm3)

<300

<300

<300

<300

<300

<300

NOx content (mg/Nm3)

<1000

<1000

<1000

<1000

<1000

<1000

152541

152541

94603

86941

138674

114689

772

772

733

720

772

734

609,704

561068

521393

526133

564622

530302

323073 / 21421

N2

72.49

71.59

72.26

72.44

72.00

71.95

75.70 / 73.45

CO2

13.36

14.17

11.38

10.76

13.48

12.63

5.00 / 1.33

1st Regeneration gas

CO Oxidizer (CO Boiler)

nd

Regeneration Gas

Flowrate (kg/h)
Temperature (C)
CO oxidizer + 2

nd

Regeneration Gas

Flowrate (kg/hr)
Composition (mol %)

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Design

DATE: 06/12/07

Normal

Start-up (Fres

CO Max

CO Min

Bach HO MG

Bach Ho MD

Mix Crude MG

Mix Crude MD

LPG/H2 rich fu
gas firing only

SOx

0.07

0.06

0.01

0.01

0.05

0.05

0.00 / 0.00

H2O

12.29

12.39

12.66

12.66

12.69

13.16

7.09 / 12.82

O2
CO

1.78

1.78

4.13

4.13

1.77

2.21

12.21 / 12.40

<300

<300

<300

<300

<300

<300

<1000

<1000

<1000

<1000

<1000

<1000

WHB Inlet

1080

938

1097

1098

1042

1097

1000 / 1000

WHB Outlet

326

309

318

314

318

313

297 / 280

Economizer Outlet

242

235

237

236

238

237

227 / 214

1st Regenerator gas inlet

1075 min

910 min

733 min

728 min

898 min

774 min

2nd Regenerator gas inlet

966 min

808 min

700 min

697 min

823 min

726 min

WHB inlet

923

767

680

679

787

701

220 / 98

WHB Outlet

728

616

534

528

624

551

172 / 76

Economizer Outlet

291

246

213

209

249

220

68 / 30

Economizer (kg/hr)

238600

183553

211153

211153

211153

211153

115696 / 76868

Generator (Total)

6949530

5346210

6150000

6150000

6150000

6150000

2528741 / 1691

Steam @ Generator Out

231651

178207

205000

205000

205000

205000

112327 / 74629

Import HP steam

61019

18092

10285

18092

61019

57527

-/-

NOx
Flue Gas Temperature (C)

Flue Gas Pressure (mm H2O g)

BFW & Steam Flowrate

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Normal

Start-up (Fres

CO Max

CO Min

Bach HO MG

Bach Ho MD

Mix Crude MG

Mix Crude MD

LPG/H2 rich fu
gas firing only

Total HP steam

292670

196299

215285

223092

266019

262527

112327 / 74629

Import MP Steam

14788

27666

8631

27666

14788

37331

-/-

Blowdown

6949

5346

6153

6153

6153

6153

3370 / 2239

Economizer Inlet

165

165

165

165

165

165

165 / 165

Economizer Outlet

219

222

216

214

219

214

214 / 212

Generator Inlet

257.7

257.7

257.7

257.7

257.7

257.7

257.7 / 257.7

HP steam Outlet

422

435

459

453

416

424

483 / 497

HP steam after desuperheater

380

380

380

380

380

380

380 / 380

MP steam Outlet

311

274

315

276

303

264

MP steam after desuperheater

250

250

250

250

250

250

BFW Preheater Inlet

50

50

50

50

50

50

50

HP steam after desuperheater

42.3

42.3

42.3

42.3

42.3

42.3

42.3

MP steam after desuperheater

14.1

14.1

14.1

14.1

14.1

14.1

BFW & Steam/Temperature (C)

BFW & Steam Pressure (kg/cm2g)

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Heating Tube Design

HP superheater

MP superheater

HP generator

HP Economizer

Material (ASTM)

SA335 GrP9

SA106 GrB

SA 106 GrB

SA 106 GrB

PWHT

Yes

No

No

No

Tube type

Bare

Bare

Bare

Bare

Outside diameter (mm)

60.3

60.3

60.3

60.3

Thickness (mm)

6.35 Avg wall

5.54 Avg wall

5.54 Avg wall

5.54 Avg wall

Orientation

Vertical

vertical

Vertical

Horizontal

Layout

Staggered

Staggered

Staggered

Staggered

Flow pass No.

88

30

Screen: 192 / Main: 1536

34

Effective Length (m)

13.99

13.99

13.99

10.55

Number of tubes per row

22

30

Screen: 24 / Main: 32

34

Number of Row

16

Screen: 8 / Main: 48

26

Heating area (m2)

933

318

Screen: 509 / Main: 4072

1769

Guide/Support Space (m)

2.4

2.3

2.4

2.3

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Steam Drum D-1512


Design Pressure (kg/cm2g)

49.92

Design Temperature (C)

283

Material
Shell / heads (ASTM)

516 Gr.70

I.D. (mm)

2000

TL to TL Length (mm)

17500

Holding Time

5 minutes (NLL to Empty)

PSV

2
Burner

Number

Heat Release per Burner (kW)

23700

Turn Down / Gas

5:1

Turn Down / Oil

3:1

Gas Pressure (kg/cm2)

2.0 at burner

Oil Pressure (kg/cm2g)

10.3 at burner

Steam Pressure 9kg/cm2g)

11.3 at burner

Steam Consumption

265 kg/hr per burner for peak firing


Fan

Number

2 (one operation + one standby)

Design/Normal Air Flow (kg/h)

315000 / 262500

Design/Normal Outlet Pressure (kg/cm2g)

1030/715

Operation range

120% to 30% (by volume)

Speed (RPM)

1485

BHP (kW)

683

Motor Rated (kW)

1230

Turbine (Rated / Normal) (kW)

1165 / 1059

Steam Consumption at rated (kg/h)

34300

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Soot Blower
Type

Retractable

Number

52 Total

Min Clearance to Tube (mm)

550 MIN.

Max Row of Tube

Steam Consumption (kg/hr each)

4536

Motor (kW/each)

0.75

3.3.8. Electrostatic Precipitator X-1507


The Electrostatic Precipitator is provided to decrease catalyst dust from the flue
gas from the Regenerator via COB/WHB package, to meet the environmental
specification. The dust fine content at precipitator outlet shall not exceed 50
mg/Nm3 dry basis. The principle of operation is to provide high voltage electric for
collection of dust by corona effect.
The electrostatic precipitator comprises of 2 electrostatic precipitators (ESP), ESP
1 and ESP 2, in parallel and ash handling facilities. The flue gas inlet and outlet of
each ESP is provided with an expansion joint and a motorized inlet damper.
Dust laden flue gas from the waste heat boiler H-1503 is directed through the
energized fields of the precipitator in which the discharge and collector electrodes
are situated. A dedicated transformer rectifier se applies a variable, negative
potential, high DC voltage to each field of the discharge electrodes. The collecting
electrodes within each field are supported directly from the casing steelwork and
are therefore at positive or earth potential.
Each ESP of the package X-1507 comprises of 2 systems of discharge and
collecting electrodes: first are the inlet discharge and collector electrodes, and
downstream of them are the outlet discharge and collector electrodes. Each
system is provided with its own dedicated transformer.
Commencing from the minimum setting, the voltage is steadily increased until a
current begins to flow from the discharge electrodes to the collecting electrodes.
This is called corona discharge. Increasing the voltage further causes this
current to rise until a maximum point is reached at which sparking or flashover
occurs between the electrodes. The gas flowing between the electrodes becomes
ionized by the corona current and the dust particles become negatively charged.
The electrostatic field causes the charged particles to migrate to the earthed
collector sheets where they adhere and give up their negative charge.
The optimum electrical precipitator conditions are at the point where the voltage is
just below that at which sparking takes place. A low rate of sparking is desirable
and this is used as a basis for the design of the automatic voltage controller (AVC)
that optimizes the output from each transformer rectifier set. The optimum voltage
varies considerably with changing gas and dust conditions but the ESP will
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typically operate at 55 kV on clean ambient air and at between 50 kV and 65 kV


on dust laden flue gases at normal operating temperatures.
As dust cannot accumulate indefinitely on the discharge and collecting electrode
systems without a loss of precipitator performance, they must be rapped on a
regular basis.
Each electrode (discharge and collector) within each ESP has its own individually
sequenced rapping equipment comprising of a geared drive motor, chain driven
cam shaft and a series of hammers arranged to operate singularly in sequence
across the width of the precipitator.
The dust released when the discharge and collecting electrodes are sequentially
rapped falls into the hoppers below each respective field where the ash is
collected and subsequently removed by an ash conveying system. Each ESP is
provided with 4 hoppers, 2 for the inlet field and 2 for the outlet field.
The dust is conveyed by means of air preheated in the steam air preheater X1507-E-01. The conveying air flows trough the bottom of each of the 8 hoppers in
series. The dust collected is then sent to the bag filter X-1507-F-01 operated
under a vacuum and provided with steam coil. Heated air is also provided from a
steam air heater X-1507-E-02 to help remove any moisture from the dust. The
heated air is sucked by the ash vacuum pumps X-1507-P-01 A/B to the air water
separators X-1507-S-01 A/B where the separated water is finally sent to the oily
water sewer.
The dried dust retained by the bag filter then falls into the transfer hopper X-507TK-02 where it undergoes another stage of drying by means of heated air from X1507-E-02 and the a steam coil. The ashes finally falls into the Ash Storage Silo
X-1507-TK-01, where ash is stored under warm and fluidized conditions by means
of a steam coil and heated air introduced at the bottom of the silo. The ash storage
silo X-1507-TK-01 is provided with a vent filter X-1507-F-02 and an exhaust fan X1507 to vent the air out of the silo.
Ash is finally removed from the bottom of the silo and is discharged into flexible
bags.
There is a tendency for a small proportion of the liberated dust to be re-entrained
into the gas flow during rapping and this is minimized by maintaining a low gas
velocity within the treatment fields. Additional design features such as the use of
vertical channel profiles on the collector electrodes, adjustable rapping intensity
and reduced rapping frequency in the outlet fields also assist the overall efficiency
of the precipitator.
X-1507
Design Volume (Am/s)

301.18

Operating Gas Temperature (C)

326

Gas Pressure in inlet duct (kg/cm2g)

0.055

Inlet dust load (mg/Nm ) (dry)

Normal: 370

Upset: 1700 mg/Nm3

Outlet Dust Emission (mg/Nm3) (dry)

Normal 50

Upset: 180 mg/Nm3


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X-1507
One ESP: 200
Gas Moisture Content (% v/v wet)

12.30

ESP Pressure Drop (Flange to Flange) (kg/cm2g)

0.020

Casing design pressure (kg/cm2g)

0.200

3.3.9. Main Fractionator


The purpose of the main fractionator T-1501 is to separate the different products
contained in the effluents leaving the disengager/stripper D-1501 in the reaction
section. The Main fractionator can be divided into 5 zones (from bottom to top):

Slurry & Quench zone (bottoms)

Heavy Cycle Oil (HCO)

Light Cycle Oil (LCO)

Heavy Naphta (HVN)

Overheads (OVHD)
Main Fractionator

Height (TL to TL) (mm):

64100

Internal Diameter (mm):

Top to bed #5: 7400

Internals:

5 beds + 30 trays

Bed Height (mm)

2000

Bottom: 3700

Packing Type / Material:


Bed #1

Structured / 11/13 Cr

Bed #2

Structured / 11/13 Cr

Bed #3

Structured / SS TP 304

Bed #4

Structured / SS TP 304

Bed #5

Grid / SS TP 304

Trays

11/13 Cr

Loading Point:

Below bed #5
Bach Ho MG

Bach Ho MD

Mixed MG

Mixed MD

Bottoms temperature (C)

340

340

340

340

Top Temperature (C)

102

96

103

100

Bottoms Pressure (kg/cm2g)

1.15

1.15

1.15

1.15

Top Pressure (kg/cm2g)

0.85

0.85

0.85

0.85

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Main Fractionator T-1501


Section

Operating
Temp. (C)

Design
Temp. (C)

Insulation
Thickness (mm)

Material

Bottom section, up to HCO


PA return (top of Bed #3)

520

545

210

1 CR 0.5 Mo

Top of Bed #3 up to LCO PA


return (top of Bed #2)

315

340

100

Carbon Steel

Top of Bed #2 up to HVN PA


return (top of Bed 1)

215

250

60

Carbon Steel

Top Section

150

200

30

HIC Resistant
Carbon

Figure 44: Main Fractionator


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3.3.10. Stripper T-1552 & Primary Absorber T-1551


In the primary absorber T-1551, most of the propane, propylene, butane and
butylene are recovered from the gas stream fed from the high pressure separator
drum D-1553. The overhead liquid from the bottom of the fractionation section is
fed to the top tray of T-1551. For other than Bach Ho MG, gasoline is also recycle
from the bottom of the bottom of the debutanizer in order to obtain the required
recovery of C3 and C4.
The purpose of the stripper T-1551 is to strip H2S, C2 and lighter from the LPG
and gasoline mixture which is fed to the top tray from the HP separator D-1553.
The heat required for stripping is provided by 2 reboilers in series, working on
debutanizer bottoms (1st one) and LCO pumparound (2nd one).
The primary absorber and the stripper are physically located in the same vessel,
with T-1551 on top of T-1552.
Primary Absorber T-1551
Height (TL to TL) (mm)

23700

Internal Diameter (mm)

2400

Number of trays / Type

31 / valve

Material

Shell / Internals: Wet H2S resistant CS


Trays: 11/13 Cr

Parameter

Bach Ho MG

Bach Ho MD

Mixed MG

Mixed MD

FG Product Flow (kg/hr)

13817

12519

18619

14509

Liquid Flow Out (kg/hr)

160094

127834

159206

126788

Top pressure (kg/cm2g)

14.8

14.8

14.8

14.8

Bottom Pressure (kg/cm2g)

15.1

15.1

15.1

15.1

Top Temperature (C)

49

48

51

50

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Figure 45: Primary Absorber T-1551


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Stripper T-1552
Height (TL to TL) (mm)

32360

Internal Diameter (mm)

Tray #1 to Tray#30: 3700


Bottoms: 5000

Number of trays / type

30 / valve

Material

Shell / Internals: Wet H2S resistant CS


Trays: 11/13 Cr

Parameter

Bach Ho MG

Bach Ho MD

Mixed MG

Mixed MD

Flow IN (kg/hr)

297311

243294

295531

244437

Product Flow (kg/hr)

267774

220591

264456

220318

Ovhd Gas Flow (kg/hr)

29537

22703

31075

24119

Top pressure (kg/cm2g)

15.7

15.7

15.7

15.7

Bottom Pressure (kg/cm2g)

16.0

16.0

16.0

16.0

Top Temperature (C)

59

60

59

20

Bottom Temperature (C)

122

126

120

122

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Figure 46: Stripper T-1552


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3.3.11. Debutanizer T-1554


The purpose of the debutanizer is to separate LPG from the gasoline in the liquid
stream fed from the stripper bottoms.
The heat required for the separation is provided by the reboilers E-1560 A/B using
HCO pumparound as heating medium.
Debutanizer T-1554
Height (TL to TL) (mm)

34550

Internal Diameter (mm)

Tray #1 to #21: 3300


Tray #22 to #40: 4000

Number of trays / type

40 / Valve

Material

Shell / Internals: Killed Carbon Steel


Trays: 11/13 Cr

Parameter

Bach Ho MG

Bach Ho MD

Mixed MG

Mixed MD

Stripper Bottoms Flow IN (kg/hr)

267774

220591

264456

220318

Reflux Flow IN (kg/hr)

113168

106325

107154

100630

Gasoline Flow (kg/hr)

190498

163547

187358

159741

Top pressure (kg/cm2g)

11.7

11.7

11.7

11.7

Bottom Pressure (kg/cm2g)

12.1

12.1

12.1

12.1

Top Temperature (C)

68

68

68

68

Bottom Temperature (C)

178

171

180

172

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Figure 47: Debutanizer T-1554


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3.3.12. LPG Amine Absorber


The purpose of the LPG absorber is to remove H2S in the LPG stream from the
debutanizer by contacting the LPG with lean amine (DEA) from the ARU. LPG and
amine are flows in counter-current flow in this packed tower.
LPG Absorber T-1556
Height (TL to TL) (mm)

14100

Internal Diameter (mm)

2700

Number of Packing Beds / Type

2 / PALL RINGS

Packing Beds Height (mm)

3500

Material

Shell: Wet H2S resistant Killed Carbon Steel


Internals: Stainless Steel 304L
Packing: Stainless Steel 304L

Parameter

Bach Ho MG

Bach Ho MD

Mixed MG

Mixed MD

LPG Flow IN (kg/hr)

77276

57044

77098

60577

DEA Flow IN (kg/hr)

31606

23331

31533

24776

DEA Flow OUT (kg/hr)

31631

23352

32055

25269

LPG Product Flow (kg/hr)

77251

57023

76576

60084

Top pressure (kg/cm2g)

17.9

17.9

17.9

17.9

Bottom Pressure (kg/cm2g)

19.7

19.7

19.7

19.7

Temperature (C)

50

50

50

50

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Figure 48: LPG Absorber T-1556


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3.3.13. Secondary Absorber T-1553


The purpose of the secondary absorber is to recover light fractions from the
overhead gas fed from the primary absorber T-1551 by using heavy naphta from
the fractionation section as lean oil. Lean oil and overhead gas flow counter in this
tower.
Secondary Absorber T-1553
Height (TL to TL) (mm)

17950

Internal Diameter (mm)

1400

Number of Tray / Type

20 / Valve

Material

Shell / Internals: Wet H2S resistant Carbon Steel


Trays: 11/13 Cr

Parameter

Bach Ho MG

Bach Ho MD

Mixed MG

Mixed MD

Primary Absorber OVHD (kg/hr)

13817

12519

18619

14509

Lean Sponge Oil (kg/hr)

34993

34990

34996

34990

Top pressure (kg/cm2g)

14.4

14.4

14.4

14.4

Bottom Pressure (kg/cm2g)

14.7

14.7

14.7

14.7

Top Temperature (C)

47

45

58

59

Bottom Temperature (C)

50

47

60

59

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Figure 49: Secondary Absorber T-1553


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3.3.14. Fuel Gas Absorber T-1555


The purpose of the fuel gas absorber is to remove H2S and CO2 from the gas fed
from the secondary absorber by contact with lean amine (DEA) in counter current
flow.
The fuel gas absorber is provided with FG absorber feed KO drum D-1557 and FG
absorber outlet KO drum D-1559 to remove any entrained/condensed liquid in the
gas.
The above 3 vessels are physically located in one unique vessel with T-1555 in
between D-1557 (below T-1555) and D-1559 (above T-1555).
Fuel Gas Absorber T-1555
Height (TL to TL) (mm)

18100

Internal Diameter (mm)

1300

Number of Tray / Type

20 / Valve

Material

Shell / Internals: Wet H2S resistant Carbon Steel


Trays: Stainless Steel 304L

Parameter

Bach Ho MG

Bach Ho MD

Mixed MG

Mixed MD

Treated Fuel Gas OUT (kg/hr)

9812

8661

13231

9720

Lean Amine IN (kg/hr)

18776

18127

44919

40654

Rich Amine OUT (kg/hr)

19225

18630

46090

41743

Top pressure (kg/cm2g)

13.7

13.7

13.7

13.7

Bottom Pressure (kg/cm2g)

13.9

13.9

13.9

13.9

Top Temperature (C)

56

56

55

55

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Figure 50: Fuel Gas Absorber T-1555


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3.3.15. Slurry Separator


The Slurry Separator is provided to decrease catalyst fine in the Fractionator
Bottom and produce Clarified Oil for fuel oil production (backflush oil recycled to
the riser). The design capacity is 30.7 ton/hr of slurry oil. The catalyst fine in the
slurry oil is maximum 4,300 PPM at peak, and outlet catalyst fine maximum is
targeting to 100 PPM.
The Slurry Separator package consist 10 module filters with automatic backwashing facilities by flushing oil.
Bach Ho MD

Parameter

Mixed Crude MG

Slurry

HCO
Backflush

Slurry

HCO
Backflush

Normal Flowrate (kg/hr)

27930

3000

30674

3000

Design Flowrate (% normal)

120

120

Operating Temperature (C)

170

170
(controllable)

170

170
(controllable)

Operating Pressure (kg/cm2g)

12.9

4.5

12.9

4.5

Pressure Drop (kg/cm2g)

2.0

3.0

2.0

3.0

Sulphur Content (wt%)

0.1

1.03

Catalyst Fines Content (wt.ppm)


Inlet (average)

1100-1700

Inlet (Peak)

4300

Outlet (Peak)

100

LCO For Cleaning


Operating Temperature (C)

150

Design Temperature (C)

220

Operating Pressure (kg/cm2g)

6.0

Design Pressure (kg/cm2g)

17.0

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Figure 51: General Arrangement of X-1504

3.3.16. Air Blower, C-1501


The air Blower C-1501 is a centrifugal compressor to supply the necessary
amount of air to burn all the coke off the catalyst and some of the resulting CO to
CO2. Depending upon the mode of operation and other factors such as feed
quality, the required air amounts to the regenerator is supplied from this Air
Blower. The design capacity is 340,483 NM3/h, and 25 MW shaft power. The
machine type is axial compressors with steam condensing turbine driven. The
capacity of air flow rate is mainly controlled by speed of turbine.
C-1501 is provided with an antisurge system.
The manufacturer of the compressor is MAN TURBO AG, model: AG090.

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The major operating conditions are as follows:


Parameter

Design

Mix MG

Mix MD

Bach Ho MG

Bach Ho MD

Flowrate (Nm3/h)

340,432

309,483

254,808

213,247

195,748

Suction Pressure
(kg/cm2g)

1.008

1.008

1.008

1.008

1.008

Suction Temp. (C)

36

36

36

36

36

Discharge Pressure
(kg/cm2g)

4.66

4.26

4.26

4.26

4.26

Discharge Temp.
(C)

227

210

223

232

238

The following are design data for the turbine of C-1501:


Parameter

Value

First Critical Speed of C-1501 (RPM)

2179

First Critical Speed of Turbine (RPM)

2324

Normal Speed (RPM)

4400

Rated Speed (RPM)

4,661 (100%)

Min. Continuous Speed (RPM)

3,263 (70%)

Max. Continuous Speed (RPM)

4,894 (105%)

Trip Speed (RPM)

5,383 (115%)

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Figure 52: Combustion Air Blower


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3.3.17. Wet Gas Compressor C-1551


The Wet Gas Compressor is a multi-stage centrifugal compressor to boost-up the
main fractionator overhead gas pressure from atmospheric level to 14-15 kg/cm2g
for Gas Recovery Section. The machine consists two stages compressor, with
external cooling (interstage cooler E-1551 and trim cooler E-1552). The Wet Gas
Compressor is driven by condensing steam turbine. The driver capacity is 8,100
kW. The capacity is mainly controlled by turbine speed, and the wet gas
compressor is provided with an anti-surge control system.
The manufacturer of the wet gas compressor is Elliott/Ebara, Model: 56M81.
The major operating conditions are as follows:
Bach Ho MG

Parameter

Mixed Crude MG

Normal

Design

Normal

Design

Flowrate (Nm3/h)

65326

75127

67578

77715

Wet Flow (kg/hr)

138964

159809

139263

160152

MW

47.68

47.68

46.19

46.19

Suction Pressure (kg/cm2A)

1.33

1.33

1.33

1.33

Suction Temperature (C)

1st Stage

41.9

41.9

41.9

41.9

Discharge Pressure (kg/cm g)

5.13

5.09

5.2

5.19

Discharge Temperature (C)

96.5

97

98.7

99.5

Flowrate (Nm3/h)

43794

50363

48195

55424

Wet Flow (kg/hr)

80749

92861

86739

99750

MW

41.33

41.33

40.34

40.34

Suction Pressure (kg/cm2A)

4.43

4.39

4.5

4.49

Suction Temperature (C)

41.9

41.9

41.9

41.9

Discharge Pressure (kg/cm2g)

17.1

17.1

17.1

17.1

Discharge Temperature (C)

111.3

112

112

112.6

2nd Stage

The following are design data of the turbine of C-1551:


Parameter

Value

Normal Speed (RPM)

5,134

Rated Speed (RPM)

5,458

Max. Continuous Speed (RPM)

5,731
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Parameter

Value

Trip Speed (RPM)

6,304

st

DATE: 06/12/07

1 Critical Speed (RPM)

2,600-2,700

2nd Critical Speed (RPM)

11,000

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Figure 53: Wet Gas Compressor


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UNIT: 15

Course Content:
Section 1 - General Description
Section 2 - Process Flow Description
Section 3 - Process Control
Section 4 - Safeguarding Devices

Section 5 - Fire & Gas Systems


Section 6 - Quality Control
Section 7 - Cause & Effects
Section 8 - Operating Procedures
Section 9 - HSE
Section 10 - Reference Document Index

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SECTION 4 : SAFEGUARDING DEVICES


4.1. Alarms and Trips
Refer to attached list:
Unit 015 Alarms & Trips List.xls
4.2. Safeguarding Description
The Emergency Shutdown System (ESD) provides trips and interlocks for preventing or
controlling emergency situations which could give rise to hazardous situations leading to
injuries to personnel, significant economic loss and/or undue environmental pollution.
Uncontrolled loss of containment is prevented by the provision of pressure safety relief
valves and by the ESD system which automatically bring the relevant part of the Unit to a
safe condition.
Trip/interlock is composed of one or more initiators and one or more actions for
preventing hazards. Each trip/interlock shall be provided with a reset and an operational
override for start-up, where necessary.
In general, if interlock is invoked, the interlock action shall be held on until all initiators
have returned to the safe state and the interlock reset has been pressed.
The following is a description of all the safety logics provided in the RFCC unit. For each
logic, the first table describes the initiators of the logic. The second table indicate each
action taken and what are the initiators triggering each action.

4.2.1. Logic UX-001 Reaction Stop


Initiators:
No.

Initiator Tag No.

P&ID

Description

UXHS-001A

121

Hardwire ESD switch active

UXHS-001B

121

Hardwire ESD switch active (ESD Bypass switch)

FXALL-405

121

Feed Flow Low Low (time delay of 10 seconds)

UX-002

121

Logic UX-002 activated: Catalyst Circulation Stopped

XHSC-002A

121

Software switch active (DCS operation is not allowed when


UX-001 is activated)

XHSO-002A

121

Software switch active (DCS operation is not allowed when


UX-001 is activated)

XHSC-003A

122

Software switch active (DCS operation is not allowed when


UX-001 is activated)

XHSC-003A

122

Software switch active (DCS operation is not allowed when


UX-001 is activated)

XHSC-004A

122

Software switch active (DCS operation is not allowed when


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No.

Initiator Tag No.

P&ID

Description
UX-001 is activated)

10

XHSC-004A

122

Software switch active (DCS operation is not allowed when


UX-001 is activated)

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

1a

XSY-002

1, 2, 3, 4, 5

121

CLOSE XV-002 to stop the .flow of feed to


the feed injectors I-1501 A to F

1b

XSY-002

121

OPEN XV-002 to allow feed to flow to the


feed injectors !-501 A to F

FSY-001

1, 2, 3, 4

121

OPEN FV-001 to re-route feed to the feed


surge drum

3a

XSY-003

1, 2, 3, 4, 7

122

CLOSE XV-003 to stop the flow of MTC to


the MTC injectors I-1502 A to D

3b

XSY-003

122

OPEN XV-003 to allow the MTC to flow to


the MTC injectors I-1502 A to D

4a

XSY-004

1, 2, 3, 4, 9

122

CLOSE XV-004 to stop the flow of


backflush oil to the backflush oil injector I1504

4b

XSY-004

10

122

OPEN XV-004 to the backflush oil to flow to


the backflush oil injector I-1504

MXS-001

1, 2, 3, 4

121

Trip the metal passivator injection pumps P1502A

MXS-002

1, 2, 3, 4

121

Trip the metal passivator injection pumps P1502B

MXS-439

1, 2, 3, 4

305

Trip the MTC recycle pump P-1512A

MXS-440

1, 2, 3, 4

305

Trip the MTC recycle pump P-1512B

MXS-481

1, 2, 3, 4

306

Trip the HCO recycle pump P-1507A


(Tripped by UX-423)

10

MXS-482

1, 2, 3, 4

306

Trip the HCO recycle pump P-1507A


(Tripped by UX-423)

11

MXS-464

1, 2, 3, 4

324

Trip the backflush oil recycle pump P-1506A


(Tripped by UX-424)

12

MXS-465

1, 2, 3, 4

324

Trip the backflush oil recycle pump P-1506B


(Tripped by UX-424)

13

FSY-005A

1, 2, 3, 4

121

OPEN FV-005A to allow MP steam to flow


to the feed injector I-1501 A

14

FSY-005B

1, 2, 3, 4

121

OPEN FV-005B to allow MP steam to flow


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Action Tag No.

Initiated by
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REV: A

DATE: 06/12/07

Description
to the feed injector I-1501 B

15

FSY-005C

1, 2, 3, 4

121

OPEN FV-005C to allow MP steam to flow


to the feed injector I-1501 C

16

FSY-005D

1, 2, 3, 4

121

OPEN FV-005C to allow MP steam to flow


to the feed injector I-1501 C

17

FSY-005E

1, 2, 3, 4

121

OPEN FV-005E to allow MP steam to flow


to the feed injector I-1501 E

18

FSY-005F

1, 2, 3, 4

121

OPEN FV-005F to allow MP steam to flow


to the feed injector I-1501 F

19

FSY-007A

1, 2, 3, 4

122

OPEN FV-007A to allow MP steam to flow


to the Stabilization injector I-1503 A

20

FSY-007B

1, 2, 3, 4

122

OPEN FV-007B to allow MP steam to flow


to the Stabilization injector I-1503 B

21

FSY-007C

1, 2, 3, 4

122

OPEN FV-007C to allow MP steam to flow


to the Stabilization injector I-1503 C

22

FSY-007D

1, 2, 3, 4

122

OPEN FV-007D to allow MP steam to flow


to the Stabilization injector I-1503 D

23

UXA-001B

1, 2, 3, 4

121

Activate the reaction stop alarm (ADP)

24

FIC-001

1, 2, 3, 4

121

FIC-001 is forced to manual mode and


output 100% to OPEN FV-001

25

FIC-003
A/B/C/D/E/F

1, 2, 3, 4

111

FIC-003 A/B/C/D/E/F is forced to manual


mode and output 0% to CLOSE FV-003
A/B/C/D/E/F respectively

26

FIC-005
A/B/C/D/E/F

1, 2, 3, 4

111

FIC-005 A/B/C/D/E/F is forced to manual


mode and output 100% to OPEN FV-005
A/B/C/D/E/F respectively

27

FIC-007 A/B/C/D

1, 2, 3 ,4

111

FIC-007 A/B/C/D is forced to manual mode


and output 100% to OPEN FV-007 A/B/C/D

28

FIC-010 A/B/C/D

1, 2, 3 ,4

111

FIC-010 A/B/C/D is forced to manual mode


and output 100% to OPEN FV-010 A/B/C/D

29

FIC-012

1, 2, 3, 4

122

FIC-012 is forced to manual mode and


output 0% to CLOSE FV-012

Reset:

DCS software switch UHSR-001 (PID No.121) resets all above actions.

XV-002, XV-003 and XV-004 need to be reset locally by XHSR-002, XHSR003 and XHSR-004 respectively.

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4.2.2. Logic UX-002: Catalyst Circulation Stops


Initiators:
No.

Initiator Tag No.

P&ID

Description

UXHS-002A

125

Hardwire ESD switch active

UXHS-002B

125

Hardwire ESD switch active (bypass switch)

PDXLL-064

124

D-1501 Stripper Differential Pressure low low (2 out of2


voting system)

PDXLL-104

125

Spent Catalyst Slide Valve SV-1502 differential pressure


low low (2 out of 2 voting system)

LXALL-010

131

Withdrawal well level low low (10 seconds average is used


as input)

PDXLL-242

131

Hot regenerated catalyst slide valve SV-1501 differential


pressure low low (10 seconds average is used as input)

FXALL-170

132

Low low air flow to first regenerator heater (10 seconds offdelay timer)

FXALL-171

132

Low low air flow to the 2nd regenerator heater H-1502

FXALL-172

132

Low low air flow to the 1st regenerator D-1502

10

PXALL-363

138

Low low pressure of MP steam supply

11

UX-005

132

MAB Protection active

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

USY-1502

ALL

125

CLOSE the spent catalyst slide valve SV1502, and generate a discrepancy alarm

USY-017

ALL

131

CLOSE the regenerated catalyst slide valve


SV-1501, and generate a discrepancy alarm

USY-016

ALL

127

CLOSE the Air lift plug valve PV-1501 of the


first regenerator

UX-001

ALL

121

Activate the Logic UX-001: Reaction Stop

UX-008

ALL

201

Activate the logic UX-008: COB/WHB 1st


regenerator flue gas bypass operation

UX-010

ALL

202

Activate the logic UX-010: COB/WHB 2nd


regenerator flue gas bypass operation

UXA-002B

ALL

125

Activate catalyst circulation stop alarm


(ADP)

LIC-002

ALL

124

LIC-002 switch to manual mode and output


0% to CLOSE SV-1502

LIC-003

ALL

124

LIC-003 switch to manual mode and output


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Action Tag No.

Initiated by
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P&ID

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REV: A

DATE: 06/12/07

Description
0% to CLOSE SV-1502

10

LIC-004

ALL

126

LIC-004 switch to manual mode and output


0% to CLOSE PV-1501

11

LIC-007

ALL

129

LIC-007 switch to manual mode and output


0% to CLOSE PV-1501

12

PDIC-103

ALL

125

PDIC-103 switch to manual mode and


output 0% to CLOSE SV-1502

13

TIC-015

ALL

123

TIC-015 switch to manual mode and output


0% to CLOSE SV-1501

14

TIC-020

ALL

123

TIC-020 switch to manual mode and output


0% to CLOSE SV-1501

Reset:
DCS software reset switch UHSR-002 resets actions 1 to 6.

4.2.3. Logic UX-003: First Regenerator Air Heater Trip


Initiators:
No.

Initiator Tag No.

P&ID

Description

UXHS-003A

133

Hardwire ESD switch active

TXAHH-069

133

High high temperature in the first regenerator heater H1501

PXALL-321

134

Low low pressure of fuel gas supply from the fuel gas
header

FXALL-170

132

Low low combustion air flow to first regenerator heater H1501

BXALL-003

133

No pilot flame in H-1501

BXALL-004

133

No main flame in H-1501

XS-801

132

Main Air Blower Trip (logic UX-801 activated)

UXHS-003B

133

Local panel ESD hardwire switch active

UXHS-003C

133

Local panel ESD hardwire switch active

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-016

ALL

133

CLOSE XV-016 to stop the fuel gas supply


to the 1st regenerator heater H-1501
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No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-017

ALL

133

CLOSE XV-017 to stop the fuel gas supply


to the 1st regenerator heater H-1501

XSY-019

ALL

133

OPEN XV-019 to vent the fuel gas to flare

UXA-003B

1 to 8

133

Activate the first regenerator heater H-1501


trip alarm (ADP)

TIC-068

ALL

133

TIC-068 switch to manual mode and output


0% to CLOSE TV-068

Once all the initiators are healthy, the logic UX-003 can be reset by:

DCS software switch UHSR-003 resets actions 1, 2 and 3.

The valves XV-016, XV-017 and XV-019 need to be reset locally by means
of the local hardwire switch XHSR-016, XHSR-017, XHSR-019

4.2.4. Logic UX-004: Second Regenerator Air Heater Trip


Initiators:
No.

Initiator Tag No.

P&ID

Description

UXHS-004A

134

Hardwire ESD switch active

TXAHH-072

134

High high temperature in the second regenerator heater H1502

PXALL-321

134

Low low pressure of fuel gas supply from the fuel gas
header

FXALL-171

132

Low low combustion air flow to first regenerator heater H1502

BXALL-001

134

No pilot flame in H-1501

BXALL-002

134

No main flame in H-1501

XS-801

132

Main Air Blower Trip (logic UX-801 activated)

UXHS-004B

134

Local panel ESD hardwire switch active

UXHS-004C

134

Local panel ESD hardwire switch active

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-014

ALL

134

CLOSE XV-014 to stop the fuel gas supply


to the 2nd regenerator heater H-1502

XSY-015

ALL

134

CLOSE XV-015 to stop the fuel gas supply


to the 2nd regenerator heater H-1502
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No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-020

ALL

134

OPEN XV-020 to vent the fuel gas to flare

UXA-004B

1 to 8

134

Activate the second regenerator heater H1501 trip alarm (ADP)

TIC-071

ALL

134

TIC-071 switch to manual mode and output


0% to CLOSE TV-071

Once all the initiators are healthy, the logic UX-004 can be reset by:

DCS software switch UHSR-004 resets actions 1, 2 and 3.

The valves XV-014, XV-015 and XV-020 need to be reset locally by means
of the local hardwire switch XHSR-014, XHSR-015, XHSR-020

4.2.5. Logic UX-005: Air Blower Protection


Initiators:
No.

Initiator Tag No.

P&ID

Description

UXHS-005A

132

Hardwire ESD switch active

UXHS-005B

132

Hardwire ESD switch active (ESD bypass switch)

XS-801

132

Air Blower trip active (logicUX-801 active)

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-163

1&3

133

CLOSE 1st Regenerator air ring assisted


check valve CV-1501 and generate
discrepancy alarm.

XSY-165

1&3

133

CLOSE 2nd Regenerator air ring assisted


check valve CV-1502 and generate
discrepancy alarm.

XSY-167

1&3

132

CLOSE air lift assisted check valve CV1503 and generate discrepancy alarm.

XSY-168

1&3

132

CLOSE other blower air users assisted


check valve CV-1504 and generate
discrepancy alarm.

UX-002

1&3

125

Activate the logic UX-002: Catalyst


circulation stop

XS-802

ALL

132

OPEN the air blower blow-off valves (logic


UC-802)

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Once all the initiators are healthy, the logic UX-005 can be reset by DCS software
switch UHSR-005.
In case of air blower ESD or automatic shutdown, the following actions will be
done automatically:
1) 015-XV-800 turbine chest valve is closed (only for ESD)
2) 015-SV-802 turbine control valve is closed (only for ESD)
3) 015-UV-822 blower blow off valve is open
4) 015-UV-823 blower blow off valve is open
5) 015-UV-824 blower blow off valve is open
6) 015-UV-825 blower interstage blow-off flap is open
7) 015-ZC-826 blower guide vanes are moved in start-up position (normal
position)
8) The flow controller 015-FIC-161 is switched off.
9) Turning gear is switched on by SSXX 803A.
Note:
For a complete description of the air blower interlocks, refer to the blower vendor
cause & effect diagram, doc. No. 8474L-015-A3505-1040-001-063.

4.2.6. Logic UX-008: COB/WHB 1st Regenerator Flue Gas Bypass Operation
Initiators:
No.

Initiator Tag No.

P&ID

Description

UXHS-008

201

DCS software switch active (hardwire signal from DCS to


ESD)

TXAHH-089 A/B

201

1st regenerator flue gas bypass temperature high high (1


out of 2 voting system)

UX-002

125

Logic UX-002 active: Catalyst circulation stop

XS-941

203

Logic UX-907 active: COB/WHB trip

MZSO-024B

201

1st regenerator flue gas bypass valve BV-1501B fully open

MZSO-023B

201

1st regenerator flue gas block valve BV-1501A fully open

XHSO-058AA

201

DCS software switch active (DCS operation is not allowed


when UX-008 is tripped)

XHSC-058AA

201

DCS software switch active (DCS operation is not allowed


when UX-008 is tripped)

XHSO-058BA

201

DCS software switch active (DCS operation is not allowed


when UX-008 is tripped)

10

XHSC-058BA

201

DCS software switch active (DCS operation is not allowed


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DATE: 06/12/07

Description
when UX-008 is tripped)

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

1a

MXSY-024

1, 2, 3, 4

201

OPEN the first regenerator flue gas bypass


valve BV-1501B

1b

MXSY-024

201

ALLOW the opening of the first regenerator


flue gas bypass valve BV-1501B

2a

MXSY-023

1, 2, 3

201

CLOSE the first regenerator flue gas block


valve BV-1501A

2b

MXSY-023

201

ALLOW the closure of the first regenerator


flue gas block valve BV-1501A

3a

XSY-058A

1, 2, 3, 7

201

OPEN the LP BFW injection valve XV-058A


in bypass line (start flue gas bypass
cooling)

3b

XSY-058A

201

CLOSE the LP BFW injection valve XV058A in bypass line (stop flue gas bypass
cooling)

4a

XSY-058B

1, 2, 3, 9

201

OPEN the LP BFW injection valve XV-058B


in bypass line (start flue gas bypass
cooling)

4b

XSY-058B

10

201

CLOSE the LP BFW injection valve XV058B in bypass line (stop flue gas bypass
cooling)

XSY-059

1, 2, 3

201

OPEN the atomizing steam injection valve


XV-059 in bypass line

Once all the initiators are healthy, the logic UX-008 can be reset by:

DCS software switch UHSR-008

The valves XV-058A, XV-058B and XV-059 need to be reset locally by


means of the local hardwire switch XHSR-058A, XHSR-058B and XHSR059 respectively.

4.2.7. Logic UX-009: Steam Drum D-1512 overfilling protection


Initiators:
No.

Initiator Tag No.

P&ID

Description

XS-944

202

H-1503 hardwire trip switch active

Page 183 of 323

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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-062

205

CLOSE XV-062 to stop the supply of BFW


to D-1512

Once all the initiators are healthy, the logic UX-009 can be reset by DCS software
switch UHSR-009

4.2.8. Logic UX-010: COB/WHB 2nd Regenerator Flue Gas Bypass Operation
Initiators:
No.

Initiator Tag No.

P&ID

Description

UXHS-010

202

DCS software switch active (hardwire signal from DCS to


ESD)

TXAHH-082 A/B

202

2nd regenerator flue gas bypass temperature high high (1


out of 2 voting system)

UX-002

125

Logic UX-002 active: Catalyst circulation stop

XS-941

203

Logic UX-907 active: COB/WHB trip

MZSO-026B

202

2nd regenerator flue gas bypass valve BV-1502B fully open

MZSO-025B

202

2nd regenerator flue gas block valve BV-1502A fully open

XHSO-056AA

202

DCS software switch active (DCS operation is not allowed


when UX-010 is tripped)

XHSC-056AA

202

DCS software switch active (DCS operation is not allowed


when UX-010 is tripped)

XHSO-056BA

202

DCS software switch active (DCS operation is not allowed


when UX-010 is tripped)

10

XHSC-056BA

202

DCS software switch active (DCS operation is not allowed


when UX-010 is tripped)

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

1a

MXSY-026

1, 2, 3, 4

202

OPEN the 2nd regenerator flue gas bypass


valve BV-1502B

1b

MXSY-026

202

ALLOW the opening of the 2nd regenerator


flue gas bypass valve BV-1502B

2a

MXSY-025

1, 2, 3

202

CLOSE the 2nd regenerator flue gas block


valve BV-1502A

2b

MXSY-025

202

ALLOW the closure of the 2nd regenerator


Page 184 of 323

TRAINING MODULE
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No.

Action Tag No.

Initiated by
initiator No:

P&ID

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Description
flue gas block valve BV-1502A

3a

XSY-056A

1, 2, 3, 7

202

OPEN the LP BFW injection valve XV-056A


in bypass line (start flue gas bypass
cooling)

3b

XSY-056A

202

CLOSE the LP BFW injection valve XV056A in bypass line (stop flue gas bypass
cooling)

4a

XSY-056B

1, 2, 3, 9

202

OPEN the LP BFW injection valve XV-056B


in bypass line (start flue gas bypass
cooling)

4b

XSY-056B

10

202

CLOSE the LP BFW injection valve XV056B in bypass line (stop flue gas bypass
cooling)

XSY-057

1, 2, 3

202

OPEN the atomizing steam injection valve


XV-057 in bypass line

Once all the initiators are healthy, the logic UX-010 can be reset by:

DCS software switch UHSR-010

The valves XV-056A, XV-056B and XV-057 need to be reset locally by


means of the local hardwire switch XHSR-056A, XHSR-056B and XHSR057 respectively.

Note:
For a detailed description of the COB/WHB trip, refer to the cause & effect matrix
of H-1503, doc No. 8474L-015-A3505-0160-001-156.

4.2.9. Logic UX-013: Economizer Bypass Cooling


Initiators:
No.

Initiator Tag No.

P&ID

Description

XS-943

205

Logic UX-906 active: Economizer bypass

XHSO-060AA

205

DCS Software Switch Active

XHSC-060AA

205

DCS Software Switch Active

XHSO-060BA

205

DCS Software Switch Active

XHSC-060BA

205

DCS Software Switch Active

Actions:

Page 185 of 323

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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

1a

XSY-060A

1&2

205

OPEN the LP BFW injection valve XV-060A


in the bypass line

1b

XSY-060A

205

ALLOW the opening of the LP BFW


injection valve XV-060A in the bypass line

2a

XSY-060B

1&4

205

OPEN the LP BFW injection valve XV-060B


in the bypass line

2b

XSY-060B

205

ALLOW the opening of the LP BFW


injection valve XV-060B in the bypass line

XSY-061

205

OPEN the atomizing steam injection valve


XV-061 in bypass line

Once all the initiators are healthy, the logic UX-013 can be reset by

DCS software switch UHSR-013

The valves XV-060A, XV-060B and XV-061 need to be reset locally by


means of the local hardwire switch XHSR-060A, XHSR-060B and XHSR061 respectively

4.2.10. Logic UX-421: Feed Surge Drum D-1513 overfilling protection


Initiators:
No.

Initiator Tag No.

P&ID

Description

LXAHH-404
A/B/C

301

High high level in the feed surge drum D-1513 (2 out of 3


voting system)

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-404

301

Close XV-404 to the stop the flow of residue


to D-1513

Once all the initiators are healthy, the logic UX-421 can be reset by DCS software
switch UHSR-421.

4.2.11. Logic UX-422: Feed Pumps P-1501 A/B Protection


Initiators:
No.

Initiator Tag No.

P&ID

Description

LXALL-403

301

Low low level in the feed surge drum D-1513


Page 186 of 323

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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

MXS-435

301

Feed Pump P-1501 A tripped

MXS-436

301

Feed Pump P-1501 B tripped

Once all the initiators are healthy, the logic UX-422 can be reset by DCS software
switch UHSR-422.

4.2.12. Logic UX-423: T-1501 & P-1507 A/B inventory isolation


Initiators:
No.

Initiator Tag No.

P&ID

Description

UXHS-423A

306

Hardwire ESD switch active

UXHS-423B

306

Hardwire LOCAL switch active

XZSM-406

306

70% limit switch of P-1507A suction valve XV-406 active

XZSO-406

306

OPEN limit switch of P-1507A suction valve XV-406 active

XZSM-405

306

70% limit switch of P-1507B suction valve XV-405 active

XZSO-405

306

OPEN limit switch of P-1507B suction valve XV-405 active

UXHS-423C

306

Hardwire local switch active

UXHS-423D

306

Hardwire local switch active

UXHS-423E

306

Hardwire local switch active

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

1a

MXS-481

1, 2, 3, 7, 8, 9 306

TRIP the HCO recycle pump P1507 A

1b

MXS-481

ALLOW the HCO recycle pump P1507 A to


be restarted:

306

Description

The pump is tripped when XV is less than


70% open and can only be restarted when
XV is fully open.
2a

MXS-482

1, 2, 5, 7, 8, 9 306

TRIP the HCO recycle pump P1507 B

2b

MXS-482

ALLOW the HCO recycle pump P1507 B to


be restarted:

306

The pump is tripped when XV is less than


Page 187 of 323

TRAINING MODULE
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CRACKER (RFCC)

No.

Action Tag No.

Initiated by
initiator No:

P&ID

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Description
70% open and can only be restarted when
XV is fully open.

XSY-405

1, 2, 7, 8, 9

306

CLOSE P-1507B suction motor operated


valve XV-405

XSY-406

1, 2, 7, 8, 9

306

CLOSE P-1507A suction motor operated


valve XV-406

XSY-407

1, 2, 7, 8, 9

306

CLOSE P-1507B discharge motor operated


valve XV-407

XSY-408

1, 2, 7, 8, 9

306

CLOSE P-1507A discharge motor operated


valve XV-408

XXA-405

1, 2, 7, 8, 9

306

Activate XV-405 trip alarm

XXA-406

1, 2, 7, 8, 9

306

Activate XV-406 trip alarm

XXA-407

1, 2, 7, 8, 9

306

Activate XV-407 trip alarm

10

XXA-408

1, 2, 7, 8, 9

306

Activate XV-408 trip alarm

Once all the initiators are healthy, the logic UX-423 can be reset by:

DCS software switch UHSR-423;

The motor operated valves must be reset locally: XV-405/406/407/408 are


reset by XHSR-405/406/407/408 respectively.

4.2.13. Logic UX-424: T-1501 & P-1508 A/B inventory isolation


Initiators:
No.

Initiator Tag No.

P&ID

Description

UXHS-424A

308

Hardwire ESD switch active

UXHS-424B

308

Hardwire LOCAL switch active

XZSM-409

308

70% limit switch of P-1508A suction valve XV-409 active

XZSO-409

308

OPEN limit switch of P-1508A suction valve XV-409 active

XZSM-410

308

70% limit switch of P-1508B suction valve XV-410 active

XZSO-410

308

OPEN limit switch of P-1508B suction valve XV-410 active

UXHS-424C

308

Hardwire local switch active

UXHS-424D

308

Hardwire local switch active

UXHS-424E

308

Hardwire local switch active

Actions:

Page 188 of 323

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P&ID

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

No.

Action Tag No.

Initiated by
initiator No:

1a

MXS-444

1, 2, 3, 7, 8, 9 308

TRIP the HCO pumparound pump P1508 A

1b

MXS-444

ALLOW the HCO pumparound pump P1508


A to be restarted:

308

Description

The pump is tripped when XV is less than


70% open and can only be restarted when
XV is fully open.
2a

MXS-445

1, 2, 5, 7, 8, 9 308

TRIP the HCO pumparound pump P1508 B

2b

MXS-445

ALLOW the HCO pumparound pump P1508


B to be restarted:

308

The pump is tripped when XV is less than


70% open and can only be restarted when
XV is fully open.
3

XSY-409

1, 2, 7, 8, 9

308

CLOSE P-1508A suction motor operated


valve XV-409

XSY-410

1, 2, 7, 8, 9

308

CLOSE P-1508B suction motor operated


valve XV-410

XSY-411

1, 2, 7, 8, 9

308

CLOSE P-1508A discharge motor operated


valve XV-411

XSY-412

1, 2, 7, 8, 9

308

CLOSE P-1508B discharge motor operated


valve XV-412

XXA-409

1, 2, 7, 8, 9

308

Activate XV-409 trip alarm

XXA-410

1, 2, 7, 8, 9

308

Activate XV-410 trip alarm

XXA-411

1, 2, 7, 8, 9

308

Activate XV-411 trip alarm

10

XXA-412

1, 2, 7, 8, 9

308

Activate XV-412 trip alarm

Once all the initiators are healthy, the logic UX-423 can be reset by:

DCS software switch UHSR-423;

The motor operated valves must be reset locally: XV-409/410/411/412 are


reset by XHSR-409/410/411/412 respectively.

4.2.14. Logic UX-425: Slurry pumps P-1519 A/B/C protection


Initiators:
No.

Initiator Tag No.

P&ID

Description

LXALL-414

310

Low low level in the main fractionator T-1501

Actions:
Page 189 of 323

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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-451

321

Activate logic UX-432


CLOSE XV-451 to stop the flow of slurry
product to D-1515

FIC-462

321

FIC-462 switch to manual mode and output


0% to close FV-462

Once all the initiators are healthy, the logic UX-425 can be reset by DCS software
switch UHSR-425.

4.2.15. Logic UX-426: T-1501 & P-1519 inventory isolation


Initiators:
No.

Initiator Tag No.

P&ID

Description

UXHS-426A

311

Hardwire ESD switch active

UXHS-426B

311

Hardwire LOCAL switch active

XZSM-413

311

70% limit switch of P-1519A suction valve XV-413 active

XZSO-413

311

OPEN limit switch of P-1519A suction valve XV-413 active

XZSM-414

311

70% limit switch of P-1519B suction valve XV-414 active

XZSO-414

311

OPEN limit switch of P-1519B suction valve XV-414 active

XZSM-415

311

70% limit switch of P-1519C suction valve XV-415 active

XZSO-415

311

OPEN limit switch of P-1519C suction valve XV-415 active

HS-419

311

DCS software switch active (DCS/Local operation is not


allowed when UX-426 is tripped)

10

XHSO-419B

311

LOCAL software switch active (DCS/Local operation is not


allowed when UX-426 is tripped)

11

XHSC-419B

311

LOCAL software switch active (DCS/Local operation is not


allowed when UX-426 is tripped)

12

HS-421

311

DCS software switch active (DCS/Local operation is not


allowed when UX-426 is tripped)

13

XHSO-421B

311

LOCAL software switch active (DCS/Local operation is not


allowed when UX-426 is tripped)

14

XHSC-421B

311

LOCAL software switch active (DCS/Local operation is not


allowed when UX-426 is tripped)

15

HS-423

311

DCS software switch active (DCS/Local operation is not


allowed when UX-426 is tripped)

16

XHSO-423B

311

LOCAL software switch active (DCS/Local operation is not


allowed when UX-426 is tripped)
Page 190 of 323

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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

No.

Initiator Tag No.

P&ID

Description

17

XHSC-423B

311

LOCAL software switch active (DCS/Local operation is not


allowed when UX-426 is tripped)

18

UXHS-426C

311

LOCAL hardwire switch active

19

UXHS-426D

311

LOCAL hardwire switch active

20

UXHS-426E

311

LOCAL hardwire switch active

21

UXHS-426F

311

LOCAL hardwire switch active

22

UXHS-426G

311

LOCAL hardwire switch active

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

1a

XSY-419

1, 2, 3, 9, 11,
18, 19, 20,
21, 22

311

CLOSE the slurry pumparound pump P1519A turbine HP steam valve XV-419

1b

XSY-419

10

311

OPEN the slurry pumparound pump P1519A turbine HP steam valve XV-419

1c

XSY-419

311

ALLOW the opening of the slurry


pumparound pump P-1519A turbine HP
steam valve XV-419:
Turbine of pump is automatically stopped
when XV is less than 70% open and can
only be restarted when XV is fully open.

2a

XSY-421

1, 2, 5, 12,
14, 18, 19,
20, 21, 22

311

CLOSE the slurry pumparound pump P1519B turbine HP steam valve XV-421

2b

XSY-421

13

311

OPEN the slurry pumparound pump P1519B turbine HP steam valve XV-421

2c

XSY-421

311

ALLOW the opening of the slurry


pumparound pump P-1519B turbine HP
steam valve XV-421:
Turbine of pump is automatically stopped
when XV is less than 70% open and can
only be restarted when XV is fully open.

3a

XSY-423

1, 2, 7, 15,
17, 18, 19,
20, 21, 22

311

CLOSE the slurry pumparound pump P1519C turbine HP steam valve XV-423

3b

XSY-423

16

311

OPEN the slurry pumparound pump P1519C turbine HP steam valve XV-423

3c

XSY-423

311

ALLOW the opening of the slurry


pumparound pump P-1519B turbine HP
Page 191 of 323

TRAINING MODULE
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CRACKER (RFCC)

No.

Action Tag No.

Initiated by
initiator No:

P&ID

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Description
steam valve XV-423:
Turbine of pump is automatically stopped
when XV is less than 70% open and can
only be restarted when XV is fully open.

XSY-413

1, 2, 18, 19,
20, 21, 22

311

CLOSE P-1519A suction motor operated


valve XV-413

XSY-414

1, 2, 18, 19,
20, 21, 22

311

CLOSE P-1519B suction motor operated


valve XV-414

XSY-415

1, 2, 18, 19,
20, 21, 22

311

CLOSE P-1519C suction motor operated


valve XV-415

XSY-416

1, 2, 18, 19,
20, 21, 22

311

CLOSE P-1519A discharge motor operated


valve XV-416

XSY-417

1, 2, 18, 19,
20, 21, 22

311

CLOSE P-1519B discharge motor operated


valve XV-417

XSY-418

1, 2, 18, 19,
20, 21, 22

311

CLOSE P-1519C discharge motor operated


valve XV-418

10

XXA-413

1, 2, 18, 19,
20, 21, 22

311

Activate XV-413 trip alarm

11

XXA-414

1, 2, 18, 19,
20, 21, 22

311

Activate XV-414 trip alarm

12

XXA-415

1, 2, 18, 19,
20, 21, 22

311

Activate XV-415 trip alarm

13

XXA-416

1, 2, 18, 19,
20, 21, 22

311

Activate XV-416 trip alarm

14

XXA-417

1, 2, 18, 19,
20, 21, 22

311

Activate XV-417 trip alarm

15

XXA-418

1, 2, 18, 19,
20, 21, 22

311

Activate XV-418 trip alarm

Once all the initiators are healthy, the logic UX-426 can be reset by:

DCS software switch UHSR-426;

The motor operated valves must be reset locally: XV-413/414/415/416/417/


418 are reset by XHSR-413/414/415/416/417/418 respectively.

4.2.16. Logic UX-427: T-1504 & P-1509 A/B inventory isolation


Initiators:

Page 192 of 323

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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

No.

Initiator Tag No.

P&ID

Description

UXHS-427A

316

Hardwire ESD switch active

UXHS-427B

316

Hardwire LOCAL switch active

XZSM-430

316

70% limit switch of P-1509A suction valve XV-430 active

XZSO-430

316

OPEN limit switch of P-1509A suction valve XV-430 active

XZSM-431

316

70% limit switch of P-1509B suction valve XV-431 active

XZSO-431

316

OPEN limit switch of P-1509B suction valve XV-431 active

LXALL-432

316

Low low level in the HCO stripper T-1504

UXHS-427C

316

Hardwire local switch active

UXHS-427D

316

Hardwire local switch active

10

UXHS-427E

316

Hardwire local switch active

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

1a

MXS-446

1, 2, 3, 7, 8,
9, 10

316

TRIP the HCO product pump P-1509 A

1b

MXS-446

316

ALLOW the HCO product pump P-1509 A to


be restarted:
The pump is tripped when XV is less than
70% open and can only be restarted when
XV is fully open.

2a

MXS-447

1, 2, 5, 7, 8,
9, 10

316

TRIP the HCO product pump P-1509 B

2b

MXS-447

316

ALLOW the HCO product pump P-1509 B to


be restarted:
The pump is tripped when XV is less than
70% open and can only be restarted when
XV is fully open.

XSY-430

1, 2, 8, 9, 10

316

CLOSE P-1509A suction motor operated


valve XV-430

XSY-431

1, 2, 8, 9, 10

316

CLOSE P-1509B suction motor operated


valve XV-431

XSY-432

1, 2, 8, 9, 10

316

CLOSE P-1509A discharge motor operated


valve XV-432

XSY-433

1, 2, 8, 9, 10

316

CLOSE P-1509B discharge motor operated


valve XV-433

XXA-430

1, 2, 8, 9, 10

316

Activate XV-430 trip alarm

XXA-431

1, 2, 8, 9, 10

316

Activate XV-431 trip alarm


Page 193 of 323

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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XXA-432

1, 2, 8, 9, 10

316

Activate XV-432 trip alarm

10

XXA-433

1, 2, 8, 9, 10

316

Activate XV-433 trip alarm

Once all the initiators are healthy, the logic UX-427 can be reset by:

DCS software switch UHSR-427;

The motor operated valves must be reset locally: XV-430/431/432/433 are


reset by XHSR-430/431/432/433 respectively.

4.2.17. Logic UX-428: Heavy Naphta Product Pumps P-1515 A/B protection
Initiators:
No.

Initiator Tag No.

P&ID

Description

LXALL-440

317

Low low level in the heavy naphta stripper T-1502

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

MXS-450

317

TRIP the heavy naphta product pump P1515A

MXS-451

317

TRIP the heavy naphta product pump P1515B

Once all the initiators are healthy, the logic UX-428 can be reset by DCS software
switch UHSR-428.

4.2.18. Logic UX-429: LCO Stripper Pumps P-1511 A/B protection


Initiators:
No.

Initiator Tag No.

P&ID

Description

LXALL-437

318

Low low level in the LCO stripper T-1503

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

MXS-452

318

TRIP the LCO stripper pump P-1511A

MXS-453

318

TRIP the LCO stripper pump P-1511B


Page 194 of 323

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REV: A

DATE: 06/12/07

Once all the initiators are healthy, the logic UX-429 can be reset by DCS software
switch UHSR-429.

4.2.19. Logic UX-430: D-1514, P-1516 A/B & P-1518 A/B inventory isolation
Initiators:
No.

Initiator Tag No.

P&ID

Description

UXHS-430A

320

Hardwire ESD switch active

UXHS-430B

320

Hardwire LOCAL switch active

XZSM-444

320

70% limit switch of P-1516 A/B & P-1518 A/B suction shutoff valve XV-444 active

XZSO-444

320

OPEN limit switch of P-1516 A/B & P-1518 A/B suction


shut-off valve XV-444 active

LXALL-444

320

Low low level in the main fractionator reflux drum D-1514

XHSO-444B

320

Hardwire LOCAL switch active

XHSC-444B

320

Hardwire LOCAL switch active

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

1a

MXS-456

1, 2, 3, 5

320

TRIP the fractionator reflux pump P-1516A

1b

MXS-456

320

Allow the fractionator reflux pump P-1516A


to be restarted:
The pump is tripped when XV is less than
70% open and can only be restarted when
XV is fully open.

2a

MXS-457

1, 2, 3, 5

320

TRIP the fractionator reflux pump P-1516B

2b

MXS-457

320

Allow the fractionator reflux pump P-1516B


to be restarted:
The pump is tripped when XV is less than
70% open and can only be restarted when
XV is fully open.

3a

MXS-460

1, 2, 3, 5

320

TRIP the overhead liquid pump P-1518A

3b

MXS-460

320

Allow the overhead liquid pump P-1518A to


be restarted:
The pump is tripped when XV is less than
70% open and can only be restarted when
XV is fully open.

4a

MXS-461

1, 2, 3, 5

320

TRIP the overhead liquid pump P-1518B


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No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

4b

MXS-461

1, 2, 3, 5

320

Allow the overhead liquid pump P-1518B to


be restarted:
The pump is tripped when XV is less than
70% open and can only be restarted when
XV is fully open.

5a

XSY-444

1, 2, 7

320

CLOSE P-1516 A/B & P-1518 A/B suction


shut-off valve XV-444

5b

XSY-444

320

OPEN P-1516 A/B & P-1518 A/B suction


shut-off valve XV-444

XXA-444

1, 2, 7

320

Activate XV-444 trip alarm

Once all the initiators are healthy, the logic UX-430 can be reset by:

DCS software switch UHSR-430;

The shut-off valve XV-444 must be reset locally XHSR-444 respectively.

4.2.20. Logic UX-431: D-1524, P-1517 A/B inventory isolation


Initiators:
No.

Initiator Tag No.

P&ID

Description

LXALL-447

320

Low low level in the main fractionator reflux drum boot

UXHS-431A

320

Hardwire ESD switch active

UXHS-431B

320

Hardwire LOCAL switch active

XZSM-445

320

70% limit switch of P-1517 A/B suction shut-off valve XV445 active

XZSO-445

320

OPEN limit switch of P-1517 A/B suction shut-off valve XV445 active

XHSO-445B

320

Hardwire LOCAL switch active

XHSC-445B

320

Hardwire LOCAL switch active

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

1a

MXS-458

1, 2, 3, 5

320

TRIP the overhead sour water pump P1517A

1b

MXS-458

320

ALLOW the overhead sour water pump P1517A to be restarted:


The pump is tripped when XV is less than
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Action Tag No.

Initiated by
initiator No:

P&ID

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DATE: 06/12/07

Description
70% open and can only be restarted when
XV is fully open.

2a

MXS-459

1, 2, 3, 5

320

TRIP the overhead sour water pump P1517B

2b

MXS-459

320

ALLOW the overhead sour water pump P1517B to be restarted:


The pump is tripped when XV is less than
70% open and can only be restarted when
XV is fully open.

3a

XSY-445

2, 3, 7

320

CLOSE P-1517 A/B suction shut-off valve


XV-445

3b

XSY-445

320

OPEN P-1517 A/B suction shut-off valve


XV-445

XXA-445

2, 3, 7

320

Activate XV-445 trip alarm

Once all the initiators are healthy, the logic UX-430 can be reset by:

DCS software switch UHSR-431;

The shut-off valve XV-445 must be reset locally XHSR-445 respectively.

4.2.21. Logic UX-432: D-1515 overfilling protection


Initiators:
No.

Initiator Tag No.

P&ID

Description

LXAHH-478

321

Low low level in D-1515

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-451

321

CLOSE XV-451 to stop the flow of slurry


product to D-1515;
Activate logic UX-425

FIC-462

321

FIC-462 switch to manual mode and output


0% to close FV-462

Reset:
Once all the initiators are healthy, the logic UX-432 can be reset by DCS software
switch UHSR-432.

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4.2.22. Logic UX-433: Slurry Product Pumps P-1504 A/B protection


Initiators:
No.

Initiator Tag No.

P&ID

Description

LXALL-450

321

Low low level in D-1515

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

MXS-462

321

TRIP the slurry product pump P-1504A

MXS-463

321

TRIP the slurry product pump P-1504B

Reset:
Once all the initiators are healthy, the logic UX-432 can be reset by DCS software
switch UHSR-432.

4.2.23. Logic UX-434: Backflush Oil Recycle Pumps P-1506 A/B protection
Initiators:
No.

Initiator Tag No.

P&ID

Description

LXALL-458

324

Low low level in the backflush oil receiver D-1517

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

MXS-464

324

TRIP the Backflush Oil Recycle Pump P1506A

MXS-465

324

TRIP the Backflush Oil Recycle Pump P1506B

Reset:
Once all the initiators are healthy, the logic UX-434 can be reset by DCS software
switch UHSR-434.

4.2.24. Logic UX-435: D-1517 overfilling protection


Initiators:
No.

Initiator Tag No.

P&ID

Description

LXAHH-459

324

High high level in the backflush oil receiver D-1517


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Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-459

324

CLOSE XV-459 to stop the flow of HCO


product from E-1510 to D-1517

Reset:
Once all the initiators are healthy, the logic UX-435 can be reset by DCS software
switch UHSR-435.

4.2.25. Logic UX-436: Backflush Oil Pumps P-1505 A/B protection


Initiators:
No.

Initiator Tag No.

P&ID

Description

LXALL-462

325

Low low level in the backflush oil draw off drum D-1516

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

MXS-466

325

TRIP the Backflush Oil Pump P-1505A

MXS-467

325

TRIP the Backflush Oil Pump P-1505B

Reset:
Once all the initiators are healthy, the logic UX-436 can be reset by DCS software
switch UHSR-436.

4.2.26. Logic UX-437: D-1516 overfilling protection


Initiators:
No.

Initiator Tag No.

P&ID

Description

LXAHH-463

325

High high level in the backflush oil draw off drum D-1516

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

FSY-467

325

CLOSE FV-467 to stop the flow of HCO


product from E-1510 to D-1516

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No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

FIC-467

325

FIC-467 switch to manual mode and output


0% to close FV-467

Reset:
Once all the initiators are healthy, the logic UX-437 can be reset by DCS software
switch UHSR-437.

4.2.27. Logic UX-438: HCO Flushing Oil Pumps P-1521 A/B protection
Initiators:
No.

Initiator Tag No.

P&ID

Description

LXALL-468

326

Low low level in HCO flushing oil drum D-1518

HS-468

326

DCS software switch active (DCS operation is not allowed


when UX-438 is tripped)

XHSO-468B

326

Hardwire local switch active (DCS operation is not allowed


when UX-438 is tripped)

XHSC-468B

326

Hardwire local switch active (DCS operation is not allowed


when UX-438 is tripped)

PAL-487

326

Low flushing oil pressure at the discharge of P-1521 A/B

XHSM-468B

326

Hardwire local switch active

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

1a

XSY-468

1, 2, 4

326

CLOSE XV-468 to stop the MP steam


supply to the turbine of P-1521A

1b

XSY-468

3, 5

326

OPEN XV-468 to allow the MP steam


supply to the turbine of P-1521A

1c

XSY-468

326

ACTIVATE the HCO flushing oil pump P1521A

MXS-468

326

TRIP the HCO flushing oil pump P-1521B

Reset:
Once all the initiators are healthy, the logic UX-438 can be reset by DCS software
switch UHSR-438.

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4.2.28. Logic UX-439: LCO Flushing Oil Pumps P-1522 A/B protection
Initiators:
No.

Initiator Tag No.

P&ID

Description

LXALL-471

327

Low low level in the LCO Flushing Oil Drum D-1519

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

MXS-469

327

TRIP the LCO Flushing Oil Pumps P-1522A

MXS-470

327

TRIP the LCO Flushing Oil Pumps P-1522B

Reset:
Once all the initiators are healthy, the logic UX-439 can be reset by DCS software
switch UHSR-439.

4.2.29. Logic UX-440: D-1522 overfilling protection


Initiators:
No.

Initiator Tag No.

P&ID

Description

LXAHH-485

329

High high level in the light slops drum D-1522

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-485

329

CLOSE XV-485 to stop the flow of light


slops to D-1522

LIC-484

329

LIC-484 switch to manual mode and output


0% to close LV-484 on the light slops line
from storage.

Reset:
Once all the initiators are healthy, the logic UX-440 can be reset by DCS software
switch UHSR-440.

4.2.30. Logic UX-441: Light Slops Pumps P-1526 A/B protection


Initiators:

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No.

Initiator Tag No.

P&ID

Description

LXALL-486

329

Low low level in the light slops drum D-1522

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

MXS-473

327

TRIP the Light Slops Pumps P-1526 A

MXS-474

327

TRIP the Light Slops Pumps P-1526 B

Reset:
Once all the initiators are healthy, the logic UX-441can be reset by DCS software
switch UHSR-441.

4.2.31. Logic UX-442: D-1523 overfilling protection


Initiators:
No.

Initiator Tag No.

P&ID

Description

LXAHH-491

330

High high level in the heavy slops drum D-1523

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-491

330

CLOSE XV-491 to stop the flow of heavy


slops to D-1523

LIC-490

330

LIC-490 switch to manual mode and output


0% to close LV-490 on the heavy slops line
from storage.

Reset:
Once all the initiators are healthy, the logic UX-442 can be reset by DCS software
switch UHSR-442.

4.2.32. Logic UX-443: Heavy Slops Pumps P-1527 A/B protection


Initiators:
No.

Initiator Tag No.

P&ID

Description

LXALL-492

330

Low low level in the heavy slops drum D-1523

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Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

MXS-475

330

TRIP the Heavy Slops Pumps P-1527 A

MXS-476

330

TRIP the Heavy Slops Pumps P-1527 B

Reset:
Once all the initiators are healthy, the logic UX-443 can be reset by DCS software
switch UHSR-443.

4.2.33. Logic UX-444: Tempered Water Pumps P-1528 A/B Protection


Initiators:
No.

Initiator Tag No.

P&ID

Description

LXALL-498

331

Low low level in the tempered water surge drum D-1524

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

MXS-478

331

TRIP the Tempered Water Pump P-1528A

MXS-479

331

TRIP the Tempered Water Pump P-1528B

Reset:
Once all the initiators are healthy, the logic UX-444 can be reset by DCS software
switch UHSR-444.

4.2.34. Logic UX-705: C-1551 Isolation and Protection


Initiators:
No.

Initiator Tag No.

P&ID

Description

UXHS-705AA

402

ESD hardwire switch active

UXHS-705B

402

LOCAL hardwire switch active

LXAHH-704
A/B/C

401

High high level in the 1st stage KO drum D-1551 (2 out of 3


voting system)

LXAHH-709
A/B/C

403

High high level in the interstage KO drum D-1552 (2 out of


3 voting system)

XS-861

403

Activate the logic UX-861: TRIP the wet gas compressor


due to low low speed.
XS-861 ALLOW the closing of the MOVs when C-1551
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No.

Initiator Tag No.

P&ID

Description
rotating speed is less than 250 RPM. C-1551 cannot be
restarted until MOVs are opened fully.

TXAHH-631

402

C-1551 discharge temperature high high

TXAHH-632

402

C-1551 discharge temperature high high

MZSO-703B

402

OPEN limit switch of MOV-703

MZSO-704B

402

OPEN limit switch of MOV-704

10

MZSO-705B

402

OPEN limit switch of MOV-705

11

MZSO-706B

402

OPEN limit switch of MOV-706

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XS-862

1, 2, 3, 4, 6,
402
7, 8, 9, 10, 11

ACTIVATE C-1551 trip

2a

MXSY-703

1, 2

402

CLOSE C-1551 first stage suction valve


MOV-703

2b

MXSY-703

402

ALLOW the closing of C-1551 first stage


suction valve MOV-703

3a

MXSY-704

1, 2

402

CLOSE C-1551 first stage discharge valve


MOV-704

3b

MXSY-704

402

ALLOW the closing of C-1551 first stage


discharge valve MOV-704

4a

MXSY-705

1, 2

402

CLOSE C-1551 second stage suction valve


MOV-705

4b

MXSY-705

402

ALLOW the closing of C-1551 second stage


suction valve MOV-705

5a

MXSY-706

1, 2

402

CLOSE C-1551 second stage discharge


valve MOV-706

5b

MXSY-706

402

ALLOW the closing of C-1551 second stage


discharge valve MOV-706

Reset:
Once all the initiators are healthy, the logic UX-705 can be reset by DCS software
switch UHSR-705.

4.2.35. Logic UX-706: Interstage drum pump P-1551 A/B Protection


Initiators:

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No.

Initiator Tag No.

P&ID

Description

LXALL-707

403

Low low level in the interstage KO drum D-1552

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

MXS-714

403

TRIP the interstage KO drum pump P1551A

MXS-715

403

TRIP the interstage KO drum pump P1551B

Reset:
Once all the initiators are healthy, the logic UX-706 can be reset by DCS software
switch UHSR-706.

4.2.36. Logic UX-707: HP separator drum D-1553 Interface Isolation


Initiators:
No.

Initiator Tag No.

P&ID

Description

LXALL-716

404

Low low level in HP separator drum D-1553

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-716

404

CLOSE XV-716 to stop the sour water draw


off from D-1553

LIC-714

404

LIC-714 switch to manual mode and output


0% to close LV-714

Reset:
Once all the initiators are healthy, the logic UX-707 can be reset by DCS software
switch UHSR-707.

4.2.37. Logic UX-708: HP separator drum D-1553 Inventory Isolation


Initiators:
No.

Initiator Tag No.

P&ID

Description

UXHS-708A

404

ESD hardwire switch active

UXHS-708B

404

LOCAL hardwire switch active

XZSM-719

404

70% limit switch of the stripper feed pumps suction valve


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No.

Initiator Tag No.

P&ID

Description
XV-719 active

XZS0-719

404

OPEN limit switch of the stripper feed pumps suction valve


XV-719 active

LXALL-719

404

Low low level in the HP separator drum D-1553

XHSO-719B

404

LOCAL hardwire switch active

XHSC-719B

404

LOCAL hardwire switch active

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

1a

MXS-717

1, 2, 3, 5

404

TRIP the Stripper Feed Pump P-1553A

1b

MXS-717

404

ALLOW the stripper feed pump P-1553A to


be restarted:
The pump is tripped when XV is less than
70% open and can only be restarted when
XV is fully open.

2a

MXS-718

1, 2, 3, 5

404

TRIP the Stripper Feed Pump P-1553B

2b

MXS-718

404

ALLOW the stripper feed pump P-1553B to


be restarted:
The pump is tripped when XV is less than
70% open and can only be restarted when
XV is fully open.

XSY-719

1, 2, 6, 7

404

CLOSE the stripper feed pumps suction


valve XV-719

XXA-719

1, 2, 6, 7

404

Activate XV-719 trip alarm

Reset:
Once all the initiators are healthy, the logic UX-708 can be reset by DCS software
switch UHSR-708.

4.2.38. Logic UX-709: Lean Oil Coalescer Interface Isolation


Initiators:
No.

Initiator Tag No.

P&ID

Description

LXALL-725

407

Low low interface level in D-1556

Actions:

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No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-725

407

CLOSE XV-725 to stop the sour water draw


off from D-1556

LIC-723

407

LIC-723 switch to manual mode and output


0% to close LV-723 on the sour water draw
off line

Reset:
Once all the initiators are healthy, the logic UX-709 can be reset by DCS software
switch UHSR-709.

4.2.39. Logic UX-710: T-1555 Interface Isolation


Initiators:
No.

Initiator Tag No.

P&ID

Description

LXALL-732

408

Low low interface level in T-1555

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-732

408

CLOSE XV-732 to stop the rich amine draw


off from T-1555

LIC-730

408

LIC-730 switch to manual mode and output


0% to close LV-730 on the lean amine
return to ARU

Reset:
Once all the initiators are healthy, the logic UX-710 can be reset by DCS software
switch UHSR-710.

4.2.40. Logic UX-712: Debutanizer T-1554 Inventory Isolation


Initiators:
No.

Initiator Tag No.

P&ID

Description

UXHS-712A

409

ESD hardwire switch active

UXHS-712B

409

LOCAL hardwire switch active

XZSM-738

409

70% limit switch of the gasoline recycle pumps suction


valve XV-738 active

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No.

Initiator Tag No.

P&ID

Description

XZS0-738

409

OPEN limit switch of the stripper feed pumps suction valve


XV-738 active

LXALL-738

409

Low low level in the Debutanizer T-1554

XHSO-738B

409

LOCAL hardwire switch active

XHSC-738B

409

LOCAL hardwire switch active

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

1a

MXS-720

1, 2, 3, 5

406

TRIP the gasoline recycle pump P-1554A

1b

MXS-720

406

ALLOW the gasoline recycle pump P-1554A


to be restarted:
The pump is tripped when XV is less than
70% open and can only be restarted when
XV is fully open.

2a

MXS-721

1, 2, 3, 5

406

TRIP the gasoline recycle pump P-1554B

2b

MXS-721

406

ALLOW the gasoline recycle pump P-1554B


to be restarted:
The pump is tripped when XV is less than
70% open and can only be restarted when
XV is fully open.

XSY-738

1, 2, 6, 7

409

CLOSE XV-738 on the debutanizer bottom


line

XXA-738

1, 2, 6, 7

404

Activate XV-738 trip alarm

Reset:
Once all the initiators are healthy, the logic UX-712 can be reset by:

DCS software switch UHSR-712;

XV-738 need to be reset locally by means of the local hardwire switch


XHSR-738.

4.2.41. Logic UX-713: D-1554 Interface Isolation


Initiators:
No.

Initiator Tag No.

P&ID

Description

LXALL-741

410

Low low interface level in debutanizer reflux drum D-1554

Actions:
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No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-741

410

CLOSE XV-741 to stop the sour water draw


off from D-1554 boot

Reset:
Once all the initiators are healthy, the logic UX-713 can be reset by DCS software
UHSR-713.

4.2.42. Logic UX-714: Debutanizer Reflux Drum D-1554 Inventory Isolation


Initiators:
No.

Initiator Tag No.

P&ID

Description

UXHS-714A

410

ESD hardwire switch active

UXHS-714B

410

LOCAL hardwire switch active

XZSM-744

410

70% limit switch of the debutanizer OVHD pumps suction


valve XV-744 active

XZS0-744

410

OPEN limit switch of the debutanizer OVHD pumps suction


valve XV-744 active

LXALL-744

410

Low low level in the Debutanizer Reflux Drum D-1554

XHSO-744B

410

LOCAL hardwire switch active

XHSC-744B

410

LOCAL hardwire switch active

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

1a

MXS-722

1, 2, 3, 5

410

TRIP the debutanizer OVHD pump P-1556A

1b

MXS-722

410

ALLOW debutanizer OVHD pump P-1556A


to be restarted:
The pump is tripped when XV is less than
70% open and can only be restarted when
XV is fully open.

2a

MXS-723

1, 2, 3, 5

410

TRIP the debutanizer OVHD pump P-1556B

2b

MXS-723

410

ALLOW the debutanizer OVHD pump P1556B to be restarted:


The pump is tripped when XV is less than
70% open and can only be restarted when
XV is fully open.

Page 209 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-744

1, 2, 6, 7

410

CLOSE XV-744 in the debutanizer OVHD


pumps suction line

XXA-744

1, 2, 6, 7

410

Activate XV-744 trip alarm

LIC-739

1, 2, 3, 4, 5

410

LIC-739 switch to manual and output 0% to


close LV-739

Reset:
Once all the initiators are healthy, the logic UX-714 can be reset by:

DCS software switch UHSR-714;

XV-744 need to be reset locally by means of the local hardwire switch


XHSR-744

4.2.43. Logic UX-715: T-1556 Interface Isolation


Initiators:
No.

Initiator Tag No.

P&ID

Description

LXALL-748

411

Low low interface level in LPG Amine Absorber T-1556

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-748

411

CLOSE XV-748 to stop the rich amine draw


off from T-1556 back to the ARU.

LIC-746

411

LIC-746 switch to manual mode and output


0% to close LV-746.

Reset:
Once all the initiators are healthy, the logic UX-715 can be reset by DCS software
UHSR-715.

4.2.44. Logic UX-716: LPG amine coalescer D-1555 Interface Isolation


Initiators:
No.

Initiator Tag No.

P&ID

Description

LXALL-751

411

Low low interface level in LPG Amine Coalescer D-1555

Actions:
Page 210 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-751

411

CLOSE XV-751 to stop the rich amine draw


off from D-1555.

LIC-749

411

LIC-749 switch to manual mode and output


0% to close LV-749 on the rich amine drawoff line.

Reset:
Once all the initiators are healthy, the logic UX-716 can be reset by DCS software
UHSR-716.

4.2.45. Logic UX-717: LPG amine absorber T-1556 depressurization


Initiators:
No.

Initiator Tag No.

P&ID

Description

UXHS-717A

411

ESD hardwire switch active

UXHS-717B

411

LOCAL hardwire switch active

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-752

411

OPEN XV-752 to depressurize to flare.

FSY-723

411

CLOSE FV-723 to stop the feed flow to T1556

Reset:
Once all the initiators are healthy, the logic UX-717 can be reset by:

DCS software UHSR-716;

XV-752 need to be reset locally by means of the local hardwire switch


XHSR-752.

4.2.46. Logic UX-718: Fuel Gas Absorber Outlet KO Drum D-1559 Interface Isolation
Initiators:
No.

Initiator Tag No.

P&ID

Description

LXALL-735

408

Low low interface level in Fuel Gas Absorber Outlet KO


Drum D-1559

Page 211 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-735

408

CLOSE XV-735 to stop the rich amine draw


off from D-1559.

LIC-733

408

LIC-733 switch to manual mode and output


0% to close LV-733 on the rich amine drawoff line.

Reset:
Once all the initiators are healthy, the logic UX-718 can be reset by DCS software
UHSR-719.

4.2.47. Logic UX-719: D-1553 depressurization


Initiators:
No.

Initiator Tag No.

P&ID

Description

UXHS-719A

408

ESD hardwire switch active

UXHS-719B

408

LOCAL hardwire switch active

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

XSY-733

408

OPEN XV-733 to depressurize to flare.

Reset:
Once all the initiators are healthy, the logic UX-719 can be reset by:

DCS software UHSR-719;

XV-733 need to be reset locally by means of the local hardwire switch


XHSR-733.

4.2.48. Logic UX-861 Wet Gas Compressor C-1551 Protection


Initiators:
No.

Initiator Tag No.

P&ID

Description

XS-862

092

C-1551 Process conditions

PAL-867

037

Low pressure of the lube oil supply to C-1551

HS-868

092

C-1551 Local/Remote Switch

Page 212 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

No.

Initiator Tag No.

P&ID

Description

LAH-861

037

High level in the rundown tank of C-1551

PAL-868

092

C-1551 control oil supply pressure low

ZAC-865

092

C-1551 T&T valve full close limit switch

PDAL-585

037

C-1551 buffer gas supply differential pressure low

UXHS-863

092

C-1551 Emergency Stop

UXHS-705 AB

092

C-1551 trip signal from ESD console

10

PALL-866

037

C-1551 lube oil supply pressure low low

11

PDAHH-863A

037

C-1551 Primary Seal Vent Pressure (FE) High High

12

PDAHH-863B

037

C-1551 Primary Seal Vent Pressure (DE) High High

13

SAHH-862

092

C-1551 overspeed trip active

14

XS-871

092

Governor fault

15

UXS-865A/B

037

Compressor Axial Disp. High high

16

UXS-866A/B

092

Turbine axial disp. High high

17

SSLL-861

092

C-1551 turbine speed low

18

PAL-861

037

C-1551 Separation gas supply pressure low

19

PAL-599

037

C-1551 secondary gas supply pressure low

20

LAL-862

038

C-1551 oil reservoir level low

21

PAL-862

038

C-1551 Lube/control oil header pressure low

22

LAL-863

039

C-1551 Surface condenser Level low

23

LALL-863/866

039

C-1551 Surface condenser Level low low

24

LAH-863

039

C-1551 Surface condenser Level high

Actions:
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

YL-861

1, 2, 3, 4, 5,
6, 7

ALLOW the wet gas compressor C-1551 to


be restarted

UXA-861

1, 8, 9, 10,
11, 12, 13,
14, 15, 16

TRIP the wet gas compressor C-1551 and


generate a common trip alarm

UXA-861

1, 8, 9, 10,
11, 12, 13,
14, 15, 16

C-1551 common trip alarm (first out)

17

CLOSE the process MOV

YL-876, 877

18, 19, 20

ALLOW the oil pump to be started

Page 213 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

No.

Action Tag No.

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Initiated by
initiator No:

P&ID

Description

21

AUTO START the standby pump

YL-876, 877

22

ALLOW the condensate pump to be started

MGL-876, 877

23

TRIP the condensate pump

24

AUTO START the condensate pump

4.3. Safeguarding Equipment


4.3.1. Pressure Safety Devices
Over pressuring of the equipment occurs in many ways. The basic cause of power
pressure is imbalance in heat and material flow in the equipment or piping.
Pressure safety devices have been installed to protect and/or section against over
pressure.
Here is the list of the pressure safety valves found in the RFCC:

TAG No.

Description

015-PSV
-570
015-PSV
-571
015-RO
-732
015-PSV
-701-A
015-PSV
-701-B
015-PSV
-705-B
015-PSV
-705-A
015-PSV
-008-A
015-PSV
-008-B
015-PSV
-008-C
015-PSV
-008-D
015-PSV
-008-E
015-PSV
-008-F

Breather
Valve
Breather
Valve
Breather
Valve
Relief Valve
(Pilot)
Relief Valve
(Pilot)
Relief Valve
(Pilot)
Relief Valve
(Pilot)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)

Type
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV

Location
MC RECYCLE PUMP P1512A
MC RECYCLE PUMP P1512B
INTER STAGE DRUM
PUMP P-1551B
PG FROM INTERSTAGE
KO DRUM D-1552
PG FROM INTERSTAGE
KO DRUM D-1552
HP SEP D-1553 VAPOR
TO T-1551
HP SEP D-1553 VAPOR
TO T-1551
BLOWER AIR TO
CATALYST LINES
BLOWER AIR TO
CATALYST LINES
BLOWER AIR TO
CATALYST LINES
BLOWER AIR TO
CATALYST LINES
BLOWER AIR TO
CATALYST LINES
BLOWER AIR TO
CATALYST LINES

PID:

Setting
(kg/cm2g)

637
637
637
403
403
404
404
132
132
132
132
132
132
Page 214 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

TAG No.

Description

015-PSV
-008-G
015-PSV
-006
015-PSV
-005
015-PSV
-009
015-PSV
-007-A
015-PSV
-007-B
015-PSV
-362-A
015-PSV
-362-B
015-PSV
-359
015-PSV
-401-A
015-PSV
-401-B
015-PSV
-406-A
015-PSV
-406-B
015-PSV
-406-C
015-PSV
-408-A
015-PSV
-408-B
015-PSV
-409-A
015-PSV
-409-B
015-PSV
-412-A
015-PSV
-412-B
015-PSV
-638-A
015-PSV
-638-B
015-PSV
-704-A
015-PSV
-704-B

Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)

Type
RV
RV
RV
RV

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

Location
BLOWER AIR TO
CATALYST LINES
SPENT CATALYST
HOPPER D-1506
AUXILIARY CATALYST
HOPPER D-1507
FRESH CATALYST
HOPPER D-1505

DATE: 06/12/07

PID:
132
135
136
137

RV

FUEL GAS DRUM D-1509

138

RV

FUEL GAS DRUM D-1509

138

RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV

AIR HEATER FG KO
DRUM D-1525
AIR HEATER FG KO
DRUM D-1525
CO BOILER FG KO DRUM
D-1526
FEED SURGE DRUM D1513
FEED SURGE DRUM D1513
DISCHARGE TO PSV408A/B
DISCHARGE TO PSV408A/B
DISCHARGE TO PSV408A/B
DISCHARGE FROM PSV406A/B/C
DISCHARGE FROM PSV406A/B/C
HCO RECYCLE MP
STEAM GEN E-1508
HCO RECYCLE MP
STEAM GEN E-1508
HCO PMPAROUND MP
STEAM GEN E-1523
HCO PMPAROUND MP
STEAM GEN E-1523
SL FROM LP BLOWDOWN
DRUM D-1527
SL FROM LP BLOWDOWN
DRUM D-1527
STRIPPER OVHD TO
COND E-1554A/B
STRIPPER OVHD TO
COND E-1554A/B

Setting
(kg/cm2g)

206
206
206
301
301
303
303
303
304
304
306
306
308
308
452
452
405
405
Page 215 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

TAG No.

Description

015-PSV
-709-A
015-PSV
-709-B
015-PSV
-710-A
015-PSV
-710-B
015-PSV
-712-A
015-PSV
-712-B
015-PSV
-714-A
015-PSV
-714-B
015-PSV
-719-A
015-PSV
-719-B
015-PSV
-721
015-PSV
-722
015-PSV
-715-A
015-PSV
-715-B
015-PSV
-003
015-PSV
-416
015-PSV
-456
015-PSV
-402
015-PSV
-415
015-PSV
-414
015-PSV
-417-A
015-PSV
-403
015-PSV
-419-A
015-PSV
-420-A

Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)

Type
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

Location
TOP SECONDARY
ABSORBER T-1553
TOP SECONDARY
ABSORBER T-1553
PL FROM LEAN OIL
COALESCER D-1556
PL FROM LEAN OIL
COALESCER D-1556
PG FROM FG ABS
OUTLET DRUM D-1559
PG FROM FG ABS
OUTLET DRUM D-1559
PG FROM TOP
DEBUTANIZER TK T-1554
PG FROM TOP
DEBUTANIZER TK T-1554
PG FROM LPG AMINE
ABS TANK T-1556
PG FROM LPG AMINE
ABS TANK T-1556
ANTIFOAMING PUMP P1557
ANTIFOAMING PUMP P1558
DEBUTANIZER REFLUX
DRUM D-1554
DEBUTANIZER REFLUX
DRUM D-1554
PA TO FIRST
REGENERATOR D-1502
SLURRY PUMP AROUND
PUMP P-1519C
PL TO FEED SURGE
DRUM D-1513
FEED FRM LCO PREHT
EXCHNG E-1512B
SLURRY PUMPAROUND
PUMP P-1519B
SLURRY PUMPAROUND
PUMP P-1519A
SLURRY TO SUPPLY PA
RETURN LINE
FEED FRM LCO PREHT
EXCHNG E-1512D
SLURRY TO SUPPLY PA
RETURN LINE
SLURRY HP STEAM
GENERATOR E-1503A

DATE: 06/12/07

PID:

Setting
(kg/cm2g)

407
407
407
407
408
408
409
409
411
411
411
411
410
410
128
311
301
302
311
311
312
302
312
312
Page 216 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

TAG No.

Description

015-PSV
-404
015-PSV
-420-B
015-PSV
-405
015-PSV
-418-B
015-PSV
-410
015-PSV
-418-A
015-PSV
-411
015-PSV
-421-A
015-PSV
-422-A
015-PSV
-422-B
015-PSV
-424-A
015-PSV
-424-B
015-PSV
-428-A
015-PSV
-428-B
015-PSV
-423-A
015-PSV
-423-B
015-PSV
-426-A
015-PSV
-426-B
015-PSV
-429-A
015-PSV
-429-B
015-PSV
-432-A
015-PSV
-432-B
015-PSV
-432-C
015-PSV
-432-D

Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)

Type
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

Location
PL FROM MP STEAM HTR
E-1522
SLURRY HP STEAM
GENERATOR E-1503B
PL FROM MP STEAM HTR
E-1524
SLURRY HP STEAM GEN
E-1503A
HCO RECYCLE MP
STEAM GEN E-1508
SLURRY HP STEAM GEN
E-1503A
HCO PMPAROUND MP
STEAM GEN E-1523
SLURRY FRM PSV417&419
SLURRY HP STEAM GEN.
E-1503 C
SLURRY HP STEAM GEN.
E-1503 C
SLURRY HP STEAM
GENERATOR E-1505A
SLURRY HP STEAM
GENERATOR E-1505A
SLURRY MP STEAM
GENERATOR E-1505A
SLURRY MP STEAM
GENERATOR E-1505A
SLURRY HP STEAM
GENERATOR E-1504B
SLURRY HP STEAM
GENERATOR E-1504B
SLURRY MP STEAM
GENERATOR E-1505B
SLURRY MP STEAM
GENERATOR E-1505B
HCO LP STEAM
GENERATOR E-1510
HCO LP STEAM
GENERATOR E-1510
FRACTIONATOR OVHD
FRM T-1501
FRACTIONATOR OVHD
FRM T-1501
FRACTIONATOR OVHD
FRM T-1501
FRACTIONATOR OVHD
FRM T-1501

DATE: 06/12/07

PID:

Setting
(kg/cm2g)

302
312
302
312
306
312
308
313
313
313
314
314
314
314
315
315
315
315
316
316
319
319
319
319
Page 217 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

TAG No.

Description

015-PSV
-432-E
015-PSV
-432-F
015-PSV
-432-G
015-PSV
-432-H
015-PSV
-434
015-PSV
-435-A
015-PSV
-435-B
015-PSV
-437-A
015-PSV
-437-B
015-PSV
-436-A
015-PSV
-436-B
015-PSV
-439
015-PSV
-438
015-PSV
-440
015-PSV
-441
015-PSV
-444-A
015-PSV
-444-B
015-PSV
-445-A
015-PSV
-445-B
015-PSV
-446-A
015-PSV
-446-B
015-PSV
-447
015-PSV
-448-A
015-PSV
-448-B

Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)

Type
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

Location
FRACTIONATOR OVHD
FRM T-1501
FRACTIONATOR OVHD
FRM T-1501
FRACTIONATOR OVHD
FRM T-1501
FRACTIONATOR OVHD
FRM T-1501
CORROSION INHABITOR
PUMP P-1520A
TOP SLRY DRAWOFF
DRUM D-1515
TOP SLRY DRAWOFF
DRUM D-1515
SLURRY HP STEAM
GENERATOR E-1506A
SLURRY HP STEAM
GENERATOR E-1506A
SLURRY HP STEAM
GENERATOR E-1506B
SLURRY HP STEAM
GENERATOR E-1506B
PS FROM SLRY LP
STMGEN E-1506A/B
PS FROM SLRY LP
STMGEN E-1506A/B
PL TO SLRY CLF COOLER
E-1507B
PL TO SLRY CLF COOLER
E-1507D
TOP BACK FLSH OIL
RECV DRM D-1517
TOP BACK FLSH OIL
RECV DRM D-1517
TOP FLSH OIL DRAWOFF
DRM D-1517
TOP FLSH OIL DRAWOFF
DRM D-1517
TOP HCO FLSHOIL DRUM
D-1518
TOP HCO FLSHOIL DRUM
D-1518
SL FRM HCO FLSHOIL
PUMP P-1521A
TOP LCO FLUSH OIL
DRUM D-1519
TOP LCO FLUSH OIL
DRUM D-1519

DATE: 06/12/07

PID:

Setting
(kg/cm2g)

319
319
319
319
319
321
321
322
322
322
322
322
322
323
323
324
324
325
325
326
326
326
327
327
Page 218 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

TAG No.

Description

015-PSV
-454-A
015-PSV
-454-B
015-PSV
-457-A
015-PSV
-457-B
015-PSV
-458-A
015-PSV
-458-B
015-PSV
-459-A
015-PSV
-459-B
015-PSV
-001-A
015-PSV
-001-B
015-PSV
-494-A
015-PSV
-494-B
015-PSV
-002
015-PSV
-538-A
015-PSV
-529
015-PSV
-530
015-PSV
-531
015-PSV
-532
015-PSV
-533
015-PSV
-534
015-PSV
-535
015-PSV
-536
015-PSV
-537
015-PSV
-566

Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)

Type
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

Location
LCO PRODUCT LP STEAM
GENTR E-1513
LCO PRODUCT LP STEAM
GENTR E-1513
LIGHT SLOPS DRUM D1522
LIGHT SLOPS DRUM D1522
HEAVY SLOPS DRUM D1523
HEAVY SLOPS DRUM D1523
TPW FROM TPW SURGE
DRUM D-1524
TPW FROM TPW SURGE
DRUM D-1524
METAL PASSVTR PUMP
DISCH P-1502A
METAL PASSVTR PUMP
DISCH P-1502B
CLARIFIED OIL TO
STORAGE
CLARIFIED OIL TO
STORAGE
MP STEAM FRM STM
INJECTION POINTS
HCO FLUSH OIL TO LP
FLH HDR
LCO PUMPAROUND
PUMP P-1510A
LCO PUMPAROUND
PUMP P-1510A
LCO PUMPAROUND
PUMP P-1510A
LCO PUMPAROUND
PUMP P-1510A
LCO PUMPAROUND
PUMP P-1510B
LCO PUMPAROUND
PUMP P-1510B
LCO PUMPAROUND
PUMP P-1510B
LCO PUMPAROUND
PUMP P-1510B
LCO STROPPER PUMP P1511A
LCO STROPPER PUMP P1511A

DATE: 06/12/07

PID:

Setting
(kg/cm2g)

328
328
329
329
330
330
331
331
121
121
323
323
123
326
637
637
637
637
637
637
637
637
637
637
Page 219 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

TAG No.

Description

015-PSV
-567
015-PSV
-568
015-PSV
-569
015-PSV
-572
015-PSV
-573
015-PSV
-574
015-PSV
-575
015-PSV
-576
015-PSV
-579
015-PSV
-602
015-PSV
-603
015-PSV
-605
015-PSV
-606
015-PSV
-607
015-PSV
-608
015-PSV
-609
015-PSV
-611
015-PSV
-613
015-PSV
-615
015-PSV
-617
015-PSV
-619
015-PSV
-620
015-PSV
-621
015-PSV
-623

Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)

Type
RV
RV
RV
RV

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

Location
LCO STROPPER PUMP P1511B
LCO STROPPER PUMP P1511B
MC RECYCLE PUMP P1512A
MC RECYCLE PUMP P1512B

DATE: 06/12/07

PID:
637
637
637
637

RV

LEAN OIL PUMP P-1513A

637

RV

LEAN OIL PUMP P-1513A

637

RV

LEAN OIL PUMP P-1513A

637

RV

LEAN OIL PUMP P-1513A

637

RV

FRACTIONATOR REFLUX
PUMP P-1516A

637

RV

LEAN OIL PUMP P-1513B

637

RV

LEAN OIL PUMP P-1513B

637

RV

LEAN OIL PUMP P-1513B

637

RV

LEAN OIL PUMP P-1513B

637

RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV

NAPHTHA PUMP AROUND


PUMP P-1514A
NAPHTHA PUMP AROUND
PUMP P-1514A
NAPHTHA PUMP AROUND
PUMP P-1514A
NAPHTHA PUMP AROUND
PUMP P-1514A
NAPHTHA PUMP AROUND
PUMP P-1514B
NAPHTHA PUMP AROUND
PUMP P-1514B
NAPHTHA PUMP AROUND
PUMP P-1514B
NAPHTHA PUMP AROUND
PUMP P-1514B
HVN PRODUCT PUMP P1515A
HVN PRODUCT PUMP P1515A
HVN PRODUCT PUMP P1515B

Setting
(kg/cm2g)

637
637
637
637
637
637
637
637
637
637
637
Page 220 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

TAG No.

Description

Type

015-PSV
-625
015-PSV
-627
015-PSV
-629
015-PSV
-631
015-PSV
-632
015-PSV
-633
015-PSV
-634
015-PSV
-635
015-PSV
-636
015-PSV
-637
015-PSV
-640
015-PSV
-641
015-PSV
-642
015-PSV
-643
015-PSV
-644
015-PSV
-649

Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)

015-PSV
-752

Relief Valve
(Spring)

RV

015-PSV
-754

Relief Valve
(Spring)

RV

015-PSV
-762
015-PSV
-764
015-PSV
-766
015-PSV
-767
015-PSV
-768

Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)

RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV

RV
RV
RV
RV
RV

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

Location
HVN PRODUCT PUMP P1515B
HCO FLUSHING OIL
PUMP P-1521A
HCO FLUSHING OIL
PUMP P-1521A
HCO FLUSHING OIL
PUMP P-1521B
HCO FLUSHING OIL
PUMP P-1521B
LCO FLUSHING OIL PUMP
P-1522A
LCO FLUSHING OIL PUMP
P-1522B
HEAVY SLOPS PUMP P1527A
HEAVY SLOPS PUMP P1527B
FRACTIONATOR REFLUX
PUMP P-1516B
OVERHEAD SOUR
WATER PUMP P-1517A
OVERHEAD SOUR
WATER PUMP P-1517B
OVERHEAD LIQUID PUMP
P-1518A
OVERHEAD LIQUID PUMP
P-1518A
OVERHEAD LIQUID PUMP
P-1518B
OVERHEAD LIQUID PUMP
P-1518B
DEBUTANIZER
OVERHEAD PUMP P1556A
DEBUTANIZER
OVERHEAD PUMP P1556B
INTER STAGE DRUM
PUMP P-1551A
INTER STAGE DRUM
PUMP P-1551B
KO DRUM LIQUID PUMP
P-1552A
KO DRUM LIQUID PUMP
P-1552B
STRIPPER FEED PUMP P1553A

DATE: 06/12/07

PID:

Setting
(kg/cm2g)

637
637
637
637
637
637
637
637
637
637
637
637
637
637
637
637
637
637
637
637
637
637
637
Page 221 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

TAG No.

Description

Type

015-PSV
-771
015-PSV
-773
015-PSV
-774
015-PSV
-720-A
015-PSV
-720-B
015-PSV
-425-A
015-PSV
-425-B
015-PSV
-427-A
015-PSV
-427-B
015-PSV
-011-A
015-PSV
-011-B
015-PSV
-390-A
015-PSV
-390-B
015-PSV
-391-A
015-PSV
-391-B
015-PSV
-417-B
015-PSV
-419-B
015-PSV
-538-B
015-PSV
-421-B
015-PSV
-004-A
015-PSV
-004-B

Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)

015-PSV
-783

Relief Valve
(Spring)

RV

015-PSV
-784

Relief Valve
(Spring)

RV

RV
RV
RV
RV
RV
RV
RV
RV
RV

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

Location
STRIPPER FEED PUMP P1553B
GASOLINE RECYCLE
PUMP P-1554A
GASOLINE RECYCLE
PUMP P-1554B
P-1603B DISCHARGE
LINE
P-1604A DISCHARGE
LINE
PS FRM STMGEN E-1504B
AND E-1505B
PS FRM STMGEN E-1504B
AND E-1505B
PS FRM STMGEN E-1504A
AND E-1505A
PS FRM STMGEN E-1504A
AND E-1505A

DATE: 06/12/07

Setting
(kg/cm2g)

PID:
637
637
637
411
411
315
315
314
314

RV

126

RV

126

RV

307

RV

307

RV

317

RV

317

RV

312

RV

312

RV

326

RV

313

RV

123

RV

123
8474L-015PID-0041653
8474L-015PID-0041653
Page 222 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

TAG No.

Description

015-PSV
-869
015-PSV
-313
015-PSV
-314
015-PSV
-801
015-PSV
-005-S
015-PSV
-639
015-PSV
-702
015-PSV
-706
015-PSV
-708
015-PSV
-713
015-PSV
-711
015-PSV
-716
015-PSV
-717
015-PSV
-718
015-PSV
-431
015-PSV
-413
015-PSV
-430
015-PSV
-433
015-PSV
-442
015-PSV
-443

Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Spring)
Relief Valve
(Thermal)
Relief Valve
(Thermal)
Relief Valve
(Thermal)
Relief Valve
(Thermal)
Relief Valve
(Thermal)
Relief Valve
(Thermal)
Relief Valve
(Thermal)
Relief Valve
(Thermal)
Relief Valve
(Thermal)
Relief Valve
(Thermal)
Relief Valve
(Thermal)
Relief Valve
(Thermal)
Relief Valve
(Thermal)
Relief Valve
(Thermal)
Relief Valve
(Thermal)

Type

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

Location

DATE: 06/12/07

PID:

Setting
(kg/cm2g)

RV
RV

654

RV

654

RV

654

RV

136

RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV
RV

CWS TO BLOWDOWN
COOLER E-1532
CWS TO WET GAS COMP
CLR E-1552A/B
CWS TO STRIPPER
CONDNSR E-1554A-D
CWS TO GASOLINE
COOLER E-1559
CWS TO LEAN OIL
COOELR E-1564
CWS TO FUEL GAS
COOLER E-1565
CWS TO DBTR CONDNSR
E-1561A/B
CWS TO LPG COOELR E1562
CWS TO LEAN AMINE
COOLER E-1566
CWS TO HVN TRIM
COOLER E-1518
BFB FROM LCO PA BFW
HTR E-1511
BFB FROM HVN BFW
HEATER E-1516
CWS TO OVRHD TRM
CONDSR E-1520A-H
TPW FROM SLRY CLF
COOLER E-1507B
TPW FROM SLRY CLF
COOLER E-1507D

452
403
404
406
407
408
410
411
411
328
307
317
319
323
323

For further details, refer to the Flare Discharge Summary of the RFCC: Doc. No. 8474L015-NM-0006-701.

Page 223 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

TRAINING MODULE

RESIDUE FLUID CATALYTIC CRACKER (RFCC)


UNIT: 15

Course Content:
Section 1 - General Description
Section 2 - Process Flow Description
Section 3 - Process Control
Section 4 - Safeguarding Devices
Section 5 - Fire & Gas Systems

Section 6 - Quality Control


Section 7 - Cause & Effects
Section 8 - Operating Procedures
Section 9 - HSE
Section 10 - Reference Document Index

Page 224 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

SECTION 5 : FIRE & GAS SYSTEMS


5.1. Fire & Gas detection
Refer to the following documents:
8474L-015-DW-1950-021

Fire & Gas Detector Layout RFCC/LTU/NTU units

8474L-015-DW-1960-001

Escape Route Layout RFCC/LTU/NTU units

8474L-015-DW-1514-610

Fire and gas Cause and Effect Chart Area 3

5.2. Fire Protection


Refer to the following documents:
8474L-015-DW-1933-001 Fire Protection Layout RFCC/LTU/NTU units
8474L-015-DW-1933-011 Safety Equipment Layout RFCC/LTU/NTU units

Page 225 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

TRAINING MODULE

RESIDUE FLUID CATALYTIC CRACKER (RFCC)


UNIT: 15

Course Content:
Section 1 - General Description
Section 2 - Process Flow Description
Section 3 - Process Control
Section 4 - Safeguarding Devices
Section 5 - Fire & Gas Systems
Section 6 - Quality Control

Section 7 - Cause & Effects


Section 8 - Operating Procedures
Section 9 - HSE
Section 10 - Reference Document Index

Page 226 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

SECTION 6 : QUALITY CONTROL


This section outlines the sampling schedule and analytical methods that the licensor
suggests for monitoring the feed and product quality. The feed must be analyzed to be
certain that it conforms to the quality of the feed that was used for the design. This is
important for setting the operating severity level and for monitoring the catalyst activity.
The products must be analyzed to ensure that the unit is producing on grade materials.
The analytical results will often determine whether the material has to be "off-graded", or
whether the material is acceptable for the next processing step. Therefore, it is obvious
that ever precaution should be taken to make the sample representative of the original
material. That is, it must be like all the rest of the material being processed or the
material collected in the vessel.
The analytical results reported by the laboratory can be no better than the sample
submitted. An analysis or test however, efficiently carried out, will be rendered valueless
if the sample has been improperly taken.
Absolute verification of out-of-specification batches of material must be made by resampling and repeating the analysis before the material is off-graded.
6.1. Sampling Analysis
For proper control of the unit it is essential to run laboratory tests on a regular basis. The
following tests are recommended as a minimum.

6.1.1. Feed Oil


Analysis

Method

Frequency

Gravity

ASTM D 1298/D 4052

Daily

ASTM Distillation

ASTM D 1160

Daily

Viscosity

ASTM D 445

Daily

Sulfur

ASTM D 4294

Daily

Nitrogen

ASTM D 4629

Daily

Conradson carbon residue (CCR)

ASTM D 189

Daily

Metals

ASTM D 5863 / D 5708 /D 5185

Weekly

Aniline point

ASTM D 611

Weekly

6.1.2. Catalyst
Analysis

Method

Frequency

Spent Catalyst

Carbon

Element Analyser

Daily

1st regenerator catalyst

Carbon

ASTM D 3178 or equivalent

Daily

2nd regenerator catalyst

Carbon

ASTM D 3178 or equivalent

Daily
Page 227 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

Analysis
Fresh Catalyst

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Method

Frequency

Particle Size
MAT Activity
Surface Area
Pore Volume
Bulk Density
Metals

By catalyst vendor
By catalyst vendor
By catalyst vendor
By catalyst vendor

Rare Earths

6.1.3. Light Cycle Oil


Analysis

Method

Frequency

Specific Gravity

ASTM D 1298 / D 4052

Daily

Distillation

ASTM D 86

Daily

Sulfur

ASTM D 4294

Daily

Nitrogen

ASTM D 4629

Daily

Color

ASTM D 1500

Daily

Flash Point

ASTM D 93

Daily

Cloud Point

ASTM D 2500

Daily

Water

ASTM D 4377 / E 0203

Daily

Viscosity at 50C

ASTM D 445

Daily

Pour Point

ASTM D 97

Daily

Analysis

Method

Frequency

Specific Gravity

ASTM D 1298 / D 4052

At Request

Distillation

ASTM D 86 / D 1160

At Request

Viscosity

ASTM D 445

At Request

Sulfur

ASTM D 4294

At Request

Analysis

Method

Frequency

Specific Gravity

ASTM D 1298 / D 4052

Daily

Distillation

ASTM D 1160

At Request

6.1.4. Heavy Cycle Oil

6.1.5. Clarified Oil

Page 228 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Analysis

Method

Frequency

Viscosity at 100C

ASTM D 445

At request

Pour Point

ASTM D 97

Daily

Flash Point

ASTM D 93

At Request

Sulfur

ASTM D 4294

Daily

Water & Sediment

ASTM D 1796

Daily

Catalyst Loading (Ash)

ASTM D 482

Daily

Analysis

Method

Frequency

Catalyst Loading

ASTM D 482

Daily

Analysis

Method

Frequency

Composition

Gas Chromatograph

Daily

H2S

Draeger Tube

Daily

Analysis

Method

Frequency

Specific Gravity

ASTM D 1298 / D 4052

Daily

Distillation

ASTM D 86

Daily

Sulfur

ASTM D 4294

Daily

RON

ASTM D 2699

Daily

MON

ASTM D 323

Daily

Analysis

Method

Frequency

Composition

Gas Chromatograph

Daily

C5 (mol%)

ASTM D 2163

Daily

C2 (mol%)

ASTM D 2163

Daily

Specific Gravity

ASTM D 1657

As required

6.1.6. Slurry

6.1.7. Absorber Gas

6.1.8. Heavy Naphta

6.1.9. LPG

Page 229 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

6.1.10. Sour Water


Analysis

Method

Frequency

pH

ASTM D 1293

At request

Copper

ASTM D 1688

At request

Iron

ASTM D 1068

At request

Phenols

ASTM D 1783

At request

Cyanides

ASTM D 4282

At request

Sulfides

ASTM D 4658

At request

Ammonia

ASTM D 4658

At request

Hydrocarbons

ASTM D 3921

At request

6.1.11. Sampling Connections


For the sampling connections details per type (as listed below), refer to the
following P&IDs:

8474L-015-PID-0021-611

Sampler Details (1/3)

8474L-015-PID-0021-612

Sampler Details (2/3)

8474L-015-PID-0021-613

Sampler Details (3/3)

Connection Type

Tag

Service

PID

SC-413

Sour water from T-1501 overhead


sour water pumps P-1517A/B to
SWS (unit 18)

320

SC-412

Heavy naphta from heavy naphta


trim cooler E-1518 to gasoline
treating

328

SC-706

Gasoline from gasoline cooler E1559 to gasoline treating

406

SC-704

Sour water from HP separator


drum D-1553 to SWS

404

SC-709

Rich Sponge Oil from Secondary


Absorber T-1553 to lean oil/rich
oil cooler E-1563

407

SC-710

Sour water from lean oil coalescer


D-1556 to SWS

407

SC-712

Rich amine from fuel gas

408

Type 1A:
Low temperature liquid sample and
low pour point products (gasoline,
diesel)
Operating Temperature 50C
Operating Pressure 8.16 kg/cm2g
Type 1B:
Low temperature liquid sample
Operating Temperature 50C
Operating Pressure > 8.16 kg/cm2g
Type 2:
Low temperature gas and flashing
liquid sample service
Operating Temperature 50C

Page 230 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

Connection Type

Tag

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Service
absorber T-1555 to ARU (unit 19)

PID

SC-713

Off gas from fuel gas absorber


outlet KO drum D-1559 to fuel gas 408
system

SC-715

Sour water from Debutanizer


Reflux Drum D-1554 to SWS

410

SC-716

LPG from LPG cooler E-1562 to


LPG amine absorber T-1556

411

SC-717

Rich amine from LPG amine


absorber T-1556 to ARU (unit 19)

411

SC-419

LCO product from LCO air cooler


E-1514 to storage

328

SC-418

LCO Product at the outlet of LCO


air cooler E-1514

328

SC-421

LCO product from LCO air cooler


E-1514 to LCO HDT

328

SC-701

Wet gas from 1st stage KO drum


outlet to wet gas compressor C1551 (1st stage)

401

SC-702

Wet gas from interstage KO drum


outlet to C-1551 (2nd Stage)

403

SC-703

Stripper overhead from T-1552 to


stripper condensers E-1554 A-D

404

Type 4A:

SC-705

405

Low temperature gas and flashing


liquid sample service

HP separator vapour from D-1553


to primary absorber T-1551

SC-707

Primary absorber overhead from


T-1551 to secondary absorber

407

SC-711

Fuel gas from secondary


absorber T-1553 to fuel gas
cooler E-1565

408

SC-714

Fuel gas from fuel gas inlet


absorber KO drum D-1557 to fuel
gas absorber inlet

408

SC-718

LPG from LPG amine coalescer


to LPG treating unit

411

SCC-401

Residue feed from feed surge


drum D-1513 to feed pumps P1501 A/B suction

301

Type 3A:
Low temperature liquid sample
Operating Temperature 50C
Operating Pressure 8.16 kg/cm2g
Type 3A:
Low temperature liquid sample
Operating Temperature 50C
Operating Pressure > 8.16 kg/cm2g

Operating Temperature 50C

Type 5A:
High temperature liquid sample and

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Connection Type
low pour point products

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Tag

Service

PID

SCC-411

Continuous blowdown from LCO


LP steam generator E-1510

316

SCC-415

Continuous blowdown from slurry


LP steam generator E-1506 B

322

SCC-416

Continuous blowdown from slurry


LP steam generator E-1506 A

322

SCC-417

Clarified Oil from the slurry


clarified oil coolers E-1507 A-D to
storage

323

SCC-422

HCO from the HCO LP steam


generator E-1510 to the HCO
flushing oil drum D-1518

316

SCC-402

Continuous blowdown from HCO


recycle MP steam generator E1508

306

SCC-403

Continuous blowdown from HCO


pumparound MP steam generator
E-1523

308

SCC-404

Continuous blowdown from the


Slurry HP steam generator E1503A

312

Type 5B:

SCC-405

312

High Temperature Liquid Sample


and low pour point products with
jacketed cooler

Continuous blowdown from the


Slurry HP steam generator E1503B

SCC-406

Continuous blowdown from the


Slurry HP steam generator E1503C

313

SCC-407

Continuous blowdown from slurry


HP steam generator E-1504B

315

SCC-408

Continuous blowdown from slurry


HP steam generator E-1504A

314

SCC-409

Continuous blowdown from slurry


MP steam generator E-1505B

315

SCC-410

Continuous blowdown from slurry


MP steam generator E-1505A

314

SCC-420

Continuous blowdown from the


LCO product LP steam generator
E-1513

328

SC-414

Slurry product from the slurry


draw-off drum to the slurry MP
steam generators E-1506 A/B

321

Operating Temperature > 50C


Operating Pressure 8.16 kg/cm2g

Operating Temperature > 50C


Operating Pressure > 8.16 kg/cm2g

Type 7:
High Temperature Liquid Sample
and high pour point products

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REV: A

DATE: 06/12/07

Tag

Service

PID

SCC-708

Stripper T-1552 bottoms to


Debutanizer T-1554

405

SC-101

Cold condensate leaving the


turbine ST-1501 of the air blower
C-1501

132

Operating Temperature > 50C


Type 8:
High Temperature gas & flashing
liquid sample service
Operating Temperature > 50C
Type 15:
Low temperature liquid sample
Operating Temperature < 50C
6.2. On-line analyzers
All the on-line analysers of the RFCC are dedicated to the control of the flue gas
composition, to ensure the environmental specifications are satisfied prior to discharging
to atmosphere.
The main components of the regenerator flue gases are as follow:
Parameter

Value Range

O2 (vol%)

0 to 5

CO (vol%)

0.01 to 8

CO2 (vol%)

5 to 20

N2 (vol%)

60 to 80

H2O (vol%)

5 to 20

SOx (vol ppm)

50 to 1000

NOx (vol ppm)

20 to 400

Catalyst fines (mg/Nm3)

200 to 3000

Temperature (C)

620 to 840

Pressure (kg/cm2g)

0.05 to 3.7

Measures of O2, CO and CO2 content are necessary for operating the unit. They are
made continuously. Dry and particle-free samples are required for both types of
analysers.
Measures of SOx and NOx content are necessary for pollution control. They can be made
continuously or from time to time.
The regenerator flue gas sampling sets 2 problems:

Elimination of catalyst fines which concentration can reach 3000 mg/Nm3

Elimination of water which concentration can reach 20 vol%

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DATE: 06/12/07

To overcome this, the sampling system comprises of the following steps:

Primary filtration in which the solid particles are eliminated at a temperature over
the flue gas dew point (250C (min.) to 840C(max.)) in order to avoid plugging
and mud build up. So the filtration chamber is equipped with superheated MP
steam tracing and heat conservation.

Carrying system: the sample is carried in stainless steel or monel tube traced with
MP steam from the filtration chamber to the conditioning system. The sample is
carried at temperature over the dew point in order to avoid acid condensation in
the pipe due to SOx.

Conditioning system, where the sample is cooled down. It goes through a


separator from condensates extraction. The condensates are drawn off by a
peristaltic pump in the bottom of the conditioning device. In case of flue gas at
atmospheric pressure the sample is compressed by a diaphragm pump prior to
being dried. In case of flue gas under pressure, the sample is expanded after
drying.

Analysers:
o O2 content is measured by paramagnetic type analyser
o CO and CO2 content is measured by infrared photometric type analyser
o SOx content is measured by infrared photometry
o NOx is measured by chemiluminescence

Service

Physical
property
analyzed

AI-004

Paramagnetic type
O2 analyzer

1st
regenerator
flue gas

AI-005

Infrared photometric
type CO2 analyzer

Analyzer
tag

Description

Design Value
PID:

CO
Min.

Norm
al

CO
Max.

O2 content

0.0
Mol%

0.0
Mol%

0.0
Mol%

1st
regenerator
flue gas

CO2 content

11.57
Mol%

9.94
Mol%

8.0
Mol%

AI-006

Infrared photometric
type CO analyzer

1st
regenerator
flue gas

CO content

4.63
Mol%

6.26
Mol%

8.00
Mol%

AI-007

Infrared photometric
type CO analyzer

2nd
regenerator
flue gas

CO content

0.00
Mol%

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DATE: 06/12/07

Design Value
AI-008

Infrared photometric
type CO2 analyzer

2nd
regenerator
flue gas

CO2 content

16.98
Mol%

AI-009

Paramagnetic type
O2 analyzer

2nd
regenerator
flue gas

O2 content

1.85
Mol%

AI-011

Infrared photometric
type CO analyzer

CO Boiler
Flue Gas

CO content

<300
ppm
vol

<300
ppm
vol

AI-012

Infrared photometric
type CO2 analyzer

CO Boiler
Flue Gas

CO2 content

13.56
Mol%

14.17
Mol%

AI-013

Paramagnetic type
O2 analyzer

CO Boiler
Flue Gas

O2 content

1.78
Mol%

1.78
Mol%

AI-018

Paramagnetic type
O2 analyzer

Flue gas
inlet to
stack

O2 content

1.78
Mol%

1.78
Mol%

205

AI-019

Infrared
Spectrophotometer

Flue gas
inlet to
stack

SOx content

0.05
Mol%

0.06
Mol%

205

AI-020

Chemiluminescence
type analyzer

Flue gas
inlet to
stack

NOx content

<1000
ppm
vol

<1000
ppm
vol

205

For further details refer to the process data sheet of the RFCC analyzers, doc. No.
8474L-015-PDS-AE-001.

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DATE: 06/12/07

TRAINING MODULE

RESIDUE FLUID CATALYTIC CRACKER (RFCC)


UNIT: 15

Course Content:
Section 1 - General Description
Section 2 - Process Flow Description
Section 3 - Process Control
Section 4 - Safeguarding Devices
Section 5 - Fire & Gas Systems
Section 6 - Quality Control
Section 7 - Cause & Effects

Section 8 - Operating Procedures


Section 9 - HSE
Section 10 - Reference Document Index

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REV: A

DATE: 06/12/07

SECTION 7 : CAUSES AND EFFECT

7.1. Cause & Effect Matrix:


Refer to the following documents:

Cause and Effect Chart, Doc. No. 8474L-015-DW-1514-602

Fire & gas Cause and Effect Chart for Area 3, Doc. No. 8474L-015-DW-1514-610

Note:
The cause & effect matrix Doc. No. 8474L-015-DW-1514-602 details the safety trips and
protection evoked in the safeguards narrative in section 4 of this document.
The fire & gas cause and effect chart deals with all the fire & gas detection system in the
area 3 (units 015, 016 and 017).
7.1.1. Example from Cause and Effect Chart
To better understand how the Cause & Effect Matrix can be interpreted, an
example is given, which details the information that can be extracted from a sheet
of the Cause & Effect Diagram. It shall be read in conjunction with the
corresponding sheet of the Cause & Effect Diagram.
7.1.1.1. Sheet 18: UX-426: T-1501 & P-1519 inventory isolation
The following table describes all the causes activating the logic UX-426:
No.

Initiator Tag No.

P&ID

Description

UXHS-426A

311

Hardwire ESD switch active

UXHS-426B

311

Hardwire LOCAL switch active

XZSM-413

311

70% limit switch of P-1519A suction valve XV-413 active

XZSO-413

311

OPEN limit switch of P-1519A suction valve XV-413 active

XZSM-414

311

70% limit switch of P-1519B suction valve XV-414 active

XZSO-414

311

OPEN limit switch of P-1519B suction valve XV-414 active

XZSM-415

311

70% limit switch of P-1519C suction valve XV-415 active

XZSO-415

311

OPEN limit switch of P-1519C suction valve XV-415 active

HS-419

311

DCS software switch active (DCS/Local operation is not


allowed when UX-426 is tripped)

10

XHSO-419B

311

LOCAL software switch active (DCS/Local operation is not


allowed when UX-426 is tripped)

11

XHSC-419B

311

LOCAL software switch active (DCS/Local operation is not


allowed when UX-426 is tripped)

12

HS-421

311

DCS software switch active (DCS/Local operation is not


allowed when UX-426 is tripped)
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REV: A

DATE: 06/12/07

No.

Initiator Tag No.

P&ID

Description

13

XHSO-421B

311

LOCAL software switch active (DCS/Local operation is not


allowed when UX-426 is tripped)

14

XHSC-421B

311

LOCAL software switch active (DCS/Local operation is not


allowed when UX-426 is tripped)

15

HS-423

311

DCS software switch active (DCS/Local operation is not


allowed when UX-426 is tripped)

16

XHSO-423B

311

LOCAL software switch active (DCS/Local operation is not


allowed when UX-426 is tripped)

17

XHSC-423B

311

LOCAL software switch active (DCS/Local operation is not


allowed when UX-426 is tripped)

18

UXHS-426C

311

LOCAL hardwire switch active

19

UXHS-426D

311

LOCAL hardwire switch active

20

UXHS-426E

311

LOCAL hardwire switch active

21

UXHS-426F

311

LOCAL hardwire switch active

22

UXHS-426G

311

LOCAL hardwire switch active

Depending on which initiators are active, the logic UX-0426 may generate
the effects detailed in the following table. For each effect, the
corresponding initiators are indicated by a letter at the junction between
the cause and the effect. The letter tells which can of action is taken.
For example A indicates the activation of a device/system, C and O
indicate the closing and opening of a valve respectively.
No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

1a

XSY-419

1, 2, 3, 9, 11,
18, 19, 20,
21, 22

311

CLOSE the slurry pumparound pump P1519A turbine HP steam valve XV-419

1b

XSY-419

10

311

OPEN the slurry pumparound pump P1519A turbine HP steam valve XV-419

1c

XSY-419

311

ALLOW the opening of the slurry


pumparound pump P-1519A turbine HP
steam valve XV-419:
Turbine of pump is automatically stopped
when XV is less than 70% open and can
only be restarted when XV is fully open.

2a

XSY-421

1, 2, 5, 12,
14, 18, 19,
20, 21, 22

311

CLOSE the slurry pumparound pump P1519B turbine HP steam valve XV-421

2b

XSY-421

13

311

OPEN the slurry pumparound pump PPage 238 of 323

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No.

Action Tag No.

Initiated by
initiator No:

P&ID

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Description
1519B turbine HP steam valve XV-421

2c

XSY-421

311

ALLOW the opening of the slurry


pumparound pump P-1519B turbine HP
steam valve XV-421:
Turbine of pump is automatically stopped
when XV is less than 70% open and can
only be restarted when XV is fully open.

3a

XSY-423

1, 2, 7, 15,
17, 18, 19,
20, 21, 22

311

CLOSE the slurry pumparound pump P1519C turbine HP steam valve XV-423

3b

XSY-423

16

311

OPEN the slurry pumparound pump P1519C turbine HP steam valve XV-423

3c

XSY-423

311

ALLOW the opening of the slurry


pumparound pump P-1519B turbine HP
steam valve XV-423:
Turbine of pump is automatically stopped
when XV is less than 70% open and can
only be restarted when XV is fully open.

XSY-413

1, 2, 18, 19,
20, 21, 22

311

CLOSE P-1519A suction motor operated


valve XV-413

XSY-414

1, 2, 18, 19,
20, 21, 22

311

CLOSE P-1519B suction motor operated


valve XV-414

XSY-415

1, 2, 18, 19,
20, 21, 22

311

CLOSE P-1519C suction motor operated


valve XV-415

XSY-416

1, 2, 18, 19,
20, 21, 22

311

CLOSE P-1519A discharge motor operated


valve XV-416

XSY-417

1, 2, 18, 19,
20, 21, 22

311

CLOSE P-1519B discharge motor operated


valve XV-417

XSY-418

1, 2, 18, 19,
20, 21, 22

311

CLOSE P-1519C discharge motor operated


valve XV-418

10

XXA-413

1, 2, 18, 19,
20, 21, 22

311

Activate XV-413 trip alarm

11

XXA-414

1, 2, 18, 19,
20, 21, 22

311

Activate XV-414 trip alarm

12

XXA-415

1, 2, 18, 19,
20, 21, 22

311

Activate XV-415 trip alarm

13

XXA-416

1, 2, 18, 19,
20, 21, 22

311

Activate XV-416 trip alarm

14

XXA-417

1, 2, 18, 19,
20, 21, 22

311

Activate XV-417 trip alarm

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REV: A

DATE: 06/12/07

No.

Action Tag No.

Initiated by
initiator No:

P&ID

Description

15

XXA-418

1, 2, 18, 19,
20, 21, 22

311

Activate XV-418 trip alarm

Once all the initiators are healthy, the logic UX-426 can be reset by:

DCS software switch UHSR-426;

The motor operated valves must


413/414/415/416/417/
418
are
413/414/415/416/417/418 respectively.

be reset locally: XVreset


by
XHSR-

The C&E chart also indicates the Maintenance Override Switches (MOS)
and Operation Override Switches (OOS) associated with the instrument
triggering the logic and allowing the operator to bypass the conditions
tripping the system:
Instrument

OOS

MOS

UXHS-426A

N/A

N/A

UXHS-426B

N/A

N/A

XZSM-413

N/A

XZHS-413-A

XZSO-413

N/A

XZHS-413-B

XZSM-414

N/A

XZHS-414-A

XZSO-414

N/A

XZHS-414-B

XZSM-415

N/A

XZHS-415-A

XZSO-415

N/A

XZHS-415-B

HS-419

N/A

N/A

XHSO-419B

N/A

N/A

XHSC-419B

N/A

N/A

HS-421

N/A

N/A

XHSO-421B

N/A

N/A

XHSC-421B

N/A

N/A

HS-423

N/A

N/A

XHSO-423B

N/A

N/A

XHSC-423B

N/A

N/A

UXHS-426C

N/A

N/A

UXHS-426D

N/A

N/A

UXHS-426E

N/A

N/A
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UXHS-426F

N/A

N/A

UXHS-426G

N/A

N/A

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

When no OOS or MOS are available, then the condition leading to the
activation of the logic cannot be bypassed.

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TRAINING MODULE

RESIDUE FLUID CATALYTIC CRACKER (RFCC)


UNIT: 15

Course Content:
Section 1 - General Description
Section 2 - Process Flow Description
Section 3 - Process Control
Section 4 - Safeguarding Devices
Section 5 - Fire & Gas Systems
Section 6 - Quality Control
Section 7 - Cause & Effects
Section 8 - Operating Procedures

Section 9 - HSE
Section 10 - Reference Document Index

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REV: A

DATE: 06/12/07

SECTION 8 : OPERATING PRACTICES


8.1. Normal Operation
8.1.1. Operating conditions
The following is a narrative of the main process conditions of the RFCC unit in
steady state and FOR THE BACH HO MAX DISTILLATE CASE ONLY. It also
details the line up during normal operation.
For a complete description of the Heat and material Balance & Operating
Conditions of the unit 015, refer to the following process flow diagrams:
8474L-015-PFD-0010-101

Reactor / Regeneration Section Case: Bach Ho

8474L-015-PFD-0010-102

Flue Gas Treatment Section Case: Bach Ho

8474L-015-PFD-0010-103

Feed Section Case: Bach Ho

8474L-015-PFD-0010-104

Fractionation Section Case: Bach Ho

8474L-015-PFD-0010-105

Gas Recovery Section Case: Bach Ho

8474L-015-PFD-0010-106

Material Balance Table Case: Bach Ho MG

8474L-015-PFD-0010-107

Material Balance Table Case: Bach Ho MD

8474L-015-PFD-0010-111

Reactor / Regeneration Section Case: Mixed Crude

8474L-015-PFD-0010-112

Flue Gas Treatment Section Case: Mixed Crude

8474L-015-PFD-0010-113

Feed Section Case: Mixed Crude

8474L-015-PFD-0010-114

Fractionation Section Case: Mixed Crude

8474L-015-PFD-0010-115

Gas Recovery Section Case: Mixed Crude

8474L-015-PFD-0010-116

Material Balance Table Case: Mixed Crude MG

8474L-015-PFD-0010-117

Material Balance Table Case: Mixed Crude MD

Normal operation Narrative


Feed Section
Drawing to be inserted here
Figure 54: Feed Preheat Section
Refer to P&IDs: 8474L-015-PID-0021-301 / 302 / 303 / 304 / 121
407,000 kg/hr of long residue is fed directly to the feed surge drum D-1513 from
the Crude Unit (CDU) through XV-404, at 115C and 4.5 kg/cm2g. The feed surge
drum pressure is maintained at 1.0 kg/cm2g by either admitting Fuel Gas via PV403A or venting excess off gas to the Flare header via PV-403B. From D-1513,
the feed flows to the suction of the Feed Pump on duty P-1501A via TI-403. P1501A pumps the feed to the LCO pumparound feed preheat exchangers E-1512

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A-D, through FIC-403. A slip stream of the feed is recycled back to the feed surge
drum via FV-403. The total duty of E-1512A-D is 14.79 MW.
The LCO PA feed preheat exchangers are constituted of 2 branches, in which the
feed flows in parallel:

1st Branch: Part of the feed is heated against LCO PA in the shell side of E1512A before flowing to the shell side of E-1512B via TW-404. The
preheated feed then exits the shell side of E-1512B via TZ-405.

2nd Branch: The remaining part of the feed flows through the shell side of
the E-1512C. The feed leaving the shell side of E-1512C flows through TW406 to the shell side of E-1512D and exits via TW-407.

The preheated feed leaving the shell side of E-1512B and E-1512D is recombined
and flows through TI-408 and PI-408 to the shell side of the MP steam feed heater
E-1522. MP steam is supplied to the tube side of E-1522 via FV-410. The duty of
E-1522 is 3.77 MW. Then the feed flows to the shell side of the HP steam feed
heater E-1524 via TI-409. HP steam is fed to the tube side of the exchanger via
FV-411.
The heated residue feed leaving E-1524 then flows to the 1st feed preheat slurry
exchangers E-1502 A/B/C, via TI-410, TIC-411, PI-409 and PV-410. The feed
flows through the shell side of these exchangers according to the following
sequence: E-1502A (shell side), TW-412, E-1502B (shell side), TW-533, E-1502C
(shell side). The total duty of E-1502 A-C is 19.95 MW.
Upstream of E-1502A, a slip stream flows through the bypass line of the slurry
feed preheat exchangers via TV-002.
The heated feed leaving the shell side of E-1502C then flows to the 2nd feed
preheat slurry exchangers E-1501 A/B via TI-421. Upstream of E-1501 A/B, the
feed is equally split into 2 streams flowing in parallel to the shell side E-1501A and
E-1501B. The total duty of the 2nd feed preheat slurry exchangers is 6.75 MW.
The feed leaving E-1501A and E-1501B flows through TW-534 and TW-535
respectively before being recombined and mixed with the feed bypass from E1524. The total preheated feed then flows towards the reactor riser via PIC-410,
TI-414, FIC-001, TI-001.
Downstream of TI-001, HCO recycle from E-1508 flows into the preheated feed
line via FIC-002 and FV-002. The temperature of the total feed is 290C. The total
feed flows to the feed line static mixer M-1501 via FXA-405 and XV-002.
Metal passivator, from the metal passivator drum D-1508, is NOT injected into the
feed line at the inlet of M-1510, since it is required for the Mixed Crude Case Only.
Reaction Section
Drawing to be inserted here
Figure 55: Reaction Section Bach Ho Maximum Distillate Case
Refer to P&IDs: 8474L-015-PID-0021-121 / 122 / 138
Downstream of the static mixer M-1501, the feed mixture flows to each feed
injectors I-1501 A-F via TI-003, FIC-003A-F, FV-003A-F and PG-003A-F.
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CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

The feed should be split evenly between the feed nozzles as observed by
individual flow indicators. Pressures PG-003A-F on each feed nozzle should be
monitored as a verification of flow and indication of nozzle condition.
162,000 kg/hr of Dispersion steam is supplied to each of the six feed nozzles to
promote atomization and vaporization of the feed. MP steam at 250C flows to
each of the six feed nozzles via TI-004, PI-004, FIC-005 A-F, FV-005 A-F and PG005A.
2,790 kg/hr of stabilization steam is supplied to the stabilization injectors I-1503 A
to D at the bottom of the riser. The MP steam at 250C is supplied from the MP
steam header to each of the 4 injectors via TI-007, FIC-007 A to D, FV-007 A to D
and PG-007 A to D.
MTC is NOT required for Bach Ho crude operation and is only used when on
mixed crudes and in high gasoline make modes. In such a case, MTC recycle is
pumped from the tray #19 of the main fractionator T-1501 by means of the duty
MTC recycle pump P-1512A to the MTC injectors I-1502 A to D. These injectors
are located downstream of the feed injectors. The pressure at the pump discharge
can be checked locally via PG-413. From the pump discharge, the MTC recycle
flows to each of the 4 MTC injectors I-1502 A to D via FI-009, PI-009, XV-003, TI031, FIC-010 A to D, FV-010 A to D and PG-010 A to D. the flow is evenly split
between each of the 4 MTC injectors.
Even though MTC is not required for the Bach Ho Crude operation, a total of 660
kg/hr of MTC dispersion steam is injected to the 4 MTC injectors I-1502 A to D.
The MP steam at 250C flows from the MP steam header to the each of the
injectors via TI-010, FIC-011 A to D, FV-011 A to D and PG-011 A to D.
Finally, 6,875 kg/hr of backflush oil at 170C is pumped by P-1506A from the
backflush oil receiver D-1517 to the riser, downstream of the MTC injectors.
Backflush oil flows from P-1506A discharge to the unique backflush oil injector I1504 through XV-004, TI-039, FIC-012, FV-012 and PG-009. The pressure at the
pump discharge can be monitored locally by means of PG-477.
200 kg/hr of MP dispersion steam is also injected into the backflush oil injector:
The MP steam at 250C flows to the injector via FIC-013, FV-013, TI-006 and PG012.
Riser/Reactor
Refer to P&IDs: 8474L-015-PID-0021-122 / 123 / 138
The sensible heat, heat of vaporization and heat of reaction required by the feed is
supplied by the hot regenerated catalyst. From the withdrawal well, 35.77 Ton/min
of hot regenerated catalyst flows to the riser wye via the Regenerated Catalyst
Slide Valve SV-1501. The riser outlet temperature (TIC-020) is controlled by the
amount of regenerated catalyst admitted to the riser through SV-1501. The
catalyst flowing from the withdrawal well is fluidized by the injection of fuel gas
from the fuel gas drum D-1509 and thru PCV-013, downstream of SV-1501. Fuel
gas is injected at several locations from SV-1501 to the riser wye.

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CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

In the wye section at the base of the riser, 500 kg/hr of steam are injected via a
steam ring to keep the regenerated catalyst in a fluid state at all times: the MP
steam flows from the header to the ring via TI-011, FT/FI-006, and PG-006.
The small droplets of feed contact hot regenerated catalyst in a counter current
way and vaporize immediately. The vaporized oil intimately mixes with the catalyst
particles and cracks into lighter, more valuable products along with slurry oil, coke
and gas.
The cracking reactions take place during the 2 seconds residence time in the riser
as the reaction mixture (composed of the products and the catalyst) accelerates
toward the Riser Outlet Separator System (ROSS) at the top of the riser.
The catalyst is quickly separated from the hydrocarbon/steam vapors in the ROSS
separator located at the end of the riser.
After exiting the ROSS separator, the vapours pass through the 6 Disengager
Cyclones CY-1501 A/B/C/D/E/F to complete the separation of catalyst from
vapours. The ROSS separator and disengager cyclones CY-1501A-F separate the
product vapors from spent catalyst and return the catalyst to the stripper bed.
544,699 kg/hr reactor product vapours at 505C, containing a small amount of
inerts, catalyst and steam, flow to the bottom of the main fractionator T-1501, via
TI-022 and MOV-011.
The reactor pressure "floats on" the main fractionator pressure and as such is not
directly controlled at the main fractionator reflux drum D-1514.
The reactor temperatures are monitored by means of TI-005 (downstream of the
stabilization injectors), TI-008 (downstream of the feed injectors) and TI-009
(downstream of the MTC injectors). The riser outlet temperature indicated by TI021 and controlled by TIC-020 is 505C.
300 kg/hr of anti-coking steam is provided at the top of the disengager/stripper
cyclones. The MP steam at 250C is supplied from the MP steam header to the
ring via FIC-033, FV-033 and PG-041.
Stripper
Refer to P&IDs: 8474L-015-PID-0021- 123 / 138
Catalyst exiting the ROSS separator is pre-stripped with 900 kg/hr of MP steam
from a steam ring located immediately at the exit of the separator diplegs. This is
an important feature for reducing coke yield. MP steam at 250C is supplied from
the header via FIC-032, FV-032 and PG-040.
The catalyst is further stripped by 7000 kg/hr of steam at 250C from the main
steam ring as the catalyst flows down the Disengager/stripper D-1501. MP steam
at 250C is supplied from the header to the main ring via FIC-030, FV-030 and
PG-038. 2 additional rings are also provided in addition to the main ring:

The upper ring, above the main ring, achieves a second stage of prestripping. For this, 3400 kg/hr of MP steam at 250C are supplied from the
steam header to the upper ring via FIC-031, FV-031 and PG-039.

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DATE: 06/12/07

The lower ring is located in the bottom head of the stripper to achieve a
stable fluidization at the inlet of the spent catalyst standpipe. For this, 2700
kg/hr of MP steam at 250C are supplied from the steam header to the
fluffing ring via FIC-029, FV-029 and PG-037.
The steam rate for this ring is part of the total steam required for good
stripping but its prime function is to aerate the catalyst entering the spent
catalyst standpipe. This is important for adequate head build-up to maintain
an adequate slide valve differential pressure for controlling the stripper
level.

The total steam flow is designed to provide about 6 kg of steam per ton of catalyst
circulated.
The contact between catalyst and steam is enhanced by the presence of fluidized
bed packing permitting cross and counter current flow of steam and catalyst. The
fluidized bed packing is located between the main ring and the lower ring.
It allows efficient contact between the catalyst and steam to displace the volatile
hydrocarbons contained on and in the catalyst particles before they enter the 1st
stage regenerator D-1502, where coke will be burnt off.
The temperature in the stripper is monitored via (from top to bottom): TI-018, TI019, TI-016, TI-017, TI-014 and TI-013.
Spent Catalyst Transfer
Refer to P&IDs: 8474L-015-PID-0021-125 / 138
Downstream of the main ring, stripped catalyst flows down the spent catalyst
standpipe. The spent catalyst is aerated by means of fuel gas flowing through
PCV-071 and PG-072 from the fuel gas drum D-1509. This fuel gas drum is
supplied with fuel gas from the fuel gas header. D-1509 is also supplied in fuel gas
from D-1559 in the gas recovery section, on pressure control with PIC-367 acting
on PV-367A. The fuel gas pressure in D-1509 can be monitored locally with PG368. The total flow of FG leaving the drum D-1509 to various locations in the
reaction section (for fluidization or aeration purpose) is monitored by FI-203.
Nitrogen is also supplied via PCV-089, PG-090 and FI-021 for catalyst aeration.
This aeration help maintain proper density and fluid characteristics of the spent
catalyst. Fuel gas aeration injectors are distributed all along the spent catalyst
stand pipe upstream of the spent catalyst slide valve SV-1502, while 4 Nitrogen
aeration injectors are evenly distributed across SV-1502.
While aerated, the catalyst flows down through the spent catalyst line expansion
joint EX-1501 and then the spent catalyst slide valve SV-1502, which regulates the
level of the stripper by regulating the flow of catalyst leaving it.
Then the spent catalyst flows into the 1st stage regenerator D-1502 through a
distributor which ensures that the entering coke-laden catalyst is spread across
the regenerator bed.
Catalyst Regeneration Section
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REV: A

DATE: 06/12/07

The first stage regenerator D-1502 burns 50 to 80% of the coke and the remainder
is burned in the second stage regenerator D-1503.
Air blower and air heaters
Refer to P&IDs: 8474L-015-PID-0021-128 / 130 / 134 / 132 / 133 / 138 / 206
The combustion air required for the combustion reactions in the 1st and 2nd
catalyst regenerators D-1502 and D-1503 is supplied by the steam turbine driven
air blower C-1501.
Atmospheric air is introduced to the air blower C-1501 through an intake filter and
silencer F-1501. At C-1501 discharge, the blower air at 238C is distributed, via
PT-834, PG-356 and PIC-311, to a header system providing combustion air to the
downstream equipment as follow:

166,001 kg/hr of combustion air at 238C is supplied to the first regenerator


air heater H-1501 via FIC-161, PV-311 and the first regenerator air ring
assisted check valve CV-1501.
In H-1501 bower air is heated up by fuel gas combustion. The air heater is
supplied with fuel gas from the air heater fuel gas KO drum D-1525 via XV016 and XV-017. The air heater fuel gas KO drum D-1525 is supplied with
pilot fuel gas from the battery limits via PV-371B in normal operation.
Preheated air leaves the 1st regenerator heater and is supplied to the inner
air rings and outer air rings at the bottom of the 1st Catalyst Regenerator D1502 via PG-314, TI-067, TIC-068 and TXA-069.
The outer air ring and inner air ring are designed to handle about 70% and
30% of the combustion air to the first stage regenerator D-1502
respectively.

31,685 kg/hr of combustion air at 238C is supplied to the 2nd regenerator


air heater H-1502 via FIC-164, FV-164 and the 2nd regenerator air ring
assisted check valve CV-1502. In H-1502, air is heated up by fuel gas
combustion. The air heater is supplied with fuel gas from the air heater fuel
gas KO drum D-1525 via XV-014 and XV-015. The air heater fuel gas KO
drum D-1525 is supplied with pilot fuel gas from the battery limits via PV371B in normal operation.
Preheated air is then supplied to the unique air ring located at the bottom of
the 2nd regenerator D-1503 via PG-317, TI-070, TIC-071 and TXA-072.

47,832 kg/hr of blower air at 238C is also used as lift air and is supplied to
the bottom of the lift line of the 1st regenerator in order to transfer partly
regenerated catalyst from D-1502 to D-1503. Air is supplied from the
discharge header of the air blower C-1501 via FIC-166, FV-166 and the air
lift assisted check valve CV-1503. Air is injected through the hollow stem of
the plug valve PV-1501 which regulates the amount of catalyst transferred
to the 2nd stage regenerator.

514 kg/hr of blower at 238C is also injected in the catalyst loading line at
the bottom of the 1st regenerator D-1502 as fluidizing medium. Air is
supplied from the discharge header of the air blower C-1501 via FT/FI-071
and PG-114.
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REV: A

DATE: 06/12/07

1029 kg/hr of blower at 238C is also injected in the catalyst loading line at
the bottom of the 2nd regenerator D-1503 as fluidizing medium. Air is
supplied from the discharge header of the air blower C-1501 via FT/FI-097
and PG-166.

Finally 336 kg/hr of blower air at 2238C is supplied in the withdrawal ring
of the withdrawal well downstream of the point where the hot regenerated
catalyst is discharged to the well, also as fluidizing medium. Air is supplied
from the discharge header of the air blower C-1501 via FIC-169, FV-169
and PG-239.

First stage regenerator


Refer to P&IDs: 8474L-015-PID-0021-126 / 127 / 128 / 201/ 203
Spent catalyst containing roughly 1 to 1.5 wt % coke flows from the spent catalyst
distributor and is spread across the bed in the first stage regenerator D-1502.
Plant air (primary) is provided along the outlet of the spent catalyst standpipe to
help for the catalyst transfer. Plant is supplied from the PA header via PCV-142
and PG-143 to several nozzles disturbed along the outlet of the standpipe.
Part of the coke is burned by combustion air supplied from the outer and inner air
rings. This regenerator operates in a counter current (air inlet at bottom and spent
catalyst inlet at top) to prevent catalyst overheating.
In order to limit hydrothermal deactivation of the catalyst, the regeneration
conditions are mild: 1st stage regenerator total combustion air is controlled to limit
the temperature in this 1st stage to maximum 730C. For this operating case, the
1st regenerator is operated at 2.28 kg/cm2g. The normal operating temperatures of
the 1st stage regenerator are: 636C (bottom) & 631C (top).
The partially regenerated catalyst flows down through the first stage regenerator
bed to the entrance of the air lift. Aeration by a fluffing ring is supplied in the
vicinity of the air lift to ensure smooth flow of catalyst to the lift. 574 kg/hr of plant
air (primary) is supplied to the fluffing ring via PCV-138, PG-139, FT/FI-070 nad
PG-113. The hollow stem plug valve PV-1501 regulates the flow of catalyst to the
lift line and is controlled by the level in the first stage regenerator D-1502 via LIC004. 47832 kg/hr of blower air injected through the hollow stem of the plug valve
into the air lift to lift the catalyst in a dilute phase up to the second stage
regenerator D-1503.
2 stage cyclones (CY-1502A-F / CY-1503A-F) separate entrained catalyst from
the flue gas. 178544 kg/hr of flue gas exits the 1st stage regenerator D-1502
towards the CO boiler H-1503 at 631C via TI-030, analysers AI-004/005/006, the
first regenerator flue gas slide valve SV-1503 and the first regenerator flue gas
block valve BV-1501A.
The temperature in the 1st stage regenerator is monitored with 6 temperature
indicators TI-032/033/034/035/036/037 and is averaged by TI-038.
Second stage regenerator
Refer to P&IDs: 8474L-015-PID-0021-128 / 129 / 130 / 202 / 203

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DATE: 06/12/07

The partially regenerated catalyst flows up the lift line through the expansion joint
EX-1502 between the regenerators and enters the 2nd stage regenerator D-1503
below the combustion air ring. A distributor at the end of the lift provides for
efficient distribution of catalyst and air from the lift.
Catalyst is then completely regenerated to less than about 0.05% carbon through
combustion at more severe conditions than in the first stage regenerator D-1502.
The following are the normal operating conditions of the 2nd regenerator D-1503
for this operating case:

Pressure: 1.30 kg/cm2g

Bottom temperature: 695C

Top temperature: 720C

4 external refractory lined cyclones CY-1504A-D are used on the 2nd stage flue
gas outlet to remove entrained catalyst. The cyclone dip legs are external to the
regenerator. Catalyst recovered in the cyclones is returned to the regenerator bed
below the normal operating level by way of the diplegs.
Aeration with PA is supplied to the diplegs to maintain a smooth fluidized catalyst
flow and the diplegs outlets are equipped with flapper (trickle) valves to prevent
catalyst and gas backflow into the cyclones. Plant Air (Primary) is supplied to the
each dipleg via PCV-164 A to D.
86,941 kg/hr of flue gas leave the 2nd stage regenerator at 720C and flows to the
Waste Heat Boiler H-1503 through TI-064, the flue gas analysers AI-007/008/009,
the 2nd Regenerator Flue gas Slide Valve SV-1504, TI-078 and the 2nd
Regenerator Flue gas Block Valve BV-1502 A.
The temperature in the 2nd stage regenerator is monitored with 4 temperature
indicators TI-050/052/058/060 and is averaged by TI-063.
Note:
The pressure drop across the ring is kept above 0.07 bar at turndown to maintain
adequate distribution and prevent intrusion of catalyst into the ring and avoid
associated erosion.
Regenerated catalyst transfer
Refer to P&IDs: 8474L-015-PID-0021-122 / 129 / 131 /
The hot regenerated catalyst flows from the 2nd stage regenerator D-1503 through
a lateral into the withdrawal well. In the withdrawal well a stable bed is established
at proper standpipe density by introduction of 336 kg/hr of fluidizing air from the
withdrawal well ring.
A smooth stable flow of catalyst down the standpipe is provided by injection of
aeration Plant Air at several elevations on the regenerated catalyst standpipe: PA
(primary) is supplied to 2 aeration nozzles on the lateral via PCV-214. PA
(primary) is also supplied to 9 aeration nozzles in the upper part of the withdrawal
well via PCV-212. Finally, PA (primary) is supplied to 9 aeration nozzles on the
lower part of the withdrawal well, upstream of the regenerated catalyst slide valve
SV-1501, via PCV-210.
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DATE: 06/12/07

At the bottom of the withdrawal well, the catalyst flows through the regenerated
catalyst slide valve SV-1501 to the riser wye at the base of the riser where a
steam ring fluidizes the catalyst. The wye steam and fluidization points in the wye
section ensure that the catalyst flow to the feed injection point is stable and
smooth in order for the feed injection system to perform at its optimum.
Catalyst handling
The catalyst handling system includes hoppers for storage of fresh catalyst and
spent catalyst, loading devices for catalyst addition and a draw-off device for
continuous equilibrium catalyst withdrawal.
Three hoppers are installed:

The fresh catalyst hopper D-1505,

The spent catalyst hopper D-1506

The auxiliary catalyst hopper D-1507, which provides flexibility in the


operation for different options:
o Storage of imported equilibrium catalyst reused as part of the makeup catalyst,
o Storage of excess spent catalyst,
o Storage of a 2nd grade of fresh catalyst for make-up.

The spent and fresh catalyst hoppers are sized to contain the entire unit inventory.
Each hopper is provided with one cyclone and with aerations in the bottom cone to
assist the catalyst circulation to the transfer lines.
Catalyst addition
Refer to P&IDs: 8474L-015-PID-0021-126 / 136
Continuous addition of fresh catalyst to the RFCC is essential for at least three
reasons:

To maintain an optimum catalyst activity and selectivity,

To keep metals on equilibrium catalyst at an acceptable level,

To make up the inventory of circulating catalyst, compensating for catalyst


losses.

Two hoppers have been provided for catalyst addition. This allows the addition
simultaneously two different types of catalyst. It allows also to load one hopper
from a truck using the ejector system while the other hopper can remain
pressurized for the normal catalyst addition operation.
A catalyst feeder is used to automatically add fresh catalyst at the desired rate.
The feeder can be adjusted for batch size and frequency of additions.
The catalyst feeders are directly located below the catalyst hoppers. The amount
of catalyst introduced to the catalyst feeder is controlled by a weight cell and a
diaphragm valve at the catalyst feeder inlet. When the desired weight is in the
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DATE: 06/12/07

loader, the diaphragm valve closes. A switch is then activated which opens
fluidizing and pressuring air to the feeder. The feeder pressures up to about 3.5
kg/cm2 g and another diaphragm valve opens which loads the catalyst into the
first stage regenerator via TI-024.
It is possible to bypass the catalyst make-up feeders during operation for repairs.
Catalyst withdrawal
Refer to P&IDs: 8474L-015-PID-0021-126 / 135
As catalyst addition is higher than the catalyst losses from the unit, catalyst must
be withdrawn in order to keep the unit inventory. This operation is achieved by a
specific continuous draw-off system, X-1501, provided on the first regenerator D1501. Hot catalyst is withdrawn by an ON/OFF valve UV-021 actuated by timer,
cooled down through a finned tube and sent to the spent catalyst hopper at a
temperature below 400C.
The amount of withdrawn catalyst is controlled by a restriction orifice RO-090.
For catalyst conveying and line cleaning, plant air is injected into the catalyst at
line downstream of the restriction orifice by another ON/OFF valve UV-022
actuated by timer.
The plant air is set in order to limit the catalyst velocity in the draw-off line (10
m/s), to limit the erosion.
The total daily amount of catalyst withdrawal is adjusted by timer setting taking
into account the operation requirements for the overall catalyst balance.
Flue gas treatment
Drawing to be inserted here
Figure 55: Flue Gas Treatment Section (Bach Ho MD case)

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DATE: 06/12/07

Figure 56: COB/WHB Package Flow Scheme


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DATE: 06/12/07

Refer to P&IDs: 8474L-015-PID-0021-201 / 202 / 203 / 204 / 205 / 206 / 306 / 308
/ 307 / 312 / 313 / 314 / 315 / 317.
For H-1503, refer to Vendor P&IDs: 8474L-015-A0103-0160-001-029 / 030 / 031 /
032 / 033 / 034 / 035 / 142 / 143 / 144.
For X-1507, refer to Vendor P&IDs: 8474L-015-A0103-4240-002-128 / 129 / 130 /
131 / 133.
194,650 kg/hr of flue gas at 631C coming from the first regenerator are sent to
the CO incinerator H-1503 at 0.085 kg/cm2g, via flue gas slide valve SV-1503, TI084 and the flue gas block valve BV-1501A for combustion completion.
The incinerator burner is supplied with 172,701 kg/hr of combustion air via the
forced draft air fans C-1502 A/B, through XV-914 A/B. Combustion air is sent to
the CO air ports of the CO combustor via FV-901 and to the auxiliary burners via
FV-902.
The flue gas from the CO Boiler is routed to the Waste Heat Boiler H-1503 for HP
steam regeneration.
86,941 kg/hr of flue gas at 720C coming from the second regenerator D-1503 are
sent straight to the waste heat boiler H-1503 at 0.085 kg/cm2g, via the second
regenerator flue gas slide valve and SV-1504 and the COB/WHB 2nd regenerator
flue gas block valve BV-1502 A.
526,133 kg/hr of flue gas exiting the waste heat boiler H-1503 at 314C are sent to
the electrostatic precipitator X-1507 before flowing through the economizer E-1525
section of the COB/WHB package, and then to the stack SK-1501 at 236C.
Heat released in WHB H-1503 is used for HP steam generation:
229,892 kg/hr of HP boiler feed water at 112C is fed from the battery limits to the
heavy naphta boiler feed water heater E-1516 where HP BFW is heated to
114.9C in the tube side against heavy naphta product.
The heated BFW is then sent to the tube side of the LCO Pumparound BFW
heater E-1511 via TI-484. There the BFW is heated to 121.4C against LCO
pumparound (shell side) drawn off from the main fractionator.
The preheated HP BFW leaving E-1511 via TI-434 is then split into 2 streams:

18,092 kg/hr of the preheated BFW is fed to the slurry HP Steam


Generators E-1504 A/B, via FV-443 and FV-441 respectively. In E-1504
A/B HP steam is generated against slurry pumparound pumped by P-1519
A/B/C from the bottom of the main fractionator.
The HP steam leaves E-1504 A & B at 200.9C via FI-444 and FI-442
respectively. It is then recombined before being fed to the HP steam
superheater of the waste heat boiler.

211,500 kg/hr of the preheated BFW at 121.4C is sent to the economiser


section of the COB/WHB Package H-1503. The preheated BFW first flows
through FV-930 to the tube side of the BFW Preheater E-1534 where it is
heated up to 165C against 19,800 kg/hr of MP steam from the MP steam
de-superheater. Then preheated BFW flows through TIC-923A and PP-943
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to the Economizer E-1525. In the economizer, the flue gas coming from the
electrostatic precipitator X-1507 is used as heating medium. The steam
leaving the economizer is then fed to the Steam Drum D-1512, via PP-942
and TI-924.
Phosphate is also injected into the Steam Drum D-1512 by means of the
Phosphate injection Pump on duty A-1502-P-01-A from the Phosphate Tank A1502-TK-01. The pressure at the pump discharge is monitored locally with PG940.
Boiler water then exits the bottom of the steam drum via 3 lines, the inlet of each
being equipped with a vortex breaker, and flows to the 4 Evaporator Coil Banks of
the WHB H-1503. In each of the Evaporator Coil Banks, steam is generated (tube
side) by means of the flue gas exiting the HP superheater of the WHB H-1503.
The mixture of steam and boiler water at the outlet of each evaporator coil bank is
then routed back to the steam drum via 4 dedicated lines.
Boiler water from the steam drum is also fed to the Screen Steam Generator
upstream the HP steam Superheater in the Waste Heat Boiler. The steam/boiler
water stream generated by the flue gas exiting the CO Combustion exits the
Screen Steam Generator and is routed back to the Steam Drum D-1512.
Saturated steam from D-1512 is sent to the HP Steam Superheater after being
mixed with 18,092 kg/hr of HP steam from E-1504 A/B. In the Superheater, flue
gas exiting the Screen Steam Generator generates Superheated HP steam (tube
side). The superheated HP steam generated is then de-superheated by means of
HP BFW prior to being sent to the Superheated HP steam header via FI-911B.
A continuous blowdown from the steam drum is sent to the continous blowdown
drum D-1531. The LP steam recovered in D-1531 is sent to the LP steam header
while the water collected is sent to the intermittent blowdown drum D-1532 via LV906. The water in D-1532 is cooled down against cooling water in the Blowdown
Cooler E-1533 before being sent to the oily water sewer via TG-926 and TI-925.
Superheated MP steam is also generated in the WHB:
LP Boiler Feed Water is fed to the following MP steam generators in parallel:

6,498 kg/hr of LP BFW are fed to the HCO recycle MP steam generator E1508, via FV-415, where LP BFW is heated (shell side) against HCO
recycle drawn-off from the main fractionator. MP steam leaves E-1508 via
FI-416.

7,300 kg/hr of LP BFW is fed to the HCO Pumparound MP steam generator


E-1523, via FV-421, where LP BFW is heated (shell side) against HCO
pumparound drawn off from the main fractionator. MP steam then leaves E1523 towards the MP steam superheater via FT-422A/B.
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RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

13,868 kg/hr of LP BFW are fed to the Slurry MP steam generators E-1505
A/B, via FV-447 and FV-445 respectively. In E-1505 A/B LP Boiler Feed
Water is heated (shell side) against slurry from the HP steam generators E1504 A/B. MP steam then leaves E-1505 A and B towards the MP steam
superheater via FT-448 and FI-446 respectively.

The MP steam streams leaving in the above exchangers are then recombined and
27,666 kg/hr of MP steam at200.9C are fed to the MP steam superheater
downstream of the 4th Evaporator Coil Bank. There, the MP steam is superheated
against the flue gas leaving the evaporator. Superheated MP steam is then desuperheated against LP BFW prior to being discharged to the MP steam header.
526,133 kg/hr of flue gas leaving the WHB H-1503 at 314C is then routed to the
Electrostatic Precipitator X-1507, via PG-382, MOV-003, TT-085, TT-086 and TT092. In X-1507, the content of catalyst dust contained in the flue gas leaving the
COB/WHB package is decreased to meet the environmental specification: The
dust fine content at precipitator outlet shall not exceed 50 mg/Nm3 dry basis.
The flue gas leaving the electrostatic precipitator is then sent to the economizer E1525 through PT-389, ROV-001 and TT-093. The flue leaves the economizer at
236C and is finally sent to the stack via TT-098A/B, and the analyzers AI-018, AI019, AI-020 and AI-021.
Steam Generation Blow-down Operation
The following steam blow down is recommended for MPS and HPS steam
generator to maintain the quality of the generated steam, which are used for
turbine:
- Continuous blow down: 3.0 % of BFW feed
- Intermittent blow down: 10 % of BFW feed
For LPS Generator, the facilities are provided to cover continuous and intermittent
operation, but blow down operation is normally not required, since LPS is not used
for the turbine. Most of LPS is used for stripping steam or heating steam.
Phospate chemical injection is required in case steam generators are operated
with blowdown. It intended the dosage of phosphate is to maintain 10-20 wt ppm,
referring conductivity of BFW in the generator.
Phosphate solution is prepared by injection package X-1510.
For COB/WHB package, the operation concept is as same as steam generation of
the process heat exchanger that injection of phosphate should be adjusted,
referring sampling data of BFW in the steam drum of WHB, and continuous blow
down flow rate.
Phosphate injection
Refer to P&IDs: 8474L-015-PID-0021-332.
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CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Phosphate solution, from the tank TK-1510 in the phosphate injection package X1510, is injected to the BFW fed to the following steam generators:

Slurry HP steam generators E-1504 A/B by means of the phosphate


injection pumps P-1531 D/E respectively. The pressure at the pumps
discharge can be monitored locally with PG-638 D/E respectively.

Slurry MP steam generators E-1505 A/B by means of the phosphate


injection pumps P-1532 A/B respectively. The pressure at the pumps
discharge can be monitored locally with PG-639 A/B respectively.

HCO LP steam generator E-1510, also from the discharge of the phosphate
injection pump P-1532B. The pressure at the pumps discharge can be
monitored locally with PG-639 B.

HCO pump pumparound MP steam generator E-1523, Slurry LP steam


generators E-1506 A/B and LCO product LP steam generator E-1513 by
means of the phosphate injection pump P-1532C. The pressure at the
pumps discharge can be monitored locally with PG-639 C.

HCO recycle MP steam generator E-1508 by means of the phosphate


injection pump P-1532D. The pressure at the pumps discharge can be
monitored locally with PG-639 D.

Fractionation Section
Drawing to be inserted here
Figure 57: Fractionation Section Bach Ho Maximum Distillate Case
The operating conditions in the main fractionator T-1501 are:
Top Pressure: 0.85 kg/cm2g

Top Temperature: 96C

Bottom Pressure: 1.15 kg/cm2g

Bottom Temperature: 340C

Fractionator bottom section


Refer to P&IDs: 8474L-015-PID-0021-303 / 304 / 310 / 311 / 312 / 313 / 314 / 315
/ 321 / 322 / 323 / 325 /
544,699 kg/hr of reactor effluent at 505C from the disengager of the reaction
section is sent to the bottom of the main fractionator T-1501 below the Bed #5.
1,040,949 kg/hr of bottom slurry pumparound at 340C flow to the suction of the
Slurry Pumparound Pumps on duty P-1519A/B via TIC-439, TI-438, XV-413 and
PG521 for P-1519A, XV-414 and PG-522 for P-1519B. At the discharge of the
pumps, the slurry PA flows through PG-431 & XV-416 for P-1519A, PG-432 & XV417 for P-1519B, and FI-423 (on the common discharge header) before being
delivered to the following downstream equipment at 339.9C:
In the case of Bach Ho feed, a large proportion of the bottom pumparound duty is
used to preheat the feed in the 1st & 2nd Feed Preheat Slurry Exchangers E-1502
A/B/C and E-1501 A/B:

Page 257 of 323

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CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

290,000 kg/hr of Slurry PA are pumped by P-1519 A/B to the shell side of
the 2nd feed preheat slurry exchangers E-1501 A & B in parallel. The slurry
leaving the shell side of E-1501A flows through TW-529, FIC-406 and FV406, before being mixed with the slurry PA leaving the shell side of E1501B through TW-530, FIC-501 and FV-501. The recombined slurry PA
leaving E-1501 A&B then flows to the slurry PA return header, thru TI-422
indicating a normal operating temperature of 309.9C.
The total duty of the 2nd feed preheat slurry exchangers is 6.75 MW.

310,000 kg/hr of Slurry PA flow from the discharge of P-1519 A/B to the 1st
feed preheat slurry exchangers E-1502 C, B and A in series as follow: the
slurry PA flows thru E-1502C (shell side), TW-413, E-1502B (shell side),
TW-532, E-1502A (shell side). Downstream of E-1502A, the slurry PA flows
through TW-531, and TI-423 indicating a normal operating temperature of
254.4C before being split into 2 streams:
o 220,000 kg/hr of slurry PA flow thru FIC-407 and FV-407 to the slurry
quenching header and are returned to the quench zone of the main
fractionator T-1501.
o 90,000 kg/hr of slurry PA flow thru FIC-408 and FV-408 to the slurry
PA return header and are returned to T-1501 above the Bed #5.
The total duty of the 1st feed preheat slurry exchangers is 19.95 MW.

The remaining slurry PA, that is 440,949 kg/hr of slurry is supplied to the Slurry HP
steam generators E-1504 A/B and the MP steam generators E-1505 A/B divided in
2 branches (A & B) as follow:

Part of the slurry PA flows through the tube side of E-1504A, exits via TI468, flows through the tube side of E-1505A. Downstream of E-1505A the
slurry flows thru TI-469, FIC-438 and FV-438 before being recombined with
the Slurry PA leaving the branch B.

An equal amount of slurry PA flows through the tube side of E-1504B, exits
via TI-466, flows through the tube side of E-1505B. Downstream of E1505B the slurry flows thru TI-467, FIC-437 and FV-437 before being
recombined with the Slurry PA leaving the branch A.

The total duty of the Slurry HP steam generators E-1504 A/B is 11.67 MW and the
total duty of the MP steam generators E-1505 A/B is 9.22 MW.
Once recombined the slurry PA leaving E-1505 A&B flows thru TI-470 indicating a
normal operating temperature of 220C before being split into 2 streams:

193,021 kg/hr of slurry PA flow thru FIC-439 and FV-439 to the slurry
quenching header and are returned to the quench zone of the main
fractionator T-1501.

17,321 kg/hr of slurry PA flow thru FIC-440 and FV-440 to the slurry PA
return header and are returned to T-1501 above the Bed #5.

At the discharge of the slurry PA pumps P-1519 A&B, 204,685 kg/hr of slurry PA
bypass is directly returned to the Bed #5 of the main fractionator thru FT-426A/B
and FV-426.
The total amount of slurry PA return to T-1501, that is 602,006 kg/hr of slurry PA
return, is returned to the bed #5 of the main fractionator T-1501 via TI-441.
Page 258 of 323

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RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

The total amount of slurry quenching, that is 413,021 kg/hr of slurry, is returned to
the quench zone of the main fractionator via TI-440.
Note:
The slurry HP steam generators E-1503 A-C are bypassed in the Bach Ho
operation.
25,930 kg/hr of slurry product at 220C is taken from the discharge of the MP
steam generators E-1505 A/B, downstream of TI-470, and flow to slurry draw-off
drum D-1515 via FIC-462, FV-462 and XV-451. D-1515 is operated at 220C and
1.0 kg/cm2g. The pressure in D-1515 is maintained at 1.0 kg/cm2g by admitting
fuel gas thru PV-468A or venting excess off gas thru PV-468B.
The slurry product flows to the suction of the Slurry Product Pump on duty P1504A, via TI494 and PG-526, which pumps it to the Slurry LP Steam Generator
on duty E-1506 A via PG-469. The duty of E-1506A is 0.879 MW.
Downstream of E-1506 A, the cooled slurry flows, via TI-495, TIC-496 and PG574, to the slurry oil pre-filter on duty F-1503A before entering the Slurry
Separator X-1504 where catalyst fines are removed. The differential pressure
across the filter is monitored with PDI-398 and PDG-395.
27,930 kg/hr of clarified oil leave the slurry separator X-1504 and flow to the
tempered water coolers E-1507 B & A in series (C & D are bypassed) before going
to storage at 90C and 8.0 kg/cm2g thru TI-499, FIC-464 and FV-464. The total
duty of E-1507 A&B is 1.32 MW.
The slurry separator X-1504 consists of 10 modules. These are automatically and
sequentially taken out of service for back-flushing while the others remain in
service. The modules are back-flushed with Backflush Oil (HCO) from the
Backflush Oil Draw Off Drum D-1516. Backflush oil flows from the bottom of D1516 to the suction of P-1505A via TI-503. The backflush oil is pumped by means
of the backflush oil pump on duty P-1505A to the slurry separator X-1504 via PG481, FIC-468, FV-468 and UV-460.
The flush oil from the separator, containing a high concentration of catalyst fines,
goes to back-flush oil receiver D-1517 via XV-459 after being mixed with HCO
flowing from E-1510 via FIC-460 and FV-460. The pressure in D-1517 is
maintained at 1.0 kg/cm2g by either admitting fuel gas inside the vessel via PV475A or venting excess off gas to the flare via PV-475B.
From D-1517, 6,875 kg/hr of backflush oil is returned to the reactor riser by means
of the backflush oil recycle pump on duty P-1506A and thru PG-477 and FIC-491.
The flow of backflush oil recycle to the backflush oil injectors of the riser is kept
constant by controlling the flow of backflush oil sent back to D-1517 via FV-491
from the discharge of P-1506A. The temperature of the recycle oil leaving the
bottom of D-1517 is monitored via TI-502.
HCO section
Refer to P&IDs: 8474L-015-PID-0021-121 / 308 / 309 / 316 / 317 / 325 / 326 / 409

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TRAINING MODULE
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CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

HCO products, pumparound and HCO recycle are taken from the draw off tray
above the Bed #4 of the main fractionator T-1501.
364,913 kg/hr of HCO pumparound at 337C flow to the suction of the HCO
Pumparound Pump on duty P-1508A via TI-444 and XV-409. HCO PA is pumped
via PG-425, XV-411 and FIC-419 to the following equipment in parallel:

199,500 kg/hr of HCO PA at 337C are pumped to the tube side of the
Debutanizer reboilers E-1560 A & B (equal amount to each exchanger).
HCO PA leaves E-1560A via TW-759 and E-1560B via TW-760 before
being recombined and sent to the HCO PA return header via FV-722 and
TI-761. The duty of the debutanizer reboilers is 18.17 MW.

32,842 kg/hr of HCO PA at 337C are pumped to the shell side of the
Heavy Naphtha Stripper Reboiler E-1509 via FIC-454 and FV-454. The
HCO PA leaves E-1509 via TI-483 to the PA return header. The duty of E1509 is 2.00 MW.

55,121 kg/hr of HCO PA at 337C are pumped to the tube side of MP


Steam Generator E-1523. The HCO PA leaves E-1523 at 220.1C and
flows thru TI-435, FT-420A/B and FV-420 to the HCO PA return header.
The duty of E-1523 is 4.83 MW.

77,450 kg/hr of HCO bypass is sent directly to the HCO PA return header
via FV-419 from the discharge of the HCO PA pump on duty.

HCO PA is then returned to the main fractionator, above the Bed #3, via TIC-446
and TI-445.
HCO for flushing oil is also taken from the draw off tray above the Bed #4 of the
main fractionator T-1501 and flows thru LV-431 to the HCO stripper T-1504 where
it is stripped by means of 788 kg/hr of LP steam at 160C. LP steam flows from
the LP steam header to T-1504 via FIC-449 and FV-449. The stripper vapour
leaving T-1504 via TI-471 and PG-443 is returned to T-1501 just below the tray
#30.
26257 kg/hr of stripped HCO at 324.2C flow from the bottom of T-1504 to the
suction of HCO product pump on duty P-1509 A, via TI-472 and XV-430. HCO
product is pumped thru FIC-474 to the tube side of the LP Steam Generator E1510. Cooled HCO leaves the tube side of E-1510 at 170C and is split into 2
streams:

3479 kg/hr of HCO are sent to the backflush oil draw off drum D-1516 (for
use in the slurry separator as described above) via FV-467. D-1516 is
operated at 170C and 1.0 kg/cm2 by either admitting fuel gas into the
drum via PV-479A or venting excess off-gas to the flare via PV-479B.

22,278 kg/hr of HCO product at 170C are set to the HCO flushing oil drum
D-1518 via FIC-469 and FV-469. The pressure in the HCO flushing oil is
maintained constant by either admitting fuel gas thru PV-483A or venting
excess off-gas to flare via PV-483B.
HCO flushing oil flows from the bottom of D-1518 to the suction of the HCO
flushing oil pump on duty P-1521A via TI-504. HCO flushing oil is pumped
to the HCO flushing oil filter on duty F-1502A via FIC-461, PIA-487 and
PG-520. Downstream of FIC-461, a slip stream of the HCO flushing oil is
recycled back to D-1518 via FV-461.
Page 260 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

Filtered HCO flushing oil then flows thru FI-470 to the HP flush oil header.
Part of the HCO flushing oil is sent to the LP Flush Header on pressure
control via PV-496.
For maximum distillate mode operation, HCO is recycled to the reactor feed.
117,100 kg/hr of HCO recycle is taken from the draw off tray above the Bed #4
and flows to the suction of the HCO recycle pump on duty P-1507A via XV-406.
HCO recycle is pumped to the tube side of the HCO recycle MP steam generator
E-1508 via PG-411 and XV-408. HCO recycle leaves E-1508 thru TW-424 and
PDV-420. Part of the HCO recycle bypasses E-1508 thru TV-425 and is mixed
with the HCO leaving E-1508 downstream of PDV-420. The recombined HCO
flows at 290C thru TIC-426, TI-426, FIC-002 and FV-002 to the reaction section
where is mixed with the preheated feed upstream of the feed line static mixer M1501.
LCO section
Refer to P&IDs: 8474L-015-PID-0021-302 / 307 / 309 / 318 / 328 / 405
LCO product and LCO pumparound are drawn off thru TI-449 from the
pumparound draw-off tray below the bed#2 of the main fractionator.
733,664 kg/hr of LCO pumparound at 230.3C flow to the suction of the LCO
Pumparound Pump on duty P-1510A. LCO PA is pumped via PG-422 and FIC417 to the following equipment in parallel:

91,555 kg/hr of LCO PA at 230.3C are pumped to the shell side of the
LCO PA BFW heater E-1511. LCO PA leaves E-1511 at 194.9C and flows
via TI-432, FT-418 A/B and FV-418 to the LCO PA return header. The duty
of E-1511 is 2.24 MW.

400,000 kg/hr of LCO PA at 230.3C are pumped to the 2 branches of the


LCO pumparound feed preheat exchangers E-1512 A/B/C/D as follow:
o 200,000 kg/hr of LCO PA flows to E-1512B (tube side), TW-416, E1512A (tube side) and TW-418 before being recombined with the
LCO PA leaving the other branch.
o 200,000 kg/hr of LCO PA flows to E-1512D (tube side), TW-417, E1512C (tube side) and TW-419 before being recombined with the
LCO PA leaving the other branch.
LCO leaving E-1502A and E-1502C is recombined and 400,000 kg/hr of
LCO at 176C flows to the LCO PA return header via FIC-409, TI-420 and
FV-409. The total duty of E-1512 A-D is 14.79 MW.

168,743 kg/hr of LCO PA at 230.3C are sent to the tube side of the 2nd
stripper reboiler E-1557 via FIC-710. The LCO PA leaves E-1557 and flows
to the LCO PA return header via TI-730 and FV-710. The duty of E-1557 is
8.97 MW.

73,366 kg/hr of LCO bypass is sent directly to the LCO PA return header
via FV-417 from the discharge of the LCO PA pump on duty.

Page 261 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

HCO PA is then returned to the main fractionator above the Bed #2, via TIC-452
and TI-451.
LCO product is taken as a slip stream at the suction of the LCO pumparound
pumps P-1510 A/B and is sent to the tray #1 the LCO stripper T-1503, via LV-436,
where the LCO is stripped with 300 kg/hr of LP steam. The LP steam flows from
the LP steam header to the LCO stripper T-1503 via FIC-452 and FV-452.
The stripper vapour leaving T-1503 via TI-475 and PG-448 is returned to T-1501
just below the tray #24. Stripped LCO flows to the suction of the LCO Stripper
Pump on duty P-1511 A via TI-476. LCO product is pumped to the tube side of the
LCO product LP steam generator E-1513 (duty = 5.65 MW) via PG-449.
Downstream of P-1511 A/B, a slip stream of the LCO product is recycled back to
the LCO stripper via FT-478. LCO product leaving the tube side of E-1513 at
158C flows through TI-505 to the LCO air cooler E-1514 (duty = 8.66 MW) and
exits via TI-512 before being split into 2 streams:

139,198 kg/hr of LCO are sent to the storage at 50C and 6.0 kg/cm2g via
FIC-472, FV-472, TI-513, FI-473 and TI-514. For maximum LCO operation
(maximum distillate operation), heavy naphtha from the Heavy Naphta Trim
Cooler E-1516 is mixed with this stream before it is sent to storage

165160 kg/hr of LCO are sent to the LCO HDT at 48.7C and 6.0 kg/cm2g
via FIC-479 and FV-479. For maximum LCO operation (maximum distillate
operation), heavy naphtha from the Heavy Naphta Trim Cooler E-1516 is
also mixed with this stream before it is sent to the LCO Hydrotreater unit.

MTC and heavy naphtha section


Refer to P&IDs: 8474L-015-PID-0021-305 / 309 / 317 / 328 / 405 / 407
MTC is NOT drawn off from tray #19 of the main fractionator in the Bach Ho Crude
operation.
Heavy naphtha pumparound and heavy naphta product are drawn off from the
draw-off tray below the bed #1 of the main fractionator.
508,243 kg/hr of heavy naphta (HVN) pumparound at 161.6C flow to the suction
of the heavy naphta PA pump on duty P-1514A. HVN PA is pumped via PG-415
and FIC-412 to the following equipment in parallel:

149,489 kg/hr of HVN PA are pumped to the HVN PA Cooler E-1521 where
it is cooled down to 54.9C. HVN PA leaving E-1521 flows through TI-427,
FT-414 A/B and FV-414 to the HVN PA return header. The duty of E-1521
is 9.52 MW.

50,824 kg/hr of heavy naphta PA are pumped to the stripper feed preheater
E-1555 in the gas recovery section via FI-726. The heavy naphta PA
leaving E-1555 flows back to the Heavy Naphta PA return header via TI725 and TV-723. The duty of E-1555 is 1.48 MW.

Page 262 of 323

TRAINING MODULE
RESIDUE FLUID CATALYTIC
CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

200,000 kg/hr of heavy naphta PA are pumped to the Propylene Recovery


Unit (PRU, unit 21) via TI-413. Heavy naphta PA is returned from the PRU
thru TI-428 to the heavy naphta PA return header.

Heavy Naphta PA is then returned thru TIC-430 and TI-429 to the main
fractionator T-1501 on top of the bed #1.
Heavy naphta product is taken as a slip stream of the pumparound draw-off at the
suction of the P-1514 A/B and is sent to the tray #1 of the heavy naphta stripper T1502 via LV-439. T-1502 bottoms flow to the tube side of the reboiler E-1509 via
TI-478 where it is heated against HCO PA. Re-boiled heavy naphta is returned t T1502, below the tray #8 via TI-482. The duty of the HVN reboiler E-1509 is 2.00
MW.
The stripper vapour leaving T-1502 via TI-477 and PG-451 is returned to the main
fractionator above the pumparound bed, Bed #1.
25,962 kg/hr of stripped heavy naphtha flow from the bottom of T-1502 to the
suction of the HVN product pump on duty P-1515A. HVN product is pumped to the
shell side of the HVN BFW Heater E-1516 via PG-452. In E-1516, HVN is used as
heating medium to preheat BFW (tube side) which is then sent to E-1511. The
duty of E-1516 is 0.985 MW.
Heavy naphta leaving the shell side of E-1516 is then sent to the heavy naphta air
cooler E-1517 (duty = 1.69 MW) via TI-479. The heavy naphta leaving E-1517 is
then sent thru TI-480 to the HVN Trim Cooler E-1518. The duty of the HVN trim
cooler E-1518 is 0.135 MW.
25,962 kg/hr of heavy naphta leaving the trim cooler E-1518 at 40C flow through
FIC-435, FV-433 and TI-485 before being mixed with the LCO product sent to the
LCO HDT and storage downstream of the LCO air cooler E-1514.
Heavy naphtha is also drawn off at the suction of the HVN PA pumps P-1514 A/B
as lean oil for the secondary absorber in the Gas recovery Section. The lean oil is
pumped by P-1513A at 9.5 kg/cm2g to the tube side of the Lean Oil / Rich Oil
Exchanger E-1563, in the gas recovery section.
Top section
Refer to P&IDs: 8474L-015-PID-0021-309 / 319 / 407
Rich oil from the bottom of the secondary absorber in the Gas Recovery Section is
fed to tray #9 of the main fractionator. Water accumulated in the partial draw-off
accumulator tray, provided below the top tray, is continuously drawn off and flows
by gravity to the inlet of overhead condenser E-1519 via TI-458, LV-416.
Fractionator overhead section
Refer to P&IDs: 8474L-015-PID-0021-309 / 319 / 320 / 403 / 404 / 405

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CRACKER (RFCC)

DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

The overhead vapor from T-1501 flows thru TI-460 and TIC-461 at 96C and 0.85
kg/cm2g to the overhead condenser E-1519 (total duty = 47.31 MW), comprising
of 16 bundles. It is mixed with the water draw-off from the tray #9 of the main
fractionator. Corrosion inhibitor is also supplied to the overhead vapour at the inlet
of E-1519: 2.5 kg/hr of corrosion inhibitor is supplied from the corrosion inhibitor
tank TK-1501 to the inlet of E-1519 by means of the corrosion inhibitor pump on
duty P-1520A. Pressure at the pump discharge can be checked locally by means
of PG-467. Downstream of the overhead air condenser E-1519, the overhead
vapour from T-1501 flows thru TI-536 to the 8 overhead trim condensers E-1520 A
to H in parallel (total duty = 16.12 MW). Partly condensed overheads leaving the
trim condensers E-1520 A-H flow thru TI-489 to the fractionator reflux drum D1514.
The following off-gases are also fed to the reflux drum:

291kg/hr of off gas from the CDU at 50C and 0.7 kg/cm2g are also fed to
D-1514 via FI-458 and TI-492.

243 kg/hr of off gas from the NHT at 40C and 0.6 kg/cm2g are also fed to
D-1514 via FI-457 and TI-491.

The liquid hydrocarbon separated in D-1514 is separated into 2 streams:

201,987 kg/hr of liquid hydrocarbon flow from the main fractionator reflux
drum thru XV-444 and TI-490 to the suction of the fractionator reflux pump
on duty P-1516A: Liquid reflux is pumped back to the tray #1 of the main
fractionator at 42.2C via PG-463, FIC-427 and FV-427.

84,726 kg/hr of net overhead liquid product flow from the main fractionator
reflux drum thru XV-444 and TI-490 to the suction of the overhead liquid
pump on duty P-1518A. Net overhead liquid is pumped at 42.5C, thru FIC455 and FV-455, to the top tray of the primary absorber T-1551.
Liquid sent to the primary absorber T-1551 is flow controlled by FIC-455
with FV-455. Excess liquid pumped by P-1518A is sent back to the main
fractionator reflux drum D-1514 via FT-477.

The sour water collected in the boot of the fractionator reflux flows to the suction of
the overhead sour water pump on duty P-1517A via XV-445. Downstream of P1517 A/B discharge, the flow of sour water is spit into 3 streams:

30,000 kg/hr of overhead sour water are pumped back to the overhead
condenser E-1519, via FIC-459, FV-459 and thru a restriction orifice.

28,000 kg/hr of overhead sour water are pumped to the inlet of E-1551,
via FIC-703, FV-703 and RO-715A, for mixing with the wet gas from the
first stage of C-1551.

5252 kg/hr of sour overhead water are pumped to the SWS (unit 18), via
FIC-456, FV-456 and TI-736, after being mixed with the sour water
collected in the boot of the HP separator drum D-1553.

Finally, 118,909 kg/hr of overhead vapour from D-1514 flows to the first stage KO
drum of the wet gas compressor D-1551 at 41.9C via PIC-458, PG-457, and TI703.

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The main fractionator reflux drum is operated at 42C and 0.4 kg/cm2g. The
pressure in the gas outlet of D-1514 is controlled by PIC-458 by venting excess
off-gas thru PV-458 to the flare.
Gas Recovery section
Drawing to be inserted here
Figure 58: Gas Recovery Section Bach Ho Max. Distillate Case
Wet gas compressor and HP condenser
Refer to P&IDs: 8474L-015-PID-0021-401 / 402 / 403 / 404
118,909 kg/hr of wet gas from the Main Fractionator Reflux Drum D-1514 flows to
the wet gas compressor first stage knock-out drum D-1551 via PIC-458, PG-457,
and TI-703. In D-1551 entrained and condensed liquids are separated. The liquid
collected in D-1551 is pumped by either of the KO drum liquid pumps P-1552 A/B
back to the fractionator reflux drum D-1514. The first stage KO drum D-1555 is
operated at 0.3 kg/cm2g and 42C.
The gas from D-1551 flows to the 1st stage of the compressor C-1551 via FT-701,
MOV-703 PG-704, and PT-703. The wet gas exits the first compression stage at
4.1 kg/cm2g and 102C and flows through PG-706, PT-705, TT-702 and MOV-704
before being split into 2 streams:

A spill back stream is returned back to E-1519 via FI-704 and UV-701

The majority of the wet gas is sent for cooling in the wet gas compressor
intercooler E-1551. Before entering the intercooler E-1551, the wet gas is
mixed with 28,000 kg/hr of sour water pumped by P-1517A from the boot of
the main fractionator reflux drum D-1514. The duty of E-1551 is 8.32 MW.

Downstream of E-1551, the wet gas flow thru TW-720A and TI-704 to each of the
two wet gas compressors trim-coolers E-1552 A&B in parallel. The total duty of E1552 A/B is 2.08 MW. Downstream of E-1552 A/B, the wet gas is sent to the interstage KO drum D-1552 via TI-709 indicating a normal operating temperature of
42C. The inter-stage KO drum D-1552 is operated at 3.4 kg/cm2g.
63,712 kg/hr of wet gas leaving D-1552 at 3.4 kg/cm2g flow to the second stage
compressor C-1551 via PG-708, PIC-707, FT-702, MOV-705, TT-710, PG-710
and PT-709. The wet gas leaving the 2nd stage is compressed to 15.9 kg/cm2g.
Downstream of the second stage compressor, the majority of the wet gas flows at
114C and 15.9 kg/cm2g to the HP condenser E-1553, via PG-712, TXA-632, PT711, TT/TI-711 and MOV-706. A slip stream of the compressed wet gas is
recycled back to the inlet of E-1551 via FI-705 and UV-702.
Before entering the HP condenser, the compressed wet gas is mixed with 83,197
kg/hr of interstage liquid at 42.3C. The interstage liquid is pumped from the
bottom of the interstage KO drum D-1552 to the inlet of the HP condenser E-1553
by means of the interstage pump P-1551A, thru FI-727 and LV-705. The duty of
the HP steam condenser E-1553 is 5.59 MW.
The partly condensed wet gas stream leaving the HP condenser E-1553 is fed to
the stripper condensers E-1554 A/B/C/D via TI-713.
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Stripper condenser and high pressure separator drum


Refer to P&IDs: 8474L-015-PID-0021-404 / 405
The following streams are combined before being fed to the stripper condensers
E-1554 A/B/C/D:

127,834 kg/hr of liquid at 56.8C from the bottom of the primary absorber T1551 via TI-721, FI-708 and LV-710.

2071 kg/hr of LPG at 52C and 20.0 kg/cm2g from the CDU (unit 11) via FI741 and TI-714.

22,703 kg/hr of stripper overhead at 59.8C from the stripper T-1552 via TI722, FIC-709 and PG-717.

The combined stream flows through TI-715 before being split into 2 equal streams,
each flowing in one of the 2 parallel branches constituting the stripper condensers
E-1554A-D (duty = 4.51 MW): One half of the combined stream flows through the
shell side of E-1554B and then E-1554A (shell side) before exiting this branch of
the stripper condensers thru TW-716. The other half of the combined stream flows
through the shell side of E-1554D and then E-1554C (shell side) before exiting this
branch of the stripper condensers thru TW-717. The mixed phase streams leaving
E-1554Aand E-1554C are recombined before entering the HP separator drum D1553 via TI-720. The HP separator D-1554 is operated at 15.1 kg/cm2g and 40C.
30,572 kg/hr of water collected in the boot of the HP separator is sent to the SWS
at 40C and 3.5 kg/cm2g via XV-716, LV-714, FI-712 and TI-736, after mixing with
5252 kg/hr of sour water pumped from the main fractionator reflux drum D-1514 by
P-1517A.
243,294 kg/hr of LPG and gasoline mixture at 40C flow from D-1554, thru XV-719
and TI-726, to the suction of the stripper feed pump on duty P-1553A. This
hydrocarbon mix constitutes the feed of the stripper T-1552; It is first pumped to
the stripper feed preheater E-1555 via PG-721, FIC-711 and FV-711. The flow of
feed to E-1555 is controlled by FIC-711 acting on FV-711. The excess liquid at the
pump discharge is recycled to the separator drum D-1554 via FT/FI-728. The duty
of the stripper feed preheater is 1.48 MW. Preheated stripper feed leaving E-1555
flows thru TIC-723 and TI-724 to the first tray of the stripper.
25,634 kg/hr of vapour phase from D-1553 is flow thru PG-719, PIC-718 and FI707 to the primary absorber T-1551 (below the last tray).
Primary absorber T-1551
Refer to P&IDs: 8474L-015-PID-0021-404 / 405
Normal operating parameters of the primary absorber for the Bach Ho MD Case:
Top Pressure: 14.8 kg/cm2g

Top temperature: 48C

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84,726 kg/hr of net overhead liquid product at 42.5C from the main fractionator
reflux drum is pumped by P-1518A, thru FIC-455 and FV-455, to the top tray of the
primary absorber T-1551.
Downstream of the Gasoline Cooler E-1559, 30,000 kg/hr of gasoline (from the
bottom of the debutanizer T-1554) are also recycled to the inlet of the primary
absorber T-1551 by means of the duty gasoline recycle pump P-1554A: Gasoline
flows to the suction of the pump via PG-728 and is pumped to the inlet of T-1551
for mixing with the net overhead liquid product, via PG-729, FIC-713 and FV-713.
This flow of gasoline recycle enables required recovery of C3 and C4.
127,834 kg/hr of bottom rich oil from leaves the bottom of the primary absorber T1551 and flows through TI-721, FI-708 and LV-710, back to the inlet of the stripper
condensers E-1554 A-D.
12,519 kg/hr of overheads leave the top of the primary absorber T-1551 at 14.8
kg/cm2g and 48C and flow thru PG-726, FI-717 and TI-738 to the secondary
absorber T-1553, below the tray #20.
Stripper
Refer to P&IDs: 8474L-015-PID-0021-404 / 405 / 409
The purpose of the stripper is to remove H2S, C2 and lighter from The LPG and
gasoline mixture.
Normal operating parameters of the stripper for the Bach Ho MD Case:
Top Pressure: 15.7 kg/cm2g

Top temperature: 60C

Bottom Pressure: 16.0 kg/cm2g

Bottom temperature: 122C

243,294 kg/hr of preheated LPG and gasoline mixture feed leaving E-1555 flows
thru TIC-723 and TI-724 to the first tray of the stripper.
The necessary heat to perform the stripping operation is supplied by two reboilers
in series: The stripper bottoms flow thru TI-727 to the shell side of the first reboiler
E-1556 (duty = 4.62) where it is heated up against gasoline form the bottom of the
debutanizer T-1554.
Stripper bottoms then flow to the shell side of the second reboiler E-1557 (duty =
8.97) where it is heated against 168,743 kg/hr of LCO PA from the main
fractionator. The heat input to E-1557 is controlled by the stripper overhead vapor
rate FIC-709. This rate, and hence the reboiler duty, is set to meet the C2
specification in the debutanizer overheads.
22,703 kg/hr of overhead vapour leaving the stripper at 59.8C is returned to and
condensed in E-1554 A-D via TI-722, FIC-709 and PG-717.
220,591 kg/hr of stripped LPG and Gasoline leave the bottom of the stripper T1552 at 126C and flow to the tray #22 of the debutanizer via TI-728, FIC-714 and
FV-714

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Secondary absorber T-1553


Refer to P&IDs: 8474L-015-PID-0021-404 / 407 / 408
The secondary absorber T-1553 recovers gasoline light fractions contained in the
overhead gas from primary absorber T-1551.
12,519 kg/hr of overheads leave the top of the primary absorber T-1551 at 14.8
kg/cm2g and 48C and flow thru PG-726, FI-717 and TI-738 to the secondary
absorber T-1553, below the tray #20.
The lean oil used for the absorption is a heavy naphtha stream draw-off from the
main fractionator T-1501 (draw-off tray below the bed #1) and pumped by P-1513
A to the tube side of the lean oil/rich oil exchanger E-1563 (duty = 1.14 MW). Lean
oil then flows thru TI-749 to the shell side of the lean oil cooler E-1564 where it is
cooled against cooling water. The duty of E-1564 is 1.36 MW.
Cooled lean oil leaving E-1564 then flows through TI-751 and PG-734 to the lean
oil coalescer D-1556 where water is separated from the hydrocarbon phase. The
sour water collected in the boot of D-1556 is then sent to the SWS via XV-725, LV723, FI-712 and TI-736, after mixing with sour water from the fractionation section,
D-1553 and D-1554.
34,990 kg/hr of lean oil at 40.2C flow from D-1556 to the top tray of the
secondary absorber T-1553 via PG-736, FIC-718 and FV-718.
Normal operating parameters of the secondary absorber for Bach Ho MD Case:
Top Pressure: 14.4 kg/cm2g

Top temperature: 45C

Bottom Pressure: 14.7 kg/cm2g

Bottom temperature: 59C

The rich oil at 59C from the bottom of the secondary absorber T-1553 flows thru
TI-739 and LV-720 to the lean oil/rich oil exchanger E-1563 where it recovers heat
before being recycled to the tray #9 of the Main Fractionator T-1501, via TI-740
and TI-787.
The stripped overhead gas leaving T-1553 flows thru TI-741, PIC-733 and PG-766
to the shell side of the fuel gas water cooler E-1565 (duty = 0.042 MW). Cooled
fuel gas then flows thru TI-743 to the Fuel Gas Absorber Feed KO Drum D-1557.
Fuel gas absorber
Refer to P&IDs: 8474L-015-PID-0021-408
The small amount of liquid in the effluent from E-1565 is separated in the K.O.
drum D-1557. The liquid is sent to mixing with rich oil at the inlet of the lean oil/rich
oil exchanger E-1563 via LV-726. The FG Absorber Feed KO Drum D-1557 is
operated at 40C and 14.1 kg/cm2g.
The overhead gas of the FG absorber feed KO drum is fed to the bottom of the
Fuel Gas Absorber T-1555 via TI-744. 18,127 kg/hr of lean amine at 55C and
22,6 kg/cm2g flow from the ARU (unit 19) thru FIC-719, FV-719 and TI-745 to the
top of the fuel gas absorber T-1555.
Normal operating parameters of the Fuel Gas Absorber for Bach Ho MD Case:
Top Pressure: 13.7 kg/cm2g

Top temperature: 56C


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Once treated by the lean amine, the overhead gas is sent to the Fuel Gas
Absorber Outlet K.O. drum D-1559, where entrained and condensed liquid are
separated. 8661 kg/hr of treated fuel gas leave the top of the FG Absorber Outlet
KO Drum D-1559 and flow to the fuel gas system at 4.5 kg/cm2g and 54C via
PG-741, TI-747, FI-720 and PV-733.
A total of 18127 kg/hr of rich amine is sent back to the ARU at 64C and 7.0
kg/cm2g. This stream is composed of:

Mainly rich amine leaving the bottom of the FG Absorber T-1555 via XV732, LV-730 and TI748;

Rich amine separated in the KO drum D-1559 and flowing thru XV-735 and
LV-733 to mixing with the rich amine from T-1555 downstream of TI-748.

Debutanizer
Refer to P&IDs: 8474L-015-PID-0021-405 / 406 / 409 / 410 / 411
220,591 kg/hr of stripped LPG and Gasoline leave the bottom of the stripper T1552 at 126C and flow to the tray #22 of the debutanizer via TI-728, FIC-714 and
FV-714
Normal operating parameters of the secondary absorber for Bach Ho MD Case:
Top Pressure: 12.1 kg/cm2g

Top temperature: 68C

Bottom Pressure: 11.7 kg/cm2g

Bottom temperature: 171C

The heat required to perform the separation is provided by the debutanizer


reboilers E-1560 A&B: An equal amount of debutanizer bottoms flow to the shell
side of each reboiler where it is heated against HCO PA from the main
fractionator. Re-boiled bottoms then leave E-1560 A and B and flow thru TI-770
and TI-758 respectively, back to the debutanizer below the bottom tray.
The reboilers duty (18.17 MW) is set to ensure that the C4 specification in the
gasoline is met.
The overhead vapour leaves the debutanizer at 68C and 11.7 kg/cm2g and flows
thru TI-762, PG-744 and PIC-745 to the debutanizer condensers E-1561 A & B in
parallel, where the overhead vapour are totally condensed. Condensed overheads
are then fed to the debutanizer feed surge drum D-1554.
The pressure in T-1554 is controlled with PIC-745 by bypassing part of the
overhead vapour around E-1561 A/B to the reflux drum D-1554, via PV-745.
The duty of the debutanizer condensers is 16.08 MW.
The sour water collected in the reflux drum D-1554 is sent to the SWS via XV-741,
LV-739, FI-712 and TI-736, after mixing with sour water from the fractionation
section, D-1553 and D-1556.

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The hydrocarbon liquid of the debutanizer reflux drum flows thru XV-744 to the
suction of the debutanizer overhead pump on duty P-1556A. Downstream of P1556A the hydrocarbon is split into 2 streams:

106,325 kg/hr of HC are sent to the tray #1 of the debutanizer as a reflux


via FIC-721 and FV-721. The reflux rate is flow controlled by FIC-721 reset
by the temperature controller TIC-754 on the sensitive tray (tray #8) in the
top section of the column. This control loop determines the C5 specification
in the overhead product.

57,044 kg/hr of overhead liquid, the LPG product, flow to the shell side of
the LPG water cooler E-1562 (duty = 0.342 MW). Cooled LPG leaving the
shell side of E-1562 at 40C then flow thru TI-768, FIC-723, FV-723 and
PG-755 to the bottom of the LPG Amine Absorber T-1556.

The gasoline product leaving the bottom of the debutanizer T-1554 at 171C then
flows thru XV-738, TI-755 to the tube side of the stripper first reboiler E-1556.
Downstream of E-1556, the gasoline product flows thru TI-731 to the gasoline air
cooler E-1558 (duty = 9.00 MW). Gasoline then flows thru TI-732 to the gasoline
water cooler E-1559 (duty = 0.957 MW). Downstream of E-1559, the gasoline
stream is split in 2:

30,000 kg/hr of gasoline are recycled by means of the gasoline recycle


pump P-1554A to the inlet of T-1551.

133,547 kg/hr of gasoline, the gasoline product, flow thru FIC-715, FV-715,
FI-716 and TI-735 to the gasoline treating unit at 8.5 kg/cm2g and 40C.

LPG amine absorber T-1556


Cooled LPG leaves the shell side of E-1562 at 40C and flows thru TI-768, FIC723, FV-723 and PG-755 to the bottom of the LPG Amine Absorber T-1556.
23,331 kg/hr of lean amine at 55C and 22.6 kg/cm2g flow from the ARU thru the
shell side of the lean amine water cooler E-1566, TI-772, FIC-724 and FV-724 to
the LPG Amine Absorber above the top packing bed.
The overhead LPG liquid flows thru PG-757, TI-795, and PDI-761 to the LPG
amine coalescer D-1555. The LPG Amine Coalescer is operated at 18.4 kg/cm2g
and 40C.
57,023 kg/hr of LPG overheads from D-1555, the LPG product, is sent to the LPG
Treater Unit (LTU, unit 16) at 40C and 18 kg/cm2g.
A total of 23,352 kg/hr of rich amine is returned to the ARU at 7.0 kg/cm2 and
41C. This stream is composed of:

Mainly rich amine leaving the bottom of the LPG Amine Absorber thru XV748, LV-746 and TI-771;

Rich amine leaving the boot of the LPG amine coalescer D-1555 thru XV751, LV-749 and sent to mixing with the rich amine from T-1556,
downstream of TI-771.

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8.1.2. Operating Parameters


For guidelines on the operating parameters of the RFCC and how to adjust the
operating conditions, refer to the chapters 7.3, 7.4, 7.5, 7.6 and 7.7 of the licensor
operating manual, doc. No. 8474L-015-ML-001.
8.2. Start-up Procedure
The following will present the main steps of the start-up procedure without detailing the
procedure to perform each action. For a detailed description of the start-up procedures,
refer to specific procedures into the RFCC Operating Manual doc. No. 8474L-015-ML001.

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8.2.1. Pre-commissioning Activities


These are the necessary pre-commissioning activities:
1. Vessel and other Major Equipment Inspection
2. Line Cleaning
3. Servicing and Calibration of Instruments
4. Run-in of Rotary machineries
5. Chemical Cleaning
6. Refractory Drying
7. System Drying
8. Loading of Chemicals, Catalysts, and Other Materials
9. Operational Tightness Test
10. Air Freeing
11. Commissioning of Additional Plant Services
8.2.2. Initial Start-up
8.2.2.1. Status of the Unit prior to first start-up
The status of the unit prior to its initial start-up is as follows:

Tightness test and nitrogen purges have been completed (O2 <
0.5% volume) on the feed preparation section.

Free water trapped has been drained at low points.

All necessary utilities are in service: blinds on the headers have


been swing open and valves opened on all users.

All instrumentation has been checked and is in service.

The emergency shutdown systems have been tested and are


ready for operation.

On disengager and first regenerator cyclones, set blocks to open


the trickle valves on the diplegs (if it not planned to re-enter the
vessel use a material that will incinerate or melt at the
temperatures expected).

Verify that the disengager and the regenerators manways are


closed.

Verify isolation and blinding of the fuel gas system.

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8.2.2.2. Chronology of first Start-up

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8.2.3. Initial & Normal Start-Up


8.2.3.1. Start-up summary of the Reaction Section
See Next Page

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8.2.3.2. Start-up summary of the Fractionation & Gas Recovery Sections


See Next Page

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8.3. Shutdown Procedures


The following presents the main steps of the shutdown procedure only. For a detailed
description of the normal shutdown procedure, refer to specific procedures into the RFCC
Operating Manual 8474L-015-ML-001.
There are three types of shutdown. The normal shutdown scheduled for a turnaround,
the shutdown due to short duration problem in part of the unit, and the emergency
shutdown.
The normal scheduled shutdown requires the catalyst unloading while, for a short time
shutdown, one will try to keep the catalyst circulation by all means in order to restart the
unit as quickly as possible.

8.3.1. Normal Shutdown


8.3.1.1. Normal Shutdown Summary of Reactor & Regenerator
Normal scheduled shutdown should be made in orderly sequences
because there is no issue of emergency.
The main points to observe are:

Keep catalyst circulation during the shutdown as long as possible.

Make sure all circuits are flushed to avoid problems during the
inspection and the next start-up.

Keep products on specification as long as possible.

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8.3.1.2. Normal Shutdown Summary of Fractionation and Gas Recovery Section

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8.4. Emergency Shutdown


8.4.1. General emergency shutdown
Emergencies, which occur in the RFCC unit, must be recognized and acted upon
immediately. The operators and supervisory personnel should carefully study in
advance, and become thoroughly familiar with the proper steps to be taken in such
situations. The emergency conditions described here could lead to serious
damage to equipment if the situation is not handled properly.
It is strongly recommended that the emergency procedures and the automatic
shutdown systems be understood by all persons involved in the operation. In
general, the objective of the emergency procedures is to avoid damage to
equipment, to the unit and to the personnel.
The most common causes of emergency shutdowns are described below,
together with their effects and the actions to be undertaken. In several cases, a
number of actions are carried out by the emergency sequences. But operators
must always check the satisfactory completion of the sequence and complement it
as described. In addition they must be able to perform the safety sequence in
manual mode, if needed.
A few actions (through hand-switches) are left to operators judgement.
The sequences must be reviewed before start-up
In most of failure cases, it is recommended or required to stop the feed to the unit.
This can be done by activating the emergency system UX-001. Each time the
following operations must be achieved:

Check that feed has been bypassed back to the feed surge drum

Check that all recycles to the riser have been stopped.

Check that passivator injection has been stopped.

Close the control valves on feed and recycle lines.

Check that dispersion steams, stabilization steam and riser bottom steam
are effective.

If the duration of the failure exceeds a couple of hours, the fuel gas purges
on the reaction section should be switched to nitrogen purges.

8.4.2. Power failure


A failure of electrical power will result in an emergency shutdown of the unit.
Steam pressure will generally be kept for a short time. However, refinery wide
power failure results in steam failure, subsequent to power failure, as sea water
and BFW will stop with a refinery wide power failure.
Instrument indications and controls should not be affected as the UPS system will
give back up for quite some time.
The consequences and emergency sequences to be followed will depend on
whether it is a localized power failure or refinery wide power failure.

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Note that Air Blower and Wet Gas Compressor will also stop with a power failure,
since sea water to the turbines surface condensers will be stopped during power
failure as most of the sea water pumps are driven by motor. Refer to the
corresponding equipment failure described hereafter.
The object is to get the unit into a safe condition while battery power or alternate
power is available to the instruments. The following will occur:

Feed oil will stop

Disengager will depressurize rapidly

SV-1502 differential pressure will fall

Cooling water supply will stop.

The following actions should be taken immediately:


a) Activate UX-001, block in all oil feed to riser. Place SV-1501, SV-1502, and
plug valve on manual and close. Shutdown passivator injection.
b) Adjust fresh feed dispersion steam and all other oil injectors dispersion steam
to minimum.
c) Adjust pressures as required to control differential pressures. Reduce
combustion air rates to 50% operating conditions if possible.
d) Due to lack of sufficient cooling in the main fractionator overhead system, any
steam usage in the riser should be minimized.
e) Stop heating steam to E-1522 and E-1524.
f) Stop stripping steam to T-1503 & T-1504
Specific note for steam demand management between RFCC and PRU.
Though, PRU is not part of RFCC, but complex of RFCC group. PRU should be
also brought into emergency mode operation, during upset of RFCC. Since PRU
compressor C-2101 consumes substantial HPS (30-35 ton/hr), stop C-2101 for
proper management of HPS demand, during emergency of RFCC.
When electrical supply is re-established check operation of pumps and air coolers.
Restart the unit following normal start-up procedures.

8.4.3. Instrument air failure


Usually instrument air failure is of short duration and the unit can be started-up
immediately after return to normal conditions.
However, loss of instrument air will require an emergency shutdown of the unit.
Supervision should set a standard for minimum instrument air pressure for
continued operation referring the minimum IA pressure where the actuators on
CVs have been designed (4.0 kg/cm2g). Although control elements will drift
toward their fail-safe positions, operator intervention is required to manage the
shutdown. If falling air pressure reaches the minimum pressure, the emergency
shutdown sequence should be enacted.
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a) Activate UX-001 to recycle feed from the riser to feed surge drum, block in oil
to the riser, and continue dispersion and stabilization steam to clear the riser.
b) Place the regenerated catalyst slide valve on manual and close.
c) When the stripper level begins to fall, place the spent catalyst slide valve on
manual and close.
d) Set the dispersion steam to about 50% flow rate and reduce the stripping
steam to 50% of the operating conditions.
e) Close the plug valve but be careful not to overfill first regenerator.
f) Adjust the air rates to about 50% flow rate but be careful not to lose air lift flow.
g) When feed is cut out of from the riser, the disengager pressure will fall rapidly.
Adjust pressures as required to maintain the spent catalyst slide valve
differential.
h) Start torch oil and on through bypass valve and keep the temperature near
600C in the regenerators. Due to loss of purge air or instrument supply air,
instruments and level indicators may begin to give false signals. Look for
correlating variables, especially temperatures to help understand the status of
the process. For this reason, extreme care should be taken in making any
moves on the levels when there is no instrument air pressure. Continuous
operator attention is required where the process is on hand valve control.
i) Determine the expected duration of the outage. If less than 24 hours the
catalyst can be maintained hot with torch oil. The disengager pressure should
be maintained at least 0.1 kg/cm2 higher than the regenerator pressure to
keep air out of the disengager.
j) When instrument air is re-established return to control on the various hand
valves that are being used. Check all instrument purges to ensure they are not
plugged and see that instruments are reading correctly.
k) Check all nozzle points to see that they are not plugged and place them in
service.
l) When this has been accomplished the unit may be started using the normal
start-up procedure.
Note:
The major problem will come from the air blower which can surge or choke during
transient operations. Snort valves, UV-822/823/824 will fail open and valve
controlling air to the air lift will fail in position. This is important to avoid return of
catalyst from second regenerator into first regenerator.

8.4.4. Fluidization / Aeration / Purge Air and FG failure


Loss of fluidization, aeration, or purge air flow will require the unit to be shutdown.
Erroneous instrument readings and or catalyst circulation instability make the unit
uncontrollable without operator action.
a) Activate UX-001 to cut feed to the riser, to go to bypass and to block in the oil
feed and adjust the dispersion steam at the rate of 50% operating conditions.
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b) Shutdown passivator injection.


c) Put the regenerated catalyst slide valve on manual and close.
d) When the stripper level begins to drop out the spent catalyst slide valve on
manual and close. Close the plug valve but be careful not to overfill first
regenerator.
e) When feed is cut out from the riser, the disengager pressure will drop rapidly.
f) Adjust pressures as required to maintain a positive spent catalyst slide valve
differential.
g) Be aware that instruments taps on the regeneration and reaction section may
plug up and give false readings. Therefore exercise extreme caution in making
any moves on the regenerators.
By closely monitoring the regenerators temperature profile the unit may be kept
hot with torch oil. All instrument taps should be checked for plugging after
aeration is re-established.
When assured that all taps are free, the unit may be re-started as for a normal
start-up.
Note:
In disengager side only, fluidization, aeration and purge are supplied with fuel gas
in normal operation, but nitrogen take place for start-up and FG failure.

8.4.5. Steam failure


Loss of steam will require a complete shutdown of the unit due to loss of the Air
blower and wet gas compressor, and loss of dispersion, stabilization and stripping
steam.
a) Actuate UX-001, to stop feed and bypass the riser, block in all oil feeds to the
riser, and shut down the passivator injection system if it is in operation.
b) Close the SV-1501 on manual control. Maintain dispersion steam as long as
possible to clear the riser of catalyst.
c) When the stripper catalyst level begins to drop, close the SV-1502)\ on manual
control. Close the plug valve being careful not to allow the first stage
regenerator to overfill.
d) When oil feed is cut out of the riser, the system pressure will drop rapidly. As
necessary, adjust system pressure to maintain the adequate differential on the
SV-1502
e) Transfer as much as possible of the catalyst retained in the stripper to the first
regenerator by carefully opening the spent catalyst slide valve. Avoid pressure
differential to go below 0.1 kg/cm2.
f) Since the air blower is steam driven the regenerator catalyst beds will slump.
Torch oil cannot be used to maintain regenerator temperatures without proper
catalyst fluidization. Ensure that the plug valve does not open as that would
cause the catalyst in the second stage regenerator to flow into the first stage
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regenerator. Block in steam headers to the process before steam header


pressure falls below regenerators pressures.
g) The wet gas compressor is also steam turbine driven and will shut down. It will
be necessary to depressure the main fractionator to prevent the potential of
hydrocarbons backing into the regenerators. The depressurizing control valve
PIC-458 at the outlet of D-1514 should be set to open at a pressure of around
0.15 kg/cm2 above the normal operating pressure to prevent the disengager
from slumping.
h) The slurry circuit should be flushed to prevent any plugging problems as the
slurry system cools down.
i) Determine the expected duration of the outage. If the expected start-up will be
within 48 hours, the unit can remain hot on torch oil control after getting the air
blower back in operation. If the outage is expected to extend beyond 48 hours
the catalyst should be emptied from the unit.
When steam supply is re-established, first ensure that steam headers are dry
all the way up to the process and then start stripping, dispersion and
stabilization steam. When this is done, the unit may be restarted using the
normal start-up procedure.
j) If no operator intervention is taken upon loss of steam pressure, the catalyst
circulation will stop due to loss of riser lift. When feed is cut off due the
temperature increases, the riser will slump. This can lead to extended
shutdown and plugged equipment which is difficult and costly to clear.
Exceedingly high temperatures in the regenerator can be experienced upon
the loss of dispersion, stabilization, and stripping steam if feed is not cut off
immediately.
k) When steam is available begin circulation of the slurry system and, if
necessary, use torch oil as in the normal start-up. Confirm that the steam is dry
and then establish both stripping and main fractionator steam. Control pressure
on the main fractionator as required to maintain differentials between the
disengager regenerators. At this point the unit can be restarted following the
normal start-up guidelines.

8.4.6. Boiler feed water failure


Loss of boiler feed water (BFW) will require a shutdown of the RFCC unit.
Actuate UX-001.
Additionally, the loss of steam production may lead to a steam failure. If this
happens, the procedure for steam failure should be followed. A BFW failure will
require bypassing the flue gas equipments (CO Boiler and waste heat boiler),
maintain water circulation through the tubes as long as possible to maintain
cooling on the tubes. The wet gas compressor and all steam generation
equipment should be shut down.
As liquid levels require, other pumps should be shut down.
When BFW is available establish levels in the steam generators and restart the
unit following normal start-up procedures.
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8.4.7. Cooling water failure


Loss of cooling to the fractionation and Gas Recovery section will require the
shutdown of the RFCC unit.
Loss of lube oil cooler of the air blower and wet gas compressor also require to trip
Air Blower and wet gas compressor.
Actuate UX-001, to stop feed to the riser, block in all oil injectors feeds, and adjust
the fresh feed dispersion steam rate for 50% operating condition. Place the SV1501, SV-1502, and plug valve on manual and close. Since the lube oil system for
the air blower and wet gas compressor require cooling water for continued
operation, shut down the wet gas compressor and air blower.
Due to reduced cooling capacity in the main fractionator system, any steam usage
in the reaction and regeneration sections should be minimized. Since the air
blower is shut down, it will be necessary to depressurize the main fractionator to
minimize disengager regenerator differential pressure and prevent to potential flow
of hydrocarbons from the disengager into the regenerators. Disengager pressure
should be held around 0.15 kg/cm2 above the first stage regenerator pressure.
When cooling water is re-established the unit may be restarted following normal
start-up procedures.
The effect of cooling water loss should be studied by refinery personnel to develop
a detailed plan of action.
8.4.8. Sea water failure
Sea water is used for coolant of the surface condenser of the air blower and wet
gas compressor.
Therefore, failure of sea water will automatically trip of air blower and wet gas
compressor, as turbine is not work properly. Follow operation procedure of Air
Blower failure and Wet Gas Compressor failure.
8.4.9. Air blower failure
In case of air blower failure, the unit will be shut down by UX-005, which will
actuate UX-002 and UX-001 systems. The pressure in the regenerators will fall
rapidly resulting in possible flow reversal at SV-1501 if the operator does not act
immediately.
Reduce the main fractionator pressure to flare to minimize the disengager /
regenerator differential pressure. Bypass the fresh oil feed to the feed surge drum,
block in all oil feeds to the riser, while reducing all other injector steam and
stripping steam to about 50% of operating conditions. Shut down passivator
injection if it is in operation. Place the SV-1501 and SV-1502 on manual and close.
Place the plug valve on manual and close. Disengager pressure should be held at
about 0.15 kg/cm2 above regenerator pressure.
Catalyst may have backed into air lines so extreme care should be taken when reestablishing air flow.
Normally the following actions are required to re-established air flow to the unit
when restarting the blower:
a) Close the control valves on the line to the first stage regenerator air rings.
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b) Open the plant air into the catalyst lift line between the first regenerator and
second regenerator. The uppermost blast point should be started first, and
then open the lower blast points stepwise down the lift line.
c) Before starting the blower it must be checked that all air lines are free of
catalyst upstream the assisted check valves. Ensure that the check valves are
in closed position.
d) Plant air connections have been provided upstream the regenerators air rings.
These connections must be put in operation to clear the air rings from the
accumulated catalyst.
e) The amount of catalyst back flow into the air heaters must be checked by
visual inspection. In case of significant catalyst amount in the heaters, the blast
connections provided on the air lines must be put in operation to clear the
lines. The connections must be put in operation one by one, starting with the
connection located close to the regenerator.
f) With all blast points open, slowly begin lift air from the air blower and then
reduce plant air to minimum purge rates.
g) After clearing of the air lines, the air blower can be restarted
h) Open the control valves on the line to the R-1 rings. This should be done
slowly so as not to lose lift air flow.
i) When all air flows are re-established, the unit may be started as in the normal
start-up procedure.
Notes:
The unit can be restarted if the catalyst temperatures are not too low (above
400C).
Loss of the blower by serious mechanical failure due to long duration problem will
necessitate the normal shutdown of the RFCC unit with catalyst unloading.
The loss of the blower causes the fluidized bed to slump. As a result, not all
catalyst is regenerated and fully cooled.
The critical items regarding the catalyst unloading without blower are:

To be able to maintain enough pressure in the regenerators to transfer the


catalyst to the hopper (a delta pressure about 0.7 kg/cm2 by plant air
injections should be sufficient).

To cool down the catalyst in the regenerators to a temperature below


300C. This is essential to avoid any coke combustion either in the catalyst
transfer lines or in the spent catalyst hopper.

During catalyst unloading, a careful survey of the temperatures in the regenerators


disengager stripper, and at the top of the spent catalyst hopper should be
performed.
Before catalyst unloading following plant safety rules, install blinds to allow the
final vacuum truck removal of the remaining catalyst as necessary.

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8.4.10. Feed pump failure


Loss of feed will activate emergency shutdown system, activate UX-001 to stop
feed and recycles to the riser and bypass the riser.
If the spare feed pump can be quickly started, the unit may be brought back on
line in a short period of time. If unable to start a fresh feed pump, maintain the unit
in a hot condition.
a) Adjust the dispersion steam at the maximum rate of operating conditions.
b) Take the regenerated catalyst slide valve on manual control to monitor the
catalyst circulation. Place the feed control on manual and close.
c) When the feed is taken out of the unit the disengager pressure will fall. Adjust
the pressure balance to maintain a positive pressure differential between the
disengager and the regenerators (higher than 0.15kg/cm2).
d) Start torch oil injection immediately in the regenerators to keep the catalyst
about 600C.
e) When feed is available, re-establish the operating conditions as required
before the normal oil-in (riser outlet temperature around 530C, pressure
balance,...) and restart the unit following normal start-up procedures.

8.4.11. Other pump failure


Loss of any other pump will not require a shut down of the RFCC unless the spare
pump cannot be started. In cases where the spare pump is unavailable, it may be
possible to continue operation by adjusting unit operations. Each system should
be studied to determine how to continue operation is case of pump failure.

8.4.12. Fuel gas failure


Typically, fuel gas failure will not require a shutdown of the RFCC. Fuel gas is
used in the CO Boiler.
Switch main fuel source from fuel gas to fuel oil so that COB operation can be
continue as far as possible.
Loss of the CO Incinerator may require a shutdown of the RFCC since the carbon
monoxide rich flue gas from first regenerator is released to the atmosphere.
Violations of the environmental permits may force reduction of the RFCC feed.
Provision is made that fuel oil can be also used for COB combustion burner. Use
fuel oil firing, maximum extent at failure of fuel gas, and maintain COB operation
as far as possible.
If feed is cut off from the unit, the reaction / regeneration sections can be
maintained in a hot condition using torch oil for 24 hours. If the outage is expected
to extend beyond 24 hours, the catalyst should be emptied as for a normal
shutdown.
As the CO Incinerator is off-line, the heat load to the Waste Heat Boiler will be
reduced and therefore steam production will diminish. A shut-down of the COB will
have a serious impact on the overall steam balance of the refinery, including Air
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Blower and WGC in RFCC. Steam from the utility boilers will be used for back-up
of steam demand. Reduce RFCC throughput, and reduce Air Blower and WGC
load to reduce steam demand, if insufficient steam can be supplied from utility
boilers. If steam availability is critical, then cut-off heating steam of HPS and MPS
to E-1522 and E-1524.
When fuel gas is available, re-establish the unit following the normal start-up
procedures.

8.4.13. Wet gas compressor failure


Loss of the WGC will require a reduction in fresh feed rate or possibly a shut down
of the RFCC. Follow any emergency procedures from the WGC vendor to
safeguard the WGC.
If this shutdown is for a short period of time, reduce feed flow rate to about 60% of
the operating condition and flare the gas at the overhead receiver.
If it not possible to flare the gas or if pressure is uncontrollable:
a) Activate UX-001 to stop feed and recycles to the riser.
b) Place slide valves and plug valve on manual control.
c) Control the disengager pressure higher than the regenerators pressures. Inject
fuel gas in the overhead receiver as necessary. The catalyst circulation can be
maintained as long as the pressure differential through the spent catalyst slide
valve is kept above 0.15 kg/cm2 and as long as the steam flow in riser is
sufficient to lift the catalyst (minimum velocity: 5 m/s).
d) If catalyst circulation is maintained, check the flue gas treatment equipments
(steam drum levels), check the main fractionator level and check the
temperatures in the regenerators; use torch oil to maintain the catalyst about
600C.
1. If catalyst circulation is difficult to maintain at adequate conditions (eg
unsteady pressure balance, high or low temperatures in regenerators),
actuate UX-002 to shut-down the unit.
2. In addition, instrument purge systems on the disengager side use
treated gas from the Gas Recovery as the primary media. Automatic
back-up by nitrogen will be made when supply of treated off gas is
stopped as consequence of the failure of the wet gas compressor.
Operations should carefully monitor the back-up nitrogen system is
working (eg PV-367B is opened).
When the WGC is ready for restarting follow vendors procedures and restart the
unit following normal start-up procedure.
Notes:
Loss of the WGC by serious mechanical failure due to long duration problem will
require the normal shutdown of the RFCC unit with catalyst unloading.

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Loss of the WGC will reduce production of RFCC off gas to the refinery fuel gas
system. Since RFCC off gas is the prime source of fuel gas, proper management
of fuel gas and fuel oil is required to avoid loss of fuel gas in the refinery. Maximize
fuel oil firing in the major users of fuel gas (Utility Boilers, CDU and COB) and
vaporize LPG, if required.

8.4.14. Catalyst slide valve / plug valve failure


For a failure of catalyst slide / plug valves, the unit may remain in operation
depending upon the type of failure and which valve fails. It may be possible to
continue operation with manual local control of the valve position. If this is
attempted, it is very important to have continuous monitoring of the control
variable and good communications between the control room and the operator at
the valve. If the plug valve fails, the unit may continue to operate by controlling the
first regenerator catalyst level with the first/ second regenerator differential
pressure. Is stable control cannot be obtained quickly, the unit should be
shutdown.
a) If stable control cannot be achieved activate UX-001 to stop feed and recycles
to the riser, block in all oil feeds, and shutdown passivator injection if it is in
operation.
b) Close the SV-1501 on manual or with the handwheel. If the SV-1502 cannot be
closed, reduce the dispersion, stabilization steam and riser bottom ring
injection to about 20-30% let the riser slump.
c) Adjust pressures to hold a positive SCSV differential. The RCSV differential
may go to zero if the riser is slumped.
d) Hold the disengager pressure 0.15 kg/cm2 above the regenerator pressure.
Notes:
If catalyst slide valve is blocked in closed position, check that UX-001 and UX-002
have been activated.
If either catalyst slide valve is blocked in open position activate UX-001 and try to
take the other catalyst valves on manual control and adjust the valves opening to
obtain a stable and constant catalyst circulation through the unit. The circulation
rate will be dictated by the opening of the failed valve.
Loss of catalyst slide valve by serious mechanical failure due to long duration
problem will necessitate the normal shutdown of the RFCC unit with catalyst
unloading.

8.4.15. Loss of regenerators pressure control (flue gas slide valve failure)
For a failure of flue gas slide valves, the unit may remain in operation depending
upon the type of failure and which valve fails. It may be possible to continue
operation with manual local control of the valve position. If this is attempted, it is

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very important to have continuous monitoring of the control variable and good
communications between the control room and the operator at the valve.
If stable control cannot be achieved, activate UX-001 to stop feed and recycles to
the riser, block in all oil feeds, and shutdown passivator injection if it is in
operation. Hold the disengager pressure 0.15 kg/cm2 above the regenerator
pressure.
Note:
Loss of flue gas slide valve by serious mechanical failure due to long duration
problem, will necessitate the normal shut down of the RFCC unit with catalyst
unloading.

8.4.16. Control system failure


For a failure of control system, the unit may remain in operation for a short time
typically 10 to 15 min. Otherwise the unit is shut down by activating UX-001 and
UX-002.
8.4.17. Oil reversal
This situation can occur when oil injected in the riser flows back into the second
regenerator instead of being lifted up in the riser. This is the consequence of a
sudden increase of disengager pressure or sudden decrease of second
regenerator pressure. It is detected by a sudden rise of the second regenerator
temperatures which can exceed the limit of the design and can be very dangerous.
a) Immediately actuate UX-002 and UX-001 and check that catalyst slide valves
are all closed. Check that oil is effectively bypassed from riser, block all oil feeds.
b) Decrease air rates if the temperatures continue to rise.
c) Establish a pressure higher in the disengager than in the regenerators. Inject
fuel gas in the fractionator overhead receiver.
d) Restart the unit as soon as the reason for the oil reversal is explained and
corrected.
Note:
Catalyst is withdrawn into an external withdrawal stand pipe. This proven system
ensures an efficient seal against oil reversal.

8.4.18. Low riser outlet temperature (ROT)


In case of too low Riser Outlet temperature (< 480C), the feed is not cracked and
the catalyst will be socked with hydrocarbons. These hydrocarbons will be carried
into the first regenerator where they will burn, causing unacceptable temperature
run away.
Loss of ROT will require a reduction in fresh feed rate or possibly a shut down of
the RFCC by activating UX-001. The catalyst circulation can continue on
automatic control, however, the operator may have to temporarily intervene to
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manually reduce the catalyst circulation rates. Feed-in can be achieved when an
acceptable Riser Outlet Temperature for start-up (510-530C) is obtained.
8.4.19. Plugged catalyst circulation
It can happen that the catalyst is plugged in the lift or standpipes, especially during
the start-up periods.
In that case feed and recycles must be stopped to the riser (actuate UX-001)
before attempting to unplugging the catalyst.
a) In case of plugging in the air lift, blast connections are provided along the air lift
to help to re-fluidize the catalyst. Put the blast connections in operation one by
one, starting with the upper connection. Lift air flow rate and pressure can be
increased to help to de-plug the air lift.
b) In case of catalyst plugging in a standpipe, the circulation can be restored by
increasing the differential pressure through the line: decrease the first
regenerator pressure in case of spent catalyst line plugging and increase the
second regenerator pressure in case of regenerated catalyst line plugging (if
increasing the aeration and fluidization rates is not sufficient). During the
deplugging operation, do not maintain the catalyst slide valve continuously fully
open; proceed with quick close/open valve operations.

8.4.20. Downstream unit failure


Depending upon the nature of the downstream equipment failure, the RFCC may
operate at reduced throughput. If unable to operate in a stable, controlled manner
the unit should be shutdown following the normal shutdown procedure. Follow as
close as possible the normal shutdown procedure. If the outage is expected to be
less than about 48 hours, the unit can be kept hot with torch oil. If the outage is
expected to extend beyond 48 hours, plan for unloading catalyst as per the normal
shutdown procedure.
In the case of continued stand-by operation, reduce the disengager pressure to
0.15 kg/cm2 above the first stage regenerator pressure and reduce stripper
catalyst level to minimum.
Once the downstream failure is repaired, the unit may be restarted following the
normal start-up procedure.
8.4.21. Fire emergency
In case of a fire emergency, it should be determined what effect the emergency
will have on the RFCC.
If shut down of the unit is required, the normal shutdown procedure should be
followed as closely as possible (activate UX-001). If the emergency requires
immediate action, it may not be possible to completely utilize the normal shutdown
procedure. In those cases, oil hydrocarbon feeds should be isolated from the
reactor section and the unit should be maintained in a hot condition using torch oil.
As required the catalyst circulation may be shut down (activate UX-002) until the
emergency situation is under control.

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8.4.22. Emergency shutdown of Fractionator and Gas Recovery Section - General


In an emergency, steps must be taken to bring the unit to a safe shutdown
condition. An emergency may be caused due to failure of a utility or failure of
equipment. Emergency shutdown of the reaction section will also necessitate
shutdown of the fractionation and gas recovery sections.
Initially, the unit should be shutdown and maintained in a hot condition by
switching the slurry steam generators to heating. Admit fuel gas to the main
fractionator overheads to maintain the pressure balance in the reactor. It may be
necessary to shut down the wet gas compressor because of steam balance
requirements or because of compressor surging.
If the emergency is anticipated to be for long duration, shutdown should proceed
as for a normal shutdown, as far as equipment is available to do so.

8.4.23. Steam failure for the Fractionation/Gas Recovery Section


On loss of steam, the air blower in the reaction section and the wet gas
compressor will be lost.
This will require a shutdown of the unit. The slurry pumparound pumps are all
steam turbine driven and these also will be lost. Depressurize the main
fractionator to prevent the possibility of flow of hydrocarbon back to the
regenerators. Flush the slurry circuit to prevent plugging problems as the slurry
circuits cool down. Shut off stripping steam to the HCO and LCO strippers.
When steam becomes available, start the slurry pumps and start slurry circulation.
Confirm the liquid level of T-1501 with LI-411A and B prior start slurry pumparound
pumps. If necessary, heat the slurry circuits as for normal start-up. Admit fuel gas
to the main fractionator overhead and start the wet gas compressor. Continue
start-up of the unit following the procedure for normal start-up.

8.4.24. Instrument air failure for the Fractionation/Gas Recovery Section


Instrument air failure will require shutdown of the unit. The control valves will go to
the failure position.
The operators should be familiar with these positions. If the wet gas compressor
has not shut down on instrument failure, it should be shut down following the
normal shutdown procedure. Maintain slurry circulation. It will be necessary to
manually control boiler feed water to the slurry pumparound steam generators,
using the control valve by-passes. Other pumps should be shut down as liquid
levels decrease.
Stop stripping steam to the strippers. As steam flow may continue to the reactor,
the main fractionator reflux drum water level will require manual control.
If necessary, heat the slurry circuit in the steam generators to maintain the main
fractionator hot. When instrument air is available, check all control valves for
proper operation. Any control valves being by-passed should be placed back in
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service and by-pass valves closed. Restart the unit following the normal start-up
procedure.

8.4.25. Boiler feed water failure for the Fractionation/Gas Recovery Section
Loss of boiler feed water will require shutdown of the unit. Loss of boiler feed
water can lead to loss of steam, depending on the duration. In this case, follow the
procedure for steam failure.
When boiler feed water is available, establish levels in the steam generators and
restart the unit following the normal start-up procedure.

8.4.26. Fuel gas failure for the Fractionation/Gas Recovery Section


Fuel gas failure will not normally require a shutdown of the fractionator section.
Fuel gas is used for pressure control on the feed surge drum. Loss of pressure
control should not result in any operating difficulty as any loss of pressure will be
gradual. Fuel gas is also used as pressure control on the surge drums associated
with the slurry separator. Loss of this control should not result in any operating
difficulty.
8.4.27. Electrical power failure for the Fractionation/Gas Recovery Section
Electrical power failure will require a shutdown of the unit. There is a possibility
that steam failure will also occur, soon after refinery wide power failure as no sea
water and cooling water.
Wet gas compressor will be shut-down, automatically, as sea water is not
available in the event of refinery wide power failure.
Try to maintain operation of the following pumps at power failure, and subsequent
steam failure:

Main fractionator bottom pump P-1519ABC

HCO flushing pump P-1521A for supplying flushing oil to P-1519ABC. In


case HCO is not available from the main fractionator, try to introduce LCO
from the tankage, if available.

In case shut-down duration is to be longer, maintain the main fractionator hot by


switching the slurry steam generators to heating.
For prolong steam available to the essential part of RFCC, i.e. steam to riser and
reactor stripping, cut off the steam to the following users, manually:

MP steam to E-1522

HP steam to E-1524

HPS to COB FD fan CT-1502B, subject to availability of HPBFW and fuel


oil and or fuel gas.

LP steam to T-1503

LP steam to T-1504

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As the fractionator overhead air condenser and overhead sour water pumps will
be lost, the use of steam to the reactor should be minimized.
When power is available restart the unit following the normal start-up procedure.

8.4.28. Cooling water failure for the Fractionation/Gas Recovery Section


Cooling water failure will require a shutdown of the unit. Cooling water is used for
main fractionator trim condenser, and trim condensers of the wet gas compressor.
Cooling water is also used for pump auxiliary coolers, and lube oil cooler of the
Wet Gas Compressor. Shut down the wet gas compressor and maintain the main
fractionator hot by switching the slurry steam generators to heating.
8.4.29. Sea water failure for the Fractionation/Gas Recovery Section
Sea water is used for coolant of the surface condenser of the wet gas compressor.
Therefore, failure of sea water will automatically trip of WGC, as turbine is not
work properly. Follow operation procedure of wet gas compressor failure.

8.4.30. Wet gas compressor failure for the Fractionation/Gas Recovery Section
On loss of the wet gas compressor, divert the fractionator overhead gas to flare
and start to reduce feed to the unit. If the wet gas compressor cannot be re-started
quickly, this will require shutdown of the unit.
Follow any emergency procedures from the vendor to safeguard the compressor.
Maintain the main fractionator hot by switching the slurry steam generators to
heating. When the wet gas compressor is ready to start, follow the normal start-up
procedure to re-start the unit.

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UNIT: 15

Course Content:
Section 1 - General Description
Section 2 - Process Flow Description
Section 3 - Process Control
Section 4 - Safeguarding Devices
Section 5 - Fire & Gas Systems
Section 6 - Quality Control
Section 7 - Cause & Effects
Section 8 - Operating Procedures
Section 9 - HSE

Section 10 - Reference Document Index

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SECTION 9 : HSE
9.1. Hazardous Areas
Refer to the following attached documents:

8474L-015-DW-0051-001 Plot Plan RFCC/LTU/NTU units

8474L-015-DW-1920-001 Hazardous Area Classification diagram


RFCC/LTU/NTU units

9.2. Safety Equipment


Refer to the following attached document:

8474L-015-DW-1933-011 Safety Equipment Layout RFCC/LTU/NTU units

9.3. Specific PPE


For the description of the PPE required for the chemicals used in the RFCC, refer to the
specific MSDS which must be supplied by the material vendor. All personnel involved in
chemical handling related work in the RFCC unit must wear the specific PPE required.
The substances used in the RFCC include:

Catalyst and additives,

Flue gases,

Cracked Hydrocarbons,

Hydrogen Sulfide

The following advice is valid for any chemical handling:

Use good work and personal hygiene practices to avoid exposure.

Keep an eye wash fountain available.

Keep a safety shower available.

If clothing is contaminated, remove clothing and thoroughly wash the affected


area.

Do not eat or drink while handling chemicals

9.3.1. Catalyst
RFCC catalyst is able to cause eyes and lungs irritations. When working with
catalyst (taking samples, catalyst containers loading and unloading) face
shields or goggles and a dust mask must be worn.
Hot catalyst will burn skin. During catalyst sampling the whole body must be
protected by adequate clothing. One should be careful with pile of hot
catalyst spillage which can be cold externally but very hot inside.

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9.3.2. Flue gas


In the RFCC process there are two different flue gases. The flue gas coming from
the first regenerator contains CO and is a very dangerous gas.
9.3.2.1. Carbon Monoxide
The following details the Personal Protection Equipment required when
entering a zone susceptible to contain CO:
Eye/Face Protection:

Safety Goggles or Glasses

Skin Protection:

Any material protective gloves

Respiratory Protection: Positive pressure air line with full-face mask and escape bottle or
self-contained breathing apparatus should be available for
emergency use.
Always wear a self contained air mask when entering in an area
or vessel suspected to contain CO.
Safety Shoes

Other:

9.3.3. H2S
The best method for prevention of H2S poisoning is to stay out of areas known or
suspected to contain it. The sense of smell is not an infallible guide as to the
presence of H2S, for although the compound has a distinct and unpleasant odor
(rotten eggs), it will frequently paralyze the olfactory nerves to the extent that
the victim does not realize that he is breathing it. This is particularly true of
higher concentrations of the gas.
Fresh air masks or gas masks suitable for use with hydrogen sulfide must
be used in all work where exposure is likely to occur. Such masks must be
checked frequently to make sure that they are not exhausted. People who must
work on or in equipment containing appreciable concentrations of H2S, must wear
fresh air masks and should work in pairs so that one may effect a rescue or call for
help should the other be overcome.
As mentioned above, the atmosphere in which people work should be checked
from time to time for appreciable concentrations of H2S.
REMEMBER - JUST BECAUSE YOUR NOSE SAYS IT'S NOT THERE, DOESN'T
MEAN THAT IT IS NOT.
PPE recommendation for protection against H2S:
Ventilation
Respiratory
Protection

Use adequate ventilation to control exposure below recommended levels


For concentrations exceeding the recommended exposure level, use
NIOSH/MSHA approved air purifying respirator.
If conditions immediately dangerous to life or health (IDLH) exist, use
NIOSH/MSHA approved self-contained breathing apparatus (SCBA)
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equipment.
Eye
Protection

For splash protection use chemical goggles and face shield

Skin
Protection

Gloves and coveralls of rubber or neoprene construction if liquid contact could


occur. Avoid unnecessary skin contamination with material

9.3.4. Nickel passivator NALCO NICKEL PASSIVATION PLUS EC9192


The following table details the PPE required when handling this chemical:
The use and choice of personal protection equipment is related to the hazard
of the product, the workplace and the way the product is handled.
In general, we recommend as a minimum precaution that safety glasses with
side-shields and workclothes protecting arms, legs and body be used.

General
Advice

In addition any person visiting an area where this product is handled should at
least wear safety glasses with side-shields.
Where concentrations in air may exceed the limits given in this section, the use
of a half face filter mask or air supplied breathing apparatus is recommended.
A suitable filter material depends on the amount and type of chemicals being
handled.

Respiratory
Protection

Consider the use of filter type: A-B-E-K-P In event of emergency or planned


entry into unknown concentrations a positive pressure, full-facepiece SCBA
should be used.
If respiratory protection is required, institute a complete respiratory protection
program including selection, fit testing, training, maintenance and inspection.
When handling this product, the use of chemical gauntlets is recommended.
PVC gloves are recommended.

Hand
Protection

Gloves should be replaced immediately if signs of degradation are observed.

Skin
Protection

When handling this product, the use of overalls is recommended. A full slicker
suit is recommended if gross exposure is possible.

Eye
Protection

Wear chemical splash goggles

9.3.5. Corrosion Inhibitor - CHIMEC 1430


The following table details the PPE required when handling this chemical:
Respiratory
protection

A localized aspiration is necessary if the warmed product forms vapours

Skin protection

protective gloves in neoprene or latex, approved for protection against


chemical substances
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Eye protection

goggles or face shield with safety glasses

Others

appropriated protective clothing

DATE: 06/12/07

9.3.6. Antifoam CHIMEC 8045


The following table details the PPE required when handling this chemical:
A localized aspiration is necessary if the warmed product forms vapours.
Ensure good ventilation.

Respiratory
protection

In closed areas or in case of insufficient ventilation, use protective mask with


filter for organic vapours.

Skin Protection

Protective gloves made of nitrile or PVA, approved for protection against


chemical substances

Eye Protection

Goggles or face shield with safety glasses

9.3.7. Phosphate NALCO 7208


The following table details the PPE required when handling this chemical:
Where concentrations in air may exceed the limits given in this section, the
use of a half face filter mask or air supplied breathing apparatus is
recommended.
Respiratory
protection

A suitable filter material depends on the amount and type of chemicals being
handled.
Consider the use of filter type: Particulate filter - HEPA (Purple) If respiratory
protection is required, institute a complete respiratory protection program
including selection, fit testing, training, maintenance and inspection.

Hand
Protection

Neoprene gloves, Nitrile gloves, Butyl gloves, PVC gloves

Skin Protection Neoprene gloves, Nitrile gloves, Butyl gloves, PVC gloves
Eye Protection

Wear chemical splash goggles

9.4. Chemical Hazards


The material safety datasheet for chemicals used in the RFCC will be provided by vendor
and serves as reference. These datasheets clearly explains what are the health hazards
specific to each chemical.
It is of the utmost importance that all employees involved in this unit read and understand
the MSDS of the chemical they will handle before proceeding to work. No work or

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operation should be allowed to commence before all employees involved in chemical


handling related work have demonstrated knowledge of the health hazards they my face.
The substances used in the RFCC include:

Catalyst and additives,

Flue gases,

Cracked Hydrocarbons,

Hydrogen Sulfide

9.4.1. Hazardous Properties of Catalyst


RFCC catalyst is able to cause eyes and lungs irritations. Hot catalyst will burn
skin. One should be careful with pile of hot catalyst spillage which can be cold
externally but very hot inside.
9.4.2. Flue gas
In the RFCC process there are two different flue gases. The flue gas coming from
the first regenerator contains CO and is a very dangerous gas. Exposure to a
concentration as low as 0.4 % vol. can be fatal in a short period of time. The
flue gas contains no or very little oxygen and is a dense gas which can
accumulate in low parts of equipments. Therefore it can cause asphyxiation
or poisoning if not sufficiently purged off.
First aid consists of taking the victim out of the dangerous area and then to use
artificial respiration.
9.4.2.1. Hazardous properties of carbon monoxide (CO)
Carbon monoxide has the ability to replace oxygen in the blood; too
high concentration in the body may cause death in a short period of
time.
CO also acts to keep the oxygen in the blood from reaching the tissues
causing a type of suffocation. Maximum allowable concentration in the air
is 100 ppm.
CO burns readily and is dangerous when exposed to heat or flames.
Its explosive limits range from 12.5% to 74% volume.
Auto ignition temperature: 650C.
Mixtures of CO and air in certain proportions are flammable.
The following table summarizes the health hazards of CO:
Eye Effects:

None reported

Skin Effects:

None Reported

Ingestion Effects:

None Reported

Inhalation Effects:

Inhaled carbon monoxide binds with blood hemoglobin to form


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carboxyhemoglobin. Carboxyhemoglobin can not take part in normal


oxygen transport, greatly reducing the bloods ability to transport oxygen.
Too high concentration in the body may cause death in a short
period of time.
Depending on levels and duration of exposure, symptoms may include
headache, dizziness, heart palpitations, weakness, confusion, nausea,
and even convulsions, eventual unconsciousness and death.

9.4.3. Hazardous Properties of Cracked hydrocarbons


Cracked hydrocarbons are skin irritants. Precautions should be taken during
maintenance operations or products sampling to avoid contact with skin and eyes.
It also contains aromatics which are poisons. In case of exposure, skin should be
washed with soap and eyes thoroughly cleaned with water. Contaminated clothes
should be removed.

9.4.4. Hazardous Properties of Hydrogen Sulfide Toxicity


Classification:

Hydrogen sulfide is both an irritant and an extremely poisonous gas. it is extremely


toxic (almost as toxic as hydrogen cyanide) and highly corrosive to certain metals.
Breathing even low concentrations of hydrogen sulfide (H2S) gas can cause
poisoning.
Hydrogen sulphide at concentrations greater than 500 ppm is highly toxic and can
cause immediate death. The unit must be completely gas tight and leaks repaired
immediately when occur. It can be lethal to under-estimate an H2S leak.
It is highly soluble in both water and oil. H2S is colorless, and heavier than air. It
will therefore accumulate in low places, in dangerous concentrations. It is
however, readily dispersed 'by the wind' movement, so areas where there is a risk
of H2S emission should be well ventilated.
H2S is explosive in air in the range of 4.3% to 45% by volume, and has an
automatic ignition temperature of 292OC. It burns with a blue flame producing
Sulphur Dioxide (SO2), which is also a toxic gas.
Human tolerance of exposure varies greatly between individuals at lower
concentrations. As concentrations increase, tolerance variations decrease rapidly.

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A feature of H2S poisoning is that the H2S immobilizes or paralyses that part of
the central nervous system, which controls the body's automatic breathing system.
H2S acts by deadening nerve endings including those associated with smell. H2S
can usually be detected by its 'bad egg' smell, but the sense of smell is quickly lost
in concentrations over 1000 ppm, even at 50 ppm the sense of smell is unreliable.
WARNING: YOU CANNOT RELY ON YOUR NOSE TO TELL YOU HOW MUCH
H2S IS PRESENT.
At concentration greater than 20 ppm it is no longer possible to smell the gas, thus
greatly increasing its hazard.
No work should be undertaken on the unit where there is danger of
breathing H2S, and one should never enter or remain in an area containing it
without wearing a suitable fresh air mask.
9.4.4.1. Acute Hydrogen Sulfide Poisoning
Breathing air or gas containing more than 500 mol-ppm H2S can cause
acute poisoning and possibly be fatal.
Symptoms of Acute Poisoning
The symptoms of acute H2S poisoning are muscular spasms, irregular
breathing, lowered pulse, odor to the breath and nausea. Loss of
consciousness and suspension of respiration quickly follow.
Even after the victim recovers, there is still the risk of edema (excess
accumulation of fluid) of the lungs which may cause severe illness or
death in 8 to 48 hours.
First Aid Treatment of Acute Poisoning
Move the victim at once to fresh air. If breathing has not stopped, keep
the victim in fresh air and keep him quiet. If possible, put him to bed.
Secure a physician and keep the patient quiet and under close
observation for about 48 hours for possible edema of the lungs.
In cases where the victim has become unconscious and breathing has
stopped, artificial respiration must be started at once. If a Pulmotor or
other mechanical equipment is available, it may be used by a trained
person; if not, artificial respiration by mouth-to-mouth resuscitation must
be started as soon as possible. Speed in beginning the artificial
respiration is essential. Do not give up. Men have been revived after more
than four hours of artificial respiration.
If other persons are present send one of them for a physician. Others
should rub the patient's arms and legs and apply hot water bottles,
blankets or other sources of warmth to keep him warm. After the patient is
revived, he should be kept quiet and warm, and remain under observation
for 48 hours for the appearance of edema of the lungs.

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9.4.4.2. Subacute Hydrogen sulfide Poisoning


Breathing air or gas containing H2S anywhere between 10 to 500 molppm for an hour or more may cause subacute or chronic hydrogen sulfide
poisoning.
Symptoms of Subacute Poisoning
The symptoms of subacute H2S poisoning are headache, inflammation of
the eyes and throat, dizziness, indigestion, excessive saliva, and
weakness. These can be the result of continued exposure to H2S in low
concentrations. Edema of the lungs may also occur.
First Aid Treatment of Subacute Poisoning
Keep the patient in the dark to reduce eyestrain and have a physician
treat the inflamed eyes and throat. Watch for possible edema.
Where subacute poisoning has been suspected, the atmosphere should
be checked repeatedly for the presence of H2S by such methods as
testing by odor, with moist lead acetate paper, and by Tutweiler H2S
determination to make sure that the condition does not continue.

9.4.5. Hazardous Properties of NALCO NICKEL PASSIVATION PLUS EC9192


Hazard Classification:

The following table summarizes the health hazards of this chemical:


Inhalation

Repeated or prolonged exposure may irritate the respiratory tract.


Product mist or vapors may cause headache, nausea, vomiting,
drowsiness, stupor or unconsciousness.
Methyl alcohol may cause central nervous system effects which may
result in permanent visual changes including blindness.

Skin Contact

Can cause moderate irritation. Harmful if absorbed through skin.


Methanol may be absorbed through the skin and cause central nervous
system effects which may result in permanent visual changes including
blindness.

Eye Contact

Can cause moderate irritation

Ingestion

Not a likely route of exposure. There may be irritation to the gastrointestinal tract. Harmful if swallowed. Can cause blindness.
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Note:
Keep out of waterways: Toxic to aquatic organisms.

9.4.6. Hazardous Properties of Corrosion Inhibitor - CHIMEC 1430


Hazard Classification:

The following table summarizes the health hazards of this chemical:


Inhalation

Vapours or fog inhalation at high temperature may produce irritation of


respiratory tract.

Skin Contact

Corrosive, may produce dermatitis and burns

Eye Contact

Corrosive

Ingestion

burning effects in mouth, throat and stomach with abdominal


cramps

9.4.7. Hazardous Properties of Antifoam CHIMEC 8045


Hazard Classification:

The following table summarizes the health hazards of this chemical:


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Slight exposure: irritation of eyes and primary respiratory tract, with


temporary reduction of smelling capacity.

Inhalation

Exposure to high vapour concentration: depressant effect on the central


nervous system with headaches, drowsiness, derangement, serious
damage to visual faculties, nausea, vomiting, drunkenness.
May cause anesthetic and/or narcotic effects.
Skin Contact

Prolonged and repeated contact may produce dermatitis and irritation

Eye Contact

Vapours may cause irritation

Ingestion

Ingestion causes severe irritation of the mouth, throat and stomach, with
nausea, vomiting, dizziness, faintness, drowsiness and lack of
coordination.
Ingestion creates a high risk of aspiration and subsequent chemical
pneumonia.

9.4.8. Hazardous Properties of Phosphate NALCO 7208


Hazard Classification:

The following table summarizes the health hazards of this chemical:


Inhalation

Not a likely route of exposure. No adverse effects expected

Skin Contact

Can cause moderate to severe irritation

Eye Contact

Can cause moderate to severe irritation

Ingestion

Can cause moderate to severe irritation

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TRAINING MODULE

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UNIT: 15

Course Content:
Section 1 - General Description
Section 2 - Process Flow Description
Section 3 - Process Control
Section 4 - Safeguarding Devices
Section 5 - Fire & Gas Systems
Section 6 - Quality Control
Section 7 - Cause & Effects
Section 8 - Operating Procedures
Section 9 - HSE
Section 10 - Reference Document Index

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SECTION 10 : REFERENCE DOCUMENTS INDEX


10.1. Operating Manual/ Licensor Documentation
8474L-015-ML-001

RFCC Operating Manual

10.2. Arrangement Drawings, Layouts and Plot Plans


8474L-015-DW-0051-001

Plot Plan RFCC / LTU / NTU

8474L-015-DW-1960-001

Escape Route Layout for RFCC / LTU / NTU

10.3. Process Flow Diagrams


8474L-015-PFD-0010-101

Reactor / Regeneration Section Case: Bach Ho

8474L-015-PFD-0010-102

Flue Gas Treatment Section Case: Bach Ho

8474L-015-PFD-0010-103

Feed Section Case: Bach Ho

8474L-015-PFD-0010-104

Fractionation Section Case: Bach Ho

8474L-015-PFD-0010-105

Gas Recovery Section Case: Bach Ho

8474L-015-PFD-0010-106

Material Balance Table Case: Bach Ho MG

8474L-015-PFD-0010-107

Material Balance Table Case: Bach Ho MD

8474L-015-PFD-0010-111

Reactor / Regeneration Section Case: Mixed Crude

8474L-015-PFD-0010-112

Flue Gas Treatment Section Case: Mixed Crude

8474L-015-PFD-0010-113

Feed Section Case: Mixed Crude

8474L-015-PFD-0010-114

Fractionation Section Case: Mixed Crude

8474L-015-PFD-0010-115

Gas Recovery Section Case: Mixed Crude

8474L-015-PFD-0010-116

Material Balance Table Case: Mixed Crude MG

8474L-015-PFD-0010-117

Material Balance Table Case: Mixed Crude MD

10.4. Piping and Instrumentation Diagrams


Interconnections:
8474L-015-PID-0021-101

Interconnecting Process Lines to RFCC

8474L-015-PID-0021-102

Interconnecting Process Lines from RFCC

8474L-015-PID-0021-103

Interconnecting Process Lines to/from LTU

8474L-015-PID-0021-104

Interconnecting Process Lines to/from NTU

8474L-015-PID-0021-105

Interconnecting Process Lines to/from PRU

8474L-015-PID-0021-106

Interconnecting Utilities

8474L-015-PID-0021-107

Interconnecting Utilities

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Specific Details:
8474L-015-PID-0021-111

Specific Details (1/4)

8474L-015-PID-0021-112

Specific Details (2/4)

8474L-015-PID-0021-113

Specific Details (3/4)

8474L-015-PID-0021-114

Specific Details (4/4)

Reactor/Regenerator Section:
8474L-015-PID-0021-121

Riser: Feed injectors

8474L-015-PID-0021-122

Riser: MTC & Backflush oil injectors

8474L-015-PID-0021-123

Disengager/Stripper: Stripping

8474L-015-PID-0021-124

Disengager/Stripper: Purging

8474L-015-PID-0021-125

Spent Catalyst Line

8474L-015-PID-0021-126

1st Regenerator Dense Phase-Upper

8474L-015-PID-0021-127

1st Regenerator Dense Phase-Lower

8474L-015-PID-0021-128

1st Regenerator Dilute Phase

8474L-015-PID-0021-129

2nd Regenerator Upper

8474L-015-PID-0021-130

2nd Regenerator Lower

8474L-015-PID-0021-131

Withdrawal Well

8474L-015-PID-0021-132

Air Blower

8474L-015-PID-0021-133

1st Regenerator Air Heater

8474L-015-PID-0021-134

2nd Regenerator Air Heater

8474L-015-PID-0021-135

Spent Catalyst Hopper

8474L-015-PID-0021-136

Auxiliary Catalyst Hopper

8474L-015-PID-0021-137

Fresh Catalyst Hopper

8474L-015-PID-0021-138

Steam Injection & Fuel Gas Inst. Purging

Flue Gas Treatment Section:


8474L-015-PID-0021-201

1st Regenerator Flue Gas

8474L-015-PID-0021-202

2nd Regenerator Flue Gas

8474L-015-PID-0021-203

CO Boiler Package

8474L-015-PID-0021-204

Electrostatic Precipitator

8474L-015-PID-0021-205

Economizer

8474L-015-PID-0021-206

Flue Gas KO Drum

Fractionation Section:
8474L-015-PID-0021-301

Feed Surge Drum and Pumps


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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

8474L-015-PID-0021-302

LCO PA/MPS/HPS Feed Heaters

8474L-015-PID-0021-303

1st Slurry preheat exchangers

8474L-015-PID-0021-304

2nd Slurry preheat exchangers

8474L-015-PID-0021-305

MTC Recycle and Heavy Naphta PA

8474L-015-PID-0021-306

HCO recycle

8474L-015-PID-0021-307

LCO PA Pumps

8474L-015-PID-0021-308

HCO PA Pumps & HCO PA MPS Generator

8474L-015-PID-0021-309

Main Fractionator Upper Section

8474L-015-PID-0021-310

Main Fractionator Lower Section

8474L-015-PID-0021-311

Slurry PA Pumps

8474L-015-PID-0021-312

Slurry PA HP steam generators A&B

8474L-015-PID-0021-313

Slurry PA HP steam generators C

8474L-015-PID-0021-314

Slurry PA HP/MP steam generators A

8474L-015-PID-0021-315

Slurry PA HP/MP steam generators B

8474L-015-PID-0021-316

HCO Stripper

8474L-015-PID-0021-317

Heavy Naphta Stripper

8474L-015-PID-0021-318

LCO Stripper

8474L-015-PID-0021-319

Fractionator Overhead

8474L-015-PID-0021-320

Fractionator Reflux Drum

8474L-015-PID-0021-321

Slurry Draw Off Drum

8474L-015-PID-0021-322

Slurry LP Steam Generators

8474L-015-PID-0021-323

Clarified Oil Cooler and Slurry Separator

8474L-015-PID-0021-324

Slurry Separator Backflushing (1/2)

8474L-015-PID-0021-325

Slurry Separator Backflushing (2/2)

8474L-015-PID-0021-326

HCO Flushing Oil

8474L-015-PID-0021-327

HCO Flushing Oil

8474L-015-PID-0021-328

LCO Product Cooling

8474L-015-PID-0021-329

Light Slops Drum

8474L-015-PID-0021-330

Heavy Slops Drum

8474L-015-PID-0021-331

Tempered Water System

8474L-015-PID-0021-332

Phosphate Injection Package

Gas Recovery Section:


8474L-015-PID-0021-401

Wet gas compressor 1st stage KO Drum

8474L-015-PID-0021-402

Wet gas compressor

8474L-015-PID-0021-403

Wet gas compressor Inter/Trim Cooler


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REV: A

DATE: 06/12/07

8474L-015-PID-0021-404

HP Separator

8474L-015-PID-0021-405

Primary Absorber and Stripper

8474L-015-PID-0021-406

Gasoline Cooldown

8474L-015-PID-0021-407

Secondary Absorber

8474L-015-PID-0021-408

Fuel Gas Absorber

8474L-015-PID-0021-409

Debutanizer

8474L-015-PID-0021-410

Debutanizer Condenser and Reflux Drum

8474L-015-PID-0021-411

LPG Amine Absorber

8474L-015-PID-0021-451

Closed Drain Recovery

8474L-015-PID-0021-452

Blowdown System

8474L-015-PID-0021-453

Amine Closed Drain Recovery

8474L-015-PID-0021-454

Oily Water Lift Station

10.5. Equipment list


Refer to the attached equipment list of unit 015:
Unit 015 Extracted Equipment List
10.6. Main Equipment Data Sheet
8474L-015-PDS-AE-401

Process Data Sheet of RFCC Analysers

8474L-015-PDS-BV-1501-719

Process Data Sheet of BV-1501

8474L-015-PDS-BV-1502-720

Process Data Sheet of BV-1502

8474L-015-PDS-D-1501-101

Process Data Sheet of D-1501

8474L-015-PDS-D-1501-210

Process Data Sheet of D-1501 (Packing)

8474L-015-PDS-D-1502-102

Process Data Sheet of D-1502

8474L-015-PDS-D-1503-103

Process Data Sheet of D-1503

8474L-015-PDS-H-1501-501

Process Data Sheet of H-1501

8474L-015-PDS-H-1502-502

Process Data Sheet of H-1502

8474L-015-PDS-H-1503-503

Process Data Sheet of H-1503

8474L-015-PDS-PV-1501-721

Process Data Sheet of PV-1501

8474L-015-PDS-SV-1501-711

Process Data Sheet of SV-1501

8474L-015-PDS-SV-1502-712

Process Data Sheet of SV-1502

8474L-015-PDS-SV-1503-713

Process Data Sheet of SV-1503

8474L-015-PDS-SV-1503-714

Process Data Sheet of SV-1504

8474L-015-PDS-T-1501-211

Process Data Sheet of T-1501


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REV: A

DATE: 06/12/07

8474L-015-PDS-T-1501-212

Process Data Sheet of T-1501 (Trays)

8474L-015-PDS-T-1501-213

Process Data Sheet of T-1501 (Packing)

8474L-015-PDS-T-1551-221

Process Data Sheet of T-1551

8474L-015-PDS-T-1551-222

Process Data Sheet of T-1551 (Tray)

8474L-015-PDS-T-1552-223

Process Data Sheet of T-1552

8474L-015-PDS-T-1552-224

Process Data Sheet of T-1552 (Tray)

8474L-015-PDS-T-1553-225

Process Data Sheet of T-1553

8474L-015-PDS-T-1553-226

Process Data Sheet of T-1553 (Tray)

8474L-015-PDS-T-1554-227

Process Data Sheet of T-1554

8474L-015-PDS-T-1554-228

Process Data Sheet of T-1554 (Tray)

8474L-015-PDS-T-1555-229

Process Data Sheet of T-1555

8474L-015-PDS-T-1555-230

Process Data Sheet of T-1555 (Tray)

8474L-015-PDS-T-1556-231

Process Data Sheet of T-1556

8474L-015-PDS-T-1556-232

Process Data Sheet of T-1556 (Packing)

8474L-015-PDS-X-1504-604

Process Data Sheet of X-1504

8474L-015-PDS-X-1507-607

Process Data Sheet of X-1507

10.7. Instrument List


Refer to attached extracted instrument list of unit 012:
Unit 012 Extracted Instrument List.xls
10.8. Cause & Effect Matrix
8474L-015-DW-1514-602
10.9. Safety Logic diagram
8474L-XX-XXXX-XXX
10.10. Fire & Gas Cause & Effect Chart
8474L-015-DW-1514-610
10.11. Fire & Gas Detectors Layout
8474L-015-DW-1950-001

Fire & Gas Detector Layout RFCC/LTU/NTU

10.12. Fire Protection Layout


8474L-015-DW-1933-001

Fire Protection Layout RFCC/LTU/NTU

8474L-015-DW-1933-011

Safety Equipment Layout RFCC/LTU/NTU


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RESIDUE FLUID CATALYTIC
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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

10.13. Hazardous Area Classification


8474L-015-DW-1920-001 Hazardous Area Classification Plan RFCC/LTU/NTU
10.14. MSDS
For the MSDS of the following chemicals, refer to the attachments of the licensor
operating manual:

Nickel Passivator EC9192

Corrosion Inhibitor CHIMEC 1430

Anti foam Chemical CHIMEC 8045

Phosphate NALCO 7208

10.15. Vendors Documentation


COB/WHB Package:
8474L-015-A0103-0160-001-029 P&ID Combustion air system
8474L-015-A0103-0160-001-030 P&ID CO Combustor
8474L-015-A0103-0160-001-031 P&ID CO Combustor
8474L-015-A0103-0160-001-032 P&ID Fuel Skid
8474L-015-A0103-0160-001-033 P&ID Waste Heat Recovery Section
8474L-015-A0103-0160-001-034 P&ID Steam Drum
8474L-015-A0103-0160-001-035 P&ID Blowdown System
8474L-015-A0103-0160-001-142 P&ID Economizer
8474L-015-A0103-0160-001-143 P&ID Ancillaries
8474L-015-A0103-0160-001-144 P&ID Economizer Sootblower
8474L-015-A1001-0160-001-098 H-1503 Package Datasheet
Electrostatic Precipitator:
8474L-015-A0103-4240-002-005 P&ID ESP
8474L-015-A0103-4240-002-009 P&ID ESP
8474L-015-A0103-4240-002-128 P&ID ESP
8474L-015-A0103-4240-002-129 P&ID ESP
8474L-015-A0103-4240-002-130 P&ID ESP
8474L-015-A0103-4240-002-131 P&ID ESP
8474L-015-A0103-4240-002-133 P&ID ESP
8474L-015-A1001-4240-001-011 Data Sheet X-1507
8474L-015-A3501-4240-002-122 X-1507 Operational Procedure
8474L-015-A3501-4240-002-135 Ash Handling Control Flowchart
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DOC NO: 8474L-015-A5016-0000-001-005


REV: A

DATE: 06/12/07

8474L-015-A3505-4240-001-023 Logic Sequence Diagram


Wet Gas Compressor:
8474L-015-A1001-1010-001-007 Data Sheet of C-1551
8474L-015-A3501-1010-001-108 Control System Description
8474L-015-A3505-1010-001-041 Cause & Effect Diagram
Air Blower:
8474L-015-A1001-1040-001-226 Blower Data Sheet
8474L-015-A3505-1040-001-063 Blower Cause & Effect Diagram

Page 323 of 323