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VIETNAM OIL AND GAS CORPORATION

(PETROVIETNAM)
DUNG QUAT REFINERY

OPERATING MANUAL
VOLUME 5

RESIDUE FLUIDISED CATALYTIC


CRACKING UNIT
UNIT 015
BOOK

8474L-015-ML-001- A

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Project n - Unit Doc. type Mat. code Serial n Rev.

8474L 015

ML

001

Page

OP Center Job No. 0-3952-20


OP Center Doc. No. S-015-1283-001
VIETNAM OIL AND GAS CORPORATION ( PETROVIETNAM )
DUNG QUAT REFINERY (DQR) PROJECT
OPERATING MANUAL UNIT RFCC (015)

OPERATING MANUAL
UNIT 015

RESIDUE FLUIDAISED CATALYTIC CRACKING UNIT (RFCC)

Document Class: Z

Pages modified under this revision:

A
Rev

02-MAR-07
Date
DD/MM/YY

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007
8474L-015-ML-001-A
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ISSUE FOR APPROVAL

T. Tsuchiya

M. Okada

M. Okada

STATUS

WRITTEN BY
(name & visa)

CHECKED BY
(name & visa)

APPROVED BY
(name & visa)

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

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
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CONTENTS
1 DESIGN BASIS

14

1.1

Introduction and Purpose of Process

14

1.2

Basis of design

16

1.2.1 Unit objectives and capacity

16

1.2.2 Feedstock properties

17

1.2.3 Product specifications

20

1.2.4 Operating conditions

25

1.2.5 Battery limit conditions

28

1.2.6 Utility operating / Design conditions

29

1.3

30

Material balances

1.3.1 Reaction - Regeneration Catalyst handling and flue gas treatment

30

2 UNIT DESCRIPTION

33

2.1

33

Reaction Regeneration Catalyst handling Flue gas treatment

2.1.1 Reaction system

33

2.1.2 Regeneration system

35

2.2

37

Technology features

2.2.1 Cold wall design

37

2.2.2 Feed injection system

38

2.2.3 MTC system

38

2.2.4 Riser Outlet Separation System

39

2.2.5 Two stage regeneration

39

2.2.6 Special valves

40

2.2.7 Riser wye steam ring

40

2.2.8 Aeration and fluidization systems

40

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DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

2.2.9 Stripper bottom ring

41

2.2.10 First stage regenerator fluffing ring

41

2.2.11 Regenerated catalyst withdrawal well ring

41

2.2.12 Combustion air rings

41

2.3

Catalyst

42

2.4

Flue gas treatment

43

2.5

Feed fractionation

43

2.5.1 Feed section

43

2.5.2 Mixed crude feed

43

2.5.3 Fractionator bottom section

44

2.5.4 HCO section

44

2.5.5 LCO section

44

2.5.6 MTC and heavy naphtha section

45

2.5.7 Top section

45

2.5.8 Fractionator overhead section

45

2.6

46

Gas Recovery section

2.6.1 Wet gas compressor and HP condenser

46

2.6.2 Stripper condenser and high pressure separator drum

46

2.6.3 Primary absorber

46

2.6.4 Stripper

46

2.6.5 Secondary absorber

46

2.6.6 Fuel gas absorber

47

2.6.7 Debutanizer

47

2.6.8 LPG amine absorber

47

2.7

47

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Theory of the Process

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


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OPERATING MANUAL
UNIT RFCC (015)

2.7.1 Chemical reactions and catalysts

47

2.7.2 Types of reactions

49

2.7.3 Desired reactions

53

2.7.4 Reactions to be limited (but not eliminated)

54

2.7.5 Undesirable reactions to be reduced to the minimum

54

2.7.6 Conversion selectivity of various hydrocarbon families

54

2.7.7 Catalyst

56

2.7.8 Catalyst regeneration

60

3 UNIT CONTROL DESCRIPTION

62

3.1

Control philosophy of the process

62

3.2

Process variables of Reactor / Regeneration Section

64

3.2.1 General

64

3.2.2 Riser Outlet Temperature

64

3.2.3 Disengager pressure

65

3.2.4 Catalyst activity

65

3.2.5 Regenerators air balance

65

3.2.6 Regenerators temperature

66

3.2.7 Regenerators residence time

66

3.2.8 Regenerators velocities

67

3.2.9 Stripper operation

67

3.2.10 Heat balance

67

3.2.11 Feedstock quality

67

3.2.12 Feed temperature

68

3.2.13 Coke yield / delta coke / catalyst to oil ratio

68

3.2.14 Catalyst circulation / pressure balance

69

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

3.3

Process Operation variables

70

3.3.2 RFCC reaction variables

70

3.3.3 Feed temperature effects

71

3.3.4 Riser / Outlet Temperature effects

72

3.3.5 Effects of contact time

74

3.3.6 Effects of catalyst activity

75

3.3.7 Effects of recycle rate

76

3.3.8 Effects of fresh feed quality

76

3.3.9 Metals and Carbon residue effects

77

3.4

78

Uninterruptible Power Supply (UPS)

4 CHEMICAL, CATALYST AND UTILITY

79

4.1

79

Specifications of catalysts

4.1.1 Catalyst inventory and addition rate

79

4.1.2 Fresh catalyst selection

79

4.2

Antimony (Nickel passivator)

79

4.3

Corrosion inhibitor

80

4.4

Amine antifoaming agent

80

4.5

Amine (outside battery limit)

80

4.6

Phosphate for Steam Generation

80

4.7

Estimated utilities

81

5 PREPARATION FOR INITIAL START-UP

82

5.1

Chronology of operations

82

5.2

Equipment and unit inspection

83

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3.3.1 Introduction

5.2.1 Equipment inspection

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


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OPERATING MANUAL
UNIT RFCC (015)

5.2.2 Unit inspection

85

5.2.3 Line Flushing Outline

88

5.2.4 Rotating Equipment Run-in

89

5.3

90

Preliminary operations

5.3.1 Definitions

90

5.3.2 Utility systems commissioning

90

5.3.3 Unit commissioning

91

5.3.4 Initial leak tests

91

5.3.5 Catalyst hoppers loading

92

5.4

92

First start-up

5.4.1 General

92

5.4.2 Status of the unit

93

5.4.3 Chronology of start-up operation

93

5.4.4 Blower start-up and checks

94

5.4.5 Dry-out of refractory

97

5.4.6 Refractory inspection

99

5.4.7 Drying out and Chemical Boiling-out of CO Boiler/Waste Heat Boiler

102

5.4.8 Soda Boiling of WHB BFW Circuit

102

5.4.9 Soda Boiling of Main Column Bottoms Generator

102

5.4.10 Degreasing of Amine Circuit

102

6 INITIAL AND NORMAL START-UP

103

6.1

103

Start-up Summary

6.1.1 Reactor and Regeneration Section

103

6.1.2 Fractionation and Gas Concentration Section

106

6.2

108

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Final Preparation

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


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OPERATING MANUAL
UNIT RFCC (015)

6.2.1 Preparation Confirmation

108

6.2.2 Off-site and relating units preparation

109

6.3

110

Reactor Regenerator Start-up Procedure

6.3.1 Unit warm-up

110

6.3.2 Main fractionator MOV-001 Opening

111

6.3.3 Catalyst loading

112

6.3.4 Establishing catalyst circulation

114

6.3.5 Oil-in into Rizers

116

6.3.6 MTC system commissioning

119

6.4

123

Start-up for the Fractionator Section

6.4.1 Objective

123

6.4.2 Status

123

6.4.3 Steam-out (or nitrogen purge)

123

6.4.4 Main fractionator cold circulation

125

6.4.5 Cold Oil Circulation of Gas-Concentration Section

126

6.4.6 Main fractionator hot circulation

127

6.4.7 Main fractionator MOV-001 Opening

127

6.4.8 Wet gas compressor start-up

128

6.4.9 Start up Procedure of Wet Gas Compressor

128

6.4.10 Inventory Gas Concentration Section and Naphtha Circulation

129

6.4.11 Heat Up the Stripper and Debutanizer

130

6.4.12 Introduction of feed

130

7 NORMAL OPERATION OF THE UNIT

132

7.1

Summary of operating conditions

132

7.2

Control philosophy of the process

133

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


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UNIT RFCC (015)

7.3

Operating parameters

135

7.3.2 Riser Outlet Temperature

135

7.3.3 Disengager pressure

136

7.3.4 Catalyst activity

136

7.3.5 Regenerators air balance

137

7.3.6 Regenerator temperatures

138

7.3.7 Regenerators residence time

138

7.3.8 Regenerators velocities

138

7.3.9 Stripper operation

138

7.3.10 Heat balance

139

7.3.11 Feedstock quality

140

7.3.12 Feed temperature

141

7.3.13 Coke yield / delta coke / catalyst to oil ratio

141

7.4

143

Adjustment of operating conditions

7.4.1 Feedstock properties

143

7.4.2 Mass balance

144

7.4.3 Product properties

144

7.4.4 Heat balance

144

7.4.5 Pressure balance

150

7.5

153

Catalyst management

7.5.1 Catalyst analyses

153

7.5.2 Catalyst replacement

156

7.5.3 Catalyst addition

156

7.5.4 Catalyst draw-off

157

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7.3.1 Capacity

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7.6

Operation of Fractionation and Gas Concentration Section

160

7.6.2 Gas Concentration section

163

7.7

164

Supporting Facility Operation

7.7.1 Steam Generation Blow-down Operation

164

7.7.2 Slurry Separator Operation

165

7.7.3 Slurry Pump Operation Note

165

7.7.4 Corrosion Monitoring

166

7.7.5 Fuel Gas and Pilot Gas Supply System

166

7.7.6 Slop Oil Injection Operation

166

7.7.7 Pump Minimum Flow Operation

167

7.7.8 Flue Gas Onstream Analyzers Operation

167

7.8

168

Troubleshooting

7.8.1 Troubleshooting situations

168

7.8.2 Catalyst circulation problems

168

7.8.3 Excessive catalyst losses

169

7.8.4 Poor quality of regeneration

170

7.8.5 Spent catalyst stripping

170

7.8.6 Product quantity and quality

170

7.8.7 Partial Shutdown of Electrostatic Precipitator

171

7.9

172

Operation Notes, Relating Hazop Follow-up Action

7.9.1 Feed Injection Atomising Steam supply failure

172

7.9.2 Temporary Strainer in Feed Line at downstream of M-1501

172

7.9.3 MOV-001 Operation and Isolation Valve of PSV-002

172

7.9.4 Avoid Solidification of Feed Oil

173

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7.6.1 Fractionation section

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UNIT RFCC (015)

7.9.5 Reactor Temperature Control for Coke Formation

173

7.9.6 MTC Atomizing Steam Injection

173

7.9.7 Avoid Vacuum Condition of Reactor Vessel

173

7.9.8 Metal Passivator Filling Operation to D-1508

174

7.9.9 PDT-103 Commisioning Note for Slide Valve SV-1502

174

7.9.10 Catalyst sampling method

174

7.9.11 Operation of Vaiable Orifice down stream of Flue Gas Slide Valve

175

7.9.12 Combustion Air Control to the First Regenerator

175

7.9.13 Combustion Air Control to the Second Regenerator

175

7.9.14 Flue Gas Operating Temperature at Economizer Outlet

175

7.9.15 Slurry Service Heat Exchanger Flush out when Idling Operation

176

7.9.16 Switch Over Operation of E-1506AB Stand-by to Operation

176

7.9.17 Operation of HP-BFW Preheating by E-1516 and E-1511

176

7.9.18 WGC Compressor Suction KO Drum Pump Out operation

176

7.9.19 Depressuring operation of T-1556 LPG Extractor

177

7.9.20 First Regenerator High High Temperature

177

7.9.21 Split Range Control of Surge Drum

177

7.9.22 Untreated Gas to F/G System during Upset Situation of F/G Absorber T-1555

178

7.10 Unit monitoring check list

179

8 NORMAL SHUT-DOWN

180

8.1

180

Normal Shut-down

8.1.1 Shutdown and restart of the unit

180

8.2

180

Normal shutdown General and Summary

8.2.1 General

180

8.2.2 Summary of Shutdown of Reactor and Regenerator

180

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


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UNIT RFCC (015)

8.2.3 Summary of Shutdown on Fractionator and Gas Recovery Section

182

8.3

Shut Down Procedure

183

8.3.1 Catalyst inventory reduction

183

8.3.2 Feed reduction

183

8.3.3 Oil out of riser

184

8.3.4 Coke burn-off

184

8.3.5 Stop catalyst circulation

184

8.3.6 Closing of MOV-001 at main fractionator inlet

185

8.3.7 Catalyst removal

185

8.3.8 Unit cooldown

186

8.4

Short period shutdown

189

8.5

Automatic emergency shutdown (ES)

189

8.6

Injectors Inspection and Maintenance

189

8.6.1 Inspection

189

8.6.2 Maintenance

190

8.7

191

Shutdown of the Fractionator Section

8.7.1 Normal shutdown

191

8.7.2 Feed reduction and removal

191

8.7.3 Main Fractionator MOV-001 closing

192

8.7.4 Fractionation section hydrocarbon removal

192

8.8

192

Gas recovery section shutdown

8.8.1 Shut-down Procedure of gas Recovery Section

192

8.8.2 Gas recovery section hydrocarbon removal

193

9 EMERGENCY SHUTDOWN PROCEDURE

194

9.1

194

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Emergency sequences Summary

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UNIT RFCC (015)

9.2

Detail Description of Emergency Trip System

194

9.2.2 Inventory Isolation and Equipment Protection

199

9.3

200

Emergency shutdown by operators

9.3.1 General

200

9.3.2 Power failure

200

9.3.3 Instrument air failure

201

9.3.4 Fluidization / Aeration / Purge Air and FG failure

202

9.3.5 Steam failure

203

9.3.6 Boiler feed water failure

204

9.3.7 Cooling water failure

204

9.3.8 Sea water failure

205

9.3.9 Air blower failure

205

9.3.10 Feed pump failure as loss of feed

206

9.3.11 Other pump failure

206

9.3.12 Fuel gas failure

206

9.3.13 Wet gas compressor failure

207

9.3.14 Catalyst slide valve / plug valve failure

208

9.3.15 Loss of regenerators pressure control (flue gas slide valve failure)

208

9.3.16 Control system failure

209

9.3.17 Oil reversal

209

9.3.18 Low riser outlet temperature

209

9.3.19 Plugged catalyst circulation

209

9.3.20 Downstream unit failure

210

9.3.21 Fire emergency

210

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9.2.1 Emergency Shut-down System

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OPERATING MANUAL
UNIT RFCC (015)

9.4

Emergency shutdown of Fractionator and Gas Concentration Section

210

9.4.2 Utility failure

210

9.4.3 Wet gas compressor failure

212

10 SAFETY EQUIPMENT AND PROCEDURES

213

10.1 Pressure Safety Devices

213

10.2 Alarm Setting

213

10.3 Trip Setting

213

10.4 Trip System Chart

213

10.5 Hazardous and Toxic Materials

213

10.5.1 General considerations

213

10.5.2 Vessel entry

213

10.5.3 Hazardous and Toxic Materials

214

10.5.4 Material Safety Data Sheet (MSDS)

215

10.6 HAZOP Recommendation for Operation Instruction

215

11 INSTRUEMNT DATA

219

11.1 Control Valves and Instruments

219

11.2 Orifice Plates

219

12 SUMMARY OF MAJOR EQUIPMENT

220

12.1 Equipment List

220

12.2 Large Rotating Equipment

220

12.2.1 Air Blower, C-1501

220

12.2.2 Wet Gas Compressor, C-1551

220

12.3 Major Special Packages

221

12.3.1 Electrostatic Precipitator, X-1507

221

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9.4.1 General

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12.3.2 COB/WHB Package, H-1503

221

12.3.3 Slurry Separator, X-1504

221

13 ANALYSIS

222

13.1 Sampling and Testing Method Schedule

222

13.2 Catalyst sampling method

224

13.3 On-Line Analyzer

227

14 PROCESS CONTROL

228

14.1 Distributed System Control (DCS)

228

15 DRAWINGS

229

15.1 Plot Plans

229

15.2 Process Flow Diagram

229

15.3 Piping and Instrumentation Diagram

229

15.4 Other Drawings

229

16 ATTACHMENT

230

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UNIT RFCC (015)

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DESIGN BASIS

1.1 Introduction and Purpose of Process


This document covers operation manual of RFCC Unit (Unit 15) of Dung Quat Refinery Project of
Vietnam Oil and Gas Corporation.
The RFCC unit design Capacity is 69,700 BPSD of Atmospheric Residue of the following crude:
- Bach Ho crude
- Mixed Crude of Bach Ho and Dubai Crude
The main purpose of the Residue Fluid Catalytic Cracking Process R2R process is to convert various
reduced crudes to lower boiling, high value products, primarily C3-C4 LPG, gasoline, and light cycle oil.
Using vapor phase chemical reactions in the presence of specialized FCC cracking catalyst, the long
molecular chain FCC feedstock is cracked to 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 but selective cracking process. The vaporization and cracking reactions occur in the reactor-riser
in roughly two seconds. As by-products of the reaction, fuel gas, slurry oil, and coke are also generated in
the reactor-riser. The majority of the FCC equipment handles catalyst / vapor 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 IFP Residue Fluid Catalytic Cracking Process (RFCC) incorporates two-stage catalyst regeneration, a
unique feed injection system, mixed temperature control, an efficient riser termination system, and effective
air / steam distribution devices. This proven IFP RFCC process offers maximum flexibility for converting
reduced crudes into valuable products.
The Fractionation section fractionates the vapor product from the Reaction section. The products from this
section are clarified oil, LCO and heavy naphtha. For Maximum Gasoline operation the heavy naphtha is
combined with the light gasoline from the Gas Recovery section. For Maximum Distillate operation the
heavy naphtha is combined with the LCO product.
The fractionator overhead vapor and liquid streams are further processed in the Gas Recovery section. The
products from this section are light gasoline, amine treated fuel gas and amine treated LPG.

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OPERATING MANUAL
UNIT RFCC (015)

List of ABBREVIATIONS
ABD
AI
API
ASTM
atm
CCR
CF
CRC
C/O
E-cat
EP
FG
HC
HCO
HDS
HF
HT
HVGO
IBP
LCO
LOI
LPG
MAT
molwt
MON
MR
MTBE
PSD
RCSV
RE
REUSY
REY
RGT
RON
RVP
ROT
SA
SCSV
VAC
VGO
TBP
TC
UCS
USY

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Apparent Bulk Density


Attrition Index
American Petroleum Institute
American Standard for Testing Metals
atmospheric
Conradson Carbon Residue
Coke Factor
Carbon on Regenerated Catalyst
Catalyst to Oil ratio
Equilibrium catalyst
End Point
Fuel Gas
HydroCarbon
Heavy Cycle Oil
Hydro DeSulfurization
Hydrogen Factor
Hydrogen Transfer
Heavy Vacuum Gas Oil
Initial Boiling Point
Light Cycle Oil
Loss On Ignition
Liquefied Petroleum Gas
Micro Activity Test
molecular weight
Motor Octane Number
Metal Resistance
Methyl Tertiary Butyl Ether
Particle Size Distribution
Regenerated Catalyst Slide Valve
Rare Earth
Rare Earth exchange Ultra Stable zeolite Y
Rare Earth exchange zeolite Y
Regenerator Temperature
Research Octane Number
Reid Vapor Pressure
Riser Outlet Temperature
Surface Area
Spent Catalyst Slide Valve
Vacuum
Vacuum Gas Oil
True Boiling Point
Thermal Cracking
Unit Cell Size
Ultra Stable zeolite Y

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DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
Rev.
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1.2 Basis of design


1.2.1

Unit objectives and capacity

The Residue Fluid Catalytic Cracking (RFCC) is designed for two 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, 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 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 on the following two
modes of operation:
- Maximize RFCC Naphtha (Max Gasoline)
- Maximize LCO (Max Distillate)
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).

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

1.2.2

February 2007
Rev.
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Chapter : 1
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Feedstock properties

1.2.2.1 Atmospheric residue properties

Cut range, TBP


Vol% on Crude
Wt% on Crude
API Gravity
SG at 15/4C
Nitrogen
Sulphur
Conradson Carbon
Vanadium
Nickel
Sodium

wt ppm
wt%
wt%
wt ppm
wt ppm
wt ppm
cSt

Viscosity @ 50C
Viscosity @ 100C
cSt
Pour point
C
Asphaltenes
wt%
Wax content
wt%
Hydrogen
wt%
Neutralization No.
mg KOH/gm
Characterization "K" factor
ASTM distillation,
C
(D1160 @ 760 mmHg)
IBP
10%
30%
50%
vol% above @ 550C

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Crude (Sour)
Blend
370+
46.6
50.0
26.95
0.893
1800
0.55
2.66
10.5
5
1.6
43.4

100% (Sweet)
Bach Ho
370+
47.3
50.1
28.9
0.882
1300
0.05
1.57
0
1
1.6
43.4

8.8
50
2.0
N/A
12.7
0.05
12.58

9
52
1.0
41
12.84
0.05
12.78

263
379

262
379

435
475
32.4

437
480
32.5

ASTM
Test method

D1266
D189
D2787
D2788
D445
D97
D128
D1018
D3242

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
Rev.
:A
Chapter : 1
Page
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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:

Flowrate
Composition
N2
H2S
C1
C2
C3
iC4
nC4
iC5
nC5
C6+
H2O
Total
Molecular weight

kg/h
mol%
mol%
mol%
mol%
mol%
mol%
mol%
mol%
mol%
mol%
mol%
mol%

Crude (Sour)
Blend
339.0
---

---

-6.3
37.0
14.3
40.6
0.4
--1.4
100.0

0.7
4.8
22.7
16.0
53.5
0.4
--1.9
100.0

50.6

52.6

Note: Sour Crude Blend data is based on 100% Dubai crude.

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100% (Sweet)
Bach Ho
291.0

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

1.2.2.3 NHT stripper off-gas to RFCC


H2O
H2S

kg mol/h
kg mol/h
kg mol/h

NH3
H2

kg mol/h
kg mol/h

C1
C2

kg mol/h
kg mol/h
kg mol/h
kg mol/h

C3
iC4
nC4
iC5
nC5
C6+
Total

kg mol/h
kg mol/h
kg mol/h
kg mol/h
(kg/h)

0.13
0.32
trace
13.17
1.69
1.37
0.83
0.06
0.40
0.14
0.10
0.63
18.84
(243)

1.2.2.4 CDU LPG rich steam


The following LPG rich stream is fed from the CDU :

Flowrate
SG at 15C
Composition
C2=
C2
C3=
C3
C4=
iC4
nC4
iC5+
Total

kg/h

mol%
mol%
mol%
mol%
mol%
mol%
mol%
mol%
mol%

Crude (Sour)
Blend
6206
0.565
-1.2
-19.3
-16.5
61.7
1.3
100.0

Note: Sour Crude Blend data is based on 100% Dubai crude.

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100% (Sweet)
Bach Ho
2071
0.572
-0.8
-10.7
-16.1
71.0
1.4
100.0

February 2007
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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


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UNIT RFCC (015)

February 2007
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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:
1.2.3

5000 BPSD

Product specifications

1.2.3.1 Distillation specifications


Gasoline
LCO
Slurry

TBP cut points


RVP (kPa)
TBP cut points
Flash point
TBP cut point
Flash point

Max Gasoline
C5 - 205C

Max Distillate
C5 - 165C
60 max

205 - 360C

165 - 390C
65C mini

360+C

390+C
100C mini

1.2.3.2 Gas recovery targets


C3 overall recovery
C4 overall recovery
C5+ content in LPG
H2S content in LPG

:
:
:
:

95% mini.
96% mini.
0.7% wt max.
25 ppm wt max.

1.2.3.3 Flue gas specifications


(after Electrostatic Precipitator and DeSOx unit)
NOx
SOx

: 1000 mg/Nm3 max


: 500 mg/Nm3 max

Catalyst fines
CO content

:
:

50 mg/Nm3 max
300 mg/Nm3 max

Note that DeSOx unit will be provide in future, since the Project is executed that Bach Ho crude operation is
initially intended, and thus SOx in flue gas could be less than 500 mg/Nm3.
1.2.3.4 Fuel gas specification
H2S content

50 ppm wt max

1.2.3.5 Decant oil specification (after slurry separation)


Catalyst content

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100 ppm wt max

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
Rev.
:A
Chapter : 1
Page
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1.2.3.6 Estimated product properties


Case
LPG
Sp. Gr 15/15
Mercaptans
COS
Total sulphur
Butadiene

wt ppm
wt ppm
wt ppm
wt ppm

GASOLINE (C5 - 165C)


Sulphur
wt ppm
RON clear
MON clear
TVP
g/cm
kPa
RVP
Sp. Gr 15/15
D-86
IP
5
10
30
50
70
90
95
EP
Olefins

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wt%

Mixed
MG

Bach Ho
MG

Mixed
MD

Bach Ho
MD

0.565
78
5.0
3786
3012

0.566
7.1
5.0
332
1647

0.565
78
5.0
4260
1358

0.565
7.1
5.0
383
1063

230
92.0
79.5
498
48

10
91.7
79.2
531
51

0.719

0.715

35
43
47
60
72
91
129
144
159

34
42
46
58
70
89
129
143
156

43

45

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

Case
GASOLINE (C5 - 205C)
Sulphur
RON clear
MON clear
TVP
RVP

wt ppm

g/cm
kPa

Sp. Gr 15/15
D-86
IP
5
10
30
50
70
90
95
EP
Olefins

wt%

LIGHT CYCLE OIL (165 - 390C)


wt%
Sulphur
Cetane number
Cloud point
C
Viscosity @
100C
cSt
Viscosity @
50C
cSt
Pour point
C
C
Flash point
Sp. Gr 15/15
D-86
IP
5
10
30
50
70
90
95
EP

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Mixed
MG

Bach Ho
MG

340

10

92.1
79.9
337
32

91.8
79.6
363
34

0.736

0.732

39
50
55
71
90
116
160
176
197

39
49
54
70
87
113
159
175
197

34

35

February 2007
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Mixed
MD

Bach Ho
MD

0.45

0.04

33.9
-1.8
1.02
2.05
-17.3
67

38.4
-0.9
1.02
2.04
-18.9
67

0.881

0.864

189
203
212
239
263
291
333
349
373

189
204
212
239
264
292
334
350
374

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

Case
LIGHT CYCLE OIL (205 - 360C)
Sulphur
wt%
Cetane number
Cloud point
C
Viscosity @
100C
cSt
Viscosity @
50C
cSt
Pour point
C
C
Flash point
Sp. Gr 15/15
D-86
IP
5
10
30
50
70
90
95
EP
SLURRY (390+ C)
Sp. Gr 15/15
Sulphur
Conradson carbon
Viscosity @
100C
Viscosity @
50C
Pour point

wt%
wt%
cSt
cSt
C

SLURRY (360+ C)
Sp. Gr 15/15
Sulphur
Conradson carbon
Viscosity @
100C
Viscosity @
50C
Pour point

wt%
wt%
cSt
cSt
C

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Mixed
MG

Bach Ho
MG

0.619
24.4
-6.1
0.99
1.92
-12.8
76

0.055
28.1
-5.3
0.97
1.88
-14.0
74

0.926

0.911

188
221
230
245
263
287
323
336
353

180
220
230
245
262
286
322
335
353

1.092
1.03
15.7
14.5
160
15-20

1.043
0.10
12.7
11.1
140
15-20

February 2007
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Mixed
MD

Bach Ho
MD

0.994
0.835
12.5
8.94
110
15-20

0.960
0.07
9.5
6.09
45
15-20

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
Rev.
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Chapter : 1
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1.2.3.7 LPG composition

Component
H2S
H2
C1
C2
ETLN
C3
PRLN
IC4
NC4
IBTE
1BUTENE
C2BUTENE
T2BUTENE
BD
20-50
TOTAL :
Component
H2S
H2
C1
C2
ETLN
C3
PRLN
IC4
NC4
IBTE
1BUTENE
C2BUTENE
T2BUTENE
BD
20-50
TOTAL :
Mercaptan (wt ppm)
COS (wt ppm)
T (C)
P (kg/cm2 g)
Density (P ; T)
Density (15C)

Note: Dry liquid.

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BACH HO
BLEND
MAX GASOLINE
MAX
MAX GASOLINE
MAX
DISTILLATE
DISTILLATE
LPG RATE (kg/h) LPG RATE (kg/h) LPG RATE (kg/h) LPG RATE (kg/h)
1
1
1
2
0
0
0
0
0
0
0
0
449
333
444
349
9
6
9
7
6 124
5 179
6 627
5 793
20 251
14 145
19 625
14 621
14 681
11 273
13 689
10 839
5 801
4 221
7 858
6 560
6 579
4 679
6 758
5 170
6 317
4 706
5 922
4 653
6 482
4 751
5 909
4 592
9 862
7 245
8 964
6 975
106
50
184
64
541
399
540
424
77203
56988
76530
60049
LPG (kmol/h)
0.04
0.00
0.00
14.94
0.31
138.87
481.23
252.58
99.81
117.26
112.59
115.53
175.76
1.96
8.07
1518.96

LPG (kmol/h)
0.03
0.00
0.00
11.07
0.21
117.44
336.14
193.94
72.63
83.39
83.88
84.68
129.12
0.93
6.10
1119.56

LPG (kmol/h)
0.04
0.00
0.00
14.77
0.32
150.28
466.37
235.51
135.20
120.45
105.54
105.32
159.76
3.41
8.00
1504.96

LPG (kmol/h)
0.06
0.00
0.00
11.62
0.24
131.37
347.44
186.49
112.86
92.15
82.93
81.84
124.31
1.18
6.47
1178.96

7
5

7
5

78
5

78
5

40
18
530.2
563.3

40
18
530.1
563.0

40
18
529.8
562.8

40
18
529.8
562.7

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

1.2.4

February 2007
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Chapter : 1
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Operating conditions

1.2.4.1 Reaction / Regeneration section


Mixed
MG

Bach Ho
MG

Mixed
MD

Bach Ho
MD

C
kg/h
C
kg/h
kg/h

520
407000
170
76400
0

518
407000
290
0
0

kg/h
kg/h
C
C
C
kg/h
C

5000
81400
183
170

5000
5000

511
407000
170
0
117100
HCO
5000
122100

505
407000
290
0
117100
HCO
5000
122100

wt%

20350
250
6.34
1.22

20350
250
5.57
0.94

170
290
20350
250
6.43
0.99

170
290
20350
250
5.27
0.91

C
kg/cmg
kg/h
C
kg/h

517
1.43
14300
250
491906

515
1.43
14300
250
425858

508
1.43
14300
250
538339

502
1.43
14300
250
544695

Mixed
MG

Bach Ho
MG

Mixed
MD

Bach Ho
MD

C
C
kg/cmg
%
kg/h
kg/h
C
t/day

678
683
2.28
70
282084
261840
210
15.2

646
651
2.28
70
194650
181520
232
5.5

641
646
2.28
70
231506
215357
223
15.2

631
636
2.28
70
178544
166575
238
5.5

772

734

733

720

Case
RISER
Outlet temperature
Feed flowrate
Feed temperature
MTC Heavy naphtha
Feed recycle flow
Feed recycle quality
HCO back flush
Total riser recycles
MTC recycle temperature
HCO back flush temperature
Recycle to feed temperature
Riser steam flow
Riser steam temperature
C/O
Delta coke

170

DISENGAGER / STRIPPER
Outlet temperature
Pressure
Stripping steam flow
Stripping steam temperature
Effluent flowrate

Case
FIRST REGENERATOR
Dilute temperature
Dense temperature
Dilute pressure
Coke burnt
Flue gas flow
Air flow
Air blower temperature (*1)
Catalyst dry make-up
SECOND REGENERATOR
Dilute temperature

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

Dense temperature
Dilute pressure
Flue gas flow
Air flow
Air blower temperature (*1)

C
kg/cmg
kg/h
kg/h
C

February 2007
Rev.
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762
1.3
138674
127775
210

713
1.3
94603
86942
232

712
1.3
114689
105427
223

695
1.3
86941
79856
238

79.94
6748/ 3213
68
42.97

80.76
0 / 1776
75
37.77

62.60
6748 /3213
55
43.61

61.88
0 / 1776
60
35.72

MISCELLANEOUS
Standard conversion
V/Ni on EQ-CAT
MAT activity
Catalyst circulation

wt%
ppm
wt%
t/min

(*1): As per air blower vendors data.

1.2.4.2 Main fractionator


Bach Ho Case
Max
Max
Gasoline
Distillate

Mixed Case
Max
Max
Gasoline
Distillate

OVERHEAD RECEIVER
Temperature
Pressure
COLUMN
Top
Temperature
Pressure
Draw-off temperature
Heavy naphtha
LCO
HCO pumparound
Bottom
Temperature
Pressure

C
kg/cmg

42
0.4

42
0.4

42
0.4

42
0.4

C
kg/cmg

102
0.85

96
0.85

103
0.85

100
0.85

152
210
306

161
230
337

156
216
305

162
227
337

340
1.15

340
1.15

340
1.15

340
1.15

C
C
C
C
kg/cmg

1.2.4.3 Gas recovery


Bach Ho Case
Max
Max
Gasoline
Distillate

Mixed Case
Max
Max
Gasoline
Distillate

HIGH PRESSURE SEPARATOR


Temperature
Pressure

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C
kg/cmg

40
15.1

40
15.1

40
15.1

40
15.1

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

Bach Ho Case
Max
Max
Gasoline
Distillate

February 2007
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Chapter : 1
Page
: 27/230

Mixed Case
Max
Max
Gasoline
Distillate

PRIMARY ABSORBER
Top
Temperature
Pressure
Bottom
Temperature
Pressure
STRIPPER

C
kg/cmg

49
14.8

48
14.8

51
14.8

50
14.8

C
kg/cmg

58
15.1

58
15.1

59
15.1

58
15.1

59
15.7

60
15.7

59
15.7

60
15.7

122
16

126
16

120
16

122
16

C
kg/cmg

47
14.4

45
14.4

50
14.4

47
14.4

C
kg/cmg

58
14.7

59
14.7

60
14.7

59
14.7

C
kg/cmg

68
11.7
0.59

68
11.7
0.66

68
11.7
0.57

68
11.7
0.62

C
kg/cmg

178
12.1

171
12.1

180
12.1

172
12.1

Top
Temperature
C
Pressure
kg/cmg
Bottom
Temperature
C
Pressure
kg/cmg
SECONDARY ABSORBER
Top
Temperature
Pressure
Bottom
Temperature
Pressure
DEBUTANIZER
Top
Temperature
Pressure
Molar reflux ratio R/F
Bottom
Temperature
Pressure

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
Rev.
:A
Chapter : 1
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FUEL GAS ABSORBER


Top
Temperature
Pressure
Bottom
Temperature
Pressure
LPG AMINE ABSORBER
Top
Temperature
Pressure
Bottom
Temperature
Pressure

C
kg/cmg

56
13.7

C
kg/cmg

61
14

C
kg/cmg

40
17.9

C
kg/cmg

42
19.7

1.2.5 Battery limit conditions


When the unit is operating at design throughput the temperature and pressure of the feed and products
shall be as follows:
Feed
Stream

Temperature
C
115
70
46-52
50
40
55
50 max
70 max

Pressure
(min at grade)
kg/cm g
4.5
4.5
17.5- 20.0 (1)
0.7
0.6
22.6
3.5
3.5

Temperature
C
54
40
40
50
50
90
40-42

Pressure
(min at grade)
kg/cm g
4.5
18.0
8.5
6.0
6.0
8.0
3.5

Atmospheric residue from Crude Distillation Unit


Atmospheric residue from storage
LPG rich stream ex CDU
Off-gas from CDU to fractionator OVHD drum
NHT off-gas
Lean amine from ARU
Light slops from off-site
Heavy slops from off-site
Note
(1) B.L pressure of CDU LPG is normally 17.5 kg/cm2g, while maximum 20.0 kg/cm2g when
CDU LPG is fed to LPG Amine Absorber when Gas Recovery Section shut-down.
Products
Stream
Unsaturated off-gas
C3/C4 to LPG treater
RFCC naphtha to naphtha treater
LCO to blending
LCO to LCO hydrotreater
CLO to blending
Sour water to SWS

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DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

Rich amine to ARU


1.2.6

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7.0

Utility operating / Design conditions


Service

Pressure (kg/cm g)

Temperature (C)

Normal

Max.

Min.

Design

Normal

Max.

Min.

Design

HHP steam
HP steam
MP steam
LP steam
Power station LP steam

105.5
42.3
14.1
3.6
4.1

107.5
44.3
15.1
4.6
4.6

103.5
40.3
13.1
3.6
3.6

118.2
48.3
16.8
6.3
6.3

500
380
250
160
160

510
400
270
180
180

490
360
230
140
148

535
450
320
230
230

Service water
Potable water
Demineralized water
HHP BFW
HP BFW
LP BFW
Fresh CW supply
Fresh CW return
Sea CW supply
Sea CW return
Refinery fire water
Salt fire water

5.0
2.5
5.0
142.0
60.0
22.0
5.2
2.2
3.3
1.3
7.0
10.0

9.5
4.0
7.5
149.0
66.0
24.0
3.5
2.5
4.0
1.4
15.0
15.0

1.5
0.5
1.5
138.0
58.0
20.0
5.0
2.1
3.3
1.3
3.0
6.0

14.2
5.5
11.0
180.0
72.6
26.4
9.2
9.2
7.4
7.4
19.3
19.3

30
30
30
112
112
112
32
47
30
38
30
30

35
35
35
131
131
131
34
60
30
40
35
30

15
15
15
105
105
105
25
25
20
20
15
20

60
60
60
160
160
160
70
70
70
70
60
70

HP condensate
MP condensate
LP condensate
Vacuum condensate(1)

7.5
7.5
3.0
2.5

3.0

2.0

48.3
16.8
6.3
4.7

170
170
133
50

80

50

450
320
230
110

Inst. air / Plant air


Refinery nitrogen
CCR nitrogen

7.5
7.0
8.5

8.0
9.0
9.0

7.0
6.5
8.5

10.5
11.7
11.7

35
30
30

40
40
40

10
10
10

65
65
65

Fuel gas collection


Fuel gas supply
LPG Fuel gas (2)
Refinery fuel oil

3.8
3.3
6.0
13

4.0
3.5

3.5
3.0

38
38

13.0

46
40
40
90

53
53

14.0

6.7
6.7
34.0
20

100

50

75
75
140
125

(1)

Applies to the condensate from both Refinery and Power Station.

(2)

Start-up fuel gas from LPG vaporizer, and also used for pilot gas to COB.

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DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
Rev.
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Chapter : 1
Page
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1.3 Material balances


1.3.1

Reaction - Regeneration Catalyst handling and flue gas treatment

1.3.1.1 Yields

Case
Standard cut points
H2S
H2
C1
C2
C2=
Dry gas
C3
C3=
iC4
nC4
iC4=
1C4=
2C4=
C4= =
LPG
C5 220
LCO 220-360
Slurry 360+
Coke
Total

Case
Operating cut points
C5 205
C5 165
205 360
165 390
360+
390+

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Mixed
MG
wt%
0.2988
0.1053
0.7996
0.7043
0.6922
2.3015
1.4020
5.0248
3.1474
0.9963
1.7001
1.4927
3.9369
0.0535
17.7536
51.8277
12.5270
7.5358
7.7555
100.00

vol%

wt%

vol%

Mixed
MD
wt%

vol%

Bach Ho
MD
wt%

vol%

0.0274
0.2554
0.0231
0.1000
0.1000
0.1000
0.5810
0.5452
0.5097
0.5139
0.4888
0.4624
0.5008
0.4634
0.4279
1.6957
1.5974
1.5000
2.4646 1.4673 2.5476 1.1771 2.0692 1.2262 2.1289
8.5796 5.0861 8.5774 3.6927 6.3051 3.5423 5.9739
4.9923 3.5602 5.5775 2.4172 3.8340 2.7052 4.2380
1.5208 1.0834 1.6334 0.6507 0.9933 0.6706 1.0111
2.5260 1.6477 2.4181 1.2930 1.9212 1.1700 1.7170
2.2179 1.5859 2.3274 1.1661 1.7327 1.1797 1.7313
5.6873 4.3295 6.1775 3.0373 4.3879 3.1645 4.5154
0.0762 0.0310 0.0435 0.0183 0.0260 0.0145 0.0204
28.0647 18.7912 29.3026 13.4525 21.2695 13.6732 21.3362
62.4783 55.0125 65.9308 40.9122 49.2568 41.8821 50.1389
11.9554 11.9778 11.4824 28.5098 28.5307 28.5567 28.8560
6.1589 7.2655 6.1373 8.8941 8.1376 9.5657 8.9264
5.2299
6.3787
4.7993
108.66 100.00 112.85 100.00 107.19 100.00 109.26

Mixed
MG
wt%

Bach Ho
MG

vol%

Bach Ho
MG
wt%

vol%

49.8000

60.3964 53.0129 63.8818

14.5547

14.0373 13.9774 13.5315

7.5358

6.1589

Mixed
MD
wt%

vol%

Bach Ho
MD
wt%

vol%

31.6707 39.3370 32.6035 40.1844


40.3576 40.9428 40.5390 41.4420
7.2655

6.1373
6.2878

5.6454

6.8619

6.2949

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
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UNIT RFCC (015)

February 2007
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1.3.1.2 Detailed material balances

INLET, t/h
Catalyst
Fresh feed
Riser steam
Stripping steam
Recycles
Carry-off from reg#2
Coke
Total

OUTLET, t/h
Catalyst
H.C. effluent & carry-off
Net injection steam
Total feed to Main Fract.
Carry-off to reg#1
Coke
Total

INLET, t/h
Catalyst
Coke
Air
Carry-off from stripper
Total

OUTLET, t/h
Catalyst
Coke
Flue gas
Carry-off to lift
Total

INLET, t/h
Catalyst
Coke
Carry-off from lift
Air

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Mixed
MG

Bach Ho
MG

Mixed
MD

Bach Ho
MD

2578.423
407.000
20.350
14.300
81.400
3.050
1.289
3105.812

2266.452
407.000
20.350
14.300
5.000
2.812
1.133
2717.047

2616.685
407.000
20.350
14.300
122.100
3.250
1.308
3184.993

2143.488
407.000
20.350
14.300
122.100
2.706
1.072
2711.016

Mixed
MG

Bach Ho
MG

Mixed
MD

Bach Ho
MD

2578.423
491.606
0.300
491.906
2.629
32.854
3105.812

2266.452
425.558
0.300
425.858
2.318
22.419
2717.047

2616.685
538.039
0.300
538.339
2.699
27.270
3184.993

2143.488
544.395
0.300
544.695
2.228
20.605
2711.016

Mixed
MG

Bach Ho
MG

Mixed
MD

Bach Ho
MD

2578.423
32.854
261.840
2.629
2875.746

2266.452
22.419
181.520
2.318
2472.709

2616.685
27.270
215.357
2.699
2862.011

2143.488
20.605
166.575
2.228
2332.896

Mixed
MG

Bach Ho
MG

Mixed
MD

Bach Ho
MD

2578.423
10.759
282.084
4.480
2875.745

2266.452
7.519
194.650
4.087
2472.708

2616.685
9.097
231.506
4.723
2862.011

2143.488
6.932
178.544
3.932
2332.896

Mixed
MG

Bach Ho
MG

Mixed
MD

Bach Ho
MD

2578.423
10.759
4.480
127.775

2266.452
7.519
4.087
86.942

2616.685
9.097
4.723
105.427

2143.488
6.932
3.932
79.856

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

Total

OUTLET, t/h
Catalyst to WW
Coke
Flue gas
Carry-off to WW
Total

REGENERATOR 1
CO
CO2
H2O
N2
NOx + NH3
SOx + H2S
Total
M.W., kg/kmol
Catalyst fines, mg/Nm3

REGENERATOR 2
CO
CO2
H2O
N2
O2
NOx + NH3
SOx + H2S
Total
M.W., kg/kmol
Catalyst fines, mg/Nm3

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2721.437

2365.000

2735.932

2234.208

Mixed
MG

Bach Ho
MG

Mixed
MD

Bach Ho
MD

2578.423
1.289
138.674
3.050
2721.436

2266.452
1.133
94.603
2.812
2365.000

2616.685
1.308
114.689
3.250
2735.932

2143.488
1.072
86.941
2.706
2234.207

Mixed
MG
mole %

Bach Ho
MG
mole %

Mixed
MD
mole %

Bach Ho
MD
mole %

6.2598
9.9362
16.2236
67.4775
0.0286
0.0742
100.0
28.00
400

5.3138
10.6274
16.3897
67.6317
0.0259
0.0115
100.0
28.08
400

6.2377
9.9011
16.5193
67.2390
0.0286
0.0743
100.0
27.97
400

5.3092
10.6182
16.4622
67.5731
0.0259
0.0115
100.0
28.07
400

Mixed
MG
mole %

Bach Ho
MG
mole %

Mixed
MD
mole %

Bach Ho
MD
mole %

0
16.9843
7.1866
73.8779
1.8561
0.0255
0.0696
100.0
30.11
900

0
16.9958
7.2909
73.8239
1.8539
0.0248
0.0108
100.0
30.08
900

0
16.9369
7.2845
73.8298
1.8541
0.0255
0.0692
100.0
30.09
900

0
16.9850
7.3139
73.8121
1.8534
0.0248
0.0108
100.0
30.08
900

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


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January 2007
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UNIT DESCRIPTION

2.1 Reaction Regeneration Catalyst handling Flue gas treatment


The R2R Process is a fluid catalytic cracking process incorporating a two-stage regeneration system, a
unique feed injection system, a proprietary catalyst disengager and catalyst cooler (optional). This proven
process eliminates or greatly reduces many of the constraints of previous FCC configurations and offers
maximum flexibility for converting reduced crudes and mixtures of gas oils and vacuum residues. The
process unit consists in feed injection system, riser, riser outlet separator system, disengager/stripper, first
stage regenerator, second stage regenerator, catalyst cooler (optional), catalyst withdrawal well, catalyst
transfer lines and control systems.
The following is a description of the full technology included in the R2R process.
2.1.1

Reaction system

2.1.1.1 General
The feed mixture is pumped to the base of the riser and divided into equal flows, to each of the feed
nozzles. The feed, which has been preheated, is finely atomized and mixed with dispersion steam in the
feed nozzles and injected into the riser. 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 product
vapors travel up the riser while carrying the catalyst. Residence time in the riser is approximately
2 seconds at design conditions. The specially designed feed injection system insures the reaction is
carried out efficiently to minimize the production of coke, gas and slurry oil.
2.1.1.2 Feed injection zone
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. Passivator
injection into the fresh feed just ahead of the feed nozzles acts to inhibit the undesirable effects of nickel
in the feed. Shutdown valves will stop the flow of feed to the riser and divert it back to the feed surge
drum in case of certain emergencies. Flow controllers regulate the flow to each of the feed nozzles. The
feed should be split evenly between the feed nozzles as observed by individual flow indicators. Pressures
on each feed nozzle should be monitored as a verification of flow and indication of nozzle condition.
Depending upon the operating case, a different quality of recycle to feed is used.
In Mixed Crude MG operation, an 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 conversion.
Dispersion steam is supplied to each of the feed nozzles to promote atomization and vaporization of the
feed. The flow to each of the feed nozzles is adjusted by flow controllers.
Upstream the feed injection, stabilization steam is injected in the riser, through the stabilization steam
injectors, 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.
MTC (Mix Temperature Control) injectors 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.
As for the feed injectors, MTC flow and dispersion steam flow to each injector are adjusted by flow
controllers.

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

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Upon emergency shutdown the steam flow control valves on all injectors automatically open to clear the
riser of oil and catalyst with steam.
2.1.1.3 Riser/Reactor
The sensible heat, heat of vaporization and heat of reaction required by the feed is supplied by the hot
regenerated catalyst. The riser outlet temperature is controlled by the amount of regenerated catalyst
admitted to the riser through the regenerated catalyst slide valve. 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 cracking reactions take place during the two second residence time in the riser as the reaction
mixture accelerates toward the Riser Outlet Separator System (ROSS).
The catalyst is quickly separated from the hydrocarbon/steam vapors in the ROSS separator located at the
end of the riser. This separation is necessary to discourage the undesirable continuation of reactions
which produce gas at the expense of gasoline. This system drastically reduces the post riser
catalyst/vapors contact time. After exiting the ROSS separator, the vapors pass through high efficiency
single stage cyclones to complete the separation of catalyst from vapors, thus minimizing the amount of
catalyst lost into the product. The reactor product vapors, containing a small amount of inerts and steam,
flow to the quench zone of the main fractionator. 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
converter section. A pressure control at the main column overhead receiver allows to achieve a steady
operating pressure in the reaction system.
The ROSS separator and disengager cyclones separate the product vapors from spent catalyst and return
the catalyst to the stripper bed. The cyclone diplegs are equipped with trickle-valves to prevent reverse
flow of gas up the diplegs. Also, the ROSS separator is equipped with diplegs fitted on its pre-stripping
chambers. These diplegs are sealed into the stripper catalyst bed in order to avoid any possibility of
vapors back mixing.
2.1.1.4 Stripper
Catalyst exiting the ROSS separator is pre-stripped with 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 stripper. Two
additional rings (upper and lower rings) are also provided in addition to the main ring. The upper ring
achieves a second stage of pre-stripping 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 total steam flow is designed to provide about 6 kg of steam per ton of catalyst circulated.
The contact between catalyst and steam is enhance by the presence of fluidized bed packing allowing for
cross and counter current flow of steam and catalyst. This highly efficient contacting displaces the
volatile hydrocarbons contained on and in the catalyst particles before they enter the first stage
regenerator. Coke remaining on the catalyst is burned off in the regenerators. The catalyst is aerated in
the spent catalyst standpipe to the proper density for stable head gain.
2.1.1.5 Spent catalyst transfer
The stripped spent catalyst flows down the spent catalyst standpipe and through the spent catalyst slide
valve. Aeration by fuel gas (or nitrogen) is added to the standpipe at several elevations to maintain proper
density and fluid characteristics of the spent catalyst emulsion. The spent catalyst slide valve controls the
level in the stripper by regulating the flow of spent catalyst from the stripper. The spent catalyst flows
into the first stage regenerator through a distributor which ensures that the entering coke-laden catalyst is
spread across the regenerator bed.

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


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2.1.2

January 2007
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Regeneration system

2.1.2.1 General
The first stage regenerator burns 50 to 80% of the coke and the remainder is burned in the second stage
regenerator. 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 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. For the very heavy feeds
(Conradson Carbon higher than 7% wt), additional heat removal is required and a (catalyst cooler) must
be provided to limit the regenerated catalyst temperature.
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. 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 can be adjusted while complete regeneration of the catalyst is accomplished in the second
stage.
2.1.2.2 Air blower and air heaters
The combustion air required is supplied by an air blower, commonly driven by a steam turbine. The
steam supply to the turbine is throttled on cascade air flow trim control/compressor speed.
Atmospheric air is introduced to the air blower through an intake filter and silencer. The blower air is
distributed to a header system providing combustion air to first regenerator rings, second regenerator ring,
lift air (and catalyst cooler fluffing air in case it is installed). Power assisted check valves at the blower
discharge prevent back-flow of catalyst in the event of blower shutdown. Blower surging is prevented by
venting air using a sophisticated anti-surge controller.
Combustion air to each regenerator is flow controlled. Low air flow to either regenerator will trigger the
emergency shutdown circuit in the case of blower failure. Combustion air to the first stage regenerator is
split between two air rings. 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 respectively.
Direct fired air heaters are located in the combustion air lines to the first regenerator combustion air rings
and second regenerator combustion air ring. The air heaters 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.
2.1.2.3 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. Part of the coke is burned by combustion air from the
air rings. 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 partially regenerated catalyst flows down through the first stage regenerator bed to the entrance of
the air lift. Aeration is supplied in this area to ensure smooth flow of catalyst to the lift. A hollow stem
plug valve regulates the flow of catalyst to the lift line and is controlled by the level in the first stage
regenerator. 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. Emergency air is
provided through blast connections to clear the lift in the event of plugging.

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
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UNIT RFCC (015)

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Two stage cyclones separate entrained catalyst from the flue gas exiting the first stage regenerator. At the
exit of the regenerator, the flue gas pressure is reduced through a double disc flue gas slide valve
controlling the regenerator pressure. Incineration of the CO in the flue gas is then accomplished at the
CO incinerator. A continuous catalyst withdrawal is necessary to maintain the unit catalyst inventory in
the normal operating region.
Torch oil is used to heat the process to its operating temperature during start-up. Oil and steam on flow
control are directed to two nozzles which spray into the bed of air preheated catalyst.
2.1.2.4 Second stage regenerator
The partially regenerated catalyst flows up the lift and enters the second stage regenerator 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 at more severe conditions than in
the first stage regenerator. Very little carbon monoxide is produced in the second stage and excess
oxygen is controlled by flow control of the second regenerator combustion air for efficient and complete
combustion. Because most of the hydrogen in coke was removed in the first 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 are used on the second stage flue gas to remove entrained catalyst.
This design expands the operating envelope for regenerator temperatures which tend to be higher for
residue type feed. The cyclone dip legs are external to the regenerator. Catalyst recovered in the cyclone
are 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 valves to prevent catalyst and gas backflow into the cyclones.
The second stage regenerator pressure is controlled by a flue gas double disc slide valve, through
differential pressure between the first and second stage regenerators.
2.1.2.5 Regenerated catalyst transfer
The hot regenerated catalyst flows from the second stage regenerator through a lateral into the
withdrawal well. In the withdrawal well a quiescent 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 air at several elevations on the
regenerated catalyst standpipe. As the head pressure increases down the standpipe and the catalyst
emulsion is compressed, these aeration points are used to replace the "lost" volume, thereby to ensure a
continuity of fluid catalyst flow properties.
At the bottom of the regenerated catalyst standpipe the regenerated catalyst slide valve controls the flow
of hot catalyst. The Riser Outlet Temperature sets the position of the slide valve which regulates the flow
of catalyst. The regenerated catalyst passes to the wye section 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.
2.1.2.6 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, the spent catalyst hopper and the auxiliary catalyst
hopper. The auxiliary catalyst hopper provides flexibility in the operation for different options:
storage of imported equilibrium catalyst reused as part of the make-up catalyst,
storage of excess spent catalyst,
storage of a second grade of fresh catalyst for make-up.

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DUNG QUAT REFINERY
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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.
a)
Hoppers loading and unloading
Fresh catalyst or equilibrium catalyst, delivered in trucks, are loaded into the fresh catalyst hopper for
fresh catalyst, and spent catalyst hopper for equilibrium catalyst, using either the truck compressor or the
steam ejector supplied for reducing the hopper pressure.
Spent catalyst is unloaded from the spent catalyst hopper to the flexible bag by hopper pressurizing with
plant air.
b)
Unit loading and unloading
Before start-up, equilibrium catalyst is loaded into the spent catalyst hopper as described above. When
the unit warm-up is completed, the catalyst is loaded into the unit through the first regenerator. The
hopper is pressurized with plant air. Air from the blower used 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. The catalyst air mixture should not exceed 400C
when entering the spent catalyst hopper.
c)
Catalyst addition and withdrawal
During normal operation, a batch feeder is used to automatically add fresh catalyst at the desired rate. It
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 in order to keep the unit inventory. This operation is achieved by a specific continuous drawoff device provided on the first regenerator. Hot catalyst is withdrawn, cooled down through a finned
tube and sent to the spent catalyst hopper at a temperature below 400C.
2.2 Technology features
The R2R technology possesses many design features to achieve flexibility of operation on a wide range
of feedstocks. It is intended to provide high yields of gasoline and distillate while minimizing the
production of coke and gas. These features such as two stage regeneration, feed injection, riser outlet
separation system, (catalyst cooler), aeration and fluidization... are described hereafter.
2.2.1 Cold wall design
When possible and practical, IFP chooses to use cold wall design for major vessels and lines. In this case,
vessels and lines are lined with internal refractory lining which isolates sufficiently from the process side
to have the metal operating at a temperature usually between 150 and 200C with high air ambient
temperature and no wind. This concept has several advantages :
By varying refractory material and thickness it is possible to hold the metal temperature within the
specified range.
The second regenerator and its external cyclones are exposed to high temperatures. Only the
refractory is exposed to these high temperatures and the rated service temperature of the refractory
(around 1250C) is far above the maximum process design temperature (around 900C) limited, now
only, by the catalyst stability.
Thermal expansion is limited. It has been possible to limit the use of expansion joints to one located
on the spent catalyst line and another small one at the junction of the two regenerators.
Conventional carbon steel can be used for all vessels and major lines reducing greatly cost and
maintenance problems.
In the transfer line to the main fractionator, the coke deposit is minimized, due to higher velocity,
higher internal temperature and less cold spots and also shorter lay out.

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DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

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In order to use cold wall design it is essential to have a good refractory design. Which implies:
A well designed anchors system,
Judicious selection of material,
Experienced refractory Vendors and refractory installation sub-Contractors.
IFP relied upon many years of cracking operations to use proven materials and design technique for a
good refractory materials selection and proven anchors design.
2.2.2 Feed injection system
The principle of the feed injection system is to atomize the oil feed into very small droplets with a high
surface area for rapid heat transfer with the hot regenerated catalyst. Vaporization of the feed is then
rapidly promoted. This enhances vapor phase cracking reactions and minimizes liquid phase coking
reactions. In catalytic cracking, the reaction takes place in the vapor phase, the importance of maximizing
the vaporization in the quickest possible time is then critical. A larger oil droplet stays in liquid phase
longer and can surround the catalyst particle, effectively blocking the active surface area. Slow
vaporization of the feed promotes the formation of coke, gas and slurry oil.
The relative direction of oil injection towards catalyst is also essential. IFP technology is to inject the oil
downwards counter current of the accelerated catalyst. This injection pattern promotes the contact
between oil droplets and hot regenerated catalyst. The heat transfer is drastically enhanced.
Uniform feed distribution and rapid vaporization also has other benefits. In the bottom of the riser the
catalyst turns upward with aid of the bottom steam, then the catalyst flow is stabilized by means of
stabilization steam and meets the oil/steam mist at the feed injection point. A well distributed, rapidly
vaporizing, feed helps accelerate the reaction mixture to its final velocity in a smooth manner. Catalyst
slippage and back mixing will promote undesirable side reactions. In this last situation, some feed vapor
sees too much catalyst and some not enough. The venturi like effected of the high energy feed injection
system associated to the counter current injection results is a faster, more uniform acceleration of the
catalyst in its upward path and more uniform catalyst densities along the cross section of the riser.
The R2R feed injection nozzle atomize the oil feed by a high energy shearing action on a specially
designed venturi type injector. High velocity steam jet shears the oil, further into a fine mist. The injector
tip is designed to discharge a wedge shaped spray that fans out from the tip in a carefully determined
angle. The action of the feed nozzles together provide uniform coverage of the riser cross section without
impingement on the riser walls.
The injectors have no moving parts and can be installed outside the riser for easier maintenance and can
be replaced during planned downtime.
2.2.3 MTC system
The MTC (Mix feed Temperature Control) has been developed to further improve the R2R process
capabilities and performances with respect to the cracking of increasingly heavier and more refractory
feedstocks.
It is designed to face the two main challenges encountered when processing very heavy, highly
contaminated feeds, namely:
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.

The MTC system basically consists of the injection of an appropriate stream into the riser, downstream of
the feed injection point, at a location and under conditions selected to obtain the desired quenching effect
and the best yield selectivity.

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In this case, the stream used is a special MTC stream located in the heavy naphtha cut recycled from the
main fractionator.
The optimum MTC flowrate depends on the feed quality (the heavier the feed the higher the recycle
flowrate) and on the desired yields structure: to switch from a maximum gasoline to a maximum distillate
mode of operation for instance, operating conditions will have to be modified directionally towards a
decrease of the conversion per pass, which will result mainly in :
A lower Riser Outlet Temperature and subsequently a lower mix temperature in the fresh feed
injection zone which will tend to increase the coke make if the mix temperature becomes lower than
the feed dew point.
A higher slurry yield with a lower aromatic content and therefore a superior potential of this product
for an additional conversion through recycle.
A lower gas make leading to an increased margin on fractionation and wet gas compressor section.
According to these observations, the MTC system is specifically useful in this situation for maximizing
the distillate yield while keeping the coke production under control.
MTC flowrate should be limited to 20% maximum of fresh feed.
2.2.4 Riser Outlet Separation System
The principle of the patented IFP 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.
The catalyst separated is collected in a hopper prorogated by a dipleg 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.
2.2.5 Two stage regeneration
Residue cracking differs from gas oil cracking in that the feed contains more asphaltenes, and is more
hydrogen deficient. Coke make, which is usually dictated by heat balance requirements, can become a
critical factor in the operability of the process. Coke make increases as residual oil is added to the feed
and regenerator temperatures rise as more heat of combustion from the coke is released. A conventional
single stage regenerator is limited in regard to cracking residues because of metallurgical limits within
the regenerator vessel.
The R2R technology splits the regeneration into two stages. The first stage burns part of the coke from
the catalyst at mild conditions and completes the regeneration in the second stage. Several benefits are
realized as a result of this configuration. Most of the hydrogen in coke is removed in the first stage at
mild conditions, i.e. a maximum operating temperature limited at 730C (usually 670 to 690C). The
resulting water vapor is in contact with catalyst at lower temperatures than those necessary for complete
regeneration, leading to much less catalyst deactivation. The relatively dry atmosphere of the second
regenerator allows to raise the temperature while the regeneration is completed. Thus the R2R two stage
regeneration results in less hydrothermal deactivation of the catalyst.

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DUNG QUAT REFINERY
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UNIT RFCC (015)

January 2007
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As the residue content of the feed increases to higher levels, the coke make increases and the heat balance
of the unit must be adjusted to maintain catalyst circulation rates and conversion. In the two stage
regenerator configuration, potential energy, in the form of carbon monoxide, is rejected from the
regenerator system by increasing the amount of total coke burned in the first stage regenerator.
Complete regeneration of the catalyst is accomplished in the second stage regenerator. Excess oxygen is
maintained to ensure complete regeneration to essentially carbon free catalyst. Since the second stage
regenerator cyclones are external to the vessel and lined with refractory, the metallurgical limitations
previously encountered with residue feeds are circumvented (the maximum operating temperature can
reach 810C relatively to the catalyst while the mechanical design is 840C).
2.2.6 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 the valves from any
catalyst particles. 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.
2.2.7 Riser wye steam ring
Its function is to straighten out the catalyst flow pattern as it makes the transition at the "wye" from its
downward flowing, partially deaerated state, to an upward flowing, evenly aerated state.
In aerating the catalyst, this ring also provides the reverse seal needed to protect against oil flow reversals.
The vertical column of catalyst below the feed nozzles provides a seal against such upsets.
This ring is designed for a normal flowrate that should be maintained at all times when the catalyst is
circulating.
2.2.8 Aeration and fluidization systems
The catalyst fluidization and aeration systems play a vital role in the stability of catalyst circulation.
Proper attention should be given to all fluidization and aeration flows to make sure that they are properly
set at their specified rates. All the aeration and fluidization services in the catalyst system are discussed
below.
The standpipe aeration systems on the unit are designed to handle a wide range of conditions and still
provide 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. New
operating conditions, if they vary widely, may require that these flows be adjusted slightly, but this
should only be done after a pressure profile is taken along the standpipe to measure variations in density.
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
number 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

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allow easier entrance. A smooth, stable flow of catalyst into vertical standpipes is very important.
Therefore, fluidization taps are either doublets or triplets. The flowrate on each fluidization service is a
function of the geometry and catalyst flow pattern at that location.
Two locations merit special notice. The regenerated catalyst standpipe handles catalyst without any coke
residue and is at high temperatures. Catalyst at this condition is inherently more difficult to maintain
fluidized. Therefore it is important to be certain that the aeration rates and instruments purges are kept at
specified settings.
The second location to note is the second stage cyclone dipleg aeration.
Instrument purges provide a large part of the required aeration and these purges should be set as specified.
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.
2.2.9 Stripper bottom ring
This ring is located in the bottom head of the stripper. 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.
2.2.10 First stage regenerator fluffing ring
This air ring is located below the main combustion air rings and aerates the catalyst in the vicinity of the
plug valve which controls the regenerator level. It ensures free travel of plug valve and smooth entry of
catalyst into the lift line.
2.2.11 Regenerated catalyst withdrawal well ring
This air ring is located in the bottom portion of the regenerated catalyst withdrawal well. The withdrawal
well serves as a vessel to condition the catalyst for smooth quiescent flow, at proper density into the
regenerated catalyst standpipe. It controls the catalyst aeration before it enters the standpipe. The
regenerated catalyst is inherently more difficult to keep in fluidized flow state and therefore it is
important to set the fluidization ring at the specified level. The ring is designed to fluidize the bed in the
withdrawal well if it has become deaerated. Setting the flowrate on the ring must be done carefully as it
may create upsets in the operation of the regenerated catalyst slide valve differential.
2.2.12 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 reduced rate to maintain adequate distribution
and prevent intrusion of catalyst into the ring and avoid associated erosion.
The catalyst air lift transports the catalyst from the first stage regenerator to the second stage regenerator
in a dilute phase. The operation of this lift should be kept as steady as possible but however it can be
changed to adjust the pressure balance on the unit. The pressure drop across the lift is mainly a function
of the lift air rate. More air creates a less dense flow regime and, hence, a lower pressure drop due to
static head. The lower limit of air flow is the choke velocity at which the air ceases to lift the catalyst.
The minimum air rate for acceptable lift is about 5 m/s. Normal air velocity in the pick-up zone is 8 to 12
m/s.

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2.3 Catalyst
The proper selection of catalyst is very important to successful residue cracking operations. The
importance magnifies as the percentage of residual oil increases in the feedstock. Several properties of
the catalyst should be examined for a particular feed. The properties are:
Zeolite content

Micro-activity

Rare earths content,

Unit cell size

Coke selectivity

Particle size distribution

Bulk density

Thermal stability

Surface area

Pore volume and pore distribution (strippability)

Attrition resistance

Metals resistance

Gasoline octane properties

The IFP recommendation for use in R2R residue cracking unit is low sodium, Ultra-Stable Hydrogen Y
type (USHY) zeolite. A USHY catalyst has a high ratio of silica to alumina. The zeolite structure has
relatively large three dimensional pores which allow more surface area available for cracking. Unit cell
size can be an indicator of coke selectivity as coke precursor molecules may be rejected from the zeolite
cage. The USHY catalyst with low rare earths content also provides a lower hydrogen transfer rate
resulting in preservation of olefins and better coke selectivity.
IFP recommends a low rare earths content for residue cracking operations. Rare earths are exchanged
onto the USHY structure to enhance activity and stability. Unfortunately rare earths also promote
hydrogen transfer reactions which increases coke selectivity.
Also the matrix activity and structure plays a key role in the cracking selectivity. The matrix achieves the
pre-cracking of heavy molecules and feeds the zeolite. Therefore the balance between matrix and zeolite
is essential. On an other hand, the matrix porosity controls the catalyst activity and strippability.
A catalyst must be hard enough to survive interparticle and wall collisions induced by various turbulent
zones in the process. Attrition of the catalyst particles into very small particle sizes will result in
increased losses through the cyclones.
Metals contamination of the catalyst is a result of contaminants in the feed. The catalyst should be
tolerant to metals levels up to about 10,000 ppm. Nickel in the feed deposits on the catalyst and promotes
undesirable dehydrogenation reactions, high gas make and increased coke yield. Antimony is used as an
effective passivator of nickel at a dosage to maintain an equilibrium level of about 25 to 40% of the
nickel loading. Vanadium in the feed and deposited on the catalyst will promote collapse of the zeolite
structure and loss of active surface area at the elevated regenerator temperatures.
Sodium is also detrimental to the catalyst activity. Feed sodium should be kept below 1 ppm through
efficient desalting in the crude unit. Caustic injection used in the crude train is not recommended without
effective removal of the sodium neutralization salts. Caustic injection, if used, should be achieved before
the desalters. The Na2O content of the equilibrium catalyst should not exceed the Na2O content of the
fresh catalyst by more than 0.10 wt %.
The effect of metals on the catalyst can be controlled through passivation and dilution. That is, catalyst
addition in residue cracking operations is governed by catalyst metals loading. There are many

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commercial units operating with metals loading from 7 000 to 10 000 ppm. To reduce operating cost a
mixture of fresh and outside equilibrium catalyst can be used to control metals loading and activity.
Catalyst used in residue cracking operations should be double calcined to enhance thermal stability.
Particle size distribution should be examined on the fresh catalyst. The zero to 20 micron fraction should
be low to minimize the direct losses through the cyclones. The cyclone system is designed to retain
enough of the equilibrium zero to 40 micron fraction to maintain good fluidization properties.
2.4 Flue gas treatment
The flue gas coming from the first regenerator contains CO and some unburned products. It is sent to the
CO boiler for combustion completion. The flue gas is routed to the Waste Heat Boiler for HP steam
regeneration.
The flue gas coming from the second regenerator is sent to the waste heat boiler, directly. Heat released
is used for HP steam generation.
The flue gas coming from the waste heat boiler is sent to an electrostatic precipitator, an economizer, and
DeSOx unit (for future), and then to a stack.
The Waste Heat boiler is equipped with a boiling steam water drum. The CO boiler is equipped with FD
fans, burners for fuel gas and also fuel oil in order to obtain a complete combustion of CO.
2.5 Feed fractionation
2.5.1 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. The preheat of the feed is designed to process 100%
cold feed.
The hot feed and cold feed flow to Feed Surge Drum D-1513. The feed rate is on level control, with a
split range level control signal to the controller inside the CDU or to the flow controller on the cold feed
from storage.
In the Bach Ho case preheating of feed is by the LCO pumparound, MP and HP steam 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 following description is based on Bach Ho feed, hot or cold; the feed is pumped from D-1513 by
feed pumps P-1501A/B to LCO Pumparound Feed Heater E-1512A/B/C/D. The preheat duty in this
exchanger is set by flow control of the LCO pumparound. The feed is further preheated in MPS Feed
Heater E-1522 and HPS Feed Heater E-1524. The MP steam to E-1522 is on flow control and the HP
steam to E-1524 is on flow control reset by the feed side outlet temperature.
Final preheating takes place in Slurry Preheat Exchangers E-1502A/B/C and E-1501A/B. The final feed
temperature is controlled by by-passing feed around E-1502A/B/C and E-1501A/B. The temperatures
controller is located after the point where feed is mixed with HCO recycle.
A constant pressure is maintained on the feed to the reactor feed control valves by the pressure control
valve upstream of E-1502A/B/C. 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.
2.5.2 Mixed crude feed
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.
The feed is preheated in the LCO Pumparound Feed Heater E-1512 A/B/C/D for hot feed and for cold
feeds also in MP Steam Feed Heater E-1522. The final temperature is controlled either by controlling
LCO Pumparound to E-1512A/B/C/D or by controlling MP steam flowrate to E-1522.

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2.5.3 Fractionator bottom section


The reactor effluent from the disengager of the reaction section is sent to the main fractionator T-1501.
The bottom slurry pumparound is circulated by Slurry Pumparound Pumps P-1519A/B/C. In the case of
Bach Ho feed, a large proportion of the bottom pumparound duty is used to preheat the feed in
E-1501A/B and E-1502 A/B/C. The remaining duty is used to generate HP steam in HP steam generators
E-1504A/B and MP steam in MP steam generators E-1505A/B. For the Mixed Crude feed case, E1501A/B and E-1502 A/B/C are not in service. In this case HP steam is generated in HP steam generators
E-1503 A/B/C.
The main part of this cooled slurry pumparound is returned to the grid section (Bed 5) where the reactor
effluent is desuperheated and the bottom slurry product is condensed. The cooled stream flowrate is reset
by the temperature controller below the HCO draw-off tray. A constant total flowrate to the grid is
maintained by by-passing hot slurry from the discharge of the slurry pumps.
Part of the cooled slurry is returned to the bottom of the column to quench the bottoms temperature to
around 340C to minimize coking. Part of this quench is taken on flow control from either the discharge
of E-1502A/B/C or E-1503A/B/C, depending on operating case. The remaining quench is taken from the
outlet of E-1505A/B on flow control reset by T-1501 bottom outlet temperature controller.
The slurry product is taken from the discharge of the MP steam generators E-1505 A/B under bottoms
level control and flows to slurry draw-off drum D-1515.
The slurry product is pumped by P-1504 A/B and is cooled in LPS generator E-1506 A/B and then flows
to slurry separator X-1504 to remove catalyst fines. The clarified oil leaving the slurry separator is finally
cooled in tempered water coolers E-1507 A/B/C/D before going to storage.
The slurry separator X-1504 consists of 10 modules. These are sequentially taken out of service for backflushing while the others remain in service. The modules are back-flushed by P-1505 A/B with HCO
from D-1516. The flush oil from the separator, containing a high concentration of catalyst fines, goes to
back-flush oil receiver D-1517. The back-flush oil is returned to the reactor riser at constant rate by P1506 A/B.
2.5.4 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. Heat is removed in Bed 3 and internal reflux from the draw tray flows to
wash section, Bed 4.
HCO pumparound is circulated by P-1508 A/B and is cooled in the debutanizer reboiler E-1560A/B,
heavy naphtha stripper reboiler E-1509 and MPS generator E-1523. Total flow is maintained constant by
by-pass control and heat removal is controlled by temperature control of flow through E-1523.
HCO for flushing oil is stripped in HCO stripper T-1504 and the stripper vapor is returned to T-1501
above the pumparound, Bed 3. The stripped HCO is pumped by P-1509 A/B and is cooled under
temperature control in HCO LPS generator E-1510.
Part of the HCO goes to Backflush Oil Receiver D-1516 on flow control, reset by D-1516 level. The
remaining part goes to the HCO flushing oil system for flushing of slurry pump seals and for instrument
flushing.
For maximum distillate mode operation, HCO is recycled to the reactor feed. The HCO recycle is
pumped by P-1507 A/B, and after cooling on temperature control by generating steam in HCO Recycle
MPS Generator E-1508, it is mixed with the feed upstream of the feed temperature control point.
2.5.5 LCO section
This section of T-1501 consists of six fractionating trays, trays 25 to 30, and a packed pumparound bed,
Bed 2.
LCO pumparound is circulated by P-1510 A/B and is cooled in stripper and reboiler E-1557, LCO
pumparound feed preheat exchangers E-1512 A/B/C/D and LCO pumparound BFW Heater E-1511.
Total flow is maintained constant by by-pass control and heat removal is controlled by temperature
control of flow through E-1511.

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LCO is drawn off the pumparound draw tray and is fed to LCO Stripper T-1503 on T-1503 bottoms level
control.
The stripper vapor is returned to T-1501 above the pumparound, Bed 2. Stripped LCO is pumped by
P-1511 A/B and is cooled on temperature control in LCO Product LPS Generator E-1513 and the air
cooler E-1514 before going to the LCO Hydrotreater unit. For maximum gasoline operation this is the
total LCO product. For maximum LCO operation (maximum distillate operation), heavy naphtha is
mixed with this stream before going to the LCO Hydrotreater unit.
In case of LCO Hydrotreater shut down, the LCO is sent directly to the storage.

2.5.6 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 P-1512 A/B to the riser injection nozzle
on flow control.
Heavy naphtha pumparound is circulated by P-1514 A/B and is cooled by Stripper Feed Preheater
E-1555, Heavy Naphtha Pumparound air cooler E-1521 and is used for reboiling in the Propylene
Recovery Unit (PRU). The air cooler E-1521 is designed for the case when the PRU is not in operation.
Total flow is maintained by by-pass control and heat removal is controlled by temperature control of the
flow through E-1521.
Heavy naphtha is drawn off the pumparound tray and is fed to Heavy Naphtha Stripper T-1502 on
T-1502 bottoms level control. The stripper is reboiled by reboiler E-1509, which is heated by the HCO
pumparound. The stripper vapor is returned to T-1501 above the pumparound bed. Stripped heavy
naphtha is pumped by 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 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 as lean oil for the secondary absorber in the Gas recovery Section. The
lean oil is pumped by P-1513 A/B on flow control 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.
2.5.7 Top section
This section of T-1501 consists of 10 fractionation trays, trays 1 to 10.
Rich oil from 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 and flows by gravity to the inlet of
overhead condenser E-1519.
2.5.8 Fractionator overhead section
The overhead naphtha cut point is controlled by the overhead temperature controller resetting the external
reflux rate.
Wash water is recycled from the fractionator reflux drum D-1514 to the inlet of the overhead condenser
E-1519 to minimize corrosion in the condenser. Corrosion inhibitor is also injected to the overhead line
of T-1501. The overhead vapor from T-1501 is partially condensed in E-1519 and E-1520A-H and the
liquid hydrocarbon, water and vapor phases are separated in D-1514. Off-gas streams from CDU and
NHT Units are fed to D-1514. Part of the liquid hydrocarbon is refluxed to T-1501 by P-1516 A/B. The
net overhead liquid product is pumped by P-1518 A/B, under flow control reset by level control, to the
primary absorber in the Gas Recovery Section. The overhead wet vapor flows to the wet gas compressor
suction drum.

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Sour water is pumped from D-1514 boot by P-1517 A/B. Part of the water is recycled on flow control to
the inlet of E-1519 and part is sent on flow control as wash water to the wet gas compressor intercooler.
The remaining sour water is sent to the sour water stripping unit on boot interface level control.
2.6 Gas Recovery section
2.6.1 Wet gas compressor and HP condenser
Wet gas from the Fractionation Section flows to the wet gas compressor first stage knock-out drum D1551. The gas is compressed in the first stage of the compressor C-1551 and is then cooled in air
intercooler E-1551 and trim cooler E-1552 A/B. Sour water from the Fractionation Section is injected at
the inlet of E-1551 to minimize corrosion. The cooled vapor and condensed liquid from E-1552 are
separated in interstage drum D-1552.
The vapor from D-1552 is compressed in the second 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 condenser E-1553.
2.6.2 Stripper condenser and high pressure separator drum
The outlet from E-1553, the primary absorber bottom liquid and the stripper overhead vapor are
combined before entering stripper condensers E-1554A/B. An LPG stream from the CDU is also fed to
the inlet of E-1554 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 D1553 boot interface level control to the sour water stripper.
The hydrocarbon liquid phase is pumped by P-1553 A/B and after preheating in E-1555 is fed to the top
of stripper T-1552.
The vapor phase from D-1553 is fed below the bottom tray of primary absorber T-1551.
2.6.3 Primary absorber
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 in order to obtain the
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 stripper strips H2S and C2 and lighter from the LPG and gasoline mixture which is fed to the top tray
from HP separator drum D-1553. Reboiler heat is supplied by two reboilers in series. The first reboiler E1556 is heated by debutanizer bottoms. The second reboiler E-1557 is heated by the LCO pumparound
from the Fractionation Section.
The heat input to E-1557 is controlled by the overhead vapor rate from the stripper. This rate, and hence
the reboiler duty, is set to meet the C2 specification in the debutanizer overheads.
The overhead vapor is condensed in E-1554. The bottom liquid is fed to the debutanizer T-1554 on flow
control reset by level control.
2.6.5 Secondary absorber
The secondary absorber T-1553 recovers gasoline light fractions from the overhead gas from primary
absorber T-1551. The lean oil is a heavy naphtha stream from the Fractionation Section.
The lean oil is cooled by exchange with the bottoms of T-1553 in E-1563 and then in lean oil cooler
E-1564. The cooled liquid flows through lean oil coalescer D-1556 to remove entrained water before
being fed to the top tray of T-1553. The bottom rich oil flows under level control, and after recovering
heat by exchange with the lean oil in E-1563, it is recycled to the main fractionator in the Fractionation
Section.

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The overhead gas is cooled in fuel gas cooler E-1565 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 from the secondary absorber by contact
with DEA.
The small amount of liquid in the effluent from E-1565 is separated in K.O. drum D-1557. The liquid is
sent to the inlet of E-1563 on level control. The overhead gas is fed to the bottom of T-1555 and the lean
amine is fed to the top tray. The temperature of the lean amine is controlled to maintain the lean amine at
a fixed temperature difference above the inlet gas, to avoid hydrocarbon condensation.
The overhead gas is sent to K.O. drum D-1559 before going to the fuel gas system. The rich amine goes
to the amine unit under T-1555 level control. Any amine accumulated in K.O. drum D1559 also goes to
the amine unit on level control.
2.6.7 Debutanizer
The debutanizer separates LPG from gasoline.
The bottom of the stripper is fed to debutanizer T-1554. The overhead vapor is totally condensed in
condenser E-1561 A/B. The pressure in D-1554 is controlled by by-passing part of the overhead vapor to
the reflux drum D-1554. The condensed liquid is pumped from D-1554 by P-1556 A/B. Part of the liquid
is refluxed on flow control reset by the temperature controller on the sensitive tray in the top section of
the column. This controls the C5 specification in the overhead product. The remaining overhead liquid,
LPG product, goes under flow control reset by D-1554 level control to the LPG amine absorber T-1556
after cooling in E-1562.
The column is reboiled by reboiler E-1560 A/B. The heat input to the reboiler is from the HCO
pumparound in the Fractionation Section. The reboiler duty is set to ensure that the C4 specification in the
gasoline is met.
The gasoline from the bottom of the column is first cooled in stripper reboiler E-1556 and then in air
cooler E-1558 and finally in gasoline cooler E-1559. Part of the cooled gasoline is pumped on flow
control by P-1554 A/B to the primary absorber as supplementary lean oil when required. The net gasoline
product is sent on flow control, reset by debutanizer level control, to the Gasoline Treating Unit. For
maximum Gasoline operation the heavy naphtha from the Fractionation section is combined with this
stream.
2.6.8 LPG amine absorber
The LPG amine absorber T-1556 removes H2S by contact with DEA.
T-1556 is a packed column. The LPG enters at the bottom and flows up through the amine. The LPGamine interface level control 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 is sent to the rich amine stream from the absorber bottom
on boot interface level control. The overhead LPG from the drum goes to the LPG Treating Unit.
2.7 Theory of the Process
2.7.1

Chemical reactions and catalysts

2.7.1.1 Introduction and Objective of this chapter


The aim of the information given in this chapter is to provide enough theoretical background, in the
simplest possible way, to the instructions given in the chapters that follow, i.e. Start-up of unit, Operation
of the unit, Shutdown of the unit.

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It is expected that this theoretical support will help the operators to better understand the reasons of the
operating instructions and enable them to make wise decisions, should the circumstances deviate from
what is covered in the Operating Instructions.
2.7.1.2 Thermodynamics and kinetics.
For any chemical reaction the thermodynamics dictates the possibility of its occurrence and the amount
of products and unconverted reactants. In fact, some reactions are 100% completed i.e. all the reactants
are converted into products. Others are in equilibrium i.e. part of the reactants only are converted. The
amount of products and reactants at equilibrium depends upon the operating conditions and is dictated by
the thermodynamics. Note that the thermodynamics does not mention the time required to reach the
equilibrium or the full completion of a reaction.
Kinetics dictates the rate of a chemical reaction (i.e. the amount of feed that disappears in, say, one
second). Kinetics (rate of reaction) is dependent upon operating conditions but can also be widely
modified through the use of properly selected catalysts. One reaction (or a family of reactions) is
generally enhanced by a specific catalyst.
In other words, thermodynamics dictates the ultimate equilibrium composition assuming the time is
infinite. Kinetics enables to forecast the composition after a finite time. Since time is always limited,
when reactions are concurrent, kinetics is generally predominant.
A catalyst generally consists of a support (earth oxide, alumina, silica, magnesia,...) on which (a) finely
divided metal(s) is (are) deposited.
The metal is always responsible for the catalytic action. Very often, the support has also a catalytic
action linked to its chemical nature.
A catalyst is not consumed but can be deactivated either by impurities in the feed or by some of the
products of the chemical reactions involved, resulting in coke deposit on the catalyst.
The different chapters of section 5-3 describe:

The various chemical reactions involved in the process as well as the effect of the
operating conditions.

The catalyst characteristics.

The catalysis mechanism.

The catalyst contaminants.

The process variables.

2.7.1.3 Catalyst activity, selectivity, stability


The main characteristics of a catalyst other than its physical and mechanical properties are:
The activity which is the catalyst ability to increase the rate of the reactions involved. It is

measured by the temperature at which the catalyst must be operated to produce a product onspecification, for a given feed, all other operating conditions being equal.
The selectivity expresses the catalyst ability to favour desirable reactions rather than others.
The stability characterizes the change with time of the catalyst performance (i. e., activity,

selectivity) when operating conditions and feed are stable. It is chiefly the polymers or coke

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deposit which affects stability, because it decreases the metal contact area. Traces of metal in
the feed also adversely affect stability.
2.7.2

Types of reactions

The reactions involved in RFCC process are of two types: thermal cracking and catalytic cracking.
A Thermal cracking
Chemical cracking reactions are characterized by the breaking of chemical bonds within the
molecules of hydrocarbons or other compounds contained in petroleum fractions.
They mainly involve the breaking of carbon-carbon bonds (- C - C -), carbon-sulfur bond
(- C - S -) and also, although to a lesser extent, carbon-hydrogen bonds (- C - H).
These reactions are the result of the heating effect, whether or not in the presence of a catalyst. However,
cracking of a petroleum cut is not confined to these breakages of bonds, since both shorter and longer
molecules than those originally present in the treated cut are simultaneously obtained. This can be
explained by a rather complex mechanism, which occurs after the first cracking reactions.
To simplify matters, one can distinguish primary cracking reactions and progress reactions.
a)

Primary cracking reactions

This type of reaction concerns various molecules in the feed.


In the case of the main groups of hydrocarbons, paraffins, naphthenes and aromatics, the following
conversions are mainly to be observed:
Paraffin

Olefin

Lighter paraffin

C30H62

C22H44

C8H18

Naphthene

Olefin (by cycle cracking)

example

example

C=C

Aromatic
with side chain
CH - R
1

example

C- C- C

C-R

+ Olefin
Aromatic
(by cracking at side chain)
+ CH = R
2

In every case, the absence of hydrogen supply is found to result in the regeneration of olefinic
unsaturated products.
b)

Progress reactions

It concerns intermediate compounds produced by primary cracking.

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These include:
Secondary cracking of paraffins producing, like primary cracking, an olefin and a paraffin.
C8H18

example

C5H10

C3H8

Conversion of highly reactive olefins.


Either into smaller olefins by cracking.
Olefin
C8H16

example

two smaller olefins


C3H6

C5H10

or into diolefins by hydrogen loss, such dehydrogenation being the result of breaking of carbonhydrogen bonds.

Olefin
C10H20

example

diolefin

hydrogen

C10H18

H2

Conversion of olefins into paraffins and diolefins or aromatics; this hydrogen transfer reaction
plays a considerable role in the case of catalytic cracking.
olefin 1 + olefin 2

Paraffin

diolefin

olefins

Paraffins

aromatic

Starting with olefins gives a product with higher hydrogen content (paraffin) and another with lower
hydrogen content (diolefin, aromatic).
Additional reactions between certain intermediate products, mainly involve progressive attachment of
diolefins to aromatics, resulting in condensed and highly aromatic polycyclic heavy products; this is
how heavy fuel oils and coke appear. This kind of reaction is called Diels Alder cycloaddition (or
condensation).
B

Catalyst cracking

The use of a catalyst in chemical reactions during hydrocarbon cracking makes a significant change in
the chemical conversions, affecting reaction mechanisms and selectively speeding up some of them.
Catalytic cracking differs from thermal cracking in the following main ways:
Lower yields of C2 gases, since catalysts theoretically do not allow the formation of short
molecules with fewer than 3 carbon atoms.
Higher yields of gasoline, which also have better stability and a higher octane number.
Smaller coke production for the same feed processing, thereby indicating better catalyst
selectivity.
Products of different chemical composition: few olefins, many isomerized structures, high
aromatic contents, etc..

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Since their discovery, catalytic cracking catalysts have changed a great deal, and now consist mainly of
mixtures of amorphous silica-alumina and crystallised silica-alumina, the latter better known as
zeolite or molecular sieves.
They take the form of a solid in powder form, the catalyst activity of which during cracking is related to
the acid properties of their surface.
They are treated during manufacture to endow them with proper acidity, quite comparable with that
existing for conventional liquid acids such as sulfuric, hydrochloric and nitric acids.

This acidity function in cracking reactions appears in the following two main mechanisms:
Appearance of a particular reaction mechanism, involving the intermediate presence of ionic
reaction compounds.
Major impact on the hydrogen transfer reactions already described.
These two specific mechanisms, which largely explain the catalytic cracking efficiency, are discussed
below.
Catalytic cracking is a reaction characterized by its endothermicity and an increase in the number of
molecules. It is therefore favored at high temperature and at low pressure.
a) Acid catalyst cracking
The cracking mechanism involving catalyst acidity is related to the appearance of intermediate ionic
compounds, which possess very specific properties governing the progress of the cracking process.
Such compounds usually appear during adsorption of an olefin produced by primary cracking on the
acid catalyst.
Whereas thermal cracking of a heavy petroleum cut involves a fairly complex mechanism, which rather
unselectively generates unsaturated lighter products, and heavier products, than the original feed (in
particular producing a great deal of gas, rather unstable gasolines and a high proportion of coke),
cracking reactions can be improved to move product yields and qualities in the desired direction, by
using a catalyst. This explains the great benefit of catalytic cracking.
Structural change in the hydrocarbon chain in the direction of branched-chain isomerised
structures. These new forms represent greater stability for the O+ cation. This stage explains the
high presence of such molecules in catalytic cracking products.
The structural change takes place spontaneously and leads to this more stable carbocation: this is
isomerization.
Secondary cracking resulting in the formation of a smaller olefin and new O+ cation with a
shorter chain, which may then undergo the same process as the previous one. This corresponds to
the standard progression of cracking, resulting in the formation of light products. O+ cations,
however, very strongly discourage the formation of short chains with fewer than 3 carbon atoms,
explaining the lower yields of C2- gases obtained by catalytic cracking.
b)

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Hydrogen transfer reactions

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As already mentioned, hydrogen transfer reactions from olefins, which are highly encouraged by zeolite
catalysts, result in the parallel formation of:
Hydrocarbons with more hydrogen, benefiting from the transfer; these are therefore mainly
paraffins;
Compounds with less hydrogen, such as aromatics.
The reaction shown below demonstrates the typical change of olefins into C6 through this type of
reaction:

4C6 olefins

3C6 paraffins

1C6 aromatic

3 (C6H14)

C6H6

hydrogen
transfer
4 (C6H12)

It involves four C6 olefins converted into three paraffins by hydrogen gain and one aromatic by hydrogen
loss.
This reaction is extremely important for overall results of cracking, since it has two main consequences:
It preserves the gasoline yield by preventing, through the very fact of its rapidity, concomitant
conversion of olefins in the gasoline carbon range into light gases by cracking.
It produces paraffin-richer products, particularly gasolines, which would have a very bad effect on
the octane number, if a large proportion of the paraffins thereby obtained did not have an isomerised
structure.
All this goes to show that the effect of the catalyst acidity and hydrogen transfer reactions are largely
responsible for the yields and qualities obtained by catalytic cracking.
An other example concerns the hydrogen transfer reaction between a naphteno-aromatic compound
(tetraline) and an -olefin (isobutene).
3CnH2n-2

2CnH2n

CnH2n-6

cyclo-olefins

naphtenes

aromatic

Hydrogen transfer is influenced by:


Feed quality.
Riser Outlet Temperature.
Cat to oil ratio.
RE2O3 on catalyst.
Catalyst composition.
More hydrogen transfer means:
More coke.

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Less LPG.
More gasoline.
Less product olefins.
Lower RON.
A glance at the general scheme of the parallel and consecutive cracking reactions shows that all the
products (gas, gasoline, LCO and coke) are primary. The LCO usually results from a single cracking
operation of the large molecules in the feed. Most of the gasoline and part of the gas also result from
primary cracking. However, a large share of the gases, especially C3 and C4, result from the secondary
cracking of gasoline and LCO.
A small part of the coke appears to form instantaneously by thermal dehydrogenation of large probably
naphteno-aromatic molecules. C1 and C2 hydrocarbons are essentially produced by thermal cracking.
This set of reactions involved can be divided into three categories.
2.7.3

Desired reactions

These reactions include cracking and isomerization.


A Cracking reactions
Hydrocarbon reactivities
A very rough order of reactivity of the main hydrocarbon categories is:
olefins > alkylaromatics > alkylnaphtenes and isoparaffins >
n-paraffins and naphtenic cycle >> aromatic ring (very stable)
In all cases, cracking results from the scission of a carbocation (or carbenium ion) located in the
neighborhood of an acid site on the catalyst. The more easily the carbocation is formed and occupies the
catalyst surface, the more it undergoes scission. This helps to define an additional reactivity rule valid
within the first four categories above:
Crackability increases with size (or number of carbon atoms) and the degree of branching of the
hydrocarbon category.
How are hydrocarbons cracked?
A few simple rules can be set forth.
Heavy linear alkanes and linear alkenes are always isomerised before cracking. The cracking
products of the molecules hence contain a majority of 1 to 2 methyl branches (or, to a lesser degree,
ethyl).
Cracking by scission at of these molecules mainly occurs in mid-chain and practically never at
less than three carbon atoms from the end. C1 and C2 are formed by a thermal homolytic
mechanism different from -scission.
The alkyl chains fixed to a cycle are cut at the edge of the ring if the cycle is aromatic, and at any
point located at three or more carbon atoms from its end if the cycle is naphthenic.
B Isomerization reaction

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Given the short residence times employed in cracking, this reaction only affects the olefins with roughly
more than four or five carbon atoms and the heavy paraffins of the feed. The light paraffins produced by
a first cracking subsequently do not have the time to isomerize. The C4 paraffins are thus present in
proportions quite different from those of thermodynamic equilibrium. C4 olefins are much closer to
equilibrium but never reach it.
2.7.4

Reactions to be limited (but not eliminated)


A Hydrogen transfer

This bimolecular reaction consists in the transfer of a hydrogen molecule from one naphthene or olefin to
another olefin, by a heterolytic acid mechanism. It leads essentially to the formation of saturated
hydrocarbons, mainly paraffins, as well as aromatic compounds (mono and essentially polyaromatics).
Polynaphthenoaromatics and other heavy coke precursors are very reactive molecules with respect to
hydrogen transfer.
This reaction plays a very important role in the quality of the gasoline obtained and the formation of coke.
Hence considerable hydrogen transfer decreases the olefinicity of the gasoline and increases the coke
production in the installation. It simultaneously improves the stability of the gasoline (i.e. its ability to
withstand overcracking) by lowering the reactive molecule content.
B Condensation reactions
The Diels-Alder cyclo-addition is the main reaction. It consists in combining a linear or cyclic olefin
with a linear or cyclic diolefin, leading to more condensed and partly unsaturated cyclic structures.
These are transformed into aromatics (mono or poly) by hydrogen transfer, or continue to undergo cycloaddition. The final stage of the successive cyclo-addition and hydrogen transfer reactions is the
deposition of very heavy condensed polyaromatics constituting coke on the catalyst.
2.7.5

Undesirable reactions to be reduced to the minimum


A Hydrogen formation

The dehydrogenation of condensed and partly unsaturated cyclic molecules by metallic contaminants, in
particular Ni and V, is responsible for most of the production of hydrogen (Ni and V) and a substantial
share of coke (mainly Ni). The production of methane is virtually unaffected by the metal content,
therefore this effect is monitored through the H2/methane ratio.
B C1 and C2 hydrocarbons
These are mainly due to non-selective thermal cracking. Hence their production is highly sensitive to the
riser temperature.
2.7.6

Conversion selectivity of various hydrocarbon families

The two families most selectively converted to gasoline are alkylmonoaromatics and condensed
polynaphthenes (mainly with two cycles).
Among the simple saturated hydrocarbons, the order of gasoline selectivities is: naphthene > isoparaffins
> normal paraffins.
Polyaromatics, especially with four and five rings, are not converted to gasoline but are excellent coke
precursors.
Definitions of conversion

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Conversion

The conversion rate is defined by the following ratio:

Conversion =

Flow rate of converted products


x 100
Flow rate of fresh feed

Depending on whether flow rates are expressed by weight or volume, the conversion rate is a weight
percentage or a volume percentage.
Converted and non-converted products are designated as follows:
Converted products:
Dry gas
C3 cut
C4 cut
Light gasoline
Heavy gasoline
Coke
Unconverted products:
LCO
HCO
Slurry
B

Industrial conversion rate

It is not easy to measure the flow rates of converted products. The flow rate of coke is not directly
measurable, and volume flow rates of dry gas are meaningless. In contrast, it is possible to measure flow
rates of non-converted products.
The flow rate of converted product is obtained by subtracting the flow rate of non-converted products
from the flow rate of fresh feed:
Converted products flow rate = fresh feed flow rate - non-converted products flow rates.
and therefore:

Industrial conversion rate =


C

Fresh feed flow rate - non - converted products flow rates


x 100
Fresh feed flow rate

Adjusted conversion rate

It can be understood that the flow rate of converted products depends on the cutpoint between gasoline
and LCO. This cutpoint is conventionally defined by the ASTM FBP of the gasoline at a constant
cutpoint of 221C (430F).

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If the initial point of the fresh feed is less than 221C, the flow rate of fresh feed is adjusted as follows:
Adjusted fresh feed flow rate = fresh feed flow rate - fraction boiling before 221C.
2.7.7

Catalyst

2.7.7.1 Catalyst characteristics


The performance of the reaction system and the regenerations is highly dependent on the kinetic
properties of the catalyst. Performance of the catalyst circulation system is also dependent on the
physical properties of the catalyst.
The FCC catalyst is a solid complex composite acid.
Modern FCC catalysts consist of several ingredients, such as:

Zeolites (Y-type Faujasites, ZSM-5).

Active matrices (Silica-Aluminas,).

Binder, Kaolin, Metal traps,...

Zeolites are microporous crystalline aluminium silicates. Procedures exist for the synthesis of zeolites
with a structure similar to known minerals as well as zeolites without a natural counterpart, such as for
example the ZSM-5 that is used in octane boosting additives. For FCC catalysts mainly the Y-type
(Faujasite) zeolite is of interest, with a silica to alumina ratio of about 5.
The framework of the zeolite is composed of silicon, aluminium and oxygen atoms, forming a rigid
structure of tetrahedra, linked together in cubo-octahedra. The silicon atoms in the SiO4 tetrahedra are
partly replaced with aluminium atoms and a corresponding number of charge-compensating sodium ion.
These sodium ions are rather mobile and can be exchanged with NH4+ or rare earth (RE3+). This ion
exchange is essential for zeolites used as cracking catalysts, because it generates active sites for cracking.
RE-exchanged zeolites (REY and REUSY) are favored in cracking catalysts because they show an
excellent stability and activity. However, as the rare earth enhances hydrogen transfer reactions, the
product olefinicity and research octanes are depressed. During the eighties the rare earth contents were
reduced somewhat, while other techniques were developed to compensate for the loss in zeolite stability
and activity.
The openings of the zeolite pores (0.8 nm) are too narrow for the average feedstock molecules, so that
precracking is required. Active matrices are applied to give the catalyst a proper pore size and
activity distribution, and a good accessibility to the highly active zeolite sites. These matrices also
protect the zeolite from catalyst poisons, such as vanadium and sodium. The pore size and activity
distribution of the catalyst should be tailored to the feedstock quality and the required product yields.
The kaolin serves as a filter and does not directly contribute to the catalyst activity. The binder gives the
catalyst the required strength. Todays spray-dried FCC catalysts consist of microspheres that have
excellent fluidization properties and are attrition resistant.
The average particle size is around 70 microns in the fresh catalyst and slightly higher in the equilibrium,
depending on the efficiency of the cyclones in the reactor and regenerator vessel.
The performance of FCC catalysts is the result of the concentration and catalytic activity of the functional
ingredients and the intraparticle accessibility of the catalyst. The catalytic activity is determined by e.g.,

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the type of zeolite, the rare earth concentration, the type of matrix and the stability of the active
components.
The accessibility depends not only on the matrix and the zeolite but also on the non-active components in
the catalyst.
A. Fresh catalyst
Refer to Chapter 4.1, Specifications of catalysts
B.

Equilibrium catalyst

Equilibrium catalyst (E-cat) withdrawn from the FCC unit can be re-used or disposed of as spent catalyst.
a) Re-useable equilibrium catalyst
Good quality E-cat can be re-used in the RFCC unit as start-up catalyst, to compensate for losses or as
flushing catalyst. In general such catalyst is characterized by:

Unpromoted catalyst is required.

A total metals content (Ni + V) 3000 and 5000 ppm maximum.

An activity level above approximately 67 wt % MAT.

An average particle size of around 70 microns.

Fine content 40 microns minus: above 10%.

Surface area:

above 125 m2g.

CRC:

below 0.1 wt %.

Rare Earths content:

below 1 wt %.

The value of re-useable E-cat depends on the market demand.


At least six months prior to start-up, a representative equilibrium fluid cracking catalyst analysis will be
submitted to IFP for approval prior to purchase.
b) Disposal of equilibrium catalyst
In case the metals content (Ni + V) of the equilibrium catalyst exceeds 15000 ppm the E-cat is in general
considered as spent catalyst, not suitable anymore for re-use in a low metals RFCC operation.
Consequently the material will have to be disposed of in an environmentally safe way.
c) FCC catalyst fines
FCC catalyst fines are in general not suitable for re-use in the RFCC unit and should therefore be
disposed of as spent catalyst. However certain qualities of fines are suitable as flow improver for units
with circulation problems.
2.7.7.2
Catalyst mechanism
It is the selection of the right catalyst together with the operating conditions (mainly the temperature)
which determines the rate of the various reactions and enables to meet the required selectivity.
The performance of RFCC catalysts is the result of the concentration and catalytic activity of the
functional ingredients and the intraparticle accessibility of the catalyst. The catalytic activity is
determined by e.g., the type of zeolite, the rare earth concentration, the type of matrix and the stability of
the active components.

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The accessibility depends not only on the matrix and the zeolite but also on the non-active components in
the catalyst.

The catalyst support must meet the following criteria:

improve the metal dispersion within its structure as well as the reactants diffusion to the
active sites,

be mechanically resistant.

withstand steam, air treatments at temperatures higher than 750C,

and keep an excellent behaviour towards thermal shocks and steam during the course of
regenerations.

Catalyst used in residue cracking operations should be double calcined to enhance thermal stability.
Particle size distribution should be examined on the fresh catalyst. The zero to 20 micron fraction should
be low to minimize losses through the cyclones. The cyclone system is designed to retain enough of the
equilibrium 0-40 micron fraction to maintain good fluidization properties.
2.7.7.3 Catalyst contaminants
Definition
Three different types of contaminants are considered: inhibitors or activity moderators, temporary
poisons, permanent poisons.
General remarks
The list of contaminants, their effects, their origin and means of removal are presented in the following
pages.
This presents a non-exhaustive list of the most commonly encountered impurities in the given type of
application. Impurities not listed here, and related to other feeds, may have a detrimental effect on
catalyst performance.
A Inhibitors or activity moderators
Inhibitors are compounds which compete with the reactants for the catalyst active surface resulting in a
reduction of the available active surface. They adsorb strongly on the catalyst metal but this adsorption is
perfectly reversible.
Carbon on catalysts is a typical inhibitor
In order to monitor the regenerator efficiency of RFCC unit, the remaining carbon on regenerated catalyst
is measured. The carbon on catalyst flowing from the stripper into the regenerator (spent catalyst) can be
measured as well, allowing direct analysis of the delta coke level.
The carbon is converted to carbon dioxide, which is analyzed using an infrared detector. Apart from
measuring the carbon on regenerated catalyst (CRC), the carbon content can be estimated by the refiner
by comparing the color of the equilibrium catalyst with the color of reference samples taken from the
same unit.
A high carbon content does not affect the measured activity but results in a loss of effective activity of
the catalyst flowing into the reactor riser (typically 1-2 wt % MAT per 0.1 wt % CRC). As a
consequence the unit conversion and selectivities may change. An improved air and/or catalyst

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distribution results in a reduced carbon content. The efficiency of carbon removal also benefits from
increasing the dense bed temperature for units operating in a partial combustion mode.
B Temporary poisons
Temporary poisons are contaminants which are so strongly adsorbed that they accumulate over the active
surface. Removal of poisons and activity recovery are obtained only by using specific procedures.
Antimony (Sb)
Antimony is only present on equilibrium catalyst if an antimony passivator is used to reduce nickel
activity. Approximately 30-50% of the value of the nickel content is sufficient to reduce hydrogen yields
to an acceptable level.
Miscellaneous
Other metals may also affect catalyst performance. For example, iron and copper can increase the
hydrogen make while calcium and magnesium may affect catalyst activity or stability. Usually these
metals are not present in such a concentration that a significant impact on the performance is noticed.
The equilibrium catalyst may also contain minor amounts of non-metallic oxides from e.g., S, P, Cl and
elements like Ti, originating from the kaolin or a metal trap. The balance usually is silica.
C Permanent poisons
Permanent poisons are not removable by procedures available on site, i.e. usually steam-and- air
decoking. The catalyst must be dumped and replaced by a fresh load. Nickel, vanadium and sodium are
typical permanent poisons.

Nickel (Ni)

Nickel is introduced with the feed and deposited on the equilibrium catalyst. Nickel is not mobile under
normal regeneration conditions and acts as a dehydrogenation catalyst. In FCC nickel enhances nonselective cracking reactions, particularly those producing more hydrogen and coke.

Vanadium (V)

Vanadium is introduced with the feed and is deposited on the equilibrium catalyst. Under regenerator
conditions, vanadium migrates and is able to enter the fresh catalyst and destroy the zeolite. As a
consequence, catalyst activity and conversion suffer. For conventional catalysts (a typical rule is that 2
points catalyst activity are lost per 1000 ppm vanadium at constant unit conditions and catalyst
consumption). As with sodium, the deactivation rate strongly depends on the highest temperature and the
vapor pressure of water in the regenerator.
By limiting the burn of coke in the first regenerator and thereby the temperature to less than about 700C
in an oxygen deficient environment, the migration of vanadium on the catalyst is inhibited and zeolite
damage limited. The damaging form of vanadium is the fully oxidized V2O5 form which requires water
to form a vanadium acid, destroying the zeolite and hence catalyst activity. Without an oxidizing
atmosphere, vanadium oxidation, mobility, and acid formation can be controlled even in the presence of
water/steam.
Vanadium in the feed and deposited on the catalyst will promote collapse of the zeolite structure
and loss of active surface area at the elevated regenerator temperatures.

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Small amounts of sodium (typically 0.1-0.4 wt %) are present in the fresh catalyst. Sodium can also be
introduced by the feed, especially if resid is processed. In case of high sodium levels on equilibrium
catalyst, the feed quality should be checked. Malfunctioning of crude desalters or processing of imported
feeds contaminated with seawater are the typical causes of high sodium levels in most cases.
Sodium is a catalyst poison which neutralizes acid sites and destroys the zeolite. Approximately 6 points
MAT activity are lost per wt % sodium originating from the FCC feed. At high sodium levels the
catalyst is more sensitive to high temperatures, due to increased rates of sintering, and surface destruction.
Feed sodium should be kept imperatively below 2 wt ppm.
Note: Caustic injection used in the crude train is not recommended without effective removal of the
sodium neutralization salts. Caustic injection, if used, should be before the desalters. The Na2O
content of the equilibrium catalyst should not exceed the Na2O content of the fresh catalyst by
more than 0.10 wt %.
2.7.8

Catalyst regeneration

The catalyst that leaves the stripper usually contains up to 1 wt % coke with a C/H ratio of about unity.
The main objectives of regeneration are to burn off the coke from the catalyst in order to restore its
activity and to maintain the heat balance of the unit. The heat generated by the major combustion
reactions is shown in table.

Heat released
kcal/kg carbon

Reaction
H2

O2

H2O

28700

O2

CO2

7830

O2

CO

2200

CO

O2

CO2

5630

The total heat generated largely depends on the hydrogen content of the coke, the level of CO
combustion and the coke yield. Depending on the stripper conditions and the strippability of the catalyst,
the H content of the coke can vary from 6 to 8 wt %.
It should also be noted that, in addition to carbon and hydrogen, coke contains sulphur and nitrogen.
These two impurities originate from sulphur and nitrogen compounds in the feed which combine with the
coke during the cracking process. During combustion in the regenerators, the sulphur and nitrogen
produce sulphur oxides (SO2 and SO3), ammonia (NH3) and nitrogen oxides (Nox) in amounts that vary
with the regenerators operating conditions. All these compounds present in the regenerator flue gases are
atmospheric pollutants and the allowable amounts released are governed by statutory regulations.
In the R2R process, catalyst regeneration is achieved in two independent regenerators.
objectives are:

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Handling, when required, high coke laden catalyst without exceeding any catalyst or
metallurgical constraints,

Regenerating the catalyst with a complete coke removal < 0.05 wt %,

Favoring CO formation over CO2 to minimize the heat of coke combustion. The heat released
from the combustion of CO (carbon monoxide) to CO2 (carbon dioxide) is about 2.5 times
greater per kilogram of carbon than that from the combustion of carbon to CO.

Letting the regeneration temperature free to float and to equilibrate to the level corresponding
to the coke deposition on spent catalyst.

Minimizing catalyst deactivation mainly with vanadium by preventing the vanadium acid
destruction of the zeolite embedded in the catalyst.

Obtaining a hot catalyst in short contact time designs to favour rapid heat transfer to feed by
radiation. This is particularly advantageous in high conversion operations.

In the first stage regenerator production of CO is encouraged, which limits the heat release and thereby
rejecting potential heat from the process to the flue gases.
The increase of the CO combustion not only results in a higher heat of combustion, but also in a higher
consumption of air per ton of coke.

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UNIT CONTROL DESCRIPTION

3.1 Control philosophy of the process


Refer to chapter 1. Process specification section.
The most critical control loop on the converter is the Riser Outlet Temperature. The temperature should
be controlled within 1C of the set point. A thermocouple located near the outlet of the riser measures
the reaction temperature. The temperature is a function of the amount of catalyst admitted to the riser by
the regenerated catalyst slide valve. Reaction temperature is basic to the conversion of RFCC feedstocks.
To enhance fresh feed vaporization and ultimately the product yields, mixed temperature control (MTC)
technology is used. 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.
NOTE: It is designed that MTC injection is required for Maximum Gasoline of Mixed Crude.
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.
The level in the first stage regenerator is measured by a differential pressure instrument and signals a
level controller which resets the position of the plug valve. 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 reentrainment from the cyclone dust bowls.
During normal operation, the second stage regenerator level 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.
The total daily amount of catalyst withdrawal is adjusted by timer setting taking into account the
operation requirements for the overall catalyst balance.
In case a (catalyst cooler) is used, the level in the catalyst cooler is not controlled and depends on the
second regenerator level. Temperatures of the regenerators are adjusted by varying the catalyst rate
through the catalyst cooler and/or adjusting the heat transfer coefficient with the amount of fluidization
air.
The regenerators pressures are controlled by flue gas slide valves 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. The differential pressure between the first stage and second stage regenerators is
controlled by the second regenerator flue gas slide valve. This differential pressure is set to provide

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adequate pressure drop across the plug valve for stable control of the regenerators levels. The disengager
pressure rides on the main fractionator pressure which is controlled at the main fractionator overhead
receiver. 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.
As a general rule any change in the vessels should be done slowly in gradual increments to allow slide
valves to reposition properly for stable catalyst circulation. The unit is designed to provide adequate
slide valve pressure differential for safe operation. Override controls are provided for action in low slide
valve differential upsets which close slide valves to prevent dangerous reverse flow. Normal catalyst
slide valve differential is around 0.3 to 0.5 bar to provide stable control. Slide valve differentials above
0.7 bar are to be avoided because they may cause valve erosion. Negative differentials should never be
permitted and the PDIC controls should be set to override the main controllers at 0.1 bar. Smooth
catalyst circulation is paramount for successful operation of R2R and is achieved by proper catalyst
aeration and fluidization in the transfer lines, as well as control of the unit pressure balance.
An emergency shutdown circuit will close the catalyst slide valves automatically upon loss of feed and
loss of combustion air.

MTC control

Control of the feed and catalyst mix temperature is critical in order to vaporize all hydrocarbons that can
be converted to lighter products. This can be achieved independently of the riser outlet temperature
which is the primary reaction control parameter. Riser Outlet Temperature is maintained conventionally
by regenerated catalyst circulation through the hot regenerated catalyst slide valve. The mix temperature,
which can be measured in an appropriate location downstream from the feed injection point, is controlled
by an additional liquid hydrocarbon injection point, provided a few meters above the feed injection.
With MTC, it is therefore 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. Like the (catalyst cooler coil), MTC provides additional heat removal,
but in this case heat removal takes place on the disengager side. Cooling is carried out by vaporization of
the liquid hydrocarbons introduced at the MTC level.
The heat absorbed by MTC vaporization is then used downstream in the fractionation section for steam
production, preheating or reboiling.
The nature of the recycle depends upon each situation. If heavy naphtha is used as MTC fluid, then MTC
acts essentially as a heat sink. The aromaticity of heavy naphtha renders it essentially inert. As a result,
LPG and light gasoline yields will be promoted and higher conversion levels will be achieved. When
using heavy naphtha, the additional coke formed in the riser (delta-coke) will be minimized and the C/O
ratio will therefore be increased. To avoid over-cracking, the Riser Outlet Temperature can be reduced
by about 10C when the recycle is 20% of feed. If the heat balance of the unit is not critical, heavier
fractions such as Light Cycle Oil (LCO) or Heavy Cycle Oil (HCO) can be used.

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3.2 Process variables of Reactor / Regeneration Section


3.2.1 General
The R2R unit will operate in a stable manner over a wide range of conditions. The operating mode
chosen will affect the distribution and quality of products produced. The unit operator chooses a mode of
operation to maximize desirable products for different feedstocks or to conform to the demands and
limitations of the refining complex. Careful attention to unit performance and process variables will
result in an operation of maximum profitability with few problems and upsets.
The quality of the reaction which determines the products quality and quantity depends on the:
riser outlet temperature,
reactor pressure,
catalyst activity.
The quality of the regeneration depends on the:
regenerators air balance,
regenerators temperatures,
regenerators residence time,
regenerators fluidization velocities.
The quality of stripping will affect the yields pattern through the delta-coke which controls the
regeneration conditions and further the catalyst circulation.
Reaction and regeneration are interdependent through the overall heat balance. The heat balance depends
on the following variables:
feedstock properties,
feed temperature,
coke production / delta-coke / catalyst to oil ratio.
Heat is carried from the regeneration zone to the reaction zone by the catalyst circulation. A proper
pressure balance is required to ensure a smooth catalyst circulation.
3.2.2 Riser Outlet Temperature
The operating temperature of the riser outlet will normally be set to achieve the desired degree of
conversion. Typically, a temperature of 510C will correspond to a maximum distillate operation and a
temperature of 525 to 530C will correspond to a maximum gasoline operation. This temperature is
controlled by the regenerated catalyst slide valve position allowing more or less hot regenerated catalyst
to contact and mix with the incoming feed.
When the hot catalyst contacts the feed in the bottom of the riser the oil vaporizes almost instantaneously.
The homogeneous mixture of oil and catalyst reaches a temperature approximately 30 to 40C higher
than the top of the riser. The initial temperature shock causes thermal cracking, while catalytic cracking
begins after the oil is converted to vapor, and the molecules contact the active catalyst sites.
As the catalytic cracking progresses and the catalyst/oil mixture flows up the riser, the temperature drops
since the heat of cracking is endothermic. At the top of riser the moles of products are 3.5 - 5.0 times
more than the moles of fresh feed.
The riser temperature has a complex interrelation with the other parameters in cracking. An increase in
the riser temperature is generally accompanied by:
an increase in conversion,
an increase in dry gas yield,
an increase in LPG production,
an increase or a decrease (over cracking) in gasoline production depending on the reaction severity,
an increase in gasoline octane,

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a decrease in LCO and slurry yield,


a slight increase in coke production.

These are only trends. A quantitative definition of the changes requires heat and material balances as well
as yield correlations. The catalyst quality also affects the extent of the changes.
3.2.3 Disengager pressure
A lower pressure in the reaction zone thermodynamically improves product yields. However the choice
of the disengager pressure must take into account the equipment size and the minimum acceptable
pressure considering the wet gas compressor. A pressure of around 0.8 barg can be considered as an
optimum value for very heavy feedstocks.
3.2.4 Catalyst activity
In conventional gas oil cracking the catalyst activity is measured in two different ways, from actual
operation and in the laboratory.
In the current practice, an equilibrium catalyst sample is forwarded each week to the catalyst supplier
laboratory. There, a standard test (feedstock and operating conditions) is performed to check catalyst
activity. Other analyses such as surface area, density, pore volume, particle size distribution, metal
content, are as well reported. The catalyst activity, thus measured, relates to the conversion that the actual
operating unit may experience with a different feedstock. The correlation of the laboratory measurement
is somewhat loose on account of the difficulty in properly quantifying the differences not only in the
feedstock, but also the relationship of the method to unit operation. This leads more to a directional
relationship in the sense that higher activity catalyst in gas oil cracking leads to greater conversion.
In residue cracking the catalyst activity does not necessarily hold the directional relationship between
laboratory measurement and unit operation. The complexity of evaluation increases which necessitates
the use of other parameters for relating to conversion. The catalyst surface area and the concentration of
the deposited heavy an alkali metals provide a more meaningful basis to predict unit performance. This is
in addition to a detailed knowledge of the specific characteristics of the catalysts. While catalyst
properties and predicted product slate are originally derived at the catalyst development stage, the true
performance of the catalyst can only be ascertained from unit operations.
The catalyst activity is best measured by the unit operation. The conversion is calculated from unit yields,
which include gas and coke productions. Close monitoring of the yields, changes in metal deposition and
catalyst surface area are the best methods for maintaining the desirable level of activity. Catalyst activity
should be interpreted to mean not only the level of conversion, but also the ability of the catalyst to yield
the maximum amount of valuable products and high octane gasoline, while at the same time coke and dry
gas productions must be minimized.
Catalyst activity is maintained by the addition of fresh catalyst on a continuous basis. The required rate
of addition varies depending on feedstock quality, desired level of conversion, operating conditions, and
type of catalyst. Normally, addition at a rate of around 1 to 4 kg of catalyst per 1000 kg of feed are
necessary to maintain desired conversion. Frequent monitoring of the equilibrium catalyst properties and
level of metal contamination (i.e. Ni, V, Na, etc...) are required to provide optimum adjustment of the
addition rate.
3.2.5 Regenerators air balance
The reduction of the coke on the catalyst to less than 0.05 wt % requires a predetermined amount of air
regardless of how the air is distributed between the two regenerators. In a unit with one regenerator the
required air rate would be the sum of what the two regenerators require as long as coke yield and the
average flue gas composition are the same. Having two regenerators provides a flexibility of how to split
the total air required. When certain constraints, such as the maximum regenerator bed temperature and
desirable flue gas composition are imposed, the freedom to arbitrarily split the required air decreases.
However, there is a great advantage in assigning a specific air rate to each regenerator.

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The first stage regenerator design temperature is 770C, therefore the coke that should be burned must be
controlled so that this temperature limits is not exceeded. The combustion of carbon monoxide is more
rapid as the temperature increases over 650C. This results in lower carbon monoxide concentration and
greater air requirement as the regenerator bed temperature rises. When coke burns to form carbon
monoxide and steam the heat generated is about half as much as when the same amount of coke burns to
form carbon dioxide and steam. The higher temperature generated by greater carbon dioxide production
further facilitates the burning of carbon monoxide. If the air rate is limited, then the conversion of CO to
CO2 is controlled and the regenerator bed temperature is kept lower. But at the same time more coke
remains on the catalyst. The objective is to determine an air rate to the first stage regenerator that will
limit the bed temperature and yields carbon monoxide in the flue gas.
The objective in the second stage regenerator is to burn all the remaining coke completely to carbon
dioxide. The bed temperature is allowed to rise around 810C (mechanical design : 840C). The air rate
is adjusted to give 2 - 3 mole % of free oxygen in the flue gas which ensures that the carbon monoxide
concentration in the flue gas is less than 0.05 mole %.
The above split of the required air also has the advantage of minimizing catalyst deactivation. Most of the
hydrogen contained in the coke burns in the first stage regenerator. The steam thus generated is at a lower
temperature and causes less catalyst deactivation. Since only a small part of the total hydrogen contained
in the coke is burnt in the second stage regenerator, the steam concentration is reduced in the higher
temperature environment. The flue gas from each regenerator is routed separately which segregates the
flue gases according to their carbon monoxide concentration.
3.2.6 Regenerators temperature
a)
Dense phase temperatures
First stage
The first stage regenerator dense phase temperature is a function of the riser temperature, the amount of
coke burned, and the catalyst circulation rate. The temperature is controlled by varying the air flow to the
vessel. The air rate should be adjusted so as not to exceed a temperature of 730C.
Second stage
The second stage regenerator dense bed temperature is also a function of the amount of coke burned and
the catalyst circulation rate. The normal operating temperature is around 100C higher than the first stage
regenerator dense bed. Control of this temperature is not independent because the air rate to the second
stage regenerator is adjusted to achieve complete CO combustion (i.e. 2 - 3 % mole O2 in flue gas) under
normal operation.
In any case, it is important to keep a minimum temperature in the catalyst dense bed, which is required
for a proper combustion (around 680C).
b)
Dilute phase temperatures
The dilute phase temperature will normally run within 10C of its corresponding dense phase temperature.
The catalyst used, while not promoted, has properties which enhance combustion in the dense bed. These
properties, together with proper inventory of catalyst in the dense phase, ensure that all oxygen required
for combustion will be burnt away in the dense bed, removing the possibility of after burning.
3.2.7 Regenerators residence time
The catalyst residence time in the regenerators is a key parameter for the regeneration quality. The
catalyst levels in the two regenerators are optimized depending on the regeneration temperatures to
achieve the required inventories.
Typically, a total residence time around 6 minutes for the two regenerators is sufficient to achieve a
carbon on regenerated catalyst leaving the second regenerator of less than 0.05 wt %, which is considered
as a target value for a good regeneration.

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During normal operation, care must be taken to keep the catalyst levels at their normal levels. Low
catalyst levels will affect the regeneration quality, whereas high catalyst levels will affect the catalyst
entrainment to the cyclones and consequently will increase the catalyst losses.
3.2.8 Regenerators velocities
The quality of the combustion depends on the catalyst fluidization. A good mixing between catalyst and
air is required for the combustion and therefore turbulent flow is desired in the regenerators dense bed.
The corresponding superficial velocities are in the range of 1 - 1.3 m/s. A minimum velocity of 0.5 m/s
should be kept in any case (especially for reduced capacity operation).
3.2.9 Stripper operation
The removal of any light hydrocarbons which may remain with the catalyst after disengagement in the
reactor is accomplished by steam injection into the stripper dense bed via different steam rings. The
amount of steam is adjusted depending on the catalyst circulation rate and feed rate. The flowrate is
adjusted on the main steam ring, keeping the flowrates on the lower ring and upper ring constant.
Stripping efficiency is measured by the hydrogen content on coke. Stripping is considered as efficient
when the hydrogen on coke is around 6 wt %.
3.2.10 Heat balance
The reaction/regeneration section can be viewed as a closed heat exchange loop where catalyst is
recirculated between a heater (regenerator) and a cooler (riser). Hot catalyst is cooled in the riser through
vaporization and cracking of feed and is reheated in the regenerator by burning the coke produced during
the cracking reaction. The Riser Outlet Temperature controls the regenerated catalyst slide valve to
provide sufficient flow of hot catalyst to maintain the riser at the desired temperature.
Sensible heats represented by normal variations in riser and regenerator temperatures are very small when
compared to the heat of combustion of coke (heating medium), the heat of vaporization of feed and the
heat of cracking (cooling medium).
The unit is heat balanced in the sense that the heat for vaporizing and cracking the feed is furnished by
the combustion of the produced coke in the regenerator.
An overall energy balance shows that the energy released by the combustion of coke (carbon and
hydrogen) becomes:
the sensible and latent heat of the fluid gases,
the sensible and latent heat of the reactor effluent,
the heat of cracking.
Expressed another way, the coke yield in this adiabatic process is essentially that required to satisfy the
heat load.
The dependent operating variable will automatically achieve conditions where enough coke is made to
produce the required heat of combustion to heat and vaporize the feed, supply the heat of chemical
reaction, and cover the various heat losses from the process.
3.2.11 Feedstock quality
In catalytic cracking a hydrogen deficiency develops as the hydrocarbon molecule split and requires that
hydrogen joins a cracked molecule. The higher molecular weight hydrocarbons have lower concentration
of hydrogen than the lower molecular weight hydrocarbons. When the cracking process produces lighter
hydrocarbons than the feed, the hydrogen is made available from the hydrogen of hydrocarbons with
higher molecular weight.
The molecule that gives up hydrogen can become deficient in hydrogen to the point that it turns into coke.
Hence, it is easy to see that the yield of lighter hydrocarbons or the conversion depends on the total
amount of hydrogen contained in the feed. API gravity and distillation determine the hydrogen
availability to yield lighter products. Even when the distillation is not properly defined, the API gravity

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gives an indication of feed quality, since lower API gravity feedstock generally has a higher boiling
range and less hydrogen.
The metals, which are part of the FCC feed, adversely affect performance. Nickel, vanadium, copper and
iron carried by the feed will deposit on the catalyst sites and through a complex mechanism, lead to
catalyst deactivation. The process is gradual up to a certain metal level on the catalyst, but above about
10 000 ppm of metals, deactivation becomes more rapid. If the metal concentration of the feed cannot be
reduced to control this, then fresh catalyst addition replacing catalyst in the unit must be at a rate high
enough to keep the metal concentration on the catalyst at the required level.
Sodium and other alkali metals also act as catalyst poisons. Exceeding 1 ppm of sodium in the feed
should be avoided. Also sodium decreases catalyst melting point making it more sensible to high
temperatures.
The nitrogen and the sulphur in the feed adversely affect cracking, but are less harmful. Both the nitrogen
and the sulphur tie up hydrogen that could be used in the formation of valuable hydrocarbons. In addition
to this, the ammonia that is formed is basic, and has a neutralizing effect on the acidic catalyst sites.
The Conradson carbon in the feed was in the past believed to convert fully to coke. The coke on the
catalyst surface must be burned off in the regenerator, and more coke produces higher regenerator
temperatures. Hence, increasing Conradson carbon in the feed was expected to lead to inoperable
conditions. In the development of the R2R process, the temperature limitation was raised to be able to
handle higher coke burning rate. At the same time, it was noted that previous beliefs stating that 100% of
the Conradson carbon converts to coke were false. Only about 50% of the Conradson carbon converts to
coke, while the rest turns into gaseous products. As the Conradson carbon concentration increases, the
second stage regenerator temperature has a tendency to increase. Adjusting certain operating parameters
such as feed temperature, disengager pressure, atomization steam flow, stripping steam flow, may
compensate for this up to a point.
Note:
Do not put slops in the unit feedstock. Additives like copper, manganese, sodium, potassium,
organic chlorides, lead from gasoline... will at least increase gas production and could damage
catalyst. Nitrogen will also neutralize catalyst acid sites and will decrease conversion.
3.2.12 Feed temperature
The preheat temperature of the feed must be adjustable:
to ensure a proper oil viscosity (around 10 to 15 cSt maximum at the injector inlet) for proper
atomization of the feed ;
to ensure a minimum temperature to avoid steam condensation in the feed injectors.
The feed temperature must also be optimized depending on the heat balance. The feed temperature affects
significantly the coke production and the second regenerator temperature (refer to the next section
concerning the coke production).
Note that an increase of the feed temperature will result in:
a decrease of coke production,
an increase of the second regenerator temperature.
3.2.13 Coke yield / delta coke / catalyst to oil ratio
The catalyst to oil ratio (C/O) is defined as the rate of catalyst divided by the rate of fresh feed.
The delta coke is defined as the difference between the coke percentage on spent catalyst and the coke
percentage on the regenerated catalyst.
The coke yield corresponds to the percentage of feed transformed into coke.
These three parameters are correlated by the following equations:
Coke yield = C/O x Coke

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T reactor + coeff x Coke

These relations reflect the heat balance between the reaction section and regeneration section.
The three process variables will automatically achieve the conditions where the heat balance is satisfied.
For a given feed quality and catalyst type, the coke production depends upon nothing except riser
temperature and feed temperature.
The unit will be optimized with the highest possible C/O and the lowest possible delta coke for the
following reasons:
a higher C/O will provide :
- more active catalyst sites for the reaction,
- a better contact between catalyst and oil,
- a higher heat transfer efficiency.
This leads to higher conversion, i.e. larger total liquid, LPG, gasoline yields while slurry yield declines.
a lower delta coke will provide :
- lower regeneration temperature.
C/O is increased by :
raising the riser temperature,
decreasing the feed temperature.
But the adjustment of the feed and riser temperatures is limited :
the feed temperature cannot be lowered below a limit value in order to maintain an acceptable feed
viscosity for proper atomization and to maintain a minimum temperature for good vaporization,
the riser temperature is fixed by the operation mode (maxi gasoline or distillate mode).
IFP has developed the MTC concept which allows to disconnect the heat balance between the reaction
section and the regeneration section, providing supplementary flexibility for the unit operation.
If the operation mode requires do decrease the Riser Outlet Temperature, the injection of a "cold" fluid,
acting as a quench, helps keeping the feed mix temperature at a desired high value for seek of
vaporization and heat transfer.
3.2.14 Catalyst circulation / pressure balance
Catalyst circulation results from different vessels elevations and from differential pressure created by
various catalyst densities.
Fluidized catalyst behaves very similarly to normal liquid fluids.
Smooth catalyst circulation requires precise control of the unit pressure balance, through the precise
control of the pressure in the vessels and the proper control of the densities in the catalyst dense beds and
standpipes.
The pressure in the disengager is controlled by the main column overhead receiver. The pressure in the
disengager is higher than the receiver pressure by the amount of pressure drop through the main column,
the condenser and the lines between top of the disengager and the receiver. The pressure in the
disengager is normally kept as low as possible within the limits of the wet gas compressor.
The first stage regenerator pressure is controlled by a double disc slide valve followed by a variable
orifice and a differential pressure controller holds a constant differential pressure (around 0.7bar)
between the first and the second regenerator. The differential pressure between the two regenerators
should be maintained constant for a smooth operation of the air lift.
Pressure of the first regenerator must be controlled so that the differential pressures on the regenerated
and spent catalyst slide valves are balanced satisfactorily, i.e. to obtain similar pressure drops through the
two slide valves. The minimum required pressure drop through the slide valves for steady control of the
valve is around 0.3bar. Maximum pressure drop should be limited to 0.7bar for avoiding erosion
problems.

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It is obviously essential for steady circulation that the pressure difference between the vessels be as
consistent as possible. Toward this end, it should be noted that the stripper and first stage regenerator
levels are kept steady. The second stage regenerator is allowed to float between its minimum and
maximum levels.
Catalyst circulation is controlled by the opening of the regenerated catalyst slide valve. The circulation
rate cannot be measured directly; it must be calculated from the heat balance or estimated from the
openings and pressure drops of the regenerated and spent catalyst slide valves.

3.3 Process Operation variables


3.3.1

Introduction

The performance of the RFCC unit is determined by the relationship between the feedstock, the process
variables, the catalyst, process design and unit control. Proper control of the FCCU requires careful
balancing of the many process variables. The unit can then be optimized within certain limitations to
provide the best possible performance. These restrictions include available feedstock, mechanical and
operational equipment limitations, and environmental constraints.
The following instructions are general and intended as a guide. The operating costs and product values
for a given yield distribution will be the major factors in any optimization effort. The process variables
are interrelated, so many of the effects may not be immediately obvious. The effects of key process
variables will be reviewed. Examples will be given illustrating the role of adjusting these variables to
achieve a particular process objective.
3.3.2

RFCC reaction variables

Process variables can be classified in two categories:


Independent variables,
Dependent variables.
Table 1 lists some of the key independent variables in the FCC process. Of these, the most critical are
the feed temperature, the Riser Outlet Temperature, the catalyst activity, the contact time, and the feed
quality. The dependent variables are presented in Table 2 and include the conversion (and yields
selectivities), the regenerator temperature and the catalyst to oil ratio.

TABLE 1
INDEPENDENT FCC VARIABLES

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Riser Outlet Temperature


Feed temperature
Feed rate
Catalyst activity
Feed quality
Contact time
Recycle rate
Catalyst circulation rate
Air rate

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TABLE 2
DEPENDENT FCC VARIABLES

Regenerator temperature
Conversion
Carbon on catalyst (spent and regenerated)
Catalyst to oil ratio
CO2 to CO ratio
Reaction and regeneration are interdependent through the overall heat balance.
Independent variables that affect the heat balance can be classified depending on whether they affect the
coke production or the delta coke on catalyst.
Independent variables that influence the heat balance

EFFECT ON COKE YIELD

EFFECT ON DELTA COKE

Feed flowrate
Feed temperature
Catalyst cooling
Air temperature/humidity

Feed properties
Reactor pressure
Catalyst activity
Catalyst selectivity

EFFECT ON COKE YIELD AND DELTA COKE


Recycle flowrate
Riser Outlet Temperature
Steam rates (atomization, stripping)
The coke yield and delta coke are examples of dependent variables that can only be changed indirectly,
i.e. by manipulation of independent variables.
3.3.3

Feed temperature effects

Table 3 summarizes the effects of increasing the feed preheat temperature at a constant Riser Outlet
Temperature. If the feed temperature is increased, and no change is made to the catalyst circulation rate,
the riser temperature would rise along with the feed temperature. This is because the catalyst is
supplying the heat needed to heat the feed from the feed preheat temperature to the riser temperature. So
if the feed temperature is increased, the catalyst circulation rate will have to decrease to prevent the riser
temperature from getting too high. Since the riser temperature is automatically set and is controlled by
the action of the regenerated catalyst slide valve, the slide valve should close slightly as the feed
temperature is increased.
This reduction in catalyst circulation rate (Cat/Oil) causes a number of other changes to occur. First,
conversion is usually reduced, while delta coke tends to increase, because the feed coke is spread over
less catalyst particles. As delta coke increases, the regenerator temperature tends to increase, making it
easier to burn the coke off the catalyst. As a result, the concentration of coke on the regenerated catalyst
tends to decrease, while the concentration of coke on the spent catalyst will increase slightly. It is
important to remember the equation:
Coke Yield = (Cat/Oil) * Delta Coke
As the feed temperature increases, delta coke increases slightly, but (Cat/Oil) is significantly reduced, so
that the coke yield drops significantly as the feed temperature is increased. Probably the most important

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effect of increasing feed temperature is that it reduces the coke yield. Conversely, lowering the feed
temperature increases the coke yield. Thus, the required air rate drops as the feed temperature is
increased. For a given air rate, more barrels of feed can be processed as the feed temperature is increased.
Following are reasons why feed temperature might be increased:
1. If more feed needs to be processed at a constant air rate.
2. If regenerator temperature needs to be increased.
3. If more feed needs to be processed at a constant catalyst circulation rate.
4. If regenerator gas velocities need to be decreased to reduce catalyst losses from the regenerator.
5. If catalyst circulation rate or air rate need to be reduced at a constant feed rate.
6. If conversion needs to be lowered.
Following are reasons why feed temperature might be reduced:
1. If conversion needs to be increased.
2. If dry gas or wet gas rates need to be reduced.
3. If regenerator temperature needs to be lowered.
4. If catalyst circulation rate needs to be increased

TABLE 3
EFFECTS OF FEED PREHEAT
Action: Increased feed temperature at constant
Riser Outlet Temperature
Reactions:

3.3.4

Catalyst circulation must decrease

Regenerator temperature increases

Carbon on regenerated catalyst decreases

Coke yield decreases

Conversion and octane usually decrease

Riser / Outlet Temperature effects

Table 4 summarizes the effects of increasing Riser Outlet Temperature at constant feed temperature.
The automatic controls on the regenerated catalyst slide valve is set to control the disengager temperature.
Usually, the disengager temperature is a few degrees lower than the Riser Outlet Temperature due to heat
loss and the continuation of endothermic cracking reactions.
In most cases, the Riser Outlet Temperature is changed by changing the catalyst circulation rate. If a
ROT increase is called for, the regenerated catalyst slide valve is opened slightly to allow more hot
catalyst to mix with the feed.

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The FCC conversion will increase for two reasons, the higher temperature and the higher catalyst-to-oil
ratio. The coke yields must increase to generate the extra heat required to heat the oil to the higher
reactor temperature. The delta coke declines slightly because the coke is spread over more catalyst
particles.
The regenerator temperature increases, but by less than the reactor temperature is increased. The carbon
on the regenerated catalyst declines because the coke is easier to burn as the regenerator temperature rises.
However, since the coke yield increases, more air is required to burn the coke.
The gasoline octanes will increase, as will the fuel gas and wet gas rates. Gasoline yields will increase
until the overcracking point, which usually occurs at ROT between about 525C and 535C. Above the
overcracking point, the gasoline yields will decline as ROT is increased, while LPG and dry gas (fuel
gas) yields will increase rapidly.
In summary, Riser Outlet Temperature is the fastest and simplest method of changing conversion in the
FCCU. Raising reaction temperature is appropriate when conversion and/or gasoline octanes must be
increased and:

Wet gas and dry gas rates are not at their maximum.

Catalyst circulation rate can be increased.

Slide valve pressure differentials are above minimum.

Air rate can be increased.

Regenerator temperatures are not at maximum limits.

Other methods of increasing conversion (such as increasing catalyst activity) may be more appropriate if:

Gas compressor capacity is at a maximum.

Catalyst circulation rate is limited.

Air blower capacity is limited.

Feed rate must be increased.

The choice of the Riser Outlet Temperature will depend on many factors, and optimizing the reaction
temperature is often a difficult and complicated procedure that requires a computer model to simulate
many variable effects. The above guidelines, however, can be used to at least indicate the proper
direction in which the reaction temperature should be moved.

TABLE 4
EFFECTS OF RISER OUTLET
TEMPERATURE
Action: Increase Riser Outlet Temperature at
constant feed temperature
Reactions:

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Catalyst circulation increases

Conversion increases

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TABLE 4
EFFECTS OF RISER OUTLET
TEMPERATURE

3.3.5

Coke yield increases

Delta coke declines

Regenerator temperature increases

Carbon on
decreases

Required air rate increases

Octane increases

Fuel gas increases

LPG yields increase, iso/olefin decreases

Gasoline yields increase

regenerated

catalyst

usually

Effects of contact time

Table 5 summarize the effects of contact time. Contact time is defined as the amount of time that the
catalyst and the oil vapor are together in the riser. This depends on the feed rate, the steam rate and both
the length and the diameter of the riser. Contact time can be changed by:
1. Changing the feed rate.
2. Changing the dispersion steam rate.
3. Changing the length and/or the diameter of the risers (in case of revamp).
4. Changing the location of the feed injectors (in case of revamp).
5. Changing the riser/disengager pressure.
The first four methods of changing contact time are obvious. Disengager pressure affects contact time
because it affects the volume that is occupied by a given amount of vapor.
Increasing the pressure by 0.1 bar will reduce the vapor volume (and will increase the contact time by
approximately 4.0%).
Reducing contact time will lower conversion because the oil molecules simply have less time to react.
The major benefit of reducing contact time, however, is that the tendency to make coke, or the delta coke,
is substantially reduced. As a result, the regenerator temperature drops significantly and the amount of
catalyst required to heat the oil increases. Conversion becomes more selective to gasoline, with less
production of dry gas and coke.
Because refiners do not generally like to see conversion decreases, when contact time is reduced, some
other adjustment is usually made to recover any conversion that may be lost. The adjustment may be an
increase in Riser Outlet Temperature or an increase in catalyst activity, depending on the other unit
limitations.

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
Rev.
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Chapter : 3
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An important point is that the volume of vapor changes as conversion takes place. The volume of
vaporized products is about 3.5 to 5 times as great as the volume of vaporized feed. As molecules crack,
the volume is proportional to the number of moles. As the volume increases, the velocity of flow up the
riser also increases. This is why the velocity at the end of the riser is about 20 m/second.
For reasons of simplicity, contact time may be calculated based on the volume of vaporized products.
In summary, shortening contact time will improve product selectivity by reducing the time available for
undesirable coking and thermal reactions. The result is lower delta coke, a lower regenerator temperature
and a higher catalyst circulation rate, with less production of dry gas. These benefits are offset somewhat
by a lower conversion, which must be regained by other means, such as higher catalyst activity or higher
Riser Outlet Temperature.

TABLE 5
EFFECTS OF CONTACT TIME
Action: Decrease time by shortening riser
Reactions:

3.3.6

Conversion decreases

Fuel gas and LPG decrease slightly

Iso/olefin ratio decreases

Regenerator temperature drops

Cat/oil increases

Coke yield decreases slightly

Octane increases slightly

Effects of catalyst activity

Table 6 summarizes the effects of FCC catalyst activity. The activity of the FCCU equilibrium catalyst is
measured by the catalyst manufacturers in a laboratory microactivity (MAT) test. The test indicates how
active the catalyst is for cracking a standard feed at standard conditions. Changes in the MAT activity
will reliably predict the activity of the catalyst in the refinery FCCU.
The equilibrium catalyst activity is controlled by how much fresh catalyst is added to the unit each day.
As the fresh catalyst addition rate is increased, the equilibrium catalyst activity will rise.
Changes in the equilibrium catalyst activity usually do not happen quickly. It may take several days to
see noticeable changes in activity after a change in catalyst addition rate is made. If, however, a unit
upset occurs and the regenerator temperature or steam concentration increases significantly, for even one
or two hours, the activity of the entire catalyst inventory can be reduced very rapidly.
Most importantly, as catalyst activity increases, conversion rises by about 0.5 to 0.7 vol. % on fresh feed
for each 1 number increase in MAT activity. The conversion increases by less than the activity because
the delta coke increases as the catalyst gets more active. This causes the regenerator temperature to
increase, which, in turn, causes the Cat/oil to be reduced, offsetting some of the conversion gain.

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
Rev.
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Increasing catalyst activity also increases the yields of coke, wet gas and dry gas, but these yields
increase by smaller amounts than they would if the same conversion increases were achieved by
increasing riser temperature. Gasoline octanes are not greatly affected by catalyst activity.

TABLE 6
EFFECTS OF CATALYST ACTIVITY
Action:

Raise catalyst make up rate

Reactions:
Equilibrium MAT activity increases
Delta coke increases
Regenerator temperature increases
Cat/Oil decreases

Conversion increases by less than MAT activity


increase
3.3.7

Effects of recycle rate

Many different streams can be recycled to the FCCU, for a variety of reasons. The most common recycle
streams are HCO and slurry oil, because these streams have the lowest value and the refiner has the most
incentive to convert these streams to more useful products.
The problem with recycle, however, is that a barrel of recycle uses close to the same amount of air as a
barrel of fresh feed, and slurry recycle makes more coke and gas than fresh feed. Often, the refiner has to
decide between running more barrels of fresh feed or adding recycle. Usually, the economics favor
adding more fresh feed. For this reason, many units do not recycle any material.
For most units, as slurry recycle rate increases, conversion will increase slightly. The effective
conversion on the slurry oil will be between 20 and 40 vol.%, depending on the recycle quality. This
compares with conversions of 60 to 80 vol.% on fresh feed.
Since slurry oil is very aromatic, it tends to make higher delta coke than fresh feed and is very difficult to
convert. The high delta coke causes the regenerator temperature to increase and the catalyst-to-oil ratio
(based on fresh feed) to decline. The slurry oil also tends to make high yields of C1 and C2, increasing
both the dry and wet gas rates.
3.3.8

Effects of fresh feed quality

Table 7 shows the most important FCC feed characteristics. The quality of the FCC feed is probably the
single most important factor in determining the yields that can be obtained from the FCCU. The
structure of the feed molecules is critical not only in defining the reactions that can take place, but also in
determining the quality of the FCC products. The following paragraphs discuss the key effects of the key
feed properties.

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
Rev.
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TABLE 7
FEEDSTOCK QUALITY
THE MOST SIGNIFICANT VARIABLE
Important feed characteristics:

API gravity

Hydrocarbon type (Aniline PT, K Factor)

Boiling range

Sulfur, nitrogen

Metals

Carbon residue

API gravity, hydrocarbon type and boiling range


These properties are discussed as a group, because they are inter-related. For a given boiling range feed
(for example, 320C to 540C), the API gravity will increase as the feed becomes more paraffinic, and
will decrease as the feed becomes more aromatic. Also, for a constant feed composition, the API will
increase as the feed becomes lighter (lower boiling points) and will decrease as the feed gets heavier.
Two key properties indicate how aromatic the feed will be. High values of the K Factor and the Aniline
Point indicate high paraffin concentrations, with lower levels of aromatics. Low K Factors and Aniline
Points indicate high levels of aromatics. Feeds with K Factors above 12.0 and Aniline Points above 90C
are considered very paraffinic. Feeds with K Factors below 11.7 and Aniline Points below 77C are
considered very aromatic.
The more aromatic feeds give lower conversions and lower yields of gasoline, C3 and C4, with higher
yields of LCO, slurry oil, coke and dry gas. Gasoline octanes generally increase as the feed becomes
more aromatic.
Feed sulfur and nitrogen contents
The sulfur content of the feed has only minor effects on the conversion and other FCC yields, except that
as sulfur increases, the yield of H2S will increase. In addition, the SOx emissions from the regenerator
will rise, as will the levels of sulfur in all of the liquid products. This may significantly affect the ability
of the refiner to make environmentally acceptable products. This is one reason that the refiner may
consider feed hydrotreating, since it will remove up to 99% of the FCC feed sulfur.
Nitrogen can significantly reduce FCC conversion. Usually, nitrogen levels are highest in aromatic feeds.
These feeds tend to make high octane gasoline, which is high in olefins (as indicated by a high bromine
number). High activity catalysts are usually needed to overcome the effects of the high feed nitrogen.
3.3.9

Metals and Carbon residue effects

The major problems for the RFCC unit are the nickel, vanadium and Conradson Carbon Residue. The
nickel and vanadium will deposit on the catalyst and will cause undesirable dehydrogenation and coking
reactions. In addition, the vanadium will react with the zeolite, destroying the crystal structure and

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OPERATING MANUAL
UNIT RFCC (015)

February 2007
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causing a large activity loss. Of course, these effects increase as the levels on nickel and vanadium on
the catalyst rise.
The carbon residue consists of large molecules that are impossible to vaporize at FCC conditions. A high
percentage of this material (roughly 80%) just lays on the surface of the catalyst and degrades to coke,
blocking the active sites. This adds to delta coke, causing a rise in the regenerator temperature and a drop
in the catalyst to oil ratio.
The first thing an operator will observe to the FCCU is the rise in regenerator temperature due to the
increase in delta coke. Then, if attempts are made to cool the regenerator by removing heat (for example,
by lowering the feed temperature), more air will be required, as the coke yields rises.
As more the metals levels on the catalyst increase, catalyst activity will decline, dry gas yields will
increase, and conversion will drop.

3.4 Uninterruptible Power Supply (UPS)


LATER.

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DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
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CHEMICAL, CATALYST AND UTILITY

4.1 Specifications of catalysts


4.1.1 Catalyst inventory and addition rate
Catalyst inventory: 675 tons
Fresh catalyst addition rate:
Feed
Mixed
Addition rate
ton/day (*)
15.2
(*): dry basis.

Bach Ho
5.5

4.1.2 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
Maxi Gasoline
Ni content (ppm)
V content (ppm)
Equilibrium catalyst
MAT activity (wt %)
Delta coke (wt %)

68

Mixed
Maxi Distillate
3213
6748
55

1.22

0.99

Bach Ho
Maxi Gasoline

75
0.94

Bach Ho
Maxi Distillate
1776
60
0.91

Two catalyst lines fit appropriately with the operation objectives:


AKZO NOBEL COBRA RMR or CENTURION
or
GRACE Davison Z14USY associated with LCM matrix.
The final guarantee catalyst will be selected by IFP after evaluation of the best candidates proposed by
Vendors.
4.2 Antimony (Nickel passivator)

Used in:

RFCC Feed Section

Type :
Antimony content:
Injection rate:

NALCO EC9192A or equivalent


23%
ratio Sb/Ni in feed: 0.5

Normal consumption:

109 kg/day

Mixed Case

0 kg/day Bach Ho Case


Maximum consumption:

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15 kg/h

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
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4.3 Corrosion inhibitor


Used in:

Fractionator overhead

Type:
Normal consumption:

CHIMEC 1430
60 kg/day

Maximum consumption:

120 kg/day

4.4 Amine antifoaming agent


Used in:

Gas recovery Section in LPG/Fuel gas amine absorber

Type:
Normal consumption:
Maximum consumption:

CHIMEC 8045
10 kg/day (1)
20 kg/day

(1) Antifoaming agent is injected batch wise in either the following tower 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. During amine absorber operation, lean amine temperature
should be always 10 deg C higher than feed gas to avoid condensation of hydrocarbon inside of the fuel
gas absorber
-

T-1555 Fuel Gas Absorber

T-1556 LPG Amine Absorber.

4.5 Amine (outside battery limit)


Type DEA:

20% wt di-ethanolamine

H2S content:

0.022 mole/mole DEA

Lean Amine Flowrate

kg/hr :

Rich Amine Flowrate

kg/hr :

50382
77623
50926
78145

Bach Ho
Mixed Crude
Bach Ho
Mixed Crude

4.6 Phosphate for Steam Generation


The following phosphate will be used for steam generation:
RFCC HPS and MPS Generation
7.0 kg/day
RFCC Waste Heat Boiler
24.0 kg/day
Total
31.0 kg/day
Note:

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DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
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(1) Phosphate injection rate is depended 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.
(2) For LPS steam generation, it is not required to operate blow down operation, and thus phosphate
injection is also not required.

4.7 Estimated utilities


Refer to the attached utility summary:
Spec No.
8474L-015-CN-0003-511

Estimated Utility Consumption Bach Ho MG Normal

8474L-015-CN-0003-512

Estimated Utility Consumption Bach Ho MD Normal

8474L-015-CN-0003-513

Estimated Utility Consumption Mixed Crude MG Normal

8474L-015-CN-0003-514

Estimated Utility Consumption Mixed Crude MD Normal

8474L-015-CN-0003-521

Estimated Utility Consumption Bach Ho MG Design

8474L-015-CN-0003-522

Estimated Utility Consumption Bach Ho MD Design

8474L-015-CN-0003-523

Estimated Utility Consumption Mixed Crude MG Design

8474L-015-CN-0003-524

Estimated Utility Consumption Mixed Crude MD Design

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Description

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
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Chapter : 5
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PREPARATION FOR INITIAL START-UP

5.1 Chronology of operations


A typical bar chart sequence of events for the first start-up is attached. No time scale has been given
since the completion of these tasks depends on site manpower, local facilities and contractual provisions
between the Unit Owner and its Contractors.
The following section will discuss the various aspects associated with the pre-commissioning of the
facilities in the refinery. The pre-commissioning operations ensure that the unit is safe, operable, and
constructed as specified.
Each start-up preparation operations shall be performed in unit by unit. In addition to the procedures, the
operator of one area (or unit) shall coordinate with the operator of the other area (or unit) to perform the
pre-commissioning operation.
A systematic program of start-up preparations must be drawn up and carried out to ensure that the startup operation proceeds properly. This is particularly important when the unit has to be brought on-stream
together with other units within a limited time.
As the construction of the unit nears completion, a large amount of work must begin in order to prepare it
for start-up. These pre-commissioning activities have three main purposes:

To ensure, by thorough inspection and testing, that the unit is safe, operable, and constructed as
specified;
To operate equipment for by flushing, running in, etc., and
To acquaint the operators with the unit.

The importance of these activities cannot be overemphasized. No matter how well a unit is designed, if
the equipment is not as specified, not properly brought on stream, or not understood by operators, it will
not perform as expected.
The following activities are major Pre-commissioning activities. However, an exact order of presentation
need not be strictly obeyed. Depending on the progress of construction, certain procedures may be
required earlier or later that suggested here. A through knowledge of the entire pre-commissioning
operation will allow the plant personnel to schedule activities in the most time-saving and labour efficient
way. These are the necessary pre-commissioning activities:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Vessel and other Major Equipment Inspection


Line Cleaning
Servicing and Calibration of Instruments
Run-in of Rotary machineries
Chemical Cleaning
Refractory Drying
System Drying
Loading of Chemicals, Catalysts, and Other Materials
Operational Tightness Test
Air Freeing
Commissioning of Additional Plant Services

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DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
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5.2 Equipment and unit inspection


5.2.1

Equipment inspection

The pieces of equipment to be inspected are the following ones:

Vessels with internals and refractory materials: riser, disengager, stripper, regenerators,
withdrawal well, cyclones, catalyst standpipe.

Catalyst hoppers,

Injectors,

Slide valves and plug valve,

Expansion joints.

Equipment is inspected for compliance with Licensor (Axens) specifications and drawings, of the Process
book.
A typical, but not exhaustive list of items to be checked is given below. The list needs to be adapted
according to the specific requirements of the unit as expressed in section 2 of the process book.
Vessels

All refractory material should be inspected for proper installation and proper type.

All cyclones and specifically the cyclones diplegs must be inspected to ensure they are free
from foreign material. Trickle valves should be inspected for freedom of movement and
proper seating.

Air rings and steam rings should be inspected, for proper nozzles size and orientation. All
nozzles should be free of refractory or pluggage by debris.
Note:

Once the rings are installed and unit construction is finished. Each air and steam ring
must be protected from falling debris. Either completely wrap the ring in a protecting
material on place removable plugs into each upward directed nozzle.

If installed, all baffles should be inspected for proper installation.

Supports of the air and steam rings should be inspected for proper movement. Wells around
air rings supports should be fitted with kaowool or equivalent material to minimize binding
that could occur from catalyst packing.

Internal guides on the riser and air lift must be inspected for proper movement.

All distributors (spent catalyst inlet in first regenerator, lift outlet, riser outlet) must be
inspected for proper construction and protection against erosion.

All instrumentation, fluidization and aeration taps must be checked for proper orientation and
penetration. The nozzles should be free of refractory or other material.

Torch oil nozzles should be inspected for proper orientation and penetration.

Thermowells should be checked for proper location and length.

Catalyst hopper vessels must be inspected, and free of foreign material.

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DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
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Injectors
Feed, MTC, steam, back flush oil injectors should be inspected for proper orientation and penetration.
The annulus around the injectors must be packed with kaowool or equivalent.
Note:

The injector Vendor installation procedure must be used, for proper orientation and penetration
of the injector using the installation tool (see Vendor inspection book) and for field welding of
the flanges on the injectors.

Slide valves/plug valve


Slide valves and the plug valve should be inspected for proper calibration movement and operation. The
valve should be operable from the primary control instrument on both manual and automatic control,
from the field mounted controller and from the hand wheel if so equipped. The valve should be tested for
proper operation upon loss of signal (typically fail lock). If the valve is equipped with low differential
pressure override control, this function should be verified to be operational. The action of the valve upon
emergency trip conditions should be tested.
If the flue gas slide valves are equipped with limit stops these should be verified for proper installation.
While observing the position of the disks or plug, all slide valves should be calibrated. External etching
can be used to mark critical valve positions. The readings for valve travel should be kept for future
reference. The plug valve should be calibrated while it is cold and again when the unit is hot during
refractory curing (or unit heat-up) due to the thermal growth of the lift line. The closed position for the
plug valve will be different between hot and cold condition. These should be marked on the valve and
recorded for future reference.
Expansion joints
Expansion joints should to be inspected for proper installation and freedom of movement. Any shipping
supports/stays should be removed and limit rods should be properly adjusted. Depending upon specific
application, the expansion joint may require areas to be packed with Kaowool or equivalent.
Direct Fired Air Preheater

Check that targets, air dampers, and lining are sound


Check the bottom of the heater for trash.
Dismantle, clean, and air-blow all burners.
Check the relative orientation of the ignitor, pilot burner, and main burner per installation
drawings.
Check the freedom of movement of air dampers, and repack glands, if necessary.
Remove and clean the sight glasses.
Check that the spark plug is dry and that a good spark is obtained.

Reactor Regenerator Structure

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Check that all the catalyst lines and expansion joints are free to move in all directions. Be
sure shipping stops are removed from the expansion joints.
Check that the platforms and other structures will not interfere with the free expansion of
the equipment in any direction.
Check that instrument piping, electrical conduit, hydraulic piping, and other equipment is
in no danger of binding.

8474L-015-ML-001-A
07
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DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
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Chapter : 5
Page
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5.2.2 Unit inspection


It shall take place prior to the mechanical completion of the unit.
A. PID's check
This check is primarily for piping, instrument and fittings. Location of instruments, valves, fittings
(including drip rings, special shut off valves, tie-ins, etc.).
A check is made against the latest revision of the P&ID to ensure plant completion and the correct installation
of all items of equipment.
Particular attention should be paid to the following:
a)
b)

The correct routing of pipework.


The installation of all valves with special attention paid to the direction of flow for control
valves (Note), globe and non-return valves.
c)
All instrumentation is installed. (Note)
d)
Safety valves are correctly installed.
(Note)
e)
Pump cooling water, lube and seal systems are complete and correctly installed.
f)
Vendor's packages should be thoroughly checked against P&ID and where possible, items of
equipment run in the presence of the Vendor's representative.
g)
The installation of fire fighting equipment and personnel safety showers.
Note: Safety valves and instrumentation such as orifice plate, control valves, etc. are installed after
line flushing is completed.
B.

Operability check

This consists of an assessment of the practicability of carrying out all the operations required for
commissioning, start-up and shutdown. It focuses mainly on access to instruments and valves (including
vents, drains), to manholes, to spectacle blinds and to parts of equipment that need to be dismantled.
The presence of the required start-up and pressurization lines is checked as well as the impact of safety
switches on start-up operations.
Ensure that all valves using for start-up, shut-down, emergency are easily accessible.
C. Instrument check

a) Prior to unit start-up all instruments (flow, level, pressure, temperature) must have been
checked with regard to:

Proper tagging,

Proper location in the process,

Correctness of assembly,

Operating range consistent with the operating conditions prevailing at the location,

Calibration,

Flow orifice coefficients must be checked and recorded,

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UNIT RFCC (015)

b)

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Level instruments will be calibrated using the most likely liquid density, and proper
installation of Dp taps for catalyst level.

Differential pressure instrument, check Dp cells for proper installation and connections.
Alarm checking

Make sure that the release mechanism on the unit actuates the corresponding light or audible alarm in the
control room.
c) Control Valves
The control valves are removed during washing operations. They will be checked for cleanness of the
seats and free movement of the plug or ball.
Check the valves motion and their response to the controller signal.
When all the single instruments have been individually checked, when all their addresses have been
verified in the DCS, then the loop checking can take place for each loop or group of control loops.
Each TRIP either linked to the process or to equipment, shall also be individually tested.
Hydraulic system for assisted valves (slide, valves, plug valve, assisted check valves) must be carefully
checked and tested.
d) Safety devices check
The process includes quite a few specific control sequences called (UC) multiple variable control,
Interlocks (I) and emergency shutdown systems (ES).
The tests of these devices must be witnessed by the Licensor (Axens) representative and remedial
works be carried out until the operation is fully satisfactory.
These devices are designed either to protect the catalyst against misoperation (too high temperature) or to
protect equipment (compressor against liquid carry over) or to fulfil certain actions related to the
operation of the catalyst regeneration or catalyst circulation.
The interlocks are independent hardwired systems which in the case of occurrence of (a) defined
potentially harmful event(s) initialize various actions (valve closure, power cut off, etc...) to alleviate the
risk. An interlock operates through a solenoid valve and the solenoid valve must be reset either locally or
in the control room in accordance with the PID.
The control sequences are a short series of simple actions in sequence which are programmed into the
DCS and are designed to ensure a trouble free, automatic and safe operation of the catalyst circulation
and regeneration.
The emergency shutdown systems are called logics, separated from the DCS, perform automatic
emergency shutdown actions upon the occurrence of potentially harmful situations.
The principles of these checks are as follows: a simulated default signal from the primary sensor will be
fed into the system and the resulting signal output to valves or equipment will be checked. Whenever
possible, the end result of the signal output (i. e., actual valve closure or machine shutdown) will be
observed. Ultimately real tests require equipment to be operating and shall be continued during unit dry
out or catalyst circulation.
Throughout this exercise, the actual physical position of the valves (or status of machines) will be
checked against the indications shown in the control room.
The check of the motorized valves is part of the same task. It includes:
A site test of the opening/closing of the valve upon the input signal.
A control room check of the reported indication and a check of the satisfactory actuation from
the control room.

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OPERATING MANUAL
UNIT RFCC (015)

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UNIT RFCC (015)

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5.2.3 Line Flushing Outline


All piping should be thoroughly cleaned of debris and scale.
Generally, liquid handling lines are flushed with water and thoroughly drained. Where practical, it is
suggested that clean water be used for flushing vessels. Care must be taken not to flush debris into equipment.
Water flushed lines which do not drain freely should be blown clear with air. Gas handling lines may be
water flushed or air blown. Water should be drained from the gas lines upon completion of flushing.
The restriction orifice plates must not be installed prior to cleaning of lines.
Steam and air utility piping may be cleaned by blowing with their normal media. Instrument air lines should
be thoroughly blown with clean dry air. Utility water lines may be flushed with normal media.
Upon completion of line flushing of any system, carefully check that all temporary breaks are reconnected,
control valves reinstalled, and pump alignments are normal. Thorough cleaning prior to pump run-in
minimizes screen cleaning requirements.
The following is a guide for flushing:
(1) Orifice plates must not be installed prior to flushing.
(2) Prior to flushing, control valves and in-line instruments should be removed.
(3) Instrument lines should be closed off or disconnected prior to flushing.
(4) Remove burners prior to flushing burner fuel lines.
(5) Flush pump suction and discharge piping while disconnected. Do not introduce any fluid into
pump casing before cleaning the pump suctions.
(6) Supply steam lines to ejectors should be disconnected while being cleaned.
(7) Flush through open end lines. Do not restrict flow in principle.
(8) Flush through all drains and vents.
(9) Where possible, flush downward or horizontally.
(10)Flush or blow the main header from source-to-end, each lateral header from the main-to-end, and
each branch line from the lateral header-to-end.
(11)Always flush through bypasses, where provided, to an open end before flushing through
equipment.
(12)For steam systems, blow out well through dirt leg drains and steam trap bypasses before placing
the traps in service.
(13)After placing the steam traps in service, check whether the traps operate properly.
(14)After flushing operation, check that all orifice plates are installed and positioned correctly as per
list.
(15)When necessary vessels or drums are used as water reservoirs for flushing, check vessels for
water-filled design. Moreover, a water-filled system must not be drained without adequate
venting to avoid a vacuum condition and probable collapse of equipment not designed for a
vacuum.
(16)Isolation valves of the Water coalescer, Slurry Separator must be closed to avoid sludge entering
to internal.

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OPERATING MANUAL
UNIT RFCC (015)

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5.2.4 Rotating Equipment Run-in


Proper installation and operation are required for all rotary machines especially. Pumps and drivers should
receive careful handling during initial run-in. The initial run-in of pumps is generally executed by circulating
water through the related equipment. Temporary fine mesh strainers are installed in the suctions of pumps.
When pumping water with centrifugal pumps intended for hydrocarbon service, the suction valve must be
wide open and the discharge throttled properly to avoid overloading the motor.
During run-in of pumps, operators must be careful to avoid any cavitation which may occur due to large
amounts of debris in the strainer, excessive internal slippage generating excessive heat, and/or loss of suction
pressure, etc.
Also, the bearing must be checked frequently for signs of overheating and vibration.
The following is a check list for pumps:
(1) Check that overall installation is complete.
(2) Verify that pumps and drivers have been aligned for cold operation. There must be no undue
strain imposed on pumps or drivers by the piping.
(3) Check cooling water piping. Verify that water piping is connected, where required, to bearing
jackets, pedestals, stuffing boxes, etc.
(4) Check steam piping. Verify that steam piping, where required, is complete. In addition to steam
for drivers, in some hot services steam may be used for cooling shaft seal oil.
(5) Check seal or gland oil piping. Conventional packed pumps in hot service are generally
furnished with gland oil - verify that this installation is correct and complete.
When a pump is furnished with mechanical seals, verify that all of the components of the orifices and coolers,
when required, have been correctly installed and are clean.
(6) Verify that packing or seals are installed.
(7) Check that temporary fine mesh strainers in suction piping, where required, have been installed.
(8) Verify that bearing and shafts have been cleaned prior to final lubrication.
(9) Check that pumps and drivers are lubricated according to the lubrication instructions.
(10)Check rotation of electric motor drivers uncoupled from the pump. Run-in uncoupled, verifying
operability.
(11)Run-in, uncoupled from pump, drivers other than electric motors. During run-in of driver, check
over-speed trip, bearings, controls, vibration, etc., to confirm operability. Abnormal conditions
must be corrected before coupling to the pump.
(12)After coupling driver and pump, check necessary items as mentioned above.
(13)Ensure good level of pump suction. Fully open valves installed on pump suction, and vent out
from high point vent and/or pump casing vent. Start pump, suitably throttle delivery valves, and
make sure of circulation route.
(14)As for the spare pumps, the run-in test should be completed in the same manner as described
above, and they should be ready for use.
(15)Pumps normally handle a material of lighter density than the water circulated during initial run-in.
The pump driver is sized for the normal pumping fluid. Consequently, when pumping water, the
electric motors are easily overloaded.

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UNIT RFCC (015)

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To avoid overloading the motor driving a centrifugal pump, the flow must be limited by throttling the pump
discharge valve.
5.3 Preliminary operations
5.3.1 Definitions
The following definitions are used throughout this chapter:
Precommissioning is the period when conformity, non-operating checks and verifications

that the installation conforms to plans, specifications, and drawings, are carried out. It
includes the calibration of instruments, cold-alignment checks, testing of safety devices, etc.
This phase leads to the mechanical completion or ready for commissioning.
Commissioning is the period when the dynamic verification of the functioning equipment,

the simulation of control loops and safety systems, and the operational tests are carried out.
Commissioning includes also a variety of activities such as cleaning and drying-out of piping
systems, tightness tests, loading of chemicals, dessicants and catalysts, running-in of pumps,
turbines, and compressors, with inert fluid (water, nitrogen).
These operations are conducted before feed introduction into the plant and end up at a point in time
called ready for start-up meaning that the plant is ready to be operated for the first time.
Well planned and carefully executed precommissioning and commissioning activities generally
result in a quick and successful start-up.
5.3.2 Utility systems commissioning
Here is a non restrictive list of these systems and the status under which they are expected to be. Some of
the systems may not be applicable, depending on the unit.
In service means the system is operational: main header and users feeder lined up. Each

individual user only is isolated either by block valves, if available, or blinds.


Ready to use means the system (main header, individual users feeder) has been cleaned, dried

if required, leak and pressure tested and left under the appropriate atmosphere. The main
header has been subsequently shut off with block valves and blinds.
Instrument air
: In service
Utility air/Plant Air
: In service
Cooling water system
: In service
Individual user isolated, drain open
Sea Water System
: In service
Individual user isolated
Nitrogen system
: In service
Checked for proper oxygen content
Steam
: In service
Drains and traps have been checked
Condensate water
: In service
Boiler Feed Water
: In service, ready to use
Potable water
: In service
Fire water
: In service
Flare system
: Ready to use
The flare main header of the unit is kept open to atmosphere and
isolated with blind from the flare collector at the battery limit
Hydrocarbon closed drain
: Ready to use

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Amine Drain
: Ready to use
Fuel gas for COB
: Ready to use
Fuel oil for COB
: Ready to use
Start-up fuel gas and pilot gas for COB: Ready to use for H-1501 / H-1502
Fuel gas from LPG vaporizer, directly. Propane or LPG gas should be used
for start-up operation.
Electrical equipment
: Ready to use
All wiring, junction boxes, breakers, switches have been checked for
correctness and compliance with specifications. Electrical motors have
been run in for 4 hours (disconnected from the driven machine).
5.3.3 Unit commissioning
The following operations related to process unit equipment are completed in accordance with the relevant
precommissioning procedures and the equipment manufacturers instructions.
Hydrostatic test of piping,
Equipment washing,
Rotating machine alignment,
Pump running in,
Air blowers running and checking of surge curve.
Refractory or ceramics lined lines will not be cleaned with water. Hand cleaning will be made,

and where it is impossible a vacuum blower will be used.


It is important to clean properly the lines to instrument nozzles and aeration / fluidization

nozzles as flow orifices installed on these lines are small and can plug easily.
Checking of each nozzle must be done and witnessed by an IFP representative.
Before starting the catalyst hoppers loading, all catalyst lines (loading, unloading, make-up,
draw-off lines) must be checked for cleanliness. It consists of checking free air circulation
along each whole line.
It is worth remembering that water wash must be avoided for equipment subject to a forthcoming drying.
5.3.4 Initial leak tests
The general instructions hereunder shall only be used as a reminder.
The initial leak tests can be performed using air. The test pressure will be the air system pressure or the
unit (or section of unit) design pressure, whichever is the lower.
The unit is isolated with blinds from adjacent sections containing hydrocarbons (liquid or gaseous), and
from utilities systems where pressure is lower than air pressure.
The pressure rise must be checked on several manometers and possibly checked on a pressure recorder.
Leaks must be carefully located and tightened. Their location must be recorded. The leak test is
satisfactory when the pressure decrease is lower than 0.05 kg/cm2/hour over a period of 4
consecutive hours.
The air used for leak tests should be purged out of the unit using low points drains to remove free water,
if any.
For the purpose of leak tests the unit will be divided into sections of approximately the same design
pressure, as defined hereunder. Air will be injected at different locations depending upon check valves.

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UNIT RFCC (015)

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The initial leak tests apply for the feed preparation section: the feed surge drum and its associated piping
from the unit battery limit and to the injectors system. The feed pump suction must be isolated with a
blind.
The leak tests of the disengager / stripper and of the regenerators are performed during the air blower
start-up and refractory dry-out by visual or sound detection.
For the catalyst handling section the tests can be followed by a vacuum test at maximum vacuum. Loss
of vacuum shall not exceed 25 mm Hg/hour over a period of 4 consecutive hours (Catalyst hoppers
and its associated piping).

5.3.5

Catalyst hoppers loading

5.3.5.1 Preliminary checking


Before the catalyst is loaded to the hoppers, all catalyst lines between hoppers and regenerators should be
inspected.
The catalyst lines and vessels must be free of foreign material, especially water or oil. The air lines
should be checked by blowing all lines until they are clear and dry. Any water in the catalyst lines and
hoppers will form a sticky mud which makes normal handling impossible, and this wet catalyst is
extremely difficult to remove.
Prolonged blowing with air or cleanout by hand will work, but the best method is prevention by keeping
the system dry.
If needed, the hoppers will be brushed and vacuum cleaned before catalyst loading start.
5.3.5.2 Recommendations
Catalyst can be dispatched to the customer by several means of transportation.
Delivery in bulk trucks is usually the most rapid and economic way to get the catalyst to refineries.
Trucks are equipped with a tank tilting device, a compressor and flexible discharge lines with several
coupling systems. In few hours all the catalyst is transferred from the trucks into the fresh catalyst
hopper.
Usually the vacuum of the catalyst hopper is sufficient to transfer the catalyst into the hopper. In case the
transport line is too long, extra transport air may be required.
Fresh catalyst is loaded into the fresh catalyst hopper and Equilibrium catalyst in the Auxiliary catalyst
hopper using either the truck compressor or the steam ejector.
To dip catalyst hopper in order to estimate quantity of catalyst transferred, it is recommended to aerate
the hopper for a period of two hours and to settle the catalyst for one hour before to attempt any accurate
measurement of the catalyst level.
It is also recommended to leave the catalyst in the hoppers under a constant flow of instrument air
sweeping in order to avoid moisture absorption in the catalyst.

5.4 First start-up


5.4.1 General
The following describes the very first start-up of the unit (reaction and regeneration section). Any
subsequent start-up of the same unit will very likely not include all the following steps but part of them

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only, depending upon the status of the unit after the shutdown. For instance the refractory dry out
procedure needs not be performed again, except in the case major turnaround.
Reference is made to other sections of the facility as required; however, the start-up of the downstream
and associated equipment is not covered in this guideline. This guideline assumes the unit is in the cold,
open condition, as would exist after construction or a major turnaround. It presumes that the unit has
been thoroughly inspected by refinery personnel, that the safety equipment is available and operational,
and that all precommissioning activities have been completed.
The following procedure is intended as a general guideline only. It is written without reference to
unforeseen difficulties which often occur during start-up. The step by step guide is not intended to
replace plant rules or established plant operating procedures and requires the safe and intelligent
judgement of experienced operating personnel.
5.4.2

Status of the unit

The status of the unit prior to its initial start-up is as follows:


Tightness test and nitrogen purges have been completed (O2 < 0.2% 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 man way are closed.
Verify isolation and blinding of the fuel gas system.
5.4.3

Chronology of start-up operation

The chronology of the various start-up tasks is shown on the typical procedures. The durations
considered are indicative and are only those required to perform the tasks; no time gap between two
consecutive tasks has been taken into account.
The chronology of the start-up is as follows:
Blower start-up and checks.
Refractory dry-out (first start-up only).
Catalyst hoppers loading (first start-up only).
Refractory inspection (first start-up only).
Unit warm-up.
Main fractionator MOV open
Catalyst loading.

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Establishing catalyst circulation.


Starting feed to the riser.
Adjustment of operating conditions.
Remarks: It is recommended to inspect the refractory after the dry-out operation, especially for the first
start-up.
The CO Boiler, waste heat boiler (or flue gas cooler), and flue gas lines are generally dried during the
reaction / regeneration section dry-out in connection with the overall start-up procedure.
5.4.4

Blower start-up and checks


a) Before starting the air blower, purges on instrument, aeration and conveying lines must be put
into operation, in order to avoid plugging of these small lines with dust or other material. On
the reaction section side (riser, disengager/stripper, spent catalyst line) the purges must be
connected to the plant air header. Plant air is also injected by temporary lines into steam rings
lines (bottom ring, main, hopper, lower, anticoking rings) and stabilization, atomization and
torch oil nozzles to avoid nozzles to be plugged.
b) Activate blower lube/seal oil systems according to manufacturers procedure.
c) Place flue gas slide valves, plug valve, regenerated slide valve and spent catalyst slide valve on
manual control and put the purges valves in service according to manufacturers procedure.
Make sure boiler feed water system is in operation. Make sure bypass emergency systems ES1
and ES2.
d) Open flue gas slide valves and plug valve at 100%, open catalyst slide valves at 60%. Close
the control valve on air lift to plug valve.
e) The disengager vapor line blind plate upstream of MOV-001 at the main fractionator feed line
should be in place, isolating the fractionator from the disengager. Be sure the vent is closed at
this time. Note that this blind plate should be removed and replace to Ring Spacer, after
drying out operation of the reactor and regenerator. Subsequent operation will be
carried out by opening of MOV-001.
f) Start the air blower as per its detailed start-up procedure. Monitor blower operation closely
during first day of operation.
g) Set air blower flow to maintain a minimum flow rate 10% above surge point at all times and
check surge point of the machine. Stabilize and check blower for vibrations and temperatures.
h) Increase the air flow control at normal operation to the first regenerator rings, and place on
automatic.
i) Increase the air flow control at normal operation to the second regenerator and place on
automatic.
j) Slowly close second regenerator flue gas slide valve on manual until it is only about 20 %
opened by PdIC. Record positions on valve stems (on D.C.S. and locally).
k) Slowly throttle first regenerator flue gas slide valve on manual to raise the pressure in the
regenerators by 0.200 kg/cm2 increments to about 1.0 kg/cm2g. Check the flanges and
manways on the unit for leaks. Adjust opening of the second regenerator flue gas slide valve

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to control smoothly regenerator pressures. Check that the reaction/regeneration section


temperature is less than 100C. Hold for 10 hours minimum. Then increase the regenerators
pressure by 0.4 kg/cm2 increments to the maximum blower discharge pressure. Make a
second leak test. Then reduce regenerators pressure to 1.0 kg/cm2g.
l) Record the first regenerator flue gas slide valve openings when 1.0 kg/cm2g is reached. Then
make an air blower check at design capacity; stabilize and check for vibrations and
temperatures. Then resume the normal operating flow rate to first regenerator and to second
regenerator.
m) Set the first regenerator pressure controller (PIC-146) to hold 1.0 kg/cm2 g and place on
automatic.
n) Set PdIC-172 to hold a 0.0 kg/cm2 differential pressure between the two regenerators and
place on automatic.
o) Open the regenerated and spent catalyst slide valves 30 % to 40 % on manual to allow air to
flow from the regenerators into the disengager stripper vessel.
p) Slowly open the vent on the disengager vapor line at the main column inlet to allow some air
flow through the disengager stripper vessel. Do not allow both flue gas valves to close below
20%. Adjust air flow rates to correct the situation.
Note:

The flue gas treatment section is normally ready to be placed in service, or bypass lines can be
used to the stack.

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UNIT RFCC (015)

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UNIT RFCC (015)

5.4.5

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Dry-out of refractory

Prior to start-up, the refractory must be cured. This can be accomplished utilizing the main air blower,
air heaters, and installed instrumentation. Depending upon the configuration, temporary vents / mufflers
may be required in the flue gas duct. During refractory dry-out the steam side of the waste heat boiler,
CO Boiler and Economizer should be boiled out in accordance with vendors procedure.
The actual procedure used, depending on the refractory type and thickness, should be developed between
the Licensor, the refractory Vendor, the Contractor, the refractory Installer, and the operating Company.
Temperature steps and times indicated in the dry-out procedure should be checked, for the initial start-up
and for start-up after a major turnaround. A typical procedure may require five days and is listed below.
During the dry-out, adjustments to slide valve position might be needed to adjust the warming rates of
each vessel. As air lift will have thermal expansion during the warm-up it will have a tendency to push
on the plug valve and severe damages to plug valve or air lift can result if the plug valve is not fully open.
During dry-out, the plug valve must remain fully open.
The catalyst loading and unloading lines will also be dried during this operation. Open the block valves
on each catalyst transfer line and the vent on the catalyst hoppers. Have the catalyst feeders by-passed.
Keep flapper valves of cyclones diplegs blocked open during the dry-out in order to drain water.
For dilatation reasons between the disengager/stripper and the regenerators it is necessary to make sure
that the temperature difference between these vessels does not exceed the design of the expansion joint
(as indicated in the specification of the expansion joint, maximum differential temperature is
350C).
Preparation of Dry-out Operation
-

COB/WHB to be dry-out prior for reactor and regenerator dryout operation.

Install blind plate at upstream of MOV-001 at feed line of the main fractionator. Note that
this blind plate should be removed after dry-out operation.

Use N2 purge to D-1509, if N2 is available at this time.

If N2 is not available use Plant Air for purge gas. For line-up Plant Air to fuel gas purge line
of the instrument of the reactor. Use 3-PA-157230 in P&ID 015-PID-0021-138. Close
isolation valve of fuel gas side. Note that 3-PA-157233 connecting to N2 line shall not be
used unless PSV-007A outlet to route atmosphere, by temporary piping avoiding Plant Air
routing to flare.

Isolate PSV-002 at the fractionator feed line by closing inlet valve.

Open isolation valves on start-up line of the reactor outlet to the flue gas line (24-PG150037 on P&ID 015-PID-0021-123).

Start-up fuel gas (Propane or LPG) is ready to use from the fuel gas LPG vaporizer.

Prepare soda boiling of the BFW system in WHB.

Line-up Air Blower discharge air to MPS header (upstream of PV-365) using 6-A-150072
on P&ID 015-PID-132/138, so that steam line to e purged by Air Blower discharge air.
Isolate MPS supply valves.

All Injection Nozzles are not removed during dry-out operation.

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Proceed as follows:
a)

Plant air purges on instrument, aeration conveying lines, steam rings lines (riser bottom,
fluffing, main, upper, pre-stripping, anticoking rings) and stabilization, atomization, torch oil
nozzles must be in operation, using temporary lines.

b)

Warm up with blower discharge temperature hold conditions until vessels heat to the blower
discharge temperature. Open drain valves at low points, mainly at the bottom of the riser.

c)

Light the air heater pilots according to air heaters Vendors start-up procedure. Allow time for
the air heaters refractory drying. Consult with air heaters Vendor.

d)

Hold around 120C to 140C for 24 hours in the regenerators dense bed at minimum stable
pilot firing. During this period of time, heat up the disengager / stripper by alternatively
opening and closing spent catalyst and regenerated catalyst slide valves at least once every hour.
Check that the withdrawal well and catalyst standpipes warm up evenly. Check the operation
of slides valves manually and automatically.

e)

Light the air heaters burner, activate UX-003(ES3) and UX-004(ES4) and rise the temperature
30C/h at air heater outlet to obtain around 340C in the regenerators. Continue to heat up
disengager / stripper as in d of the above. Check thermal expansion of lines and equipment
and watch free movement of small lines. Monitor expansion joints and pipe supports.

f)

Hold 340C for 24 hours in the regenerators.


During this period of time proceed to the hot bolting of flanges.
Observe piping, supports, and spring hangers during the entire heat-up period to ensure free line
movement without binding or deformation. Closely inspect the equipment for leaks while the
unit is relatively cold. Any leaks found should be stopped before further heat-up.

g)

Close the block valves on each catalyst transfer line and keep the system dry before the catalyst
is loaded to the hoppers.

h)

Raise air heater temperature at 30C/h to obtain the maximum temperatures:


Adjust catalyst slide valves position and disengager vent line on transfer line to ensure flow
of air through all vessels. At least once per hour the slide valve and plug valve positions
should be moved to check for binding.
Air heaters outlet

maxi

760C

Regenerators

about 650C (evenly distributed)

Disengager

mini
maxi

480C
540C

Hold for 24 hours and hot bolt again. Check skin temperatures. Contact thermometers can be
used to ensure heat up of the spent and regenerated catalyst stand pipes.
Due to air heaters limitations, it may be necessary to fit the air flow rate to obtain the desired
temperature.
Note 1:

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UNIT RFCC (015)

Note 2:

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In case of a restart, which means with coke deposited on the refractory of the riser /
disengager / stripper wall, keep disengager and riser temperature under 340C to
avoid to start coke burning.

When this is completed, cool down at 60C/h by reducing firing in air heaters gradually. Shut-off air
heaters, blind fuel gas and cool with blower discharge air.
After Dry-out of the refractory, the line-up to revert to the normal operation.
-

Remove blind plate and replace to Ring Spacer at upstream of MOV-001 on feed line of
the main fractionator. Note that subsequent isolation operation between the Reactor and
Main Fractionator should be made by open / close of MOV-001.
Note: During drying out of refractory, blind plate should be inserted upstream of MOV001 for secure isolation between Reactor and Fractionator. This blind plate is only used
during refractory drying operation.

Remove Plant Air connection for line-up to fuel gas purge line of the instrument of the
reactor. Used 3-PA-157230 in P&ID 015-PID-0021-138. Open isolation valve of fuel gas
side.

Open isolation valve of PSV-002 at the fractionator feed line, and ready to use during
heating-up operation.

Close isolation valves on start-up line of the reactor outlet to the flue gas line (24-PG150037 on P&ID 015-PID-0021-123).

Remove line-up Air Blower discharge air to MPS header (upstream of PV-365) using 6-A150072 on P&ID 015-PID-132/138, so that MPS steam line is ready to use.

5.4.6

Refractory inspection

Open and inspect the vessels and internals of reaction regeneration section and flue gas treatment section.
Repair refractory where found necessary.
Plant air injection should be stopped where necessay, because this operation is dangerious for personels
inside of vessel.
Make sure that plant air for all instruments, aeration coveying lines and steam rings should be re-injected
after completion of refractory inspection (to be confirmed nobody is in the vessel inside, when plant air
valves are opened).

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OPERATING MANUAL
UNIT RFCC (015)

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UNIT RFCC (015)

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DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

5.4.7

February 2007
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Drying out and Chemical Boiling-out of CO Boiler/Waste Heat Boiler


Dryout of the COB/WHB refractory should be carried out according to the manufacturer's
instructions. The source of heat for the dryout of the COB/WHB will be the COB combustion
burner. Soda boiling for removal of oil and scale from the steam generation sections will be also
simultaneously executed.

1.
2.

3.

4.
5.
6.

Drying out of COB and WHB must be carried out before refractory dry-out of Reactor and
Regenerator.
Ensure the isolation dampers at COB and WHB inlet are closed.
Open the block and globe valves in the vent line on the super-heated steam line located at
the WHB outlet. Unblock the steam line battery limit block valve.
Open the boiler feed water flow control valve, inventory the WHB water circuit, and
establish a level in the steam disengaging drum. Line up boiler feed water to the steam
drum.
Control the makeup feed water flow manually until steady steam generation begins. When
an increasing flow of steam appears from the vent line, raise the steam pressure by
gradually closing the venting globe valve. The reason for venting steam is to maintain a
flow through the tubes, and to remove air from the system. When the superheater outlet
pressure increases the normal pressure level, close the vent line valves and put steam into
its normal header.
Commission the boiler feed water flow to the desuperheater using the desuperheater outlet
temperature controller.
Prepare the chemical injection systems for use
Commission the continuous and intermittent blowdown systems.

Reference shall be made to the manufacturer's instructions for detailed precommissioning


procedures.
5.4.8

Soda Boiling of WHB BFW Circuit


During Refractory drying out operation, chemical cleaning of WHB BFW circuit shall be also
conducted.
For detail procedure, see commissioning procedure

5.4.9

Soda Boiling of Main Column Bottoms Generator


Prior to cold/ hot circulation on main column section, Soda Boiling of Main Column Bottoms
Steam Generator shall be conducted.
For detail procedure, see commissioning procedure.

5.4.10 Degreasing of Amine Circuit


In order to remove oil and/or grease from lines or equipment internal surface to prevent foaming
trouble, degreasing operation using alkaline is applied for Amine circulation circuit.
Details including the scope of degreasing operation procedure.

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OPERATING MANUAL
UNIT RFCC (015)

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INITIAL AND NORMAL START-UP

6.1 Start-up Summary


6.1.1 Reactor and Regeneration Section
The chronology of the various start-up tasks is as follows
Line-up Flue Gas Ducting
Start Electric Precipitator Pre Start Mode for warm-up
Commission COB/WHB with Fresh Air Operation, and start HP steam generation
Air Blower start-up and checks,
Reactor & Regenerator warm-up and heating up by air heaters
Main Fractionator inlet open MOV-001
Catalyst loading to Regenerator
Establishing catalyst circulation,
Starting feed to the reactor riser,
Adjustment of operating conditions.
1.
2.
3.
4.
5.
6.

7.
8.
9.
10.
11.
12.
13.

Before start-up of the blower check that all airlines are free of catalyst upstream of the assisted check
valves. Ensure that the check valves CV-1501, CV-1502, CV-1503, CV-1504 are in closed position.
Start purges on instrumentation, aeration and conveying lines. Connect plant air purges to the riser,
disengager /stripper and spent catalyst lines.
Activate the Air Blower lube and seal oil systems according to the VENDORs operating procedures.
Place the flue gas slide valves, plug valve, regenerated catalyst slide valve and spent catalyst slide
valve on manual control. Put the purge valves in service.
Put BFW system in operation in COB/WHB and bypass Emergency systems UX-001(ES1) and UX002(ES2).
Confirm line-up of flue gas ducting and isolation dampers of Economizer, Electric Precipitator,
COB/WHB. Start Electric Precipitator with Pre-Start mode and heating and warming up of Ash
handling section of Electric Precipitator, as per Vendors procedure.
Start firing COB package as fresh air operation, as per COB/WHB package operation procedure.
Open the flue gas slide valves and plug valves at 100%, open the catalyst slide valves at 60%. Close
the control valve on the airlift to the plug valve.
Start the Air Blower as per its detailed start-up procedure. Set the air flow and speed of Air Blower
to maintain a flow rate 10% above the surge point.
Increase the air flow to the First Regenerator rings to the normal operating flow and place it on
automatic control.
Increase the air flow to the Second Regenerator to the normal operating flow and place it on
automatic control.
Commission of purge blower air to BV-1501AB and BV-1502AB, if not opened.
Warm up the reaction/ regeneration section as follows.

Warm the UNIT with Air Blower discharge temperature for two hours prior to
lighting the Air Heaters.
Light the Air Heaters according to VENDORs procedures and maintain at minimum
firing for two hours.
14. Heat up the Regenerators at a rate of 60 C/ hr to 340 C and start to heat up the Disengager/Stripper.
Hold at 340 C for one hour.

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UNIT RFCC (015)

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15. Increase the Air Heaters outlet temperatures at a rate of 60 - 100 C per hour up to their maximum
outlet temperature. However do not exceed 760 C at the outlets of the Air Heaters.
16. At least every hour during warm-up, pinch and open the spent and regenerated catalyst slide valves
and check that the riser and the catalyst standpipes are heating up evenly.
17. Check for leaks and watch closely all the spring hangers and expansion joints.
18. Heat both Regenerators up to 650 C as measured in the dilute phases and heat the
Disengager/Stripper up to 340 C. Hold at these temperatures for a minimum of two hours.
For initial start-up, it is recommended to hold these temperature for four (4) hours minimum to avoid
catalyst plugging in the cyclone leg, due to high potential containing moisture in E-catalyst while
transporting from outside of Refinery.
19. The instrument purges, aeration and conveying lines to the Disengager section should be switched
from air to nitrogen. All steam rings and stabilization, atomisation nozzles should be switched from
air to steam.
20. When the UNIT heat up is stable prepare to open MOV-001 at inlet of the main Fractionator in coordination with the RFCC Gas Plant operation. (Note that inlet blind upstream of MOV-001 is
already removed and replaced to the ring spacer after refractory drying out operation).
21. The hot oil circulation and dry-out of the Main Fractionator should be complete.
22. Reduce the Main Fractionator bottom level to minimum and stop the hot oil circulation.
23. Close the spent and regenerated catalyst slide valves.
24. Open the Disengager vent line and drain upstream of MOV-001.
25. Reduce the steam flow to a minimum at the Main Fractionator, Stripper and riser. Allow both sides
of MOV-001 to depressurise.
26. With the steam still going to the Disengager/Stripper and to the Main Fractionator, open MOV-001.
27. After MOV-001 fully open, slowly close the Disengager vent line and re-establish stripping steam
and riser steam flows at the normal operating rates.
28. Commission purge HPS to MOV-001 after MOV-001 fully opened. Refer to Vendors operation
manual of MOV-001 for more detail.
Caustion: Do NOT open pruge HPS under MOV-001 operation (both moving to open and close).
29. The Main Fractionator is pressurised with fuel gas or nitrogen.
30. Set the Disengager pressure to approximately 0.1 kg/cm2 higher than the First Regenerator pressure
to avoid air flow into the Main Fractionator until catalyst loading is started.
31. Equilibrium catalyst should now be loaded from the Spent Catalyst Hopper or Auxiliary Catalyst
Hopper to the First Regenerator.
32. Close the catalyst slide valves and plug valve.
33. Set the First Regenerator pressure to 1.1 kg/cm2g and the Second Regenerator pressure to 1.0
kg/cm2g.
34. Reduce the combustion air flows to 30 - 40% of normal flow until the diplegs of the Regenerator
cyclones are sealed.
35. Start the lift air at 50 % of normal flow.
36. Record the initial catalyst level in the hopper, before catalyst loading. Confirm E-catalyst inventory
in the hopper before catalyst loading.
37. Start loading the catalyst by slowly opening the gate valve at the Hopper bottom. Adjust catalyst
flow by the gate valve opening and by lift air flow rate.
38. Load catalyst into the First Regenerator while maintaining the dense phase above 370 C.
39. When the level in the First Regenerator is at least 500 mm above the torch oil nozzles and the dense
phase temperature is at least 370 C, torch oil may be started at a minimum rate.
40. Adjust torch oil flow to achieve 650 C in the dense phase.
41. Continue loading the catalyst to the First Regenerator until the maximum bed level is achieved.

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UNIT RFCC (015)

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42. Increase the differential pressure between the First and Second Regenerators to 0.7 kg/cm2 by PDIC.
Adjust air flow rate to the second regenerator to achieve 0.3-0.4 m/sec at dense phase to minimize
catalyst loss. Slowly open the plug valve and begin to transfer the catalyst to the Second Regenerator.
43. When the level in the Second Regenerator is at least 500 mm above the torch oil nozzles, the torch
oil may be started if the dense phase temperature in the Second Regenerator is above 370 C.
44. Adjust the torch oil flow to maintain 650 C in the dense phase of the second regenerator.
45. Record hopper level, time to time to confirm how many catalyst are loaded into the regenerators.
Continue loading catalyst and transferring from the First to the Second Regenerator until all the
catalyst inventory has been loaded.
46. Hold the regenerator levels and dense phase temperatures near 650 C while preparing for catalyst
circulation.
47. Before establishing the catalyst circulation, achieve the following process conditions
Disengager at 300 C, under steam, pressure controlled at the Main
Fractionator by the Wet Gas Compressor.
First Regenerator at 650 C, 1.1 kg/cm2g, air rings flow rate at 50%.
Second Regenerator at 650 C, 0.4 kg/cm2g, air rings flow rate at 50%.
48. Increase air lift flow to the normal flow rate.
49. Set the PDIC on the spent and regenerated slide valve at 0.1 kg/cm2 and place on automatic control.
50. Reduce stripping steam flow rates to minimum, set the stabilisation and dispersion bottom wye
steam to normal flow rate.
51. Slowly open the regenerated slide valve on manual to 20% open. Monitor and maintain the
regenerated slide valve differential pressure to above 0.2 kg/cm2.
52. Continue batch-wise circulation and transfer until the Stripper temperature is above 370 C. When it
reaches 480 C, increase the Stripper level to the normal operating level.
53. Adjust the regenerated and spent catalyst slide valves to keep the levels in the vessels, and to
maintain an equal differential operating pressure on the two catalyst slide valves. Then the valves
may be put on automatic control.
54. Continue to circulate catalyst until a temperature of at least 510 C is reached at the riser outlet.
55. At this stage oil can be introduced into the system, the fractionation section should be ready to
receive products from the reactor section. The feed system to the riser should be circulating through
the reaction section bypass to the feed surge drum and ready to be lined
up to the feed injectors.
56. Switch the Disengager/Stripper purges from nitrogen to fuel gas. Check flow rates of all purges.
57. Check that emergency systems UX-001(ES1) and UX-002(ES2) are ready for activation.
58. Put the regenerated catalyst slide valve on manual control.
59. Drain water from feed injectors and open the isolation block valves on the feed lines keeping the
control valves closed.
60. Feed Cut-in to Riser. Put injectors in operation three by three opening the control valves to give
50% of normal flow. The riser outlet temperature should not fall below 480C.
61. Raise feed rate to 70% of the normal capacity within 1 hour of feed cut-in.
62. Adjust air flow rates to the Regenerators so that a temperature of 650-700C is maintained in the
First Regenerator and 2% excess oxygen is obtained in the Second Regenerator flue gas.
63. Start the metal passivator injector as required. For initial operation, start metal passivator injection at
later stage, after establishing line-up all the operating condition and stable operation.
Note: Metal passivator will be used Mixed Crude Case only.
64. After the Main Fractionator has stabilised, increase feed rate to the design capacity in increments of
10%.
65. Adjust air flow rates to the Regenerators accordingly, sample and check the regenerated catalyst.
66. Start to load fresh catalyst and to withdraw spent catalyst, referring sampling data of the all product,
and maintain catalyst activities.
67. Sample the Main Fractionator bottoms for signs of catalyst carry-over from the Disengager.

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UNIT RFCC (015)

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68. Sample flue gases to adjust combustion air rates.


6.1.2 Fractionation and Gas Concentration Section
The following are summary of Start-up of Fractionation and Gas Concentration Section
1
2

3
4
5

6
7
8

9
10
11
12
13

14
15
16
17

18
19

Inform all concerned of the proposed time of the start-up.


All precommissioning and commissioning activities have been completed. Sections leak tested and
water flushed as necessary. Instruments tested, utility systems have been commissioned. Safety
equipment is in place, required blinds removed / installed as appropriate. The UNIT has not been air
freed.
Purge air from the sections of the UNIT using steam and nitrogen and leave under nitrogen or fuel
gas to maintain a positive pressure.
Charge the UNIT with light oil (LCO or LGO) into the Feed Surge Drum. Drain free water from the
drum and piping before introducing oil.
Transfer oil from the Feed Surge Drum into the Fractionator via feed oil pumping and preheating
system, using start-up line upstream of XV-002. When a level is established in the bottom of T-1501,
start circulation through the slurry circuits. Drain free water from low points in the circulating
circuits before hot circulation is started.
Continue to add LCO feed to the Fractionator and run oil to slops or to storage via the clarified oil
circuit.
Stops LCO feed to the Fractionator and continue circulation. The clarified oil circuit can be recirculated via the minimum flow line back to the Fractionator.
Hot circulation of the slurry pumparound can commence using medium pressure steam heat input in
the slurry steam generators E-1505A/B. In case COB/WHB is already commissioned, and saturated
HP steam, generating by WHB, is available, use E-1504A/B for heating-up operation, as well to
support heating up operation.
Open the blinds in the lines to the condensate traps on the steam generators of E-1505AB. These
traps are used only for start-up.
Continue circulation through the slurry circuits. Pumps should be switched from time to time so that
all three pumps and piping are heated.
Allow the system to heat up to the steam condensing temperature of around 200 C.
Drain off water, which collects in the pumparounds, product draw-off lines and overhead reflux
drum.
Bring naphtha into the Fractionator Reflux Drum from outside of the unit. Conduct cold naphtha
circulation in Gas Concentration Unit, using start-up naphtha. Introduce start-up naphtha into the
overhead receiver, then supply naphtha to stripper. Establish cold circulation loop in Gas
Concentration and main fractionator receiver, using start-up naphtha. Operate Wet Gas Compressor
with fuel gas under closed condition of MOV-001 at Fractionator inlet to pressurize Gas
Concentration Unit.
Continue hot circulation until it is time to open MOV-001 at the Main Fractionator inlet.
Stop hot circulation and depressure the fractionator to flare. Open MOV-001 of the Main
Fractionator inlet. Be sure that purge HPS to MOV-001 is closed prior MOV-001 operation.
Once MOV-001 is opened, restart circulation and heat the circulating oil to around 200 C. Reopen
the purge HPS line to MOV-001 after confirmation of MOV-001 full opening.
For the initial start-up, fill the LCO pumparound by bringing in LGO via the suction of the LCO
Pumparound Pumps. Circulate the LGO in the LCO circuit and drain water from the low points in
the circuit. For subsequent start-ups LCO will be available as flushing oil.
Fill the HCO pumparound circuit by overflowing the LCO chimney tray. Circulate through the HCO
pumparound circuit and drain water from the low points in the circuit.
Start hot circulation of HCO pumparound using heating-up by E-1523, introducing MPS.
Commission steam trap at bottom of E-1523.

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UNIT RFCC (015)

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20 Transfer warmed oil from HCO pumparound to LCO pumparound using start-up line from P1508AB. After sufficient volume of warm oil is available in LCO pumparound, transfer warm oil to
Heavy Naphtha pumparound using start-up line from P-1510AB discharge. Maintain hot oil
circulation of HCO PA, LCO PA, and Heavy Naphtha PA to eliminate water in the system.
Note: Hot oil circulation of Heavy Naphtha PA is option, subject to situation of cold oil circulation
of Heavy Naphtha PA using start-up naphtha.
21 Continue to bring naphtha into the Fractionator Reflux Drum from outside of the unit. Start a reflux
pump and fill the heavy naphtha pumparound circuit. Circulate through the heavy naphtha
pumparound circuit and drain free water from the low points.
22 Continue hot circulation on the slurry pumparound and fill the Fractionator reflux drum to normal
liquid level with naphtha until feed is brought into the reactor riser.
23 Start the Wet Gas compressor by opening the suction and discharge valves on each stage and startup following the VENDORs procedures. The compressor start-up step is optional at this stage. The
consequence of delaying the compressor start-up until feed is brought into the reactor riser is that
more gas will be vented to flare.
24 If the molecular weight of the fuel gas is too low it may cause surging of the compressor, increase it
by bringing LPG into the fuel gas system in the utility supply system (Unit 37), via LPG vaporizer.
25 Start cooling water to the Main Fractionator Trim Condenser and the Wet Gas Compressor Trim
Cooler as required.
26 Establish cooling water flow through all the water cooled exchangers, and start all air coolers.
27 Start steam to the LCO and HCO Strippers
28 Switch the slurry HP steam generators E-1504AB from heating mode to steam generation, and MP
steam generator E-1505AB to manual operation by shutting off the medium pressure heating steam
and admitting boiler feed water. Isolate the medium pressure steam and then start-up condensate
traps.
29 Initially send steam to atmosphere via the start-up silencer. Use both the continuous and intermittent
blowdowns to bring the blowdown water within specification.
30 Monitor closely the Main Fractionator bottoms level. Check the slurry for catalyst fines several
times per shift until operation has stabilised.
31 If the Wet Gas Compressor was not already started, start now WGC.
For initial start-up, it is recommendable that Wet Gas compressor to start operation after feed cut-in
so that sufficient gas is available and simpler control of pressure control of the reactor section.
32 As liquid builds up in the Interstage Drum, start liquid flow to the High Pressure Separator.
33 If the HCO, LCO and Heavy naphtha pumparounds have been stopped, they should be restarted.
Check the circuits frequently for water at the low points. Start the air coolers if not already started.
34 When the level starts to rise in the Fractionator Reflux Drum, start reflux to control the overhead
temperature. Keep this temperature high enough to prevent condensation of steam at the top of the
column.
35 Start drawing off LCO to the LCO Stripper and adjust stripping steam rate. Send the LCO to slop
header.
36 Start drawing off heavy naphtha to the Heavy Naphtha Stripper and start re-boiling the stripper with
the HCO pumparound. Send the heavy naphtha to slops.
37 Start drawing off HCO to the stripper and adjust the stripping steam rate. Prepare to start the LP
steam generator.
38 When the level in the HCO Stripper starts to rise switch the flushing oil system to HCO.
39 Start the water wash to the overhead condenser.
40 Open the line to flare at the top of the Fuel Gas Absorber and set the pressure controller at the top of
the Secondary Absorber. Pressurise the HP Separator, Primary Absorber, Secondary Absorber, and
the Fuel Gas Absorber with gas from the Wet Gas compressor.
41 Start the overhead liquid distillate pump and send liquid to the primary absorber in Gas Con Section.
42 Send HP Separator liquid to feed the Stripper.

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43 When heat is available from the LCO pumparounds, start re-boiling the Stripper. Pressurise liquid to
the Debutaniser.
44 Fill start-up LPG to the debutanizer receiver. As level available in the debutanizer receiver,
gradually fill LPG to LPG treater using the debutanizer reflux pump. Fill lean Amine to LPG treater.
45 When a level is established in the Debutaniser bottom start re-boiling with the HCO pumparound.
Vent light ends to the flare from the debutanizer receiver.
46 Start the lean sponge oil pump and feed lean oil to the Secondary Absorber. When a liquid level is
established start sending rich oil back to the Main Fractionator.
47 Send the liquid from the Debutaniser reflux drum to the LPG Treating Unit.
48 When a level is established in the Debutaniser bottom start the Gasoline Recycle Pumps and
circulation to the Primary Absorber.
49 Send the liquid from the Debutaniser bottom to the RFCC Naphtha Treating Unit.
50 Start the amine flow to the Fuel Gas Absorber and switch the outlet of the fuel gas absorber to fuel
gas.
51 Start the amine flow to the LPG treater, and start routing treated LPG to LTU.
52 Start the water wash to the Wet Gas Compressor Intercooler.

6.2 Final Preparation


6.2.1

Preparation Confirmation
The final preparations described here are from the point where the UNIT is cold, air is in the
equipment (and piping) and the UNIT remains blinded at all battery limit locations and at the
locations in the UNIT for the refinery fuel gas.
Prior to the final preparations all preliminary checks will have been carried out for
commissioning or a start-up following a turnaround. Other start-ups from cold will
incorporate preliminary checks as applicable. The preliminary checks are:
1.
2.
3.
4.
5.

6.
7.
8.

9.
10.

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All concerned have been informed of the proposed time of start-up.


Tightness test and nitrogen purges have been completed and the oxygen level is
less than 0.2 vol% in the feed preparation section.
All lines and equipment have been cleaned and all flanges and manways are
bolted with the correct gaskets, and equipment blinds removed or swung open.
Strainers are installed where required and orientated correctly. Temporary fine
mesh strainers are installed for initial operation of the pumps.
For initial start-up only, confirm installation of the temporary strainer in the feed
line upstream of the feed injectors at down stream of M-1501 of the feed line.
(See Note 4 of P&ID 8474L-015-0021-121). This temporary strainer is provided
to remove construction debris. Remove this temporary strainer at appropriate
timing, soon after initial operation and temporary shut-down chance, when
construction debris are considered to removed.
All distributors (spent catalyst inlet in First Regenerator, lift outlet, riser outlet)
inspected for proper construction and protection against erosion.
Air rings and steam rings inspected for proper nozzle size and orientation.
Feed, MTC and steam injectors inspected for proper orientation and penetration.
The annulus around the injectors packed with kaowool or equivalent. Injector
VENDOR installation procedure must be followed.
Orifice plates; tab diameters checked against data sheets and orientated properly.
All instrumentation, fluidisation and aeration taps including torch oil nozzles
checked for proper orientation and penetration. The nozzles are free of refractory
or other material.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
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UNIT RFCC (015)

11.
12.
13.
14.
15.
16.

17.

18.

19.
20.
21.
22.
23.
24.
25.
26.
27.

28.

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All control valves have correct flow orientations and have been stroked and left
closed on manual. Their bypasses checked as tightly shut off.
Slide valves and plug valves inspected for proper calibration, movement, and
operation.
Expansion joints inspected for proper installation and freedom of movement.
All check valve orientations are confirmed, correctly.
All instruments and analysers have been calibrated and are ready for use.
All rotating machinery has been run, has correct lubrication inventories
established, has been aligned, has had rotation direction checked, and guards
securely installed.
Relief valves (systems) shop certified and installed with seals, chained open /
close valves, and interlocking open / close devices checked for correctness per
check list. Blinds and restrainers removed per check list.
On the Disengager and First Regenerator cyclones, set blocks to open the trickle
valves on the diplegs. Verify that the Disengager and the Regenerators manways
are closed.
UNIT drains and vents not required for start-up purging or draining have been
checked as capped, plugged or blinded.
Dampers, air registers of the air heaters have been checked for easy movement.
All utility services are available at the battery limit. All relief, slops and drainage
systems are ready for use and the Main Flare has been commissioned.
The UNIT has been checked free of all debris, scaffolding, planking etc.,
especially at the upper levels.
All alarm circuits have been checked and are ready for use.
Emergency shut-off valves have been tripped and reset twice and the emergency
shutdown systems have been tested and ready for operation.
Fire fighting, safety equipment and gas emission analysers checked for
operability and completeness.
Remove or swing blinds to normal operating positions at battery limit lines.
Leave MOV-001 closed at inlet of the Main Fractionator.
Make a final check to remove or swing out of use any isolating blinds at unit
equipment or in lines. Check distance spools are made up or disconnected per
check list. Recheck all relief systems are in an operable position, any upstream
and downstream isolation blinds removed, and where double relief valve
arrangements exist that the installed valve in the system has its isolation valves
in the locked open position.
Commission all utilities.

6.2.2 Off-site and relating units preparation


Confirm off-site and relating units are ready to start sending feed, product and off-spec material from
RFCC.
- CDU is operating to supply feed Atm Residue
- LCO tank is filled with LGO from CDU for initial start-up operation
- Start-up naphtha is available from CDU
- Start-up LPG is available from offsite
- LTU (Unit 16) and PRU (Unit 21) are ready to receive RFCC LPG.
- NTU (Unit 17) is ready to receive RFCC Gasoline
- LCO unit is ready to receive LCO product
- Fuel Oil Pipeline is ready to receive Clarified Oil
- Amine treating unit is ready to supply lean amine and receive rich amine
- Sour water stripper unit is ready to receive sour water

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DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
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All product rundown system are ready to receive product


Slop handling facilities are ready to receive all slop.

6.3 Reactor Regenerator Start-up Procedure


6.3.1

Unit warm-up

The status of the unit prior to warning up of reaction / regeneration section is as follows:
Refractory has been repaired and ready for operation in whole section as well as flue gas
treatment section.
Equilibrium catalyst is loaded into the spent catalyst hopper or Auxiliary Hopper
Fractionation and Gas Recovery section has been warmed up, dried out and is ready
from oil in.
EP is ready as Pre-Heat Mode, and CO Boiler is ready for operator in fresh air mode.
Waste heat boiler is in operation with boiler water filling in the steam drum.
Steam drum of Waste heat boiler is ready for operation.
Electrostatic precipitation is grounded.
Economizer is bypassed, but under BFW filling is available.
In stripper/disengager side, plant air is injected by temporary connection at minimum
flow rate to avoid small lines, and rings nozzles to be plugged.
Air is also injected into fuel gas lines (instrument, aeration, conveying lines).
Air is also injected into steam ring lines (bottom ring, main, hopper, lower, anticoking
rings, stabilization, atomization, and torch oil nozzles.
Confirm blind plate upstream of MOV-001 is removed and replaced to ring spacer.
As for the refractory dry-out operation, during the warm-up operation, it will be necessary to adjust the
position of the slide valves and plug valve periodically to control the heat-up rates of each vessel. The
objective is to have all three vessels arrive at their final operating temperature at the same time while
maintaining heat-up rates at about 60C to 100C per hour. At least once per hour the slide valve
positions should be moved to check for binding. All spring hangers and expansion joints should be
watched closely during this time. Portable contact thermometers can be used to ensure heat-up of the
spent catalyst and regenerated catalyst standpipes.
The flue gas COB/WHB section must be ready to be placed in service.
During the warm-up, the pressure in the three vessels is maintained at 1.0 kg/cm2g.
a)

Warm the unit with blower discharge temperature for two hours prior to lighting the air heaters.

b)

Light the air heaters according to Vendors procedures and maintain at minimum firing rate for
two hours.

c)

Heat up the regenerators at a speed of 60C/h to 340C and start to heat-up the
disengager/stripper.

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UNIT RFCC (015)

d)

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Hold one hour at 340C.


Try to obtain as high temperature as possible in the
disengager/stripper around 340C.
Note 1: In case of restart (coked refractory), keep disengager/stripper and riser temperatures
about 330C 10C to avoid starting coke burning.

e)

Increase the air heaters outlet temperatures at a rate of 60C to 100C per hour up to their
design maximum outlet temperature.
Note 2: Do not exceed 760C at air heaters outlet.

f)

At least every hour during warm-up:

1.

Alternatively pinch and open the spent and regenerated catalyst slide valves and check by
contact thermometers or by feeling that the riser and catalyst standpipes are heating up evenly.

2.

Check the unit for any leaks. All spring hangers and expansion joints should be watched closely
during this time.

g)

Heat both regenerators up to about 650C as measured in the dilute phases and heat the
disengager up to preferably 340C. Hold at these temperatures for a minimum of two hours.
For initial start-up, hold these temperature as long as practical, preferably more than four hour
to keep regenerator hot condition to avoid stick of catalyst in the cyclone leg while catalyst
loading to the regenerator, due to possible moisture during catalyst transfer from the outside of
the refinery.

h)

Once again check the unit for leaks.

i)

During the final stage of warm-up, instrument purges, aeration and conveying lines to the
disengager/stripper section should be switched from air to nitrogen. They will later be switched
to fuel gas before introducing oil to the unit.
All steam rings and stabilization, atomisation nozzles should be switched from air to steam.

WARNING:

6.3.2

New refractory linings should not be exposed to steam for a long duration prior to
catalyst circulation, depending on pressure/temperature conditions in the vessels,
in order to avoid steam migration into the refractory and as a result possible
condensation between shell and refractory.

Main fractionator MOV-001 Opening

In preparation for opening MOV-001 of the main fractionator, all steam lines to the process should be hot
and free of condensate. The hot oil circulation and dry-out of the main fractionator should be completed.
Reduce the main fractionator level to minimum, stop the hot oil circulation.
a)

Close spent and regenerated catalyst slide valves.

b)

Time to time open the drain at riser bottom and bottom of the stripper, and the drain at spent
catalyst sampling connection to check if there is some condensate.

c)

Establish a steam purge at the bottom of the main column.


Depressure the main fractionator completely to flare.

d)

Open the disengager/stripper vent line to the Silencer and drain just upstream of MOV-001.

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OPERATING MANUAL
UNIT RFCC (015)

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e)

Assure that a supply of dry steam is available at the stripper and riser steam injection locations
and start all steam injections. Set stripping steam and dispersion steam at 50% of normal
operating flow.

f)

Observe the disengager/stripper vent line exhaust until a continuous flow of steam has been
venting for a minimum of 15 minutes. Watch the disengager pressure instrument and reduce
steam flow if necessary to avoid over-pressuring the disengager/stripper.

g)

Reduce the steam flows to a minimum at the main fractionator, stripper and riser. Allow both
sides of MOV-001 to depressure.

h)

Be sure that purge HPS line to MOV-001 is closed.

i)

Open MOV-001, slowly. Make sure that steam is still going to stripper / disengager and to
fractionator to avoid air entry.

j)

After full opening MOV-001, slowly close the disengager vent line to the Silencer and reestablish stripping steam and riser steam flows at normal operating flow rates. Restart purge HPS
to MOV-001.
Provide positive Locking that MOV-001 shall never be closed during subsequent operation,
including normal operation.
The main fractionator may now be pressured with fuel gas (or nitrogen).
Use the steam vent to set disengager pressure at approximately 0.1 kg/cm2 higher than the first
regenerator pressure. This is to avoid air flowing through the spent catalyst standpipe
stripper/disengager until catalyst loading is started and a catalyst seal is established above the
spent catalyst slide valve.

k)

6.3.3

Leave the drain at riser bottom slightly open to drain condensates, close the drain on the spent
catalyst sampling connection.
Catalyst loading
1. Equilibrium catalyst is loaded from the spent catalyst hopper or auxiliary hopper to the first
regenerator. Record initial catalyst inventory level in the hoppers by manual dipping scale
wire from the manual gauge valve nozzle (4) at top of the hopper.
2. Before starting the loading, open all fluidization air nozzles to spent hopper bottom at
normal flow rate, and pressurize at 3.5 kg/cm2g by plant air. Open all the valves on the
catalyst loading line, except the one located at the hopper bottom.
3. Start blower air through the catalyst loading line at the rate of about 1500 to 2000 kg/h
enough to create air / catalyst mixture density of 40 to 60 kg/cm3 (catalyst velocity in
loading line must not exceed 10 m/s for erosion purpose). The catalyst hopper is ready for
loading. Check and record the catalyst level in the hopper.
4. In the regenerators, during the start of loading, take care not to increase blower air flow rate
too high in order to avoid losing catalyst through the cyclones dipleg. The air velocity in
the first regenerators dense phase must be kept within the range of 0.3 to 0.4 m/s during
catalyst loading.

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UNIT RFCC (015)

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5. The air flow rate could be as follow to maintain 0.3 to 0.4 m/sec. at dense phase of the first
regenerator.
-

Diameter of Dense phase (first Regenerator): 8.9 m

Center Riser Pipe: 1.8 m

Segmental Area excluding center pipe: 59.64 m2

First Regenerator Pressure : 1.1 kg/cm2G

Temperature: 650 deg C

Air density: 0.816 kg/m3

Air rate to first Reg to maintain 0.3 0.4 m/sec: 52,600 to 70,100 kg/hr (40,700
54,200 NM3/hr)

It might be necessary to snort some air at the blower discharge to avoid surging. Refer to
performance curve of the main Air Blower.
6. Close the catalyst slide valves and plug valve. Ensure the slide valves cannot be opened
accidentally. Note the position of the plug valve in the hot closed position for future
reference. Set the first regenerator pressure to about 1.1 kg/cm2g. The disengager pressure
is set 0.1 kg/cm2 higher than the first regenerator pressure (on automatic control). The
second regenerator pressure is around 1 kg/cm2g.
7. Reduce the combustion air flow rates to the above rate (about 30-40 % of the normal
operating flow rates of Bach Ho Gasoline Case) until such time that the regenerators
cyclones diplegs are sealed to minimize catalyst losses.
8. Start lift air to the plug valve at 50% of normal flow. (47,832 kg/hr)
9. Start loading the catalyst by slowly opening the gate valve at the hopper bottom. A
pressure gage and sight glass located on the catalyst loading line will indicate if the catalyst
transfer is established. Adjust the catalyst flow by the gate valve opening and by the
carrying air flow rate. During the loading, the amount of loaded catalyst must regularly be
checked by measuring the level decrease in the hopper. Record catalyst level in the hopper
to check the loading speed. The tentative amount of loaded catalyst should be about 35
t/hour for a 6" loading line. Be careful not to exceed significantly these values in order to
limit the catalyst damages.
10. Load the first regenerator while maintaining the dense phase above 370C.
11. When the level in first regenerator is at least 500 mm above the torch oil nozzles and the
dense phase temperature is at least 370C, torch oil may be started. Start torch oil at
minimum rate and observe the dense phase temperature closely. If a substantial increase in
dense phase temperature is not registered within about 30 seconds the torch oil flow should
be stopped or the catalyst may become saturated with oil and may make run away
temperatures later. The dense phase temperature should be raised about 30C before
attempting torch oil again. If the torch oil does not produce a response above 450C,
suspect a flow stoppage.

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UNIT RFCC (015)

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12. Adjust the torch oil flow to achieve 650C in the dense phase. The first regenerator air
heater can be reduced to minimum firing but should remain in operation until the unit is onstream, so that it can be used in case a problem develops with the torch oil flow.
13. Continue loading catalyst to first regenerator until the maximum bed level is achieved. The
air rate to first regenerator may be increased after the diplegs are sealed.
14. Increase the differential pressure by dPIC between first and second regenerator to
0.7 kg/cm2. Slowly open the plug valve and begin to transfer the catalyst from first to
second regenerator.
15. Reduce air flow to the second Regenerator to maintain 0.3 0.4 m/sec at dense phase of the
Second regenerator (diameter: 8.0 m) to minimize loss of catalyst, until catalyst level is
higher than the dip leg of the cyclone. The equivalent total air flow rate is 42,200 56,300
kg/hr. Since lift air is already set to 24,000 kg/hr (50 % of normal), air flow rate via H-1502
could be 18,200 32,300 kg/hr.
Ideally the differential pressure and plug valve opening should be adjusted to transfer
catalyst to second regenerator just fast enough to slowly empty first regenerator to the
minimum operating level. Do not empty the first regenerator below the cyclones diplegs
and torch oil nozzles. Monitor the density readings of the regenerated catalyst standpipe to
see when it is filled.
16. When the level in second regenerator is at least 500 mm above the torch oil nozzles, the
torch oil may be started if dense phase temperature in second regenerator is above 370C.
After torch oil ignites in the second regenerator, set the torch oil flow to maintain 650C in
the dense phase. Second regenerator air heater firing may be reduced to minimum firing.
17. Continue loading catalyst and transferring from first to second regenerator until all the
catalyst inventory has been loaded into first and second regenerator.
18. Hold the regenerator levels and dense phase temperatures near 650C while preparing for
catalyst circulation.
6.3.4

Establishing catalyst circulation

The isolation valve MOV-001 between the main fractionator and the disengager must be opened before
starting the catalyst circulation: the liquid level in the main column is reduced to minimum, the main
column pressure is set to the disengager pressure, the valve MOV-001 is slowly opened and
simultaneously the vent valve is slowly closed.
Before establishing the catalyst circulation, the unit must be under following conditions:
Disengager

: Around 300C, under steam, pressure controlled at main


fractionator overhead drum by wet gas compressor if
possible (*1) and/or by FG system or nitrogen at
1.2 kg/cm2g. Bottom pumparound is circulating through
the MF.

First regenerator

: Around 650C, pressure at 1.1 kg/cm2g.

Second regenerator

: Around 650C, pressure at 0.4 kg/cm2g.

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OPERATING MANUAL
UNIT RFCC (015)

February 2007
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First and second regenerators air rings flow rates at about 50% of the normal operation flow
rate.
Prior to beginning catalyst circulation, the drain at the bottom of the stripper, and riser wye
should be checked for water, and any water found should be drained.
Confirm sufficient catalyst has loaded into the both regenerators, by:
- Hopper level reduction
- Level in both regenerators at dense phase
(*1) For initial start-up, it is recommended that Wet Gas Compressor not to operate until feed
cut-in, so that pressure control of the main fractionator is easily made. Subsequent
operation, Wet Gas compressor could be commissioned, as gain of operation experience and
minimize flaring of hydrocarbon.
Start catalyst circulation by the following steps:
a) Air lift flow rate is increased up to the normal flow rate.
b) Set the PDICs on the spent and the regenerated slide valves at 0.1 kg/cm2 and place these
controllers on automatic. The Riser Outlet Temperature control (RCSV) and stripper level
control (SCSV) controllers should be on manual and in the closed position. During pressure
balance modification, always maintain a positive differential of 0.1 kg/cm2 between the
disengager and first regenerator.
c) Reduce stripping steam flow rates to minimum, set the stabilization, dispersion bottom wye
steam to normal flow rate.
d) Slowly open the regenerated slide valve on manual to about 20% open. The first indication of
catalyst flow will be an increase in riser differential pressure, and then later, an increase in riser
temperatures (the first catalyst above the regenerated slide valve may be relatively cold).
Monitor the regenerated slide valve differential pressure and try to maintain above 0.2 kg/cm2.
e) The first indication of catalyst in the spent catalyst line will be an increase in the slide valve
differential pressure. When an increase is noted on the spent slide valve differential pressure,
very slowly open the spent catalyst slide valve to initiate the circulation. When the spent
catalyst slide valve differential drops, close the valve. The first portion of catalyst may be
difficult to circulate because it is cold, and possibly wetted. A batch wise transfer is
recommended until the temperatures are higher. It may be necessary to increase the differential
pressure between the stripper and the first regenerator, i.e. to decrease the first regenerator
pressure to overcome difficulty in the initial catalyst movements. The minimum delta pressure
through the lift is 0.3 kg/cm2.
f) Continue batch-wise circulation and transfer until the stripper temperature is above 370C. At
this time, start to rise the pressure in the first regenerator to the normal operating pressure and
adjust the second regenerator pressure. Put pressure controllers on automatic control.
g) When the stripper temperature reaches 480C, the stripper level can be increased to the normal
operating level. During these operations adjust the plug valve opening to keep the level in the
second regenerator and put the level in the second regenerator on automatic control.

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UNIT RFCC (015)

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h) Manually adjust the opening of the spent catalyst slide valve to keep the level in the stripper.
Note :

Do not let the level in the stripper get above high level at any time. If this level is
being approached, slow or stop the flow of catalyst from the second regenerator as
required by manually pinching the regenerated catalyst slide valve until the stripper
level is back to its normal level, in order to avoid catalyst loss through the disengager
cyclones.

i) Adjust the regenerated and spent catalyst slide valves to keep the levels in the vessels and to
maintain approximately an equal differential opening pressure on the two catalyst slide valves.
Then the valves may be put on automatic control.
j) Catalyst addition or withdrawal may be necessary in order to adjust the unit inventory.
k) Continue to circulate catalyst until a temperature of preferably 530C and at least 510C is
reached at riser outlet.
l) At this point the fractionation system should be ready to receive products from the reaction
section. The feed system to the riser should be circulating through the reaction section bypass
and ready to be lined up to the feed injectors.
m) During catalyst circulation, check that no water is present in Riser Wye section (taking
precautions, as a lot of catalyst may go out).
Note :

6.3.5

To stop catalyst transfer, always close first the gate valve at the bottom of the hopper,
in order to get the transfer line completely rid of catalyst.

Oil-in into Rizers

Prior to oil in, provided all other sections (gas recovery flue gas treatment) are ready to handle disengager
effluents.
Before oil-in the unit must be in the following conditions:
Pressures:

Disengager

Normal operating conditions on automatic control from PIC.


Controlling by WGC or Flaring through pressure control
valve.

First regenerator

Normal operating conditions on automatic control acting on


the first regenerator flue gas slide valve.

Second regenerator

Normal operating conditions on P automatic control acting


on the second regenerator flue gas slide valve PdIC.

Levels:

Disengager

On automatic control acting on the spent catalyst slide valve


from LIC.

First regenerator

At normal level on automatic control acting on the plug


valve from LIC.

Second regenerator

Is not controlled directly, but is a function of catalyst


inventory.

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UNIT RFCC (015)

February 2007
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Temperatures:

Riser outlet

Preferably 530C.

Regenerators

650C with torch oil and fuel gas firing in the heaters.

Flow rates:
First and second regenerators air flows are at about 50% of the normal operating flow rate.

Air lift flow is at 100% of the normal operating flow rate.

Riser and stripping steams are all in service at normal operating flow rates.

Aeration, conveying and instrument purges are all in service at normal operating flow rates.

All injections steams (stabilization, feed, MTC) are all in service at normal operating flow rates.
Catalyst is circulating and catalyst slide valves are opened in order to have a minimum of 0.35
kg/cm2 pressure drop in each slide valve.
Monitor the oxygen in the main fractionator reflux drum (oxygen < 0.2% vol.).
Analysers on flue gas lines (O2, CO, CO2) will be operational.
Oil-in will be performed as follows:
Caution:

As hydrocarbons will be present in the unit it is important that all vents and drains be closed
and opened only with an operator present. Drain condensate from all low points, being
careful not to vent fuel gas.

a) Switch the disengager/stripper purges from nitrogen to fuel gas. Check all purges flow rates.
Special Note:
1. Since purge gas to Detail B2 and A2 for instrument tapping of the disengager /
stripper is normally supplied from the Gas Con Section, fuel gas should be temporary
used until commission of Gas Con Section. Open 3 fuel gas connection at the inlet of D1509 on P&ID 8474L-015-PID-0021-138. Upon treated gas from Gas Con Section is
available switch purge gas from fuel gas to treated gas.
2. Since fuel gas pressure is normally 3.0 3.3 kg/cm2g, opening of bypass valves of the
following control valves are required to maintain pressure at the purge points, when fuel
gas is used as purge gas.
- PCV-015: Rizer instrument purge Detail B2 (PID 15-122)
- PCV-013: Regnerated catalyst conveying Detail A2(PID-15-122)
-PCV-044: Disengager instrument purge Detail B2 (PID-15-124)
-PCV-042: Stripper instrument purge Detail B2 (PID-15-124)
3. In case Wet Gas Compressor is operating and treated gas from Gas con Section is
available, the above fuel gas purge operation is not required.
b) Check that emergency systems UX-001(ES1) and UX-002(ES2) are activated.
c) Put the regenerated catalyst slide valve on manual control.

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UNIT RFCC (015)

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d) Drain water from feed injectors and open the block valves on the feed lines, keeping the control
valves closed.
e) Injectors will be put in operation three by three. First, on three opposite injectors open the
control valves at 50% of the normal flow; then proceed with the next three injectors, etc... As
soon as feed is injected into the riser, the riser outlet temperature will tend to drop. To
compensate the temperature drop, the opening of the regenerated catalyst slide valve can be
slowly increased to admit more hot catalyst into the riser. Do not get pressure drop getting less
than 0.15 kg/cm2g. The second regenerator temperature can also be increased by increasing the
torch oil flow rate. The riser outlet temperature should not drop below 480C as catalyst
stripping will become ineffective.
Feed rate should be quickly increased to 70% of the normal capacity as rapidly as possible,
within 1 hour of oil-in.
Beginning of coke combustion will be noted by an increase of the first regenerator dense phase
temperature.
Adjust the regenerators temperatures by adjusting the torch-oil flow rates and stop firing in both
air heaters. Keep the temperatures below 700C.
f) Adjust air flow rates to regenerators so that a temperature of 650C-700C is kept in the first
regenerator and an oxygen excess of minimum 2% is obtained in the second regenerator flue
gas.
g) When catalyst circulation is stabilized, put the Riser Outlet Temperature on automatic control
(RCSV).
h) Proceed to a pressure survey of each injector (steam and oil) for equal flows and inlet nozzles
pressures.
i) Start metal passivator injection as required. For initial operation, start metal passivator injection
at later stage, after establishing line-up all the operating condition and stable operation.
j) Check catalyst levels. After main fractionator stabilization, increase the capacity at design
capacity by increaments of 10% of capacity.
k) Adjust air flow rates to regenerators, accordingly.
l) Check the regenerated catalyst by samples.
m) Check the unit inventory of catalyst (add or withdraw catalyst if necessary).
n) Start to load fresh catalyst and to withdraw spent catalyst.
o) Sample the main fractionator bottoms for signs of catalyst carry-over from the disengager.
p) Sample flue gases to adjust combustion air rates.
Note:

During the increase of capacity, the two regenerators are running with about 50% of the normal
air flow rates and torch oil under complete combustion mode. While the capacity is increased,
the torch oil is progressively reduced to balance the coke formation. After a given capacity is
reached, the coke make is enough to shift to partial combustion in the first regenerator. At this
moment the CO content can increase rather quickly (in 2 to 3 minutes).

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UNIT RFCC (015)

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After stabilization, the flue gas from the first regenerator can be sent directly to CO Boiler.
CO Boiler can be put on stream progressively when the CO content is high enough and stable in
the flue gas at about 5%.
It may be necessary to adjust the position of flue gas bypass valves (quench sprayers) to
achieve a good control range on CO Boiler or flue gas bypass lines according to the
manufacturers procedures.
6.3.6
Notes:

MTC system commissioning


1. Dispersion steam is constant whatever the flow of MTC recycle.
2. The optimum MTC flow rate depends on the feed quality and on the desired yields
structures (switch from maxi gasoline to a maxi distillate mode of operation for instance).
3. For design intention MTC injection is only used for the Maximum Gasoline Operation
of Mixed Crude.

a)

Drain water from MTC injectors and open block valves on the recycle lines.

b)

Make sure lines from pumps to riser are clean by checking the drains before the control valves.
Check that dispersion steam is at the normal operating flow rate.

c)

Put the Riser Outlet Temperature control (RCSV) on manual.


Slowly open MTC control valves by steps of about 5%. The cracking severity of the fresh feed
will increase.
Adjust the set point of the Riser Outlet Temperature controller to obtain the desired conditions
for optimized cracking operation:
Fresh feed mix temperature,
Catalyst to fresh feed ratio (C/O).

d)

Injectors will be put in operation one by one. Confirm that flow rate of MTC injection should
be higher than pump minimum flow. Increase again MTC injection by 5% increments and
adjust the Riser Outlet Temperature accordingly.

f) Put Riser Outlet Temperature on automatic control (RCSV).

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R-20
7-MA

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
Rev.
:A
Chapter : 6
Page
: 123/230

6.4 Start-up for the Fractionator Section


6.4.1 Objective
The following guidelines describe the first start-up of the unit. For subsequent start-ups some procedures
will be omitted, depending on the status of the unit.
6.4.2 Status
All precommissioning and commissioning activities have been completed:

Each section has been leak tested


All sections have been water flushed
Instruments have been tested
Utility systems have been commissioned
All safety equipment is in place
Required blinds have been removed/installed as required
The unit has not been air freed
6.4.3 Steam-out (or nitrogen purge)
Prior to bringing hydrocarbons into the unit, it is necessary to remove all air from the unit. This is done
by steaming out the unit and then admitting nitrogen or fuel gas to prevent vacuum conditions when the
steam condenses.
Caution : If steam-out is stopped with the vessel vents closed, and gas is not introduced, vacuum
conditions will occur. However, most equipment is designed for steam-out conditions of
160C and full vacuum.
Caution: Reactor and Regenerators are not designed Full vacuum. Special care shall be taken
that vent valve shall never kept to close while steaming into the system, especially under
situation of MOV-001 closed condition.
For steam-out, the unit can be considered to be divided up into the following sections :

Feed section
Main fractionation section including side strippers, from main fractionator inlet to the wet gas
compressor suction
Flushing oil
Slops
Wet gas compressor interstage
Wet gas compressor (N2 purge)
HP separator drum, absorber-stripper, secondary absorber and fuel gas absorber
Debutanizer section
LPG amine absorber section
Before admitting steam into the unit cooling water should be shut-off to exchangers, instruments which
could be damaged by steam should be isolated, pumps blocked in and vessel vents opened.

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8474L-015-ML-001-A
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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

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The 1st and 2nd stages of the wet gas compressor are isolated from the interstage section, so that the
compressor stages can be nitrogen purged and the interstage section steamed out.
1) Feed section
Steam out via the vent or drain connections on the lines feeding the unit and on the feed surge drum.
Continue steaming out until there is a good flow of steam from the feed surge drum vent. The preheat
piping and exchangers should be hot with steam coming from the various vents and drains.
After steam has been venting for a minimum of one hour, this section can be pressure tested by closing
vents and drains to raise the pressure to 1.5 to 2.0 kg/cmg.
After pressure testing is complete, the section is pressurized with fuel gas.
Block in the steam and admit fuel gas to maintain a positive pressure on this section.
2) Main fractionator to wet gas compressor
This section consists of the main fractionator, reflux drum, wet gas compressor suction drum, product
stripping sections, slurry system and pumparounds. This section can be further sub-divided as considered
necessary, with the same procedure being carried out for each subsection.
Steam-out is carried out with MOV-001 closing position in the reactor vapor line. Steam out connections
on the main fractionator, strippers and drums in the section are all used for steam out.
Continue steaming out until there is a good flow of steam from all the vessels in the section. All piping
and exchangers in the section should be hot, with steam coming from the various vents and drains.
After steam has been venting for a minimum of one hour, this section can be pressure tested by closing
vents and drains to raise the pressure to 1.5 to 2.0 kg/cmg.
After pressure testing, the sections are pressurized with fuel gas. Block in the steam and admit fuel gas to
maintain a positive pressure on the sections.
3) Slops section
Steam out via the steam out connections on the light slops drum and the heavy slops drum.
Continue steaming out until there is a good flow of steam from the drum vents and piping vents and
drains.
After steam has been venting for a minimum of one hour, the heavy slops and light slops sections can be
pressure tested by closing vents and drains to raise the pressure to 1.5 to 2.0 kg/cmg.
After pressure testing, the two sections are pressurized with fuel gas. Block in the steam and admit fuel
gas to maintain a positive pressure on the two sections.
4) Flushing oil
Steam out via the steam out connections on the HCO and LCO flushing oil drums.
Continue steaming out until there is a good flow of steam from the drum vents and piping vents and
drains.
After steam has been venting for a minimum of one hour, the HCO and LCO flushing oil sections can be
pressure tested by closing vents and drains to raise the pressure to 1.5 to 2.0 kg/cmg.
After pressure testing, the two sections are pressurized with fuel gas. Block in the steam and admit fuel
gas to maintain a positive pressure on the two sections.
5) Wet gas compressor interstage
Steam out via the steam out connection on the wet gas compressor 2nd stage K.O. drum. Continue
steaming out until a good flow of steam is venting from the drum.
After steam has been venting for a minimum of one hour, this section is pressure tested by closing vents
and drains to raise the pressure to 1.5 to 2.0 kg/cm2 g.
After pressure testing is complete the section is pressurized with fuel gas. Block in the steam and admit
fuel gas to maintain a positive pressure on this section. Drain condensate from all low points while
ensuring that fuel gas is not vented.
6) Wet gas compressor purge

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8474L-015-ML-001-A
07
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7-MA

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
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Each stage is isolated by the suction and discharge valves. Pressurize each stage with nitrogen to 2 to 3
kg/cm2 g (or as specified by vendor), then depressurize to atmosphere.
This procedure should be repeated 4-5 times and then leave the compressor stages under a pressure of 1.5
to 2 kg/cm2 g.
7) HP separator drum, absorber-stripper, secondary and fuel gas absorbers
Use the steam out connections on the HP separator drum, absorber-stripper, secondary and fuel gas
absorbers to steam out this section. Steam out until there is a good flow of steam from the vents on the
HP separator drum, stripper-absorber and secondary absorber and fuel gas absorber.
After steam has been venting for a minimum of one hour, this section can be pressure tested by closing
vents and drains to raise the pressure to 1.5 to 2.0 kg/cm2 g.
After pressure testing is complete the section is pressurized with fuel gas. Block in the steam and admit
fuel gas via the line to fuel gas from the fuel gas absorber knock-out drum via reverse flow from the
refinery fuel gas system opening by-pass valve of the last control valve PV-733, to maintain a positive
pressure on this section. Drain condensate from all low points while ensuring that fuel gas is not vented.
8) Debutanizer section
Use the steam out connections on the debutanizer and debutanizer reflux drum. Steam out until there is a
good flow of steam from the vents on the debutanizer and the reflux drum.
After steam has been venting for a minimum of one hour, this section can be pressure tested by closing
vents and drains to raise the pressure to 1.5 to 2.0 kg/cm2 g.
After pressure testing is complete the section is pressurized with fuel gas. Block in the steam and admit
fuel gas to the debutanizer reflux drum, to maintain a positive pressure on this section. Drain condensate
from all low points while ensuring that the fuel gas is not vented.
9) LPG amine absorber section
Isolate the section from the inlet of the LPG cooler to the outlet of the LPG amine coalescer.
Use the steam out connections on the LPG amine absorber and LPG amine coalescer to steam out the
section. Steam out until there is a good flow of steam from the vents on the absorber and coalescer.
After steam has been venting for a minimum of one hour, this section is pressure tested by closing vents
and drains to raise the pressure to 1.5 to 2.0 kg/cmg.
After pressure testing is complete, block in the steam and pressurize with nitrogen.
6.4.4 Main fractionator cold circulation
When all sections of the fractionation and gas recovery section are under stable pressure, with fuel gas,
nitrogen or LPG as applicable, cold hydrocarbon liquid is introduced to the main fractionator. Prior to
bringing in hydrocarbon liquid, check throughout the unit to ensure that all instrumentation and electrical
equipment is energized and ready for operation. Place all pumps in the stop position.
It is suggested to use a light oil (LCO, LGO) for the initial flush as this does not form an emulsion as
stable as that with heavier oils. Normally, residue type feed will not be brought into the unit until the unit
is ready for feed to the riser.
All vents and drains should be plugged or flanged and blinds should be put in the proper position for
operation.
LCO is used for pump mechanical flushing during start-up, until HCO is available. Fill LCO to D-1518,
HCO flushing Oil Drum and start supply pump mechanical flushing oil to the various pumps. Ensure
that external flushing oil system are commissioned prior to start the relevant pump.
The purpose of the cold circulation is to remove as much foreign material and water as possible and to
establish levels to test pumps.
1.

Drain any water from the boot of the feed surge drum D-1513 and start to bring in LCO from
outside of B.L. When there is sufficient level in the feed surge drum, start one of the feed pumps,

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8474L-015-ML-001-A
07
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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

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ensuring that the minimum flow line is open. Each pump can be started separately, for testing and
running in.
2.

Filling LCO to the preheat heat exchangers from the feed pumps, and establish the following cold oil
circulation loop, using start-up line 8-PL-150024.
D-1513 P-1501AB E-1512ABCD E-1522 E-1524 E-1502ABC E-1501AB FCV001 8-PL-150024 D-1513

3.

Start filling the bottom of the main fractionator through the start-up line (6-PL-150025) from the
feed section E-1501AB outlet. Bring LCO into the feed surge drum as required. Line up the slurry
pumparound circuits and start two of the three pumps and start circulation through the slurry
pumparound circuits, using maximum circulation rates to flush the circuits. Alternate the pumps for
testing and running-in. Drain free water from low points.

4.

Fill the HCO and LCO pumparound circuits with LCO. The LCO circuit is filled directly using the
LCO start-up connection (3-PL-150604) to the pumparound pumps P-1510AB suction line. Fill the
HCO circuit by flowing LCO down the column.

5.

Start circulation in the two circuits, bringing in LCO as required. Alternate the pumps for testing and
running-in. Drain free water from low points.

6.

To help to remove water quickly from the circuits, continue to add feed to the fractionator and run
oil to slops via the slurry product, HCO product and LCO product circuits. Open all by-passes to
flush these lines. Drain free water from low points in the circulating circuits. It is important to
remove all free water before hot circulation is started. When running to slops via the slurry product
line, by-pass the slurry separator.

7.

After stopping flushing to slops, stop LCO feed to the fractionator and continue circulation.

8.

Commission level control of D-1518 HCO flushing oil drum as necessary to supply sufficient
mechanical seal flushing oil to the various pump, which are used external flushing oil. LCO should
be continuously supplied from over filling from main fractionator LCO pumparound to HCO
pumparound and HCO stripper.

6.4.5 Cold Oil Circulation of Gas-Concentration Section


Proceed cold oil circulation of Gas-Concentration section using start-up naphtha to remove water and any
sludge in the system and reedy to receive feed gas from the main fractionator.
Subsequet steam out operation of Gas Concentlation unit, admit fuel gas from the fuel gas
system to the outlet of HP Separator, D-1553, using start-up fuel gas line (3 inch).
Maintain pressure of Gas con unit as high as possible by fuel gas. If CDU LPG is available
at this moment, introduce CDU LPG to HP Separator, D-1553 for increasing operation
pressure, by self vaporization.
Start Wet Gas Compressor to pressurize Gas Con Section, under MOV-001 closed
condition to segrigae operation of Reactor/Regeneration and Fractionator/Gas
Concentration Section.
Introduce fuel gas to D-1554, and subsequently bring start-up LPG to D-1554, debutanizer
Reflux drum to pressurize D-1554 and T-1554, Debutanizer, by self vaporization. Startheating up of Debutanizer Reboiler to boost-up operation pressure of Debutanizer.
Fill start-up naphtha to the main fractionator reflux drum D-1514, and start P-1515AB for
transfer start-up naphtha to T-1551, and establish cold oil circulation of Gas Concentration
section.

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8474L-015-ML-001-A
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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
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D-1514 P-1515AB T-1551 D-1553 P-1553AB E-1555 T-1552 T-1554


E-1556 E-1558 E-1559 6 inch Start-up line D-1514
Drain water from the low point of piping, and remove water as far as possible, before feed
cut in to the reactor.

6.4.6 Main fractionator hot circulation


Hot circulation is carried out to check the pumps under hot conditions and thus ensure the availability of
pumparound cooling when hot feed is introduced to the fractionator. Hot bolting can be carried out and
the circuits checked for any thermal stress problems. Both the slurry pumparound and HCO pumparound
can be heated during hot circulation.
In the slurry pumparound, circulating LCO is heated by condensing MP steam in the slurry MP steam
generators E-1505A/B. The slurry pumparound circuit can be heated up to approximately the MP steam
condensing temperature. In the HCO pumparound, the HCO MP steam generator E-1523 can be used for
heating.
The main requirement of hot oil circulation is to reach around 110 deg C at the top of the main column.
Using MPS a temperature in the slurry pumparound and bottom temperature around 200 deg C can be
reached. As higher temperature is preferred, if saturated HPS is available from COB/WHB section,
admit saturate HPS to E-1504AB utilizing reverse flow, by-passing check valves.
In order to assist heating up upper sections of the main column, the following jump over lines are
provided to warming/heating-up of LCO pumparound and Heavy Naphtha pumparound.
-

Start-up line (6-PL-151010) from HCO pumparound pump discharge to LCO pumparound circuit
return.

Start-up line (6-PL-151009) from LCO pumparound pump discharge to Heavy Naphtha
pumparound circuit return.
As the fractionator heats up, any remaining water will be vaporized up the column. This will condense
and should be drained off from low point of the LCO pumparound, the heavy naphtha section and the
reflux drum.
Before it is time to open MOV-001 at the column inlet, allow the circulating pumparounds to cool down
to around 120C.
6.4.7 Main fractionator MOV-001 Opening
Opening MOV-001 between the main fractionator and the reactor must be carefully co-ordinated between
the two sections. Allow the slurry and HCO pumparounds to cool down to 120C. Reduce the main
fractionator level to a minimum (below the steam out connection) and stop slurry circuit circulation. Stop
the HCO and LCO pumparounds circulation. Depressurize the main fractionator section to the flare and
start steam flow to the bottom of the fractionator, using 3 steam out connection.
Follow the procedure for opening MOV-001 as outlined in the Reaction/Regeneration Section.
After full opening MOV-001, steam flows to the reactor and main fractionator may be re-started, and fuel
gas admitted to pressurize the main fractionator using HCV-434 at the overhead off gas line.
The main fractionator pressure is controlled by the pressure control from the reflux drum to flare. A
constant pressure is required to allow smooth catalyst circulation.
Stop the steam to the bottom of the fractionator and bring oil into the fractionator from the feed section.
Re-start slurry and HCO pumparounds circulation and heat the circulating oil to avoid the condensing
steam temperature.
Start LCO pumparound circulation. Bring in LCO as required. During circulation drain water from the
low points in the circuit.
To fill the heavy naphtha pumparound circuit, bring start-up naphtha into the fractionator reflux drum.
Start a reflux pump and fill the heavy naphtha pumparound circuit. Start heavy naphtha pumparound
circulation and during circulation, drain free water from the low points.

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8474L-015-ML-001-A
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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
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The hot circulation on the slurry pumparound and HCO pumparound should be continued until feed is
brought into the riser.
Fill the fractionator reflux drum to normal liquid level with start-up naphtha to provide initial top reflux
when feed is brought into the riser.
6.4.8 Wet gas compressor start-up
Start-up of the wet gas compressor at this stage is optional. The only consequence of delaying the
compressor start-up until feed is brought into the riser is that more gas will be vented to flare. It is
recommended that Wet gas Compressor to start operation after reactor feed cut-in as enough gas is
available, and avoiding surge concerning.
If the molecular weight of the fuel gas is too low this may cause surging of the compressor. If this is the
case the molecular weight may be increased by bringing LPG into the fuel gas system, using LPG
vaporizer E-3701 in the fuel gas system (Unit 37). Communicate operation of Fuel Gas supply system.
To start the wet gas compressor introduce fuel gas to the system via HIC-434 at the main fractionator
overhead, and 3 fuel gas supply to the interstage KO drum.
Open the suction and discharge valves and start the compressor following the vendors procedures. If gas
is not being produced from the reaction section, it will be necessary to bring in more fuel gas as the
fractionator pressure will decrease as the compressor is started.
When required, start the fractionator overhead air cooler and compressor intercooler and start cooling
water to the fractionator trim condenser and compressor interstage trim cooler.
The wet gas compressor is run on full spill-back until gas is available from the fractionator reflux drum.
Dry gas seal of the wet gas compressor is normally supplied from the treated off gas. When starting the
wet gas compressor, use nitrogen for the source of dry gas seal. Soon after the wet gas compressor is
operating and treated gas being available switch over seal gas source from nitrogen to treated gas.
6.4.9 Start up Procedure of Wet Gas Compressor
Check instrumentation and commission any instruments not already in operation.
Prepare to startup the wet gas compressor (C-1551) in accordance with manufactures instructions. The
steam turbine driver exhausts to a surface condenser which must be placed in operation prior to the
compressor.
1. Nitrogen Purge of Compressor
Purge all air from the compressor by Nitrogen prior to unblocking the suction and discharge lines for both
stages.
2. Lube Oil and Dry Gas Seal
The lube oil and dry seal gas systems should be in operation per manufacturer's recommendations.
3. Open Compressor Isolation MOVs
Slowly open the suction MOV and allow the pressure in the compressor to equalize with the connecting
piping and vessels. Add fuel gas as necessary to maintain pressure in the unit.
4. Draining
Check drain from suction line and the compressor casing to remove any liquid.
5. Line-up
Make sure the line-up as follows:

Spillback valves UV-701 and UV-702: Full Open

MOV-703/704/705/706: Full Open


6. Increase Fuel Gas Injection
Increase the fuel gas makeup to the Compressor suction KO drum to provide an operating cushion before
starting the gas compressor. Maintain the Main Column overhead pressure at 0.7 kg/cm2g
7. Interstage Coolers
Make sure operation of inter cooler and trim cooler by opening the cooling water to the interstage trim
cooler.

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8474L-015-ML-001-A
07
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7-MA

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
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8. Start Compressor
Start the compressor on line according to manufacturer's procedure.
Watch the pressures in the Main Fractionation main column receiver (D-1514), the compressor suction
drum (D-1551) and the compressor interstage suction drum (D-1552) carefully. Add fuel gas as necessary
to maintain pressure.
The compressor should be running at the minimum normal operating speed with the spillbacks open and
PCV-733 closed condition at outlet of the fuel gas absorber outlet drum D-1559.
9. Pressurize System
Watch the pressures in the Main Fractionation main column receiver (D-1514), and the compressor
interstage suction drum (D-1552) carefully. Add fuel gas as necessary to maintain pressure.
The system pressure may be increased up to approximately 5 kg/cm2g at Stripper to enable gasoline cold
circulation.
6.4.10 Inventory Gas Concentration Section and Naphtha Circulation
Once the vessels are under pressure with fuel gas, they can be inventoried with start-up naphtha and
internal circulation can be established. This will allow smoother control of levels and flows while feed is
being started from the Main Fractionation Section. This must be coordinated with the Fractionation
Sections as the initial inventory is provided through the normal operating flow schemes.
1) Preparation
Prior to introducing start-up naphtha, establish the stripper (T-1552) pressure higher than the
debutanizer (T-1554) pressure by 3 kg/cm2 if possible. The stripper (T-1552) bottoms are
pressured to the debutanizer (T-1554) and there must be enough pressure available to allow flow
between the two vessels if circulation is to be established.
2) Inventory Startup Naphtha to Main Column Receiver
Start up naphtha is introduced to the Main Column Receiver Drum (D-1514). Once the Main
Column Receiver (D-1514) is inventoried and levels are stabilized, naphtha can be brought into
the primary absorber (T-1551) using the overhead liquid pumps (P-1518A/B).
3) Inventory Naphtha to Gas Concentration Section
Start the flow slowly and do not lose the level in the Main Column Receiver (D-1514). Continue
make-up naphtha flow from storage as necessary. Build a high level in the primary absorber (T1551) bottoms and then start flow to the high pressure separator condenser (E-1554). Continue
to establish levels in the high pressure separator (D-1553), the stripper (T-1552) and the
debutanizer (T-1554).
4) Establish Naphtha Circulation
Once a level is in the bottom of the debutanizer (T-1554), then bottoms liquid to recycle
gasoline back to the Main Fractionation column receiver (D-1514), using start-up circulation line
(6-PL-150761).
Once all levels are established, the make-up start-up naphtha to the Main Fractionation Receiver
can be stopped. Continuous circulation from the main column receiver (D-1514) through the
primary absorber (T-1551), the high pressure receiver (D-1553) should now be in operation.
Control may be somewhat difficult due to low flow rates so it is important that all levels are
carefully monitored. Also the pressure differential between the stripper (T-1552) and the
debutanizer (T-1554) must be maintained monitoring compressor operation.
At this moment, for the debutanizer overhead pressure control, to maintain stable pressure in the
column at approximately 2 kg/cm2 of differences between T-1552 and T-1554. Or, if Stripper
pressure is not enough due to lack of compressor head with low molecular weight gas, the
Debutanizer pressure may be lowered to enable naphtha transfer from Stripper to Debutanizer.

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8474L-015-ML-001-A
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7-MA

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
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6.4.11 Heat Up the Stripper and Debutanizer


Heat to the stripper (T-1552) and debutanizer (T-1554) is supplied from the circulated LCO and HCO
from/ to Main Fractionation Section. It is desirable to warm up the reboilers on these vessels prior to start
up if possible. This is entirely dependent upon available heat from the Main Fractionator and must be
closely coordinated with the warm-up activities of Main Fractionator to prevent too much heat removal
from the Main Fractionator (T-1501).
(1)
Heat up Debutanizer Reboiler
Begin a small flow of heavy cycle oil (HCO PA) through the debutanizer reboiler (E-1560AB). It
may be necessary to use the control valve bypass on the HCO flow to limit heat removal from the
Main Fractionator (T-1501).
Watch the bottoms level so as to not boil away all the naphtha and monitor the debutanizer (T1554) temperatures. Do not overheat the column.
(2)
Heat up Stripper Reboiler
Begin a small flow of light cycle oil (LCO PA) through the Stripper Reboiler (E-1557). Again
this must be closely coordinated with the warm-up activities of Main Fractionator to prevent too
much heat removal from the Main Fractionator (T-1501). During this start-up, sampling is
needed to frequently check there is no water content in pumparound stream.
The bottoms level and the temperatures in the stripper (T-1552) must also be monitored for
proper heating up.
(3)
Inventory Secondary Absorber
Begin a small flow of lean oil to the Secondary Absorber (T-1553) from the Lean Sponge Oil
Pump (P-1513AB) and establish a level in the bottom of the secondary absorber (T-1553).
If possible begin to circulate this hydrocarbon back to the Main Fractionation section. This flow
depends upon the sponge absorber pressure, which depends upon the compressor operation with
low molecular weight gas, being higher than the LCO return pressure so it may not be possible to
establish this flow until normal operating pressure is achieved in the secondary absorber (T1553).
6.4.12 Introduction of feed
1) Fractionation section
Prior to introduction of feed, the slurry pumparound and HCO pumparound circuits are on hot circulation.
Ensure that there is always a sufficient flowrate to the grid (Bed 5) during start-up and subsequent normal
operation. Failure to maintain adequate flow to the grid will result in coking.
The LCO pumparound should be checked for water. Cooling water flow should be established through all
water cooled exchangers. Steam can be started to the HCO and LCO strippers.
Switch the slurry MP steam generators and HCO MP steam generator to normal operation by shutting off
the medium pressure heating steam and admitting boiler feed water. Bring in boiler feed water to the HP
steam generators.
After feed is introduced to the fractionator and as the slurry pumparound temperature increases, initially
send steam to atmosphere via start-up silencers. Open the block valves in the lines to the steam headers
and pressurize the steam generators by throttling the valves in the lines to the silencers. During start-up
both the continuous and intermittent blowdowns can be used to bring the blowdown water within
specification.
The main fractionator bottoms level should be closely monitored as it may increase when feed is
introduced. Shortly after feed has started the slurry should be checked for catalyst. This will indicate if
there is excessive catalyst carry-over from the reactor. This should be checked several times per shift
until operation has stabilized.
If the wet gas compressor was not already started it will now be necessary to do so. Open the isolation
valves and start the compressor according to the vendors procedures.

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DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

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The compressor must be started smoothly to prevent any pressure surge on the main fractionator, which
could upset catalyst circulation. As liquid builds up in the interstage drum start liquid flow to the HP
separator drum.
When the level starts to rise in the fractionator reflux drum, slowly start reflux to control the overhead
temperature. The temperature should be kept high enough to prevent condensation of steam at the top of
the column.
Start the overhead sour water pumps and send the sour water initially to the sour water stripper.
Start slowly drawing off LCO to the stripper and adjust the stripping steam rate, and prepare to start the
LP steam generator. Send the LCO to slops, before sending LCO to storage.
Start drawing off heavy naphtha to the stripper and start reboiling the stripper with the HCO pumparound.
Send the heavy naphtha to slops.
Start drawing off HCO to the stripper and adjust the stripping steam and prepare to start the LP steam
generator. When the level in the stripper starts to rise switch the flushing system to HCO.
When stable operation is reached in the fractionation section, start the water wash to the overhead
condenser.
2) Stripper, absorbers and debutanizer
The HP separator drum, primary absorber, secondary and fuel gas absorber are pressurized with gas
coming from the wet gas compressor.
Open the line to flare at the outlet of the fuel gas absorber outlet K.O. drum and set the pressure
controller at the top of the secondary absorber.
When the liquid level rises in the fractionator reflux drum, start the overhead liquid pumps and send
liquid to the primary absorber. When the liquid level rises in the HP separator, start the stripper feed
pump and begin to feed the stripper. When heat is available from the LCO pumparound, start reboiling
the stripper. Liquid from the stripper is pressurized to the debutanizer. When a level is established in the
debutanizer start reboiling with the HCO pumparound. When the level in the debutanizer reflux drum
starts to rise, start the debutanizer reflux pump. During the start-up period, light ends may be carried over
to the debutanizer and it may be necessary to vent the reflux drum to the flare.
In the absorber section, start the lean sponge oil pump and feed lean oil to the secondary absorber on flow
control. When there is a liquid level in the secondary absorber start sending rich oil back to the main
fractionator on level control. When the level rises in the debutanizer reflux drum, start sending LPG to
the LPG amine absorber.
When a level is established in the debutanizer bottom, flow of gasoline is started to slops, via the stripper
first reboiler, air cooler and water cooler. Start the gasoline recycle pumps and slowly start circulation to
the primary absorber. Adjust the reboiler duty of the stripper.
Start amine flow to the fuel gas absorber and switch the outlet of the fuel gas absorber from flare to fuel
gas. When stable operation of the gas plant is reached, start the water wash to the wet gas compressor
intercooler.
3) LPG amine absorber
Prepare the LPG amine absorber for start-up prior to introduction of feed. The section is under nitrogen
pressure. Start slowly the flow of lean amine to the LPG amine absorber and fill up to 50% of the level
control range. Vent nitrogen to the flare as necessary.
When LPG is available in the debutanizer reflux drum, introduce LPG to the bottom of the absorber and
slowly fill the top of the absorber and the coalescer. Vent nitrogen to flare as the system is filled. Set the
lean amine at design flowrate and start sending LPG to the LPG treating unit

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DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
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NORMAL OPERATION OF THE UNIT

7.1 Summary of operating conditions


For the sake of easy reference throughout this section, a summary of the operating conditions is given
below.
For more details refer to the Process flow diagram(s) and Basis of design.
The parameters marked * are those which can be set by operators and must be set as indicated in order to
achieve the above objective.
The other parameters are expected ones and depend upon the conditions (flow rate, feed quality...) at the
time. The figures shown are related to the normal operating flow and design feed.
Bach Ho
Bach Ho
Mixed
Mixed
Reaction-regeneration

Riser
Outlet temperature*
Feed flow rate*
Feed temperature*
Recycle flow rate*
Recycle temperature
MTC flow rate*
MTC temperature
Dispersion steam flow
rate*
Riser steam temperature
Backflush oil
Disengager/stripper
Dilute phase pressure*
Stripping steam flow rate*
Regenerator 1
Dilute phase temperature
Dense phase temperature
Dilute phase pressure*
Coke burnt
Flue gas composition
CO
CO2
Air ring flow rate*
Air blower temperature
Regenerator 2
Dilute phase temperature
Dense phase temperature
Dilute phase pressure*

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Maxi
Gasoline

Maxi
Distillate

crude
Maxi
Gasoline

crude
Maxi
Distillate

C
kg/h
C
kg/h
C
kg/h
C
kg/h

518
407 000
290
0
0
20 350

505
407,000
290
117,100
0
20,350

520
407 000
170
0
76 400
181
20 350

511
407 000
170
117,100
0
20 350

C
kg/h

250
7379

250
6875

250
7605

250
7097

kg/cm2g

1.43

1.43

1.43

1.43

14 300

14,300

14 300

14 300

C
C
kg/cm2g

646
651
2.28

631
636
2.28

678
683
2.28

641
646
2.28

%
%
mole %
mole %
kg/h
C

70

70

70

70

5.3
10.6
181 520
232

5.3
10.6
166,575
238

6.3
9.9
261 840
210

6.2
9.9
215,357
223

C
C
kg/cm2g

734
713
1.3

720
695
1.3

772
762
1.3

733
712
1.3

kg/h

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

Maxi
Distillate

Mixed
crude
Maxi
Gasoline

Mixed
crude
Maxi
Distillate

0
16.9
1.8
38 773
232
47 832

0
16.9
1.8
31685
238
47832

0
16.9
1.8
79 610
210
47 832

0
16.9
1.8
57261
223
47 832

t/min
t/d

0.94
5.57
37.7
5.5

0.91
5.27
35,7
5.5

1.22
6.34
42.9
15.2

0.99
6.43
43.6
15.2

wt ppm
wt ppm
wt %
wt %

0
1 776
75
80.76

0
1776
60

6 748
3 213
68
79.94

6 748
3 213
55

Reaction-regeneration

Flue gas composition


CO
CO2
O2
Air ring flow rate*
Air blower temperature
Air lift flow rate*
Catalyst
Delta coke
C/O
Catalyst circulation
Catalyst make-up* (dry
basis)
Metals on catalyst V
Ni
Catalyst activity MAT
Standard conversion

%
mole %
mole %
mole %
kg/h
C
kg/h
wt %

Bach Ho

Bach Ho

Maxi
Gasoline

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7.2 Control philosophy of the process


The R2R unit will operate in a stable manner over a wide range of conditions.
Careful attention to unit performances and process variables will result in an operation of maximum
profitability with few problems and upsets.
As a general rule any change in the vessels should be done slowly in gradual increments for stable
catalyst circulation.
In the present chapter we will look at these variables again from more practical standpoints such as MTC
control.
The most critical control loop on the converter is the Riser Outlet Temperature. The temperature should
be controlled within 1C of the set point. A thermocouple located near the outlet of the riser measures
the reaction temperature. The temperature is a function of the amount of catalyst admitted to the riser by
the regenerated catalyst slide valve. Reaction temperature is basic primary variable to the conversion of
RFCC feedstocks.
To enhance fresh feed vaporization and ultimately the product yields, mixed temperature control (MTC)
technology is used. MTC flow rate is set to maintain the desired temperature at the fresh feed injection
point. A thermocouple TI-008 located uptream of the MTC injectors measures the catalyst / vapor
mixture temperature.
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 to provide a seal at the diplegs outlet of the Riser Outlet Separation System.

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DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

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The level in the first stage regenerator is measured by a differential pressure instrument that signals a
level controller which resets the position of the plug valve. 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 reentrainment from the cyclone dust bowls.
During normal operation, the second stage regenerator level 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.
The total daily amount of catalyst withdrawal is adjusted by timer setting taking into account the
operation requirements for the overall catalyst balance.
The regenerators pressures are controlled by flue gas slide valves 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. The differential pressure between the first stage and second stage regenerators is
controlled by the second regenerator flue gas slide valve. This differential pressure is set to provide
adequate pressure drop across the plug valve for stable control of the regenerators levels. The disengager
pressure rides on the main fractionator pressure which is controlled at the main fractionator overhead
receiver. 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.
As a general rule any change in the vessels should be done slowly in gradual increments to allow slide
valves to reposition properly for stable catalyst circulation. The unit is designed to provide adequate
slide valve pressure differential for safe operation. Override controls are provided for action in low slide
valve differential upsets which close slide valves to prevent dangerous reverse flow. Normal catalyst
slide valve differential is around 0.3 to 0.5 kg/cm to provide stable control. Slide valve differentials
above 0.7 kg/cm are to be avoided because they may cause valve erosion. Negative differentials should
never be permitted and the PDIC controls should be set to override the main controllers at 0.1 kg/cm.
Smooth catalyst circulation is paramount for successful operation of R2R and is achieved by proper
catalyst aeration and conveying in the transfer lines, as well as control of the unit pressure balance.
An emergency shutdown circuit will close the catalyst slide valves automatically upon loss of feed and
loss of combustion air.

MTC control

Control of the feed and catalyst mix temperature is critical in order to vaporize all hydrocarbons that can
be converted to lighter products. This can be achieved independently of the riser outlet temperature
which is the primary reaction control parameter. Riser Outlet Temperature is maintained conventionally
by regenerated catalyst circulation through the hot regenerated catalyst slide valve. The mix temperature,
which can be measured in an appropriate location downstream from the feed injection point, is controlled
by an additional liquid hydrocarbon injection point, provided a few meters above the feed injection.

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DUNG QUAT REFINERY
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UNIT RFCC (015)

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With MTC, it is therefore 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.
The heat absorbed by MTC vaporization is then used downstream in the fractionation section for steam
production, preheating or reboiling.
The nature of the recycle depends upon each situation. If heavy naphtha is used as MTC fluid, then MTC
acts essentially as a heat sink. The aromaticity of heavy naphtha renders it essentially inert. As a result,
LPG and light gasoline yields will be promoted and higher conversion levels will be achieved. When
using heavy naphtha, the additional coke formed in the riser (delta-coke) will be minimized and the C/O
ratio will therefore be increased. To avoid over-cracking, the Riser Outlet Temperature can be reduced
by about 10C when the recycle is 20% of feed. If the heat balance of the unit is not critical, heavier
fractions such as Light Cycle Oil (LCO) or Heavy Cycle Oil (HCO) can be used.
7.3 Operating parameters
Chapter 3.3.2 has listed the process variables, i.e. the variables (pressures, temperatures, catalyst activity,
regenerators air balance, heat balance, feedstock quality, coke yield, delta coke, catalyst to oil ratio)
which according to the thermodynamics and the kinetics have an impact on the reaction involved in the
process. This rather theoretical approach did not outline whether the operators could actually change the
considered variable. Chapter 3.3.2 has listed the effects of key process variables illustrating the role of
adjusting these variables to achieve a particular process objective. In the present chapter we will look at
these variables again from a more practical standpoint such as operating parameters and how the
operators can actually use them to adjust the performance of the unit.
7.3.1

Capacity

The R2R unit is capable of operating in a stable manner at turndown capacity with some adjustment of
the operating parameters. The mass flow of the circulating catalyst and combustion air is nearly
proportional to the feed rate. The basic design of the unit has taken into consideration the turndown rates
for catalyst velocities and air distribution at turndown rate. Proper air distribution and catalyst flow will
be stable at turndown rates. During operation below design capacity, oil feed should be reduce
proportionally to each feed injector.
The quantity of dispersion steam, stabilization steam, and MTC steam should be maintained as per the
design operating conditions.
7.3.2

Riser Outlet Temperature

The operating temperature of the riser outlet will normally be set to achieve the desired degree of
conversion. Typically, a temperature of 510C will correspond to a maximum distillate operation and a
temperature of 525 to 530C will correspond to a maximum gasoline operation. This temperature is
controlled by the regenerated catalyst slide valve position allowing more or less hot regenerated catalyst
to contact and mix with the incoming feed. When the hot catalyst contacts the feed in the bottom of the
riser the oil vaporizes almost instantaneously. The homogeneous mixture of oil and catalyst reaches a

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temperature approximately 30 to 40C higher than the top of the riser. The initial temperature shock
causes thermal cracking, while catalytic cracking begins after the oil is converted to vapor, and the
molecules contact the active catalyst sites.
As the catalytic cracking progresses and the catalyst/oil mixture flows up the riser, the temperature drops
since the heat of cracking is endothermic. At the top of riser the moles of products are 3.5 - 5.0 times
more than the moles of fresh feed.
The riser temperature has a complex interrelation with the other parameters in cracking. An increase in
the riser temperature is generally accompanied by:
an increase in conversion,
an increase in dry gas yield,
an increase in LPG production,
an increase or a decrease (over cracking) in gasoline production depending on the reaction
severity,
an increase in gasoline octane,
a decrease in LCO and slurry yield,
a slight increase in coke production.
These are only trends. A quantitative definition of the changes requires heat and material balances as well
as yield correlations. The catalyst quality also affects the extent of the changes.
7.3.3

Disengager pressure

A lower pressure in the reaction zone thermodynamically improves product yields. However the choice
of the pressure must take into account the equipment size and the minimum acceptable pressure
considering the wet gas compressor. A pressure of around 0.8 to 1.4 kg/cm g can be considered as an
optimum value for very heavy feedstocks. Typically the pressure is maintained constant and is only
changed to adjust disengager pressure during unit start-up or upsets.
7.3.4

Catalyst activity

In conventional gas oil cracking the catalyst activity is measured in two different ways, from actual
operation and in the laboratory.
In the current practice, an equilibrium catalyst sample is forwarded each week to the catalyst supplier
laboratory. There, a standard test (feedstock and operating conditions) is performed to check catalyst
activity. Other analyses such as surface area, density, pore volume, particle size distribution, metal
content, are also reported. The catalyst activity, thus measured, relates to the conversion that the actual
operating unit may experience with a different feedstock. The correlation of the laboratory measurement
is somewhat loose on account of the difficulty in properly quantifying the differences not only in the
feedstock, but also the relationship of the method to unit operation. This leads more to a directional
relationship in the sense that higher activity catalyst in gas oil cracking leads to greater conversion.
In residue cracking the catalyst activity does not necessarily hold the directional relationship between
laboratory measurement and unit operation. The complexity of evaluation increases which necessitates
the use of other parameters for relating to conversion. The catalyst surface area and the concentration of
the deposited heavy alkali metals provide a more meaningful basis to predict unit performance. This is in

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addition to a detailed knowledge of the specific characteristics of the catalysts. While catalyst properties
and predicted product state are originally derived at the catalyst development stage, the true performance
of the catalyst can only be ascertained from unit operations.
The catalyst activity is best measured by the unit operation. The conversion is calculated from unit yields,
which include gas and coke productions. Close monitoring of the yields, changes in metal deposition and
catalyst surface area are the best methods for maintaining the desirable level of activity. Catalyst activity
should be interpreted to mean not only the level of conversion, but also the ability of the catalyst to yield
the maximum amount of valuable products and high octane gasoline, while at the same time coke and dry
gas productions must be minimized.
Catalyst activity is maintained by the addition of fresh catalyst on a continuous basis. The required rate
of addition varies depending on feedstock quality, desired level of conversion, operating conditions, and
type of catalyst. Normally, addition at a rate of around 1 to 4 kg of catalyst per 1000 kg of feed are
necessary to maintain desired conversion. Frequent monitoring of the equilibrium catalyst properties and
level of metal contamination (i.e. Ni, V, Na, etc...) are required to provide optimum adjustment of the
addition rate.
7.3.5

Regenerators air balance

The reduction of the coke on the catalyst to less than 0.05 wt % requires a predetermined amount of air
regardless of how the air is distributed between the two regenerators. In a unit with one regenerator the
required air rate would be the sum of what the two regenerators require as long as coke yield and the
average flue gas composition are the same. Having two regenerators provides a flexibility of how to split
the total air required. When certain constraints, such as the maximum regenerator bed temperature and
desirable flue gas composition are imposed, the freedom to arbitrarily split the required air decreases.
However, there is a great advantage in assigning a specific air rate to each regenerator.
The first stage regenerator design temperature is 770C, therefore the coke that should be burned must be
controlled so that this temperature limit is not exceeded. The combustion of carbon monoxide is more
rapid as the temperature increases over 650C. This results in lower carbon monoxide concentration and
greater air requirement as the regenerator bed temperature rises. When coke burns to form carbon
monoxide and steam the heat generated is about half as much as when the same amount of coke burns to
form carbon dioxide and steam. The higher temperature generated by greater carbon dioxide production
further facilitates the burning of carbon monoxide. If the air rate is limited, then the conversion of CO to
CO2 is controlled and the regenerator bed temperature is kept lower. But at the same time more coke
remains on the catalyst. The objective is to determine an air rate to the first stage regenerator that will
limit the bed temperature and yields carbon monoxide in the flue gas.
The objective in the second stage regenerator is to burn all the remaining coke completely to carbon
dioxide. The bed temperature is allowed to rise to around 810C (mechanical design : 840C). The air
rate is adjusted to give 2 - 3 mole % of free oxygen in the flue gas which ensures that the carbon
monoxide concentration in the flue gas is less than 0.05 mole %.
The above split of the required air also has the advantage of minimizing catalyst deactivation. Most of the
hydrogen contained in the coke burns in the first stage regenerator. The steam thus generated is at a
lower temperature and causes less catalyst deactivation. Since only a small part of the total hydrogen
contained in the coke is burnt in the second stage regenerator, the steam concentration is reduced in the
higher temperature environment. The flue gas from each regenerator is routed separately which
segregates the flue gases according to their carbon monoxide concentration.

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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

7.3.6
a)

Regenerator temperatures
Dense phase temperatures

First stage

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The first stage regenerator dense phase temperature is a function of the riser temperature, the amount of
coke burned, and the catalyst circulation rate. The temperature is controlled by varying the air flow to
the vessel. The air rate should be adjusted so as not to exceed a temperature of 730C.

Second stage

The second stage regenerator dense bed temperature is also a function of the amount of coke burned and
the catalyst circulation rate. The normal operating temperature is around 100C higher than the first
stage regenerator dense bed. Control of this temperature is not independent because the air rate to the
second stage regenerator is adjusted to achieve complete CO combustion (i.e. 2 - 3 % mole O2 in flue
gas) under normal operation.
In any case, it is important to keep a minimum temperature in the catalyst dense bed, which is required
for a proper combustion (around 680C).
b)

Dilute phase temperatures

The dilute phase temperature will normally run within 10C of its corresponding dense phase temperature.
The catalyst used, while not promoted, has properties which enhance combustion in the dense bed.
These properties, together with proper inventory of catalyst in the dense phase, ensure that all oxygen
required for combustion will be burnt away in the dense bed, removing the possibility of after burning.
7.3.7

Regenerators residence time

The catalyst residence time in the regenerators is a key parameter for the regeneration quality. The
catalyst levels in the two regenerators are optimized depending on the regeneration temperatures to
achieve the required inventories.
Typically, a total residence time around 6 minutes for the two regenerators is sufficient to achieve a
carbon on regenerated catalyst leaving the second regenerator of less than 0.05 wt %, which is considered
as a target value for a good regeneration.
During normal operation, care must be taken to keep the catalyst levels at their normal levels. Low
catalyst levels will affect the regeneration quality, whereas high catalyst levels will affect the catalyst
entrainment to the cyclones and consequently will increase the catalyst losses.
7.3.8

Regenerators velocities

The quality of the combustion depends on the catalyst fluidization. A good mixing between catalyst and
air is required for the combustion and therefore turbulent flow is desired in the regenerators dense bed.
The corresponding superficial velocities are in the range of 1 - 1.3 m/s. A minimum velocity of 0.5 m/s
should be kept in any case (especially for reduced capacity operation).
7.3.9

Stripper operation

The removal of any light hydrocarbons which may remain with the catalyst after disengagement in the
disengager / stripper is accomplished by steam injection into the stripper dense bed via different steam
rings. The amount of steam is adjusted depending on the catalyst circulation rate and feed rate. The flow

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rate is adjusted on the main steam ring, keeping the flow rates on the lower ring and upper ring constant.
Stripping efficiency is measured by the hydrogen content on coke. Stripping is considered as efficient
when the hydrogen on coke is around 6 wt %.
7.3.10 Heat balance
The reaction/regeneration section can be viewed as a closed heat exchange loop where catalyst is
recirculated between a heater (regenerator) and a cooler (riser). Hot catalyst is cooled in the riser through
vaporization and cracking of feed and is reheated in the regenerator by burning the coke produced during
the cracking reaction. The riser outlet temperature controls the regenerated catalyst slide valve to provide
sufficient flow of hot catalyst to maintain the riser at the desired temperature.
Sensible heats represented by normal variations in riser and regenerator temperatures are very small when
compared to the heat of combustion of coke (heating medium), the heat of vaporization of feed and the
heat of cracking (cooling medium).
The unit is heat balanced in the sense that the heat for vaporizing and cracking the feed is furnished by
the combustion of the produced coke in the regenerator.
An overall energy balance shows that the energy released by the combustion of coke (carbon and
hydrogen) becomes:
the sensible and latent heat of the flue gases,
the sensible and latent heat of the disengager effluent,
the heat of cracking.
Expressed another way, the coke yield in this adiabatic process is essentially that required to satisfy the
heat load.
One of the unique features of the RFCC process is that it will always attempt to reach an equilibrium
operating point that is heat balanced. That is, the dependent operating variables will automatically
achieve conditions where enough coke is made to produce the required heat of combustion to heat and
vaporize the feed, supply the heat of chemical reaction, and cover the various heat losses from the
process.
The most important independent variable in the RFCC unit is the Riser Outlet Temperature. Two other
important independent variables are feed preheat temperature and MTC oil flow rate. A Riser Outlet
Temperature 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

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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-to-oil 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.
7.3.11 Feedstock quality
In catalytic cracking a hydrogen deficiency develops as the hydrocarbon molecule splits and requires that
a hydrogen joins a cracked molecule. The higher molecular weight hydrocarbons have lower
concentration of hydrogen than the lower molecular weight hydrocarbons. When the cracking process
produces lighter hydrocarbons than the feed, the hydrogen is made available from the hydrogen of
hydrocarbons with higher molecular weight.
The molecule that gives up hydrogen can become deficient in hydrogen to the point that it turns into coke.
Hence, it is easy to see that the yield of lighter hydrocarbons or the conversion depends on the total
amount of hydrogen contained in the feed. API gravity and distillation determine the hydrogen
availability to yield lighter products. Even when the distillation is not properly defined, the API gravity
gives an indication of feed quality, since lower API gravity feedstock generally has a higher boiling
range and less hydrogen.
The metals, which are part of the RFCC feed, adversely affect performance. Nickel, vanadium, copper
and iron carried by the feed will deposit on the catalyst sites and through a complex mechanism, lead to
catalyst deactivation. The process is gradual up to a certain metal level on the catalyst, but above about
10,000 ppm of metals, deactivation becomes more rapid. If the metal concentration of the feed cannot be
reduced to control this, then fresh catalyst addition replacing catalyst in the unit must be at a rate high
enough to keep the metal concentration on the catalyst at the required level.
Sodium and other alkali metals also act as catalyst poisons. Exceeding 1 ppm of sodium in the feed
should be avoided. Also sodium decreases catalyst melting point making it more sensible to high
temperatures.
The nitrogen and the sulphur in the feed adversely affect cracking, but are less harmful. Both the
nitrogen and the sulphur tie up hydrogen that could be used in the formation of valuable hydrocarbons.

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In addition to this, the ammonia that is formed is basic, and has a neutralizing effect on the acidic catalyst
sites.
The Conradson carbon in the feed was in the past believed to convert fully to coke. The coke on the
catalyst surface must be burned off in the regenerator, and more coke produces higher regenerator
temperatures. Hence, increasing Conradson carbon in the feed was expected to lead to inoperable
conditions. In the development of the R2R process, the temperature limitation was raised to be able to
handle higher coke burning rate. At the same time, it was noted that previous beliefs stating that 100% of
the Conradson carbon converts to coke were false. Only about 50% of the Conradson carbon converts to
coke, while the rest turns into gaseous products. As the Conradson carbon concentration increases, the
second stage regenerator temperature has a tendency to increase. Adjusting certain operating parameters
such as feed temperature, disengager pressure, atomisation steam flow, stripping steam flow, may
compensate for this up to a point.
Notes: 1. Do not put slops in the unit feedstock. Additives like copper, manganese, sodium,
potassium, organic chlorides, lead from gasoline... will at least increase gas production
and could damage catalyst. Nitrogen will also neutralize catalyst acid sites and will
decrease conversion.
2. Recycle of the slurry backwash oil to feed injectors is NOT recommended. The
recycle slurry will tend to increase both coke and dry gas production and will result in
excessive erosion of the feed injectors. As result, this backwash material is directed to
a single injector located in the top section of the riser, specifically designed for erosive
service.
7.3.12 Feed temperature
The preheat temperature of the feed must be adjustable:
to ensure a proper oil viscosity (around 10 to 15 cSt maximum at the injector inlet) for proper
atomization of the feed,
to ensure a minimum temperature to avoid steam condensation in the feed injectors.
The feed temperature must also be optimized depending on the heat balance. The feed temperature
affects significantly the coke production and the second regenerator temperature (refer to the next section
concerning the coke production).
Note that an increase of the feed temperature will result in:
a decrease of coke production,
an increase of the second regenerator temperature.
7.3.13 Coke yield / delta coke / catalyst to oil ratio
The catalyst to oil ratio (C/O) is defined as the rate of catalyst divided by the rate of fresh feed.
The delta coke is defined as the difference between the coke percentage on spent catalyst and the coke
percentage on the regenerated catalyst.
The coke yield corresponds to the percentage of feed transformed into coke.
These three parameters are correlated by the following equations:
Coke yield
= C/O x Coke
= T reactor + coeff x Coke
T reg 2
These relations reflect the heat balance between the reaction section and regeneration section.
The three process variables will automatically achieve the conditions where the heat balance is satisfied.
For a given feed quality and catalyst type, the coke production depends upon nothing except Riser Outlet
Temperature and feed temperature.
The unit will be optimized with the highest possible C/O and the lowest possible delta coke for the
following reasons:

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a higher C/O will provide:

more active catalyst sites for the reaction,

a better contact between catalyst and oil,

a higher heat transfer efficiency.


This leads to higher conversion, i.e. larger total liquid, LPG, gasoline yields while slurry yield declines.

a lower delta coke will provide:

lower regeneration temperature.

C/O is increased by maintaining a minimum temperature for good vaporization,


the Riser Outlet Temperature is fixed by the operation mode (maxi gasoline or distillate mode).
IFP has developed the MTC concept which allows to disconnect the heat balance between the reaction
section and the regeneration section, providing supplementary flexibility for the unit operation.
If the operation mode requires to decrease the Riser Outlet Temperature, the injection of a "cold" fluid,
acting as a quench, helps to keep the feed mix temperature at a desired high value for sake of
vaporization and heat transfer.
Catalyst circulation / pressure balance
Catalyst circulation results from different vessels elevations and from differential pressure created by
various catalyst densities.
Fluidized catalyst behaves very similarly to normal liquid fluids.
Smooth catalyst circulation requires precise control of the unit pressure balance, through the precise
control of the pressure in the vessels and the proper control of the densities in the catalyst dense beds and
standpipes.
The pressure in the disengager is controlled by the main column overhead receiver. The pressure in the
disengager is higher than the receiver pressure by the amount of pressure drop through the main column,
the condenser and the lines between top of the disengager and the receiver. The pressure in the
disengager is normally kept as low as possible within the limits of the wet gas compressor.
The first stage regenerator pressure is controlled by a double disc slide valve followed by a variable
orifice and a differential pressure controller holds a constant differential pressure (around 0.7 kg/cm)
between the first and the second regenerator. The differential pressure between the two regenerators
should be maintained constant for a smooth operation of the air lift.
Flue gas slide valves should operate with a pressure differential between 0.3 to 0.7 kg/cm for good
control and minimal disk erosion. These valves are designed to never fully close by means of a
mechanical stop or a slot cut into the disks. Complete closure of these valves could potentially overpressure the disengager / stripper / regenerator system.
Pressure of the first regenerator must be controlled so that the differential pressures on the regenerated
and spent catalyst slide valves are balanced satisfactorily, i.e. to obtain similar pressure drops through the
two slide valves. The minimum required pressure drop through the slide valves for steady control of the
valve is around 0.30 kg/cm. Maximum pressure drop should be limited to 0.7 kg/cm for avoiding
erosion problems.

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It is obviously essential for steady circulation that the pressure difference between the vessels be as
consistent as possible. Toward this end, it should be noted that the stripper and first stage regenerator
levels are kept steady. The second stage regenerator is allowed to float between its minimum and
maximum levels.
Catalyst circulation is controlled by the opening of the regenerated catalyst slide valve. The circulation
rate cannot be measured directly; it must be calculated from the heat balance or estimated from the
openings and pressure drops of the regenerated and spent catalyst slide valves.
7.4 Adjustment of operating conditions
Monitoring and optimization of the performance of a RFCC can add significantly to the overall refinery
margins. It requires careful data collection and validation procedures to ensure that a proper evaluation is
made and the right conclusions are drawn with respect of the catalyst effects. The relevant data for this
exercise include the unit conditions, feedstock properties, product yields and qualities as well as
equilibrium catalyst analyses.
Unit monitoring includes data collection, validation and interpretation. The number of available
measurements will determine the extent of the evaluation. The required data can be grouped as follows:

Feedstock properties (density, sulfur, metals etc..),


Mass balance data (product flows, densities),
Essential product properties (distillation, octanes, sulfur, viscosity),
Heat balance data (temperatures, flue gas composition, air rates),
Pressure balance data (vessels pressures, valves P, standpipe operation, catalyst levels),
Equilibrium catalyst analyses (activity, surface area, metals, etc).
In most cases heat and mass balance data are available on a continuous basis from the process computer.
Feed and product analyses are made periodically. The equilibrium catalyst analyses are normally
available once per week. A careful survey of the operating conditions must be constantly performed.
To minimize analyses, a good definition of essential product properties is required for the refinery
engineer. Apart from that it is also important that the essential analyses are from samples taken at the
same time.
All this together allows a proper monitoring of the RFCC unit.
The modification of the feedstock properties, operation mode (maxi distillate / maxi gasoline...) and
catalyst activity (metals content, new catalyst) requires to adjust the operating variables. For the detailed
monitoring of the operating variables, refer to section above.
7.4.1

Feedstock properties

The feed must be analyzed on a daily basis. The metals content must be carefully checked, especially the
sodium content which should be limited to 2 wt ppm maximum to avoid catalyst poisoning and
deactivation. Malfunctioning of crude desalters or processing of imported feeds contaminated with
seawater are the typical causes of high sodium levels in most cases.
The nickel introduced with the feed is partially passivated by passivator injection (Sb or Bi solutions).
The passivation efficiency can be checked by measuring the ratio H2/C1 in the dry gas. This ratio should
not exceed 1.0. Otherwise, the amount of passivator should be increased accordingly.

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Metals contents as high as 10000 ppm (total content) are acceptable on the equilibrium catalyst but
sudden increases of metals in the feed, especially sudden changes in vanadium content, should be
avoided.
7.4.2

Mass balance

To monitor the product yields, it is very useful to calculate the yields for constant cut points (typically
221C TBP for gasoline end point and 360C TBP for LCO end point).
A TBP distillation curve of the total disengager effluent must be built based on the ASTM distillation and
yield of each product. Product flow measurements must be corrected carefully in order to obtain accurate
yields patterns. All the products are measured at the fractionation unit/gas recovery unit outlets except
the coke production. For the coke production calculation, see next section, heat balance.
7.4.3

Product properties

Product properties will be checked regularly and the operating conditions will be adjusted to meet the
desired properties: operating mode, cut points,...
Some specific properties should be watched carefully, such as the slurry fines content in order to check
any troubles on the disengager cyclones or such as the slurry viscosity in order to optimize the control of
the main fractionator bottom.
7.4.4

Heat balance

In a commercial unit, the coke production will always be such that the energy released by the combustion
of coke keeps the unit in heat balance. This energy is used in the regenerator to:
heat the spent catalyst from stripper outlet to regenerators bed temperature,
heat the air from blower discharge to the flue gas temperature,
compensate for regenerator heat losses.
The heat transferred by the circulating catalyst provides the energy for:
vaporization of the feed, including the recycles,
heating any riser stabilization/dispersion medium,
the heat of reaction,
compensation of disengager stripper heat losses.
The regenerators mass balance gives the coke production whereas the heat balance is used to calculate the
catalyst circulation. The accuracy of the calculation depends mainly on the accuracy of the flue gas
analyses.
A)
Coke yield
It is possible to estimate the amount of coke burned in each regenerator when one knows the amount of
air going to the regenerators and the flue gas analysis (CO, CO2, O2).
"A" is flow rate of air to the regenerator expressed in kg/h.
CO, CO2, O2 are % moles in the flue gas sample where all the water from combustion and from air
humidity is supposed to be condensed (dry sample).

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One can therefore assume that the concentration of nitrogen N2 in % moles in the dry flue gas sample is:
N2 = 100 - (CO + CO2 + O2 + H2 + CH4 + C2H6)
In the air to the regenerators there are:

A
x 0.79 kmoles of nitrogen
29
The amount of nitrogen moles crossing the regenerators does not change and if "NFG" is the amount of
dry flue gas moles not including the water, it is possible to write that:

NFG x N 2
A
=
x 0.79
100
29
Therefore:

NFG =

A
100 x 0.79
x
N2
29

The amount of carbon moles burnt in the flue gas is the amount of moles of CO + CO2. That is:

CO + CO 2
x NFG
100
Therefore the weight of burnt carbon is:

12 x A x 0.79 x (CO + CO 2 )
N 2 x 29
The weight of carbon "CB" burnt in the coke is:
"CB" =

0.328 x A x (CO + CO 2 )
kg/h
N2

The weight of stripped carbon "CS" in kg/h is:


"CS" =

0.328 x A x (CH 4 + 2 x C 2 H 6 )
kg/h
N2

The number of moles of oxygen in the air to the regenerators is calculated from H2O, O2, CO and CO2 in
the flue gas.
The number of moles of oxygen in the air is:

A
x 0.21 kmoles
29
The number of moles of oxygen in the flue gas calculated from CO, CO2 and O2 is:

NFG
1

CO
O 2 + CO 2 +

100
2
Therefore the number of moles "O" of oxygen which are found in the flue gas under H2O is:

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"O" =

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0.79 (O 2 + (0.5 x CO ) + CO 2 )
A x 0.21 A
x
29
N2
29

or:
"O" =

A
0.79
1

x 0.21 x O 2 + CO 2 +
CO

29
N2
2

The weight of water made from the hydrogen of the coke is:
"O" x 2 x18
Therefore the weight of hydrogen burnt in the coke "HB" is:
"HB" =

"HB" =

2 x "O" x 2 x 18
= 4 x "O"
18

4A
0.79
1

x 0.21 x O 2 + CO 2 +
CO

29
N2
2

or
"HB" =

A
0.79
1

x O 2 + CO 2 +
CO (kg/h)
x 0.21

N2
2
7.25

The weight of stripped hydrogen "HS" is:

H 2 + (2 x CH 4 ) + (3 x C 2 H 6 )
x NFG
100
2 x A x 0.79 x (H 2 + (2 x CH 4 ) + (3 x C 2 H 6 ) )
"HS" =
29 x N 2
"HS" = 2 x

The weight of stripped coke is:


Stripped coke = "CS" + "HS"
The weight of coke burnt is:
Coke burnt = "CB" + "HB"
The total amount of coke is:
Total coke = "CS" + "HS" + "CB" + "HB"
B)

Catalyst circulation rate

The catalyst circulation rate can be estimated by two different methods:


By the heat balance around the regenerators.
a)

By calculating the catalyst circulation through the slide valves.


Catalyst circulation rate from heat balance

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Likewise previous calculation of coke production, the following formulas apply as well for the first
regenerator as for the second regenerator. The goal here is to get a simple but reliable circulation rate
calculation. For this purpose, the following approximation have been made:
Sulfur in coke is not taken into account.
Specific heats are kept constant, corresponding to an average temperature.

The general formula is yielded from the heat balance around the regenerator:

CCR =

Hair + Hcoke + Hcombustion - Hdesorption - Hflue gas Losses


CpCAT x (Tout - Tin )

with

CCR

= Catalyst Circulation rate

(kg/h)

CpCAT

= Specific heat of catalyst = 0.2862

(kcal/kg/C)

Tout

= Regenerator dense phase temperature

(C)

Tin

= Catalyst inlet temperature

(C)

Hair

= Wet air enthalpy

(kcal/h)

Hcombustion

= Coke combustion enthalpy

(kcal/h)

Hflue gas

= Flue gas enthalpy

(kcal/h)

Losses

= Heat losses

(kcal/h)

Hcoke

= Enthalpy of coke burnt in the vessel

(kcal/h)

Hdesorption

= Coke desorption enthalpy

(kcal/h)

Wet air enthalpy calculation:

Hair = Qair [(1 - m) x [(CpN x WN 2 ) + (CpO x WO 2 ) + (m x CpW )] x (Tair - To)


with

Hair

= Wet air enthalpy

(kcal/h)

Qair

= Air rate

(kg/h)

= Air water content (weight fraction)

CpN

= Nitrogen specific heat = 0.249 kcal/kg/C

WN2

= Air nitrogen content = 0.768 wt fraction

CpO

= Oxygen specific heat = 0.223 kcal/kg/C

WO2

= Air oxygen content = 0.232 wt fraction

CpW

= Water specific heat = 0.453 kcal/kg/C

Tair

= Air temperature

(C)

To

= Reference temperature = 0C

(C)

Coke enthalpy calculation:

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Hcoke = Qcoke1 x (0.24 x Tstripper + 12.96 x 10-5 x Tstripper2)


with

Qcoke1

= CS + HS + CB + HB

(kg/h)

Tstripper

= Catalyst inlet temperature average stripper


temperature
(C)

Coke combustion enthalpy calculation:


Hcombustion = Qcoke2 x AA + BB

AA =
CO + CO x [(7.831 x FC O 2 ) + (2198 x FCO)]
2

BB = (28869 x FH ) - [((- 57.11 x FH ) + 440.78 ) x C]


with

Hcombustion

= Coke combustion enthalpy

(kcal/h)

Qcoke2

= CB + HB

(kg/h)

= Coke carbon weight fraction

(kg/kg)

FCO

= Dry flue gas CO content mole fraction

(mole/mole)

FCO2

= Dry flue gas CO2 content mole fraction

(mole/mole)

FH

= Coke hydrogen weight fraction

(kg/kg)

Coke desorption heat calculation:


Hdesorption = 354 x Qcoke3 x C
with

Hdesorption

= Coke desorption heat

(kcal/h)

Qcoke3

= CS + HS

(kg/h)

= Coke carbon content weight fraction

(kg/kg)

Losses (including aeration enthalpy variation):


Default values are 1.5 x 106 kcal/h
Flue gas enthalpy calculation:
Hflue gas = Qflue gas x [A + (B x (C + D + E + F + G + H + I ))] x (TFLUEGAS - TO )
with

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= y x CpW1

= 28 x CO x CpCO

= 44 x CO2 x CpCO2

= 32 x O2 x CpO2

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= 2 x H2 x CpH2

= 16 x CH4 x CpCH4

= 30 x C2H6 x CpC2H6

= 28 x N2 x CpN2

Hflue gas

= Flue gas enthalpy

(kcal/h)

Qflue gas

= Total wet flue gas rate

(kg/h)

= Flue gas water content water/air wt fraction


(kg/kg)

FCO

= Dry flue gas CO content mole fraction

(mole/mole)

FCO2

= Dry flue gas CO2 content mole fraction

(mole/mole)

FO2

= Dry flue gas O2 content mole fraction

(mole/mole)

FN2

= Dry flue gas N2 content mole fraction

(mole/mole)

CpCO2

= CO2 specific heat = 0.261 kcal/kg/C

CpO2

= O2 specific heat = 0.223 kcal/kg/C

CpCO

= CO specific heat = 0.262 kcal/kg/C

CpN2

= N2 specific heat = 0.249 kcal/kg/C

Tflue gas

= Regenerator temperature

MW

= Molecular weight of dry flue gas

(C)

= (28 x FCO) + (44 x FCO2) + (32 x FO2) + (28 x FN2) + (2 x FH2) + (16 x FCH4) + (30 x FC2H6)
FH2

= Hydrogen content mole fraction

(mole/mole)

FCH4

= Methane content mole fraction

(mole/mole)

FC2H6

= Ethane content mole fraction

(mole/mole)

FCpH2

= H2 specific heat = 3.483 kcal/kg/C

FCpCH4

= CH4 specific heat = 0.788 kcal/kg/C

FCpC2H6

= C2H6 specific heat = 0.703 kcal/kg/C

FCpW1
= Water specific heat = 0.491 kcal/kg/C
Catalyst circulation rate from slide valves

b)

The circulation through a catalyst slide valve can be estimated as follows:

CCR = 0.036 x
with

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A
x OPEN x K x 2 x G x cata x P
60000

CCR

= Catalyst circulation rate

(t/min)

= Delta pressure through the slide valve

(kg/cm2)

cata

= Catalyst density

(kg/m3)

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c)

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OPEN

= Percentage of open area if proportional. Usually the valve


manufacturer provides the correlation between the open area and the
valve stroke.

= Slide valve area at 100% opening

cm2

= Gravity acceleration

cm/s2

= Valve coefficient, typically 0.85, to be confirmed during unit


operation.

Delta coke

The delta coke corresponds to the difference between the coke amount deposited on the spent catalyst
and the coke amount remaining on the regenerated catalyst. This value can be determined by catalyst
analyses. It can also be estimated roughly by the following correlation:

coke =

Tbed regen2- ROT HCOOL


+
100
195

with

d)

coke

= Delta coke (wt %)

Tbed regen2

= Second regenerator dense phase average temperature (C)

ROT

= Riser outlet temperature

(C)

HCOOL

= Catalyst cooler duty


(if applicable)

(106 kcal/h)

Overall heat balance

The achievement of the overall heat balance can be translated into the following equation:
coke = C/O x coke
with

7.4.5

coke

= Coke yield

(wt %)

C/O

= Catalyst to oil ratio

(massic ratio)

coke

= Delta coke

(wt %)

Pressure balance

An adequate pressure balance will ensure a smooth catalyst circulation in the unit. The key parameters
are the catalyst slide valves pressure drops. A good pressure balance will result in equilibrated pressure
drops through the regenerated catalyst slide valve and the spent catalyst slide valve (around 0.5 kg/cm2).
The pressure drop through the valves should not be lower than 0.3 kg/cm2, to keep a sufficient margin to
avoid reverse flow and should not exceed 0.7 kg/cm2 to avoid excessive erosion in the valve.
The pressure balance results from the balance between the pressure lost to lift the catalyst (in the air lift
and riser) and the pressure gained in the catalyst dense beds and standpipes. The monitoring of the
pressure balance requires the checking of the catalyst levels in the vessels and the checking of the
regenerated and spent catalyst standpipes behaviour.
A)
Catalyst levels

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Normal catalyst levels have been defined in the design. These levels must be kept as constant as possible,
and in any case in between the operating margin (minimum level-maximum level). The levels should not
be too high to avoid excessive catalyst fines carry-over to the cyclones and should not be too low to
maintain minimum residence times in the vessels for proper stripping and proper regeneration.

There is no direct measure of the levels. The levels are measured through dP cells located in the dense
beds:
A first dP cell measures the pressure difference between the dense phase and the dilute phase. The
height of catalyst above the lower pressure tap is then:

H =

dP1
x 10 4
d

with H

= Catalyst height above lower dP tap

(in m)

dP1

= Pressure drop

(in kg/cm2)

= Catalyst density

(in kg/m3)

L1 x S1
100

dP1 =

with L1
S1

H =

= Reading 0-100% on level recorder


= Scale of level transmitter

(in kg/cm2)

L1 x S1
x 100
d

A second dP cell measures the catalyst density in the dense bed. This cell measures the pressure
drop in the bed for a given and known distance between two pressure taps (typically 1.5 meters).

d =

dP2 x S2
x 100
L

with d

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= Catalyst density

(in kg/m3)

dP2

= Reading 0-100% on dPI recorder

S2

= Scale of dPI transmitter

(in kg/cm2)

= Distance between dPI impulse lines

(in m)

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Finally, the catalyst level can be estimated by:

Hcata = Hlow + L x
with Hcata

L1 x S1
dP2 x S2

= Catalyst level

(in m)

Hlow

= Elevation of lower level tap

= Distance between the two pressure taps


of catalyst density measure
(in m)

L1

= Reading on level recorder

(in %)

S1

= Scale of level transmitter

(in kg/cm2)

dP2

= Reading on dPI recorder

(in %)

S2

= Scale of dPI transmitter

(in kg/cm2)

The accuracy of the level measurement depends on the accuracy of the catalyst density measure. It is
critical that the two pressure taps of the density measure are covered by catalyst. This means that during
the catalyst loading, as long as the catalyst level has not reached the upper density tap, the measured
density is not correct. It is recommended to use the design density during the loading.
In case of failure of the density measurement, the design densities can be used to estimate the levels.
Actual densities can also be determined by the fluidization curve which gives for each catalyst, the
density versus the superficial fluidization velocity in the vessel.
B)

Catalyst standpipes

A significant part of the pressure recovery in the unit takes place in the catalyst standpipes. It is
important to check regularly the behaviour of the standpipes, especially the regenerated catalyst
standpipe.
The monitoring of the regenerated catalyst standpipe should be done in such a way that aerations are
adjusted to keep a constant catalyst density along the standpipe. Aerations are located all along the
standpipe. The purpose of these aerations is to compensate the air compression effect due to the pressure
increase along the standpipe and consequently to maintain a constant density. An easy way to control the
standpipe behaviour is to check pressure profile. The profile must be a continuous curve straight line
showing the increase of pressure.

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Theoretical pressure recovery chart


with correct individual aeration setting
flow.
Individual aeration rate shall be reset.
Pressure decrease due the catalyst
acceleration at the slide valve inlet.
Pressure

Bottom

The aerations flow rates must be adjusted in order to obtain the smoothest profile. The aeration rate is
proportional to the catalyst circulation rate.

7.5 Catalyst management


7.5.1

Catalyst analyses

The equilibrium catalyst analyses are carried out on a frequent basis, in order to monitor the catalyst
performance in commercial operation and to optimize product yields and quality.
A)
Activity and selectivity
A standard procedure to determine the activity of equilibrium catalyst by means of the Micro Activity
Test (MAT) has been developed and standardized. In the MAT a sample of cracking catalyst is contacted
with gas oil in a fixed bed reactor. Gas chromatographic analyses on gas and liquid products are used to
determine the yield structure.
MAT conversion (wt %)
The MAT conversion or catalyst activity is calculated from the mass balance with:
% conversion = 100 - LCO - Slurry = gas + LPG + gasoline + coke
The equilibrium catalyst activity is measured at a set of standard conditions (constant cat/oil ratio, contact
time, reactor temperature, etc,...). It can be related to the commercial unit performance, and allows the
refiner to distinguish between catalyst activity effects and the influence of process or feed quality
parameters.
In general, a higher catalyst activity results in:
improved conversions,
higher regenerators temperatures,
lower cat/oil ratios.
A detailed study of the unit performance should be made to find the optimum catalyst activity.
Hydrogen factor (HF)

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The hydrogen factor is a relative number and is proportional to the specific hydrogen yield. Specific
hydrogen is defined as:
spec. H2 = H2 yield x (100 - conversion) / conversion
The hydrogen factor depends on the catalyst quality and is affected by the nickel deposited on
equilibrium catalyst. Only the trend of the hydrogen factor is of importance and this can be correlated
with the H2/CH4 ratio in the unit.
Coke factor (CF)
The coke factor is a relative number, proportional to the specific coke, which is defined as:
spec. coke = coke yield x (100 - conversion) / conversion
Like the hydrogen factor, the coke factor is affected by metals deposited on the equilibrium catalyst.
Only the trend is of importance, indicating the contribution of the equilibrium catalyst quality to the delta
coke in the commercial unit. However the delta coke depends mostly on the feed quality and the catalyst
activity.
B)

Metal analyses

Usually, the X-ray fluorescence spectrometry is applied to determine the metals content of the catalyst.
The metals on equilibrium RFCC include the heavy metals taken up from the feed.
Alumina (Al2O3, wt %)
Alumina is present in several components of the catalyst, such as zeolite, clay (kaolin) and active
matrices. The total alumina content is the result of the contributions of each component. The alumina
content of equilibrium catalyst can often be used to calculate the degree of exchange when switching to a
catalyst with a different composition.
Rare Earth (RE2O3, wt %)
The rare earth content of the zeolite indicates its hydrogen transfer activity. A higher rare earth content
results in more hydrogen transfer and consequently reduces the product olefinicity and research octane
level of the gasoline. Cracking reactions are terminated by hydrogen transfer, thus reducing overcracking
from gasoline to LPG. The rare earth content of the catalyst usually depends on both the zeolite type and
the zeolite content of the catalyst. The specific activity (per m2/g surface area) increases in general with
the rare earth content.
Sodium (Na, wt %)
Small amounts of sodium (0.1 - 0.4 wt %) are present in the fresh catalyst. Sodium can also be
introduced by the feed. In case of high sodium levels on the equilibrium catalyst, the feed quality must
be checked. The sodium content in the feed be limited to 2 wt ppm maximum.
Vanadium (V, ppm)
Vanadium is introduced with the feed and is deposited on the equilibrium catalyst. Under regenerator
conditions, vanadium migrates and is able to enter the fresh catalyst and destroy the zeolite. As a
consequence catalyst activity and conversion suffer. For conventional catalysts a rule of thumb is that 2
points catalyst activity are lost per 1000 ppm vanadium at constant unit conditions and catalyst
consumption. As with sodium, the deactivation rate strongly depends on the highest temperature and the
vapor pressure of water in the regenerator.
Nickel (Ni, ppm)

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Like vanadium, nickel is introduced with the feed and deposited on the equilibrium catalyst. Nickel is
not mobile under normal regeneration conditions and acts as a dehydrogenation catalyst. In RFCC nickel
enhances non-selective cracking reactions, particularly those producing more hydrogen and coke.
Antimony (Sb, ppm)
Antimony is only present on equilibrium catalyst if an antimony passivator is used to reduce nickel
activity. Approximately 30-50% of the value of the nickel content is sufficient to reduce hydrogen yields
to an acceptable level.
C)

Carbon on catalyst

In order to monitor the regenerators efficiency, the remaining carbon on regenerated catalyst is measured.
The carbon on catalyst flowing from the stripper into the regenerator (spent catalyst) must be measured
as well, allowing direct analysis of the delta coke level.
The carbon is converted to carbon dioxide. Apart from measuring the carbon on regenerated catalyst
(CRC), the carbon content can be estimated by the refiner by comparing the color of the equilibrium
catalyst with the color of reference samples taken from the same unit.
A high carbon content does not affect the measured activity but results in a loss of effective activity of
the catalyst flowing into the reactor riser (1-2 wt % MAT per 0.1 wt % CRC). As a consequence the unit
conversion and selectivities may change.
An improved air and/or catalyst distribution results in a reduced carbon content. The efficiency of
carbon removal also benefits from increasing the dense bed temperature.
D)
Physical properties
Surface Area (SA, m2/g)
RFCC catalysts in general contain micropores smaller than 2 nm (10 ngstrom radius) that originate
mostly from the zeolite, mesopores of 2-60 nm (10-300 radius), which provide the area often referred
to as matrix surface area and the macropores, that allow penetration of large feedstock molecules into the
catalyst particle. The latter have a negligible contribution to the surface area.
The surface area in general is a measure of the catalyst activity and has a strong effect on the
performance of the RFCC unit. However, when a switch to a different catalyst type is made, the surface
area may change while the activity remains constant. As a high surface area also results in increased
adsorption of hydrocarbons, a higher steam rate in the stripper may be required to keep the delta coke and
regenerator temperature at acceptable levels.
Apparent Bulk Density (ABD, g/ml)
The apparent bulk density is determined by measuring the mass of a known volume of catalyst, settled
freely under its own weight. The apparent bulk density is of importance for the circulation and cyclone
efficiency. A higher bulk density in general means a higher particle density, which improves the
efficiency of the cyclones. The effect of the apparent bulk density on catalyst circulation depends on the
unit design and operation as well as the particle size distribution.
Particle Size Distribution (PSD, wt %)
The particle size distribution is determined using laser light scattering and is important to monitor the
cyclone efficiency and catalyst circulation properties. If catalyst losses and the average particle size
(APS) of the equilibrium catalyst both increase at the same time, the cyclone efficiency is reduced and

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damaged cyclones are suspected. This can be confirmed with PSD analyses of fines from the
regenerators or disengager cyclones showing increased 40+ micron material. The coarser the equilibrium
catalyst, the more difficult it is to circulate catalyst.
If catalyst losses increase while the average particle size drops, then the cause may be related to:
soft catalyst usage (poor attrition resistance),
high velocities in the unit damaging the catalyst (hardware attrition source),
increased fresh catalyst and/or fines additions.
The PSD of equilibrium catalyst is more affected by the attrition factors and cyclone efficiency than by
the fresh particle size distribution.
Fresh catalyst analyses
Analyses that are only performed on fresh catalyst samples are the loss on ignition and attrition.
Loss on Ignition (LOI, w %)
The loss on ignition is determined by measuring the loss of weight (mainly water) upon ignition at 815C
for 1 hour. The measurement is required because catalyst is only paid for on a dry basis. In general the
LOI has no influence on the performance of the catalyst
Attrition Index (AI, w %)
A sample of fresh catalyst is subjected to fluidization by high velocity air jets. In this process, wear on
the particles occurs as they are blown against each other and against the wall with a high velocity. The
fines formed are removed from the attrition zone and weighed.
A lower attrition index means a higher attrition resistance. Low catalyst losses can be expected under
normal unit conditions with attrition index levels up to 10 wt %. However, in some cases also higher
values can be tolerated depending on the catalyst composition and its ageing in the regenerator.
7.5.2

Catalyst replacement

During normal operation, in order to keep a given catalyst activity, fresh catalyst is added on a semicontinuous basis. To keep a constant catalyst inventory in the unit, equilibrium catalyst is automatically
withdrawn from the unit. Catalyst addition and withdrawal are done to/from the first regenerator.
Three catalyst hoppers are installed in the unit: the spent catalyst hopper, the fresh catalyst hopper and
the auxiliary catalyst hopper. The spent catalyst hopper is used for the unit inventory loading and
unloading and for the continuous equilibrium catalyst withdrawal. The fresh catalyst and auxiliary
catalyst hoppers are used for fresh catalyst addition.
7.5.3

Catalyst addition

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.
The primary criterion governing fresh catalyst addition is activity maintenance. The following factors
may serve as a guide for the catalyst replacement:

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the optimum E-cat activity level as determined by feed quality, unit limitations and yield
product quality requirements;
the range of metals, primary Ni, V and Na to be tolerated on the equilibrium catalyst, on a
temporary or permanent basis;
the response of equilibrium (E-cat) activity to fresh cat addition.
The optimum fresh catalyst activity level must be determined for any specific operation. Generally, the
cleaner the feed, the higher the E-cat activity that can be applied to boost conversion. As the feed
becomes heavier and more contaminated, more moderate catalyst activities are optimum, due primarily to
heat balance constraints (i.e. the delta coke).

In principle three alternative catalyst policies exist:


1. Balanced addition: the amount of fresh catalyst added equals the catalyst losses. The optimum
catalyst activity and selectivity is often not obtained with balanced addition only.
2. Catalyst withdrawal: the fresh catalyst addition rate is equal to the sum of catalyst losses and
withdrawal. This type of operation is practiced to reduce metal poisoning, or to enhance catalyst
replacement.
3. Catalyst flushing: the addition of E-cat or low activity flush catalyst is applied to avoid too high
equilibrium activity or delta coke and reduce total catalyst costs especially during high losses, or
a high metals operation.
Two hoppers have been provided for catalyst addition. This allows to add 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 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.
It is possible to bypass the catalyst make-up feeders during operation for repairs.
For detailed operation, refer to the Manufacturers instructions.
7.5.4 Catalyst draw-off
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 provided
on the first regenerator. Hot catalyst is withdrawn by a ON/OFF valve 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.
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 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.

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The total daily amount of catalyst withdrawal is adjusted by timer setting taking into account the
operation requirements for the overall catalyst balance.

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7.6 Operation of Fractionation and Gas Concentration Section


7.6.1 Fractionation section
The Fractionation Section fractionates the vapor product from the Reaction Section. The products from
this section are clarified oil, LCO, heavy naphtha and overhead liquid distillate and wet gas streams.
A heavy naphtha lean oil stream from the fractionator goes to the secondary absorber in the Gas
Recovery Section and the absorber rich oil is returned to the fractionator.
There are two streams that can be recycled to the reaction section. For Maximum Distillate operation, for
both the Bach Ho and Mixed Crude feeds, HCO is combined with the preheated feed to the riser. For
Maximum Gasoline operation, only in the case of Mixed Crude feed, a heavy naphtha stream (MTC) is
recycled directly to the riser.
The main fractionator has a grid section at the bottom where the superheated vapor feed is desuperheated
and the bottom product is condensed. Above the grid there is a wash oil structured packing section.
Above this there are three heat removal (pumparound) structured packing sections and three trayed
fractionation sections.
Each section of the column has a relatively independent system for control of the fractionation and
product draw-off rates. Product draw-off rates are interrelated ; a change in one product rate must be
balanced by a change in one or more other product rates to maintain the material balance on the column.
The basic parameters used to establish correct operating conditions in a section of the column are product
end point and product separation. End point is corrected by adjusting product draw-off rate. Separation
between products is corrected by controlling reflux rates in the column. This is done by adjusting
pumparound duties. Product separation efficiency is determined from ASTM distillation curves for
adjacent products.
The basic criteria used in setting the fractionator operation are related to operating pressure and
temperature profile.
7.6.1.1 Pressure control
The main fractionator pressure is controlled at the reflux drum by speed control of the wet gas
compressor in the gas recovery section. 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.
7.6.1.2 Temperature profile
The major indicator for correct operation of the main fractionator is the column temperature profile.
Temperature is the variable most responsive to changes in the operation of the column. For stable feed to
the reactor and stable reactor operating conditions, the heat input to the main fractionator remains
constant. The heat removal in the pumparounds and the product draw rates are the variables available to
the operator in the operation of the column.
A column side draw temperature is a good indication of the side draw end point. If draw temperature is
recorded against on-specification product end points, the draw temperature can be used as a means of
setting product end point. In a column with good fractionation, the relationship between end point and
draw temperature will be fairly constant.
Product draw rates, and hence product end point, are set based on draw temperature. If a product draw
rate is increased, the end point increases. If the rate for one product is changed, the end point of the
products below will also change, unless the rate of the product immediately below is changed to
compensate for the change in the product rate above. If, for example, the heavy naphtha end point is too
low, the draw rate is increased and hence the end point. If the LCO end point is not to increase, the LCO
draw must be decreased accordingly.

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Separation requirements are achieved by adjusting the reflux rates in the various sections of the column.
This is done by controlling the pumparound duties. If the pumparound duty is increased the vapor rate
leaving the pumparound is reduced and hence the liquid reflux in the section above is reduced. A
decrease in pumparound increases reflux in the sections above and therefore improves separation. For
example, if it is required to improve separation between HCO and LCO, the HCO pumparound is
reduced and more vapor leaves the pumparound section, bed 3. This additional vapor is condensed
further up the column, resulting in higher reflux in trays 25 to 30. The duty decrease in the HCO
pumparound must be compensated for by increasing the duty of the pumparounds above and/or the
condenser. Reducing pumparound duties results in better separation at the expense of high level heat
recovery. Each pumparound should be set to provide adequate fractionation between products while
maximizing heat recovery.
In practice, once the pumparound duties have been established to give good fractionation in the column
they should not require changing, except for changes in feedstock rate and quality. With stable feed, the
main changes carried out in the fraction section will be related to achieving end point and flash point
specifications.
7.6.1.3 Bottom section
The bottom pumparound flowrates and duty are set to maintain the bottom temperature at or below
340C and to satisfy reflux and/or heat duty requirements in the sections above. The bottom pumparound
duty determines the wash rate in bed 4, above the grid.
If the bottom temperature is too high, coking on the grid and in the bottom of the column can occur.
Coking is a function of both temperature and residence time. In the design, the column bottom has a
reduced diameter to limit residence time and the bottom pumparound and quench are designed to limit
temperature.
It is essential to have adequate flow to the grid to ensure good distribution. The hot slurry by-pass and the
flow control system allows for constant flowrate to the grid whilst allowing for changes in heat removal.
For Bach Ho feed, slurry pumparound is required for unit feed preheat whereas it is not required for
Mixed Crude feed. For other (non-design) feeds slurry may or may not be required for preheat,
depending on the required temperature to the riser.
Five HP steam generators (E-1503 A/B/C and E-1504 A/B) and two MP steam generators (E-1505 A/B)
are provided. For the Bach Ho feed case the design is based on having two HP (E-1504 A/B) and two MP
(E-1505 A/B) steam generators in service, along with the feed preheat slurry exchangers, E-1501A/B and
E-1502 A/B/C. For this case, the slurry must be flushed from the non-operating steam generators and
associated lines to prevent settling of catalyst fines.
For the Mixed Crude feed, the design is based on all five HP and both MP steam generators in service.
The preheat exchangers are not required and these must be flushed out.
The total heat removal in the slurry pumparound is controlled by the temperature controller above bed 4
by resetting the flowrate of slurry through the HP and MP steam generators E-1504 A/B and E-1505 A/B
or resetting the flowrate of slurry through HP steam generators E-1503 A/B/C.
The bottom temperature is controlled by resetting quench flow from E-1504 A/B and E-1505 A/B, or by
resetting quench flow from E-1503 A/B/C.
7.6.1.4 HCO section
The HCO pumparound provides heat to the debutanizer reboiler and heavy naphtha stripper reboiler.
Constant heat removal in the pumparound is controlled by controlling total pumparound flow, and by
controlling return pumparound temperature by controlling heat removal in the HCO PA MP steam
generator.
HCO for flushing oil and for slurry separator backflushing is stripped in the HCO stripper. The stripping
rate is set to adjust HCO flash point to ensure that there are no problems with pump seal flushing due to
flushing oil vaporization. The temperature of the HCO is controlled by pressure control on the steam side
of the HCO LPS generator.

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For the Maximum Distillate case for both Bach Ho and Mixed Crude feed HCO is recycled to the
reaction section. The flowrate is controlled in the reaction section. The temperature of the recycled HCO
is controlled by by-passing the HCO recycle MPS generator. A start-up line for E-1508 is provided from
the outlet of E-1508 to the HCO pumparound return.
7.6.1.5 LCO section
The LCO pumparound provides heat for the stripper second reboiler and is used to preheat the unit feed.
The pumparound rate is on flow control and return temperature is controlled by controlling heat removal
in the LCO PA BFW heater.
The LCO draw-off rate controls the end point of the LCO product. An increase/decrease in draw rate will
increase/decrease the end point.
The TBP cut point range for LCO is 205C 390C for Maximum Distillate operation and 205C
360C for Maximum Gasoline operation. The total LCO for Maximum Distillate, 165C 390C, is
obtained by combining LCO from this section with the heavy naphtha cut.
Adjust LCO flowrate to obtain the required ASTM end point and set stripping steam rate to meet the
flash point specification. The initial point will be set by adjusting end point of the heavy naphtha draw.
7.6.1.6 MTC recycle
The MTC (Mix Temperature Control) is drawn off the main fractionator at tray 20.
The MTC is taken off at this point in the column to provide the appropriate stream composition to
minimize cracking in the riser.
MTC is used only for the Mixed Crude Maximum Gasoline case. The required flowrate is set in the
reaction section. It may also be required for other non-design feed cases.
7.6.1.7 Heavy naphtha section
The heavy naphtha pumparound is used to preheat the feed to the stripper and is also used for reboiling in
the PRU. The pumparound is on flow control and the return temperature is controlled by controlling flow
through the heavy naphtha pumparound air cooler. This air cooler is designed for the case when the PRU
is not in operation.
The lean oil for the secondary absorber is drawn off along with the pumparound. The flowrate is set in
the Gas Recovery Section.
Heavy naphtha product is also drawn off with the heavy naphtha pumparound.
For Maximum Distillate operation, the heavy naphtha is combined with the LCO.
For Maximum Gasoline operation, the heavy naphtha is combined with gasoline from the debutanizer
and is sent to the gasoline treating unit.
The cut point between LCO and heavy naphtha is controlled by the temperature controller below the
heavy naphtha draw tray. This resets the heavy naphtha flowrate. The cut point between heavy naphtha
and overhead distillate is controlled by fractionator overhead temperature controller resetting reflux
flowrate. 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. This controls total naphtha flowrate.
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, 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.
For Maximum Gasoline operation the cut point between LCO and heavy naphtha is critical to ensure that
the specified maximum gasoline ASTM end point (205C) is not exceeded.

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7.6.1.8 Top section and overhead system


As discussed for the heavy naphtha section, the overhead cut point is controlled by the temperature
controller resetting reflux flowrate.
A water draw-off tray is provided below the top tray. 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. This can occur during start-up with the unit at turndown as the steam rates are
not reduced proportionately to feed rate. Water is drawn off under interface level control to the inlet of
the overhead air condenser.
The water wash to the overhead condenser should be kept at the design flowrate to minimize corrosion.
Overhead water is also sent to the wet gas compressor interstage cooler and some is sent to the sour water
stripper to maintain the interface level in the reflux drum boot. Corrosion inhibitor is also injected in the
overhead line. The inhibitor injection rate should be set initially at a rate corresponding to 10 wt ppm in
the overheads. This rate can be reduced based on operating experience.
7.6.2

Gas Concentration section

7.6.2.1 Gas Concentration Flow Scheme


The overhead wet gas and liquid distillate are separated in the gas recovery unit into gasoline, LPG and
fuel gas. This is accomplished in a series of absorption steps to maximize LPG and C5+ recovery, a
stripper to reduce H2S and C2 in the LPG and a debutanizer to separate LPG from gasoline.
Fuel gas is treated in the fuel gas absorber and LPG is treated in the LPG amine absorber.
Operating pressures are set by the design of the unit and are not considered as operating variables.
7.6.2.2 Wet gas compressor
The wet gas compressor operation is controlled by the pressure controller on the fractionator reflux drum.
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. Secondary control is spill-back control on the two compressor stages. The compressor is protected
from surge by the compressor anti-surge control system. For detailed operation of this compressor follow
vendor operating instructions.
The water wash to the inlet of the compressor intercooler must be maintained during normal operation to
prevent corrosion. The water rate should be adjusted to the normal rate.
7.6.2.3 Primary absorber, secondary absorber and stripper
The primary and secondary absorbers recover C3+ components from the fuel gas. In the primary absorber,
most of the propane, propylene, butane and butylene is recovered from the gas stream from the high
pressure separator drum. The lean oil streams to the primary absorber are the fractionator overhead liquid
distillate and recycled light naphtha from the bottom of the debutanizer. The overhead liquid distillate
rate and temperature are fixed by the fractionation section operation. The lean oil recycle rate from the
debutanizer is set to obtain the specified C3 and C4 recovery. Increasing this rate will increase recovery,
as long as the total liquid rate does not flood the column.
The secondary absorber recovers practically all of the C5+ from the fuel gas. The lean oil to this absorber
is a heavy naphtha stream from the fractionator. The rich oil is returned to the fractionator. As with the
primary absorber, increasing lean oil rate will increase absorption as long as the liquid rate does not flood
the column.
In both absorbers, a decrease in temperature will improve absorption. The absorbers operating
temperature is not considered as a variable. The design operating temperature has been set based on the
design cooling water temperature, but will vary based on actual cooling water temperature.
Correct operation of the stripper is critical to the operation of the gas recovery section. The feed preheat
temperature should be set initially at the design value. If this temperature is too low, there may be water

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condensation in the stripper. If it is too high it can reduce C3 recovery. The reboil rate is reset by the
stripper overhead flowrate. 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.
7.6.2.4 Fuel gas absorber
H2S and CO2 is removed in the fuel gas absorber. Set the lean amine rate at the normal flowrate and
adjust as necessary to meet the fuel gas specification.
The lean oil rate should also be set to maintain a maximum mole ratio of acid gas (H2S + CO2) to DEA of
0.4 in the rich DEA.
The temperature difference between the fuel gas to the absorber and the lean amine is set by controlling
the amine temperature, to maintain it approximately 15C above the gas temperature. This is to minimize
condensation of hydrocarbons in the rich amine.
If there is a high pressure drop across the absorber, as indicated by the PDIC, this could be due to
foaming.
Inject anti-foam at a rate of 5 to 10 ppm in lean amine as required to prevent foaming.
7.6.2.5 Debutanizer
The debutanizer is designed to separate the gasoline from LPG. 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 and the reboiler duty.
The overhead C5 specification is controlled by the temperature controller in the top section of the column.
Decreasing the temperature controller set point decreases C5 concentration in the LPG. The reboiler duty
should be set manually to obtain the gasoline RVP specification and/or the overall C4 recovery.
If the C2 content in the debutanizer overheads is too high the reflux drum pressure will rise. An HIC
valve is provided to vent to flare. The stripper operating conditions should be adjusted to reduce C2 in the
overheads and hence in the LPG product.
7.6.2.6 LPG amine absorber
The LPG amine absorber removes H2S from the LPG prior to LPG treatment for the removal of
mercaptans. The column operates liquid-filled, with the LPG rate from the column controlled by
DEA/LPG interface level control.
Set lean amine rate to meet the H2S specification and also to maintain a maximum H2S to DEA mole ratio
of 0.4 in the rich DEA.
Inject anti-foam at a rate of 5 to 10 ppm in lean amine as required to prevent foaming.

7.7 Supporting Facility Operation


7.7.1 Steam Generation Blow-down Operation
The design intention is that 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.
-

Continious blow down : 3.0 % of BFW feed

Intermittent blow down : 10 % of BFW feed

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For LPS Generator, the facilities are provided to cover continious and intermittent operation, but blow
down operation is normaly 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 operates blowdown operation. It
intended the dosage of phosphate is to maintain 10-20 wtPPM, referring conductivity of BFW in the
generator. Therefore inject phosphate at the following flow rate (10 PPM case):
Net Inj Rate kg/hr = Blow down BFW (kg/hr) x (10 /1000,000)
Actual Inj Rate of solution = Net Inj (kg/hr) / ( Wt % Concent /100)
Phosphate solution is prepare 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 continious blow down flow rate.
7.7.2 Slurry Separator Operation
1) Back Flushing Frequency
Back flsuhing frequency is depended on the catalyst content in feed oil. For the design purpose, the
following are considered. Therefore, back flushing frequency should be adjusted as concentration of
catalyst (PPM) in feed slurry oil.
Catalyst in feed Back flushing Average flushing oil
Times/Day
M3/hr
Wt PPM
1,700
83
4.2
4,300
209
11.8
2) Temperature Control
Maintain operating temperature at 170 deg C, by adjusting operating pressure of E-1506A (or B) LP
steam side. Operation temperature of back flushing oil (HCO) should be the same level temperature of
slurry feed temperature.
3) Back Flushiong Oil to Rizer Minimum Flow Rate
Maintain flow rate of back flushing oil return to rizer at 8.0 SM3/hr set by FIC-012 to keep velocity (1.21.5 m/sec) in the 2 inch pipe to avoid accumulation of slurry, even if the back flushing flow rate is less
than 8.0 SM3/hr. Level in D-1517 could be maintained by additional HCO supply via FCV-460.
7.7.3 Slurry Pump Operation Note
There are operation concerning to avoid accumulation of slurry, especialy during idling service, or standby condition. The following are operation note of the slurry pump P-1519ABC to minimize accumulation
of catalyst inside of pump when pump is not in service.
-

Isolate AOV at suction and discharge, in case idling service

Flush out slurry oil by flushing oil (FLS) to heavy slop header (HSO) soon after stopping of duty
pump.

Do not retain slurry oil in idling condition to avoid accumulation of catalyst slurry in pump.

Open AOVs at suction and discharge just before restarting pump, and proceed warming up operation
with certain period prior spare pump start-up.

Commission of external flushing and external barriers for spare pump prior start up.

Clean-up drain valves soon after stopping of pump, by flushing oil. (FLH).

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7.7.4 Corrosion Monitoring


Corrosion Probes (CP) and Corrosion Coupons (CC) are provided on the following points to monitor
corrosion situation. Periodical monitoring of corrosion status should be made during normal operation.
Location
P&ID
Tag No.
CP/CC-401
E-1519 outlet
015 - 319
CP/CC-402
E-1520 outlet
015 - 319
CP-406, CC-405
D-1514 boot outlet
015 - 320
CP-702,CC-701
E-1551 outlet
015 - 403
CP-704,CC-703
E-1554 outlet
015 - 404
CP-706,CC-705
D-1553 boot outlet
015 - 404
CP-708, CC-707
E-1565 outlet
015 - 408
CP-710, CC-709
E-1561 outlet
015 - 410
CP-712, CC-711
D-1554 boot outlet
015 - 410
7.7.5 Fuel Gas and Pilot Gas Supply System
The following provisions are considered for fuel gas and pilot gas supply to RFCC unit.
1) Start-up fuel gas for H-1501 & H-1502
Since operating pressure of H-1501 and H-1502 is 2.3 -2.5 kg/cm2g, normal fuel gas is not sufficient for
these operation. LPG vapor from the LPG vaporizer in the fuel gas system is used for firing H-1501 & H1502. LPG vapor from fuel gas system is supplied to D-1525 via PCV-371A (large control valve) during
heating up operation using H-1501 & H-1502.
2) Pilot gas for COB (H-1503)
Pilot gas is required only for start-up of COB (H-1503). Once main burners of COB (H-1503) are ignited,
this pilot gas can be stopped.
Pilot gas is supplied from LPG vaporizer in fuel gas to D-1525 via PCV-371B (Small control valve).
Selection switch HS-371 is used for selection of duty either the following :
-

Pilot gas to COB (H-1503)

Main fuel gas to H-1501 & H-1502 during start-up of Regenerator

3) Fuel gas to COB (H-1503)


Fuel gas to COB is supplied from the fuel gas net work, via D-1526, dedicately.
7.7.6 Slop Oil Injection Operation
There are facilties that heavy slop oil and light
the following facility :
Drum No.
Pump No
Slop System
Light slop
D-1522
P-1526AB
Heavy slop
D-1523
P-1527AB

slop oil could be reprocessed to the main fractionator by


Rated Flow, M3/hr
55.0 at condition
55.0 at condition

In case reprocessing these heavy slop oil to the main fractionator, the following procedures should be
followed to minimize upset of the operation.
-

Reduce RFCC charge flow rate to provide a room for additional duty of gasoline and LCO draw-off
system.

Adjust heat balance of the main fractionator, especially shift the duty from the bottom PA to LCO &
HCO PA so that additional duty for fractionatoion can be covered.

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Reinjection to the fractionator should be conducted very slowly, minimum affect to the heat balance
of the main fractionator and gas concentration unit. Monitor temperature profile and flow balance of
the all pump around, when reprocessing these slop oils.

Monitor water level in the boot of the respective slop drum, and avoid water reprocessing to the main
fractionator. Water carry over into the system results in violent boiling and causes pressure swing.

Reinjection should be carried out one by one, and not simultanious of heavy and light slop to avoid
serious effect to the main fractionator heat balance.

7.7.7 Pump Minimum Flow Operation


The pump minimum flow recycle facilities are provided for the following pumps, since the rated pump
capacity could not cover turn-down operation for certain operation cases. Operate minimum flow line in
case pumping flow rate is closed to the pump minimum flow of the selected pump.
Item No.
P-1511AB
P-1518AB
P-1553AB

Service
LCO Product
Overhead Liquid
Stripper Feed

Rated, M3/hr
208.2
225.0
535.3

Minimum Flow, M3/hr


72.0
75.0
260

7.7.8 Flue Gas Onstream Analyzers Operation


The following Onstream Analyzers are provided on the flue gas lines :
1) On First Regenerator Flue Gas
-

AI-004 : O2 analyzer

AI-005 : CO2 analyzer

- AI-006 : CO analyzer
2) On Second Regenerator Flue Gas
-

AI-007 : CO analyzer

AI-008 : CO2 analyzer

- AI-009 : O2 analyzer
3) On WHB outlet Flue Gas
-

AI-011 : CO analyzer

AI-012 : CO2 analyzer

- AI-013 : O2 analyzer
4) On Stack Inlet
-

AI-018 : O2 analyzer

AI-019 : SOx analyzer

- AI-020 : NOx analyzer


Since these analizers are provided the condition for dusty and water moisture, it is requires the following
handling procedures to operate these analayzers propely.
-

Close inlet isolation valve(s) of the sampling filters while start-up of RFCC, especially until line-up
catalyst loading. During catalyst loading to the regenerator, it is anticipated high load of catalyst will
be blowing to the regenerator outlet line.

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These analyzers could be switch-on after stable condition is achieved on the regenerator, to avoid
plugging of filters with high dust load.

Spare filters are provided for on-stream switch over of the sampling set. During normal operation,
check cleanness of the sampling filters, regularly, and replace to the sapred filter, as necessary.

Confirm tracing of sampling lines is properly working to prevent condensation of water in flue gas.
During precommisioning, ensure that secure tracing is provided.

7.8 Troubleshooting
7.8.1

Troubleshooting situations

The problems often encountered in a RFCC are due mainly to changes in the feedstock, catalyst,
operating variables, and mechanical equipment. As stated previously, the solution can take the form of
improving yields, avoiding shutdowns or, increasing unit reliability.
Troubleshooting consists of investigating and correcting the causes of unsatisfactory operations (typically
off-spec products or unexpected operating conditions) before they deteriorate any further.
Troubleshooting actions must be undertaken when:
The product is off-specifications,
Unexpected operating conditions are noticed.
The main causes of concern, related to process are:
Catalyst circulation problems,
Excessive catalyst losses,
Poor quality of regeneration,
Spent catalyst stripping,
Product quantity and quality.
7.8.2

Catalyst circulation problems

Catalyst circulation problems are mainly correlated with:


Inadequate equilibrium catalyst properties,
Improper catalyst fluidization and aeration.
In case of unstable circulation (unstable catalyst valve P, sudden loss of pressure above the slide valve,
ragged ROT temperature and/or stripper level control, levels swings in the regenerators), the problem
must first be localized by checking the complete pressure balance of the unit. Improper catalyst
fluidization and/or aeration will result in erratic pressure profile, i.e. no pressure gain or limited pressure
gain in the catalyst standpipes or catalyst dense beds. In that case, the adjustment of the fluidization rates
or aeration rates will help to restore the proper circulation. Especially aeration and fluidization nozzles
and lines must be checked for cleanness and flow conditions.
The catalyst circulation stability depends often on the equilibrium catalyst properties. The following
factors appear to improve the fluidization:

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A lower particle size distribution and lower catalyst density,


A higher fines content (40 microns).
Typically, no circulation problems are observed with catalyst containing more than 5 wt % of fines (0-40
microns). In case of too low fines content (< 5 wt %) adding more fresh catalyst and/or using a softer
catalyst can help to improve the catalyst properties. Adding fines directly in the unit is inefficient and
can overload the cyclones. The circulation can also be improved by increasing the pressure level in the
regenerators if pressure margin is available on the catalyst slide valves.
Erratic circulation occurs when catalyst is not developing a smooth and uniform static head over the
entire length of the stand pipe. When this appears, the catalyst packs and bridges across the stand pipe.
7.8.3

Excessive catalyst losses

Excessive losses can occur through the disengager cyclones or through the regenerators cyclones. In the
first case, the fines content in the slurry product will become too high, causing plugging of the slurry
circuit equipments: exchangers, pumps. In the second case, flue gas dust emissions will be excessive.
Monitoring the catalyst losses requires periodic analyses of fines content in the flue gases and in the
slurry product.
Excessive losses can be due to:
Catalyst attrition,
High or low catalyst levels in the vessels,
A)

Cyclone performances deterioration.


Catalyst attrition

Catalyst attrition mainly occurs in the lift, the riser and around the air rings, where high velocities are
achieved. Excessive velocities will dramatically increase the attrition phenomenon. Excessive attrition
will result in a high fines content in the equilibrium catalyst (> 15 wt % of 40 microns).
In case of high attrition, the lift air flow rate and riser steam flow rates must be checked and adjusted if
necessary to keep reasonable velocities in the lines: about 10 m/s in the air lift, 20 m/s in the riser.
The cause of tremendous attrition can also be the mechanical weakness of the catalyst. In that case,
harder catalysts with lower attrition index must be used.
B)

High or low catalyst levels

It is critical to keep the catalyst level below the maximum or above the minimum admissible level. In
case of high level, the required disengaging height will not be sufficient and the cyclones will be
overloaded, causing efficiency decreasing and losses increasing. A low level may unseal the diplegs
which could result in backflow of flue gas up to the diplegs and loss of catalyst fines. Specific care must
be taken for checking the levels reading, especially during transient operations (start-up, shutdown,
catalyst change,...).
C)

Cyclone performances deterioration

There are several reasons for deteriorating cyclone performances:


increased load, either solids or vapor,

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holes in cyclone body, outlet, dipleg, or plenum chamber,


erosion of the internal lining,
lost dipleg seal or blocked trickle valve,
dipleg plugged or partially plugged by foreign material.
An increased load can be caused by poor air distribution due to localized high velocity and catalyst
entrainment. This also results in higher cyclone outlet temperatures due to after burning and lower air
rings back pressure. Increasing the regenerator bed level can help alleviate this problem. Once the
cyclones are badly eroded, little can be done to keep the unit on-stream for a long time with losses under
control. If the holes are formed in the lower part of the dipleg, increasing the bed level to seal the holes
may be successful.
7.8.4

Poor quality of regeneration

A poor quality of regeneration will result in:


High carbon content on the regenerated catalyst,
Non-homogeneous dense bed temperatures distribution in the regenerators,
The catalyst regeneration can be improved by:
Improving the mixing between the catalyst and the combustion air. This can be achieved by
increasing the air flow rate or by decreasing the operating pressure in the regenerators,
Increasing the catalyst residence time in the regenerators, by increasing catalyst levels,
Increasing the bed temperatures in case of too low temperatures (650C in the first regenerator,
730C in the second regenerator).
7.8.5

Spent catalyst stripping

Poor spent catalyst stripping causes an increase in delta coke, which results in a decrease of the catalyst
circulation rate at a given heat balance requirement. The regenerators temperatures will then increase and
eventually the feed throughput may have to be decreased. A stripping problem is apparent from an
increase in hydrogen in coke, as calculated from the flue gas analyses.
The optimum steam rate to ensure proper stripping depends on the catalyst circulation rate, the stripper
design and the equilibrium catalyst surface area. Good stripping occurs when the delta coke is minimized.
For a given design, the stripping steam rate is optimized by adjusting it to a value slightly above the one
which minimizes the regenerators temperatures.
The catalyst architecture can directly affect the observed stripper performance. Entrainment of
hydrocarbons in the catalyst pores and the resulting carry-over to the regenerators will be minimized with
the use of a large pore catalyst.
7.8.6

Product quantity and quality

The amount and quality of products obtained from the RFCC unit are influenced largely by feed quality,
catalyst properties, operating variables, and mechanical conditions of the unit. The indicators which are
often employed to measure the units performance are:
Conversion,

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Dry gas yield,


Gasoline yield,
Gasoline octane.
The conversion is affected by feed quality, catalyst properties, operating variables and mechanical
conditions. The common causes that affect the conversion are:
Feedstock quality (increase in reside content, increase in feed impurities such as nickel,
vanadium, sodium etc..), increase in the CCR.
Catalyst properties (decrease in micro activity and surface area).
Operating variables (decrease in ROT, in C/O ratio, in fresh catalyst addition rate).
Mechanical conditions (a damaged or plugged feed nozzle and/or damaged stripping steam
distribution).
Note:

The apparent conversion is affected by the distillation cut point and the main fractionator
operation.

The dry gas yield gasoline yield and gasoline octane are also affected by feed quality, catalyst properties,
operating variables and mechanical conditions.
The operating parameters having the most negative impact on dry gas yield are:
Increase in ROT,
Increase in slurry or HCO recycle.
The main operating parameters that favor gasoline yield are:
Decrease in the feed preheat temperature and subsequent,
Increase in C/O ratio,
Decrease in carbon content of the E-Cat,
Increase in ROT if overcracking is not occurring.
In general, any parameters which increase the gasoline yield will also decrease its octane, one reason is
that high octane components in the gasoline tend to be denser than the low octane components.
Increase in the naphthene and aromatic fraction of the feedstock enhance the octane. The factors that
increase octane are:
Increase in ROT,
Decrease in the C/O ratio,
Increase HCO recycle.
Note: Mechanical conditions for critical equipment or system failures (air blower, catalyst circulation,
feed outage etc) which lead to emergency shutdown are covered in Chapter 9.2.
7.8.7

Partial Shutdown of Electrostatic Precipitator

The electrostatic precipitator (X-1507) is located at the downstream of COB/WHB Package (H-1503) in
flue gas duct. It removes the catalyst fines in the flue gas from the first and second regenerators to
50mg/Nm3, in order to meet the environmental regulation in Vietnam. The electrostatic precipitator

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consists of two chambers, arranged in parallel. The electrostatic precipitator can be operated with single
chamber, in case one of the chambers is under shutdown condition, e.g., mechanical trouble, equipment
maintenance. The isolation dampers, which are installed at the inlet and outlet ducts, will isolate the
chamber. However, when either of the chambers is not in operation, it is impossible to meet the
environmental regulation for particle emission in flue gas under normal RFCC load. Therefore, the
operator shall reduce RFCC load to approximately 50% to follow the environmental regulation.

7.9 Operation Notes, Relating Hazop Follow-up Action


This section summarizes the operation note, and procedures, relating Hazop Follow-up action. Operation
should take note that these actions are highly relating safety and operability review at the design review.
7.9.1

Feed Injection Atomising Steam supply failure

Referring HAZOP Action No. 4003, when fail of steam supply to the feed injectors I-1501A-F are
detected by FAL-005A-F, the following actions should be taken to avoid coking-up of feed injectors.
-

Loss of atomizing steam to the feed injector causes inadequate vaporizing and mist generation of the
feed oil, and cause coke-up of feed inadequate separation in the reactor.

At event of atomizing steam low flow of either FI-005 A to F, check the site condition of FV-005 A
to F, while manual by-passing of the relevant control valve.

Check MPS are properly line-up for atomizing steam.

7.9.2

Temporary Strainer in Feed Line at downstream of M-1501

Referring Hazop Action 4009, a temporary strainer on the feed line at down stream of M-1501 was
provided for the initial start up. See Note 4 of P&ID 8474L-015-PID-0021-121.
This temporary strainer is provided to remove any debris during construction, and avoid
blocking/plugging of the feed injectors. It is recommended to remove this temporary strainer, after
appropriate timing of commissioning operation (at least 5-10 days operation), assessing debris are
removed, and utilize chance of temporally stopping RFCC feed after feed cut-in to the raiser.
7.9.3

MOV-001 Operation and Isolation Valve of PSV-002

Referring Hazop Action 4015/4040, ensure the following operating procedure of opening and closing of
MOV-001 and isolation valve of PSV-002
1) MOV-001 shall be opened as per detail procedure in the start-up procedure. Once open MOV-001,
kept open by locking devices that MOV-001 shall never closed during operation.
2) Once MOV-001 closed and during normal operation, isolation valve at inlet of PSV-002 should be
locked closed position. Isolation blind at down stream of this valve should be also closed position.
These considerations should be strictly followed to avoid hydrocarbon release to atmosphere
via PSV-002, as the result of fault popping. During start-up and MOV-001 is closed position and
steaming operation is progressing before catalyst circulation, this isolation valve at inlet of PSV-002
shall be kept open so that PSV-002 is protecting the system while steaming the riser and reactors.

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3) It should be noted that there is a high tendency of coke deposit at dead end portion up stream of
isolation valves. Therefore, commission HPS purging to the following ROs and steam rings when
isolation valves are closed during normal operation. See P&ID 8474L-015-PID-0021-123.
-

RO-027: HPS to upstream of isolation valve of PSV-002

RO-025: HPS to upstream of isolation valve of SL-1501

RO-028: HPS to upstream of isolation valve of 24 start-up vent line (24-PG-150037-B1AS)

7.9.4 Avoid Solidification of Feed Oil


Referring Hazop Action No.4019 the following appropriate procedure should be taken to avoid
solidification of feed oil system.
-

Pour point of feed oil (Atmospheric Residue) is 50-52 deg C.

Routine checking that steam trace is working properly to maintain piping temperature is higher than
pour point.

In case equipment isolation for onstream maintenance or idling operation of heat exchangers and
pumps, flush out by LCO from FLS header. Do not drain feed oil to the closed drain header, prior
flush out by LCO.

In case shut-down duration is relatively long, introduce LCO from BL to the feed surge drum, and
replace feed oil by LCO.

7.9.5 Reactor Temperature Control for Coke Formation


Referring Hazop Action No. 4023, that Reactor Outlet temperature control is the primary operation
variable to control coke formation and yield.
Refer to Section 7.3.1 for process vaiable control.
The following are design intended Reactor Outlet temperature :
Bach Ho Max gasoline : 518 deg C
Bach Ho Max distillate : 505 deg C
Mixed Crude Max gasoline : 520 deg C
Mixed Crude Max gasoline : 511 deg C
Adjust riser outlet temperature and other process variables to meet the desired conversion and product
specification.
Refer to Process variable, Effect of Riser Outlet temperature (Sect 7.3.2)
High high temperature of the rizer outlet is caused by the following situation :
-

Loss of feed oil to the injectors

- Excessive regenerated catalyt circuration via the slide valve SV-1501


Remedial actions are required to avoid coke-up of the reactor.
7.9.6 MTC Atomizing Steam Injection
Referring Hazop Action No. 4026, MTC injection is intended during Mixed Crude Max Gasoline Case
only. It is recommended that MPS injection shall be maintained while no MTC injection to avoid catalyst
accumulation in the MPS line and injection nozzle of I-1502A-D.
7.9.7 Avoid Vacuum Condition of Reactor Vessel
Referring Hazop Action No. 4036, the following procedure should be strictly followed to avoid vacuum
condition of the reactor, which are not designed for full vacuum condition.

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Steaming of reactor and raiser will be proceeded during start-up, under MOV-001 closing condition.

Venting line to SL-1501 shall never be closed while steam out operation to avoid creating vacuum
condition, as steaming accidentally stopped, and cool down of the equipment.

Once MOV-001 is opened, then venting line to SL-1501 could be closed, since there is fuel gas
purging from the main fractionator overhead section.

7.9.8 Metal Passivator Filling Operation to D-1508


Referring Hazop Action No. 4041, the following procedure should be taken when metal passivator filling
to D-1508 to avoid releasing chemical vapor to the grade area.
-

As shown in the chemical injection setion, NALCO EC9192 or equivalent is used for Nickel
passivator. Dosage rate is 109 kg/day for Mixed Crude(Ni in feed is 10.5 PPM), and 0.0 kg/day for
Bach Ho Crude case (as Ni in feed is only 1.0 ppm). Since inventory of D-1508 is 2.0 M3, filling
operation to D-1508 is required approximate 30 days interval at Mixed Crude Operation. No filling
operation is anticipated for Bach Ho Crude case.

In case differnt feed oil other than design, check Ni content (PPM) in feed oil and adjust dosage
injection, as proportional to Ni content.

Filling operation will be carried out using portable air pump from the chemical drum. Prior to refilling operation, confirm the level in D-1508. As progressing of filling, care no over-filling D-1508.

A valve of overflow should be opened during filling, and be closed during normal operation.

Refer to MSDS of NALCO EC9192

7.9.9 PDT-103 Commisioning Note for Slide Valve SV-1502


Referring Hazop Action No. 4048, PDT-103 for Slide Valve SV-1502 should be commissioned properly
that LP side shall never left open condition, opening manual bleed valve at low pressure side.
PDT-103 is provided to close SV-1502, when pressure differential is less than 0.1 -0.15 kg/cm2 to ensure
catalyst level and seal is available with minimum catalyst level upstream of SV-1502. Hence in case low
pressure side kept open to atmosphere, there could be fault measuring of pressure drop across SV-1502.
Ensure that pulsation line-up of the low pressure side (down stream of SV-1502) are properly made and
confirm manual vent valve should be closed during commissioning of PDT-103.
7.9.10 Catalyst sampling method
Referring Hazop Action No. 4050, the following are sampling procedure of hot catalyst.
- The following Sampling points are provided for hot catalyst sampling:
SP-022: Regenerated catalyst at downstream of SV-1501
SP-001: Spent catalyst upstream of SV-1502
SP-002: First Regenerator Bottom
- See sketch on P&ID 8474L-15-PID-0021-122/125/127. Sample buffer pot is used for hot catalyst
sampling.
- When sampling is not in operation, valve 3 is always opened to purge the nozzles with nitrogen
and valves 1, 2 and 4 are closed.
- At the time of catalyst sampling, close valve 3 to get catalyst in the sampling line. Then open
valves 1 and 2 to allow the sampling in the buffer pot. When the buffer is full, close 2 and
open 4 to back-flush the sampling line. Finally open 3 and close valves 1 and 4.

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7.9.11 Operation of Vaiable Orifice down stream of Flue Gas Slide Valve
Referring Hazop Action No. 4080 and 4092, the following variable orifice are provided to support
smooth slide valve operation of the respective flue gas of the regenerator :
- SV-1503-VO-01, First Variable Orifice of SV-1503 (First Regenerator Flue gas slide valve)
- SV-1503-VO-02, Second Variable Orifice of SV-1503 (First Regenerator Flue gas slide valve)
- SV-1504-VO : Variable Orifice of SV-1504 (Second Regenerator Flue gas slide valve)
Operation note of variable orifice and slide valve
- Opening of Variable Orifice should be adjusted so that smooth operation of the respective slide valve
are achieved, depended on the flue gas flow rate. i.e. opening of slide valves SV-1503 & SV-1504 to
be the operation and control range. (30-60 % opening, HOLD)
- It should be avoided condition that slide valves SV-1503 & SV-1504 operates almost closed position
(less than 10% open, HOLD), or full open condition (higher than 90 %, HOLD) to make secure
control of the pressure. Adjust opening of variable orifices referring opening of SV-1503 and SV1504 are operation range.
Since design intention of the slide valve and variable is that pressure drop are evenly distributed between
these facilities, set the respective opening as follows :
-

Set flow rate of air to the regenerator, under 50 % opening of SV-1503, VO1, and VO2.

Adjust opening VO2 to 1/3 of the desired pressure under full open of SV-003 and VO1.(e.g.in case
2.3 kg/cm2g of pressure in the regenerator is the desired pressure, first set to 2.3/3=0.77 kg/cm2g)

Then slowly adjust VO1 opening to achieve 2/3 of the desired pressure. (e.g 1.54 kg/cm2g) under
full opening of SV-1503.

Finaly adjust SV-1503 to achieve the desired pressure (e.g 2.3 kg/cm2g).

7.9.12 Combustion Air Control to the First Regenerator


Referring Hazop Action No.4082, combustion air to the first regenerator should be adjusted to control
CO in the flue gas.
As stated in the design basis and operation variable sections, it is intended that 70 % of cokes in the spent
catalyst is burnt in the first regenerator, by adjusting combution air flow rate, referring CO content in the
flue gas is 5 - 6 %.
7.9.13 Combustion Air Control to the Second Regenerator
Referring Hazop Action No.4097, combustion air to the second regenerator should be adjusted to attain
complete combustion of CO in the flue gas.
As stated in the design basis and operation variable sections, it is intended that remaining 30 % of cokes
in the spent catalyst is completely burnt in the second regenerator, by adjusting combution air flow rate,
referring CO content in the flue gas is 0.0 % with presense of 2-3 % of excess air.
7.9.14 Flue Gas Operating Temperature at Economizer Outlet
Referring Hazop Action No. 4144, flue gas temperature should be always 50 deg C higher than its acid
dew point.
The following are expected acid dew point at design case :
-

Bach Ho Crude : 164 deg C

- Mixed Crude : 190 deg C


Economizer outlet temperature is the concerning area, since other sections are operating more than 300
deg C. Economizer outlet temperature of the flue gas is controlled by BFW inlet temperature at the inlet
of the economizer, controlled by MPS heater. In order to achieve 50 deg C higher than its acid dew point,

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BFW temperature to control properly. For design purpose, the following are recommended BFW
temperature down stream of MPS heater.
-

Bach Ho Crude : 140 deg C

Mixed Crude : 165 deg C

7.9.15 Slurry Service Heat Exchanger Flush out when Idling Operation
Referring Hazop Action No.4320, flush-out operation should be carried out when idling of heat
exchanger of the slurry service to avoid accumulation of slurry oil and solidification in the heat
exchangers, as pour point of slurry oil is 15-20 deg C.
The following provisions are provided for flushing operation.
-

FLS connection for LCO supply

HSO connection to the heavy slop header

Closed drain connection

- Steam out connection by Low Pressure Steam


Prior to drain out to the closed drain system, the relevant exchanger should be firstly flushing by LCO,
opening HSO connection. After sufficient flushing by LCO (confirmed by bleed operation from HSO
connection), and confirmed the fluid is completely replaced by LCO, then open the drain to the closed
drain.
7.9.16 Switch Over Operation of E-1506AB Stand-by to Operation
Referring Hazop Action No. 4345, the following are switch over operation of E-1506AB.
-

E-1506AB is designed that one shell is stand-by service during normal operation.

Switch over from operation service to idling service, time to time.

Fill BFW in the idling shell, opening feed isolation valve.

Gradualy open tube side to warm-up the heat exchanger.

Operate stand-by exchanger using vent to the Silenser. After sufficient venting steam to atomosphare,
open isolation valve of the generated steam line. Then close vent valve to Silensor.

After line-up of steam generation, then close hot fluid to the original operating shell. Subsequently,
isolate BFW supply to the original operating shell.

Change the line-up blow down and chemical injection of the service side.

7.9.17 Operation of HP-BFW Preheating by E-1516 and E-1511


Referring Hazop Action No. 4381, ensure that isolation valves HP-BFW at E-1516 and E-1511 should be
always Locked Open to provide secure supply of BFW to the subsequent section.
HP-BFW is preheated by E-1516 and E-1511, then supplied to the following HP steam generators :
-

E-1504AB : Slurry HPS Generator

E-1503ABC : Slurry HPS Generator

E-1534 : BFW Preheater (at Economizer inlet)

7.9.18 WGC Compressor Suction KO Drum Pump Out operation


Referring Hazop Action No. 4601, the following are specific operation note of liquid pump-out operation
from D-1551, WGC Suction KO drum.

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Pump out pump P-1552A or B will be operated automatically, when liquid level is detected by LIA701. High level start the pump, and low level stop the pump.

Since the drum is normaly empty, operation should be aware that LAL-703 detection of low level is
the normal situation.

In order to avoid lose suction of these pumps, confirm site sitation that P-1552A or B should never
running under sitaution of low liquid level, detected by LAL-703.

7.9.19 Depressuring operation of T-1556 LPG Extractor


Referring Hazop Action No. 4697, the following care shall be taken for Depressuring operation of LPG
vessel.
-

Depressuring facility (UX-717 for activating XV-752) is provided on top of T-1556 for safety
provision during external fire.

This UX-717 shall be activated during external fire, only.

Depressuring of LPG other than external fire situation results in self refrigeration of LPG, since self
vaporization temperature is -25 deg C at atmospheric pressure. Self refrigeration will also cause icing
and solidification of amine solution.

In case operation faulty activates UX-717 (depressuring), immediate remedial action are required to
stop depressuring by resetting activation of XV-752 from the local panel, avoiding freezing of T1556 and icing of amine solution. There is a substantial time for operator's intervention to check the
realistic situation at the case of operation fault, and to reach complete frozen condition of T-1556.

The stroke test procedure for the depressuring valve should be carried out that the downstream
locked open isolation valve has to be shut and could only be carried out under permit to work
system.

7.9.20 First Regenerator High High Temperature


Referring Hazop Action No. 4058, the following are procedure in case high high temperature of the first
regenerator.
- Reduce Reactor feed rate to reduce coke quantity in the spent catalyst
- Reduce catalyst circulation rate from the reactor, if possible.
- Reduce combustion air to the first regenerator
- Check torch oil is injected or not, if torch oil is used, stop injection.
Refer to Process variable section for temperature control of the regenerator.
7.9.21 Split Range Control of Surge Drum
Referring Hazop Action No. 4449, 4468, 4482, and 4488, the following surge drums have pressure
control that fuel gas is introduced to the drum when pressure is reduced, and purge out to flare when
pressure is increased. These controls are made by split range control that both control valves never open,
simultaneously. Hazop Action is requested that the relevant PIC and PV to check, time to time, whether
both PVs are opened or not, by driven open, in case mal-function of the relevant PIC controller.
There are local PGs for back-up of PIC. Time to time, operator should check local PG to confirm PIC is
operating properly.
PV to Flare
Controller No.
PV for Fuel
Drum No
Gas In
D-1513
PIC-403
PV-403A
PV-403B
D-1515
PIC-468
PV-468A
PV-468B
D-1516
PIC-479
PV-479A
PV-479B

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D-1517
D-1518
D-1519
D-1522
D-1523

PIC-475
PIC-483
PIC-489
PIC-505
PIC-510

PV-475A
PV-483A
PV-489A
PV-505A
PV-510A

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PV-475B
PV-483B
PV-489B
PV-505B
PV-510B

7.9.22 Untreated Gas to F/G System during Upset Situation of F/G Absorber T-1555
Referring Hazop Action No. 2070, provide a rapid communication of FG absorber problem to FG
customers so that they can initiate appropriate safety measures.
This action is highlighted in HAZOP Action of Unit 12 for the failure situation of the fuel gas absorber
T-1555 that H2S in fuel gas will be higher than normal, and special attention for handling is required for
the relating unit, using treated fuel gas.
RFCC off gas is the major source of fuel gas of the whole refinery. The off gas is treated by Fuel Gas
Absorber T-1555 to remove H2S by 20 % DEA solution, then routes to the fuel gas mixing drum in the
fuel gas system (Unit 37). The maximum H2S content of the treated off gas is controlled to 50 wt PPM.
During upset of this fuel gas absorber, such as foaming in the absorber tower, loss of control of lean
amine solution, or upset of Amine Regeneration Unit, then untreated off gas with high concentration of
H2S will be routed to the fuel gas system of the Refinery.
The following are expected H2S concentration in T-1555 feed gas (untreated RFCC off gas):
Bach Ho Max Gasoline: 0.47 wt % (4,700 wt PPM)
Bach Ho Max Distillate: 0.53 wt % (5,300 wt PPM)
Mixed Crude Max Gasoline: 4.55 wt % (45,500 wt PPM)
Mixed Crude Max Distillate: 2.51 wt % (25,100 wt PPM)
Referring H2S in treated gas 50 wt PPM, upset condition of Fuel Gas Absorber expects very high
concentration of H2S in the treated gas, and spoil fuel gas system seriously.
It should be informed to the all concerned section of the refinery that untreated off gas is routing to the
fuel gas system, and special attention shall be taken for the all fuel gas users for handling of fuel gas.
For RFCC unit, the following procedures should be taken to recover upset of Fuel Gas Absorber:
1) Foaming Prevention of Fuel Gas Absorber
-

Operate proper differential temperature between absorber feed gas and lean amine. Lean amine
solution should be always 15 deg C higher than feed gas to avoid condensation of hydrocarbon in
this Absorber. To achieve this situation, monitor TI-743 at outlet of E-1565, and TDIC-746 which
reset temperature control of lean amine solution in ARU (outlet of E-1904).

Filtering of lean amine solution properly in ARU (F-1901, F-1902, and F-1903) for clean-up of lean
amine solution. Dirty amine solution causes foaming in Absorber or Regenerator.

Injection of anti-foam chemical is the final resolution to control foaming, properly. Injection of antifoam chemical should be limited only foaming occurred in Absorber. Over-dosing of anti-foam
results in adverse effect.

Upon foaming is observed in Absorber, such unsteady pressure drop of the tray, measured by PDI740, or unsteady level indicator of T-1555 bottom, change operating parameters such as reduction of
RFCC throughput to cover operation range, or reduce lean amine solution to be operable range.
Check whether temperature of feed gas is higher than lean amine solution. Start anti-foam chemical
injection, even if various process variable could not recovered foaming operation.

2) Regeneration Section Operation (ARU)


The following operation should be made properly, referring the operation manual of Amine Treating Unit.

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Remove hydrocarbon from rich amine, properly

Filtering of lean amine, regular basis

Anti-foam injection properly (only foaming duration)

Proper temperature control of lean amine solution

Proper regeneration of amine solution (reboiler)

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7.10 Unit monitoring check list


For smooth operation and to avoid breakdowns of the system, the unit engineer should examine certain
information daily. Other operating data should be checked on a weekly basis.
Daily checks
1. Yield distribution versus the feed properties and riser outlet temperature.
2. Complete a heat and material balance of the unit, calculate coke yield and catalyst-to-oil
ratio.
3. Temperatures and pressures at the suction and the discharge of the blowers.
4. Flue gas flow rate and composition.
5. Disengager and regenerator pressures, and slide/plug valve differential pressures and
positions.
6. Regenerator temperatures and temperature gradients.
7. Riser Outlet Temperature.
8. Composition of coke on the spent catalyst (H2 and S).
9. Carbon on regenerated catalyst.
10. Density in the stripper and regenerator catalyst beds.
11. Flow rates of aeration / fluidization air and steam in the standpipes and catalyst cooler (if
applicable).
12. Fresh and equilibrium catalyst addition rates. Spent catalyst withdrawal rate.
13. Dispersion and stabilization steam rates.
14. Flow rates of main combustion air, stripping steam, withdrawal well air, and wye
stabilization steam.
15. Solids content of slurry oil.
16. Product properties and flow rates.
17. Passivator injection rate.
Weekly checks
1. Catalyst properties.
2. Complete catalyst balance to calculate losses.
3. Steam and oil pressures at the fresh feed injectors and MTC oil injectors.
4. Complete utilities balance for steam, air, and fuel.
5. Complete pressure survey.
6. Confirm that instrument tap purges are operational.
7. Perform unit performance test including a complete heat and material balance.

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NORMAL SHUT-DOWN

8.1 Normal Shut-down


8.1.1 Shutdown and restart of the unit
Important recommendations for shutdown and restart
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.

8.2 Normal shutdown General and Summary


8.2.1 General
This is a shutdown guideline for the reaction/regeneration section of the RFCC process. Reference is
made to other sections of the process as required; however, the shutdown of the other sections of the unit
is not covered in this guideline. This guideline relates to a shutdown as it would occur on a planned basis
prior to a major turnaround. Prior to shutting down, other operations in the refinery must be properly
notified. As equipment temperatures will be rapidly changing during the course of this procedure,
operators should be aware of the possibility of equipment binding, flange leaks or other associated
process hazards and maintain constant vigilance.
Normal scheduled shutdown should be made in orderly sequences because there is no character 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 product quality as long as possible.
8.2.2 Summary of Shutdown of Reactor and Regenerator
1 This guide relates to a planned shutdown where all concerned have been informed of the time of the
shutdown.
2 Normal scheduled shutdown should be done in an orderly sequence with the main points to observe
as follows:
Keep the catalyst circulating as long as possible during the shutdown.
Flush all circuits to avoid problems during inspection and the next start-up.
Maintain product quality as long as possible.
3 Start reducing the catalyst inventory
Prior to shutdown, check that there is adequate room in the Spent Catalyst Hopper to hold the
UNIT catalyst inventory.
Activate Hopper steam ejector and pull a vacuum on the Spent Catalyst Hopper.
About 8 hrs before reducing feed, begin to lower catalyst levels in all three vessels to minimum.
Withdraw catalyst slowly and avoid overheating the Spent Catalyst Hopper ( 400 C maximum).
4 Start feed reduction
Close recycle to the MTC injectors. Keep the dispersion steam to the MTC injectors in operation
at normal flowrate.

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Reduce the feed by 5% decrements to 60% of normal operating flow.


Reduce air rates and stripping steam rate generally in the same proportion to the feed. Maintain
excess oxygen of 1 to 3 vol% in the Second Regenerator flue gas.
Adjust the flows of the steam generation system and watch levels in the steam drums.
Adjust the regenerator pressures as necessary to maintain an adequate differential pressure across
the spent catalyst slide valve.
Maintain feed at 60% capacity for one hour, decrease the Disengager temperature to 510 C.
Inject fuel-gas or nitrogen in the Fractionator Reflux Drum to maintain control of the Disengager
pressure.
As coke make decreases, Regenerator temperatures will fall, light the Air Heater to keep a
minimum of 650 C in the Regenerators. Maintain catalyst circulation for at least 15 minutes to
regenerate the whole batch of catalyst.
Shut off the burners in the CO Boiler, and shutdown the CO Boiler as per VENDORs
instructions.
Shutdown passivator injection and isolate the chemical injection from the feed line.
5 Start removing oil from the riser as follows:
Reduce the feed rate to 10-20% as quickly as possible. Maintain stabilisation and dispersion
steam at operating flow rates to maintain riser lift.
Reduce air rates to 50% of the normal operating flow.
Activate reaction section bypass and block in oil feed to the riser feed injectors.
Flush feed lines and torch oil lines with LCO to HSO header in order to avoid the plugging
concern with hiher pour point fluid..
Reduce Regenerator pressures and increase the Main Fractionator pressure as necessary while
maintaining adequate catalyst slide valves differential pressure.
Continue catalyst circulation on steam with dispersion and stabilisation steam.
Switch fuel gas purges to nitrogen purges on the Disengager Stripper section.
Close the isolation valve between the Main Fractionator and the Disengager after opening the
Disengager vent line.
6 Using manual control, lower the level in the Catalyst Stripper to minimum without losing the spent
catalyst slide valve differential pressure.
7 Continue catalyst circulation until there is no appreciable temperature difference between the
Regenerators.
8 Begin unloading the catalyst when dense phases cool down to 400 C.
9 Close the regenerated slide valve and stop the catalyst circulation. Close the plug valve on manual
hydraulic control
10 Lower the Catalyst Stripper level until the pressure differential across the spent catalyst slide valve
reaches 0.1 kg/cm2. Close the spent catalyst slide valve and prevent it from opening except to dump
any additional catalyst which may collect in the Stripper.
11 Control the pressures on both Regenerators at the same value, between 0.7 and 0.9 kg/cm2g.
Continue to unload the catalyst.
12 Close MOV-001 at the Main Fractionator inlet.
Blind the hydrocarbon sources to the feed system and to the riser.
Reduce the dispersion and the stripping steam flow rates to 50% of the normal operating flows.
Steam out to atmosphere through the vent for 15 minutes.
Reduce the steam flow in the Main Fractionator, and to the feed, MTC, and stabilisation injectors,
and adjust stripping steam to minimum. Open the purge bleeder.
Be sure that purge HPS to MOV-001 is clised prior MOV-001 operation.
Close MOV-001 at the Main Fractionator inlet.

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UNIT RFCC (015)

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The Main Fractionator and RFCC Gas Plant shutdown operation may proceed independently
after closing MOV-001 at the Main Fractionator inlet.
13 Re-establish dispersion steam flow at about 50% of the normal flow rate and stripping steam at 30%
of the normal flowrate.
14 Continue catalyst removal.
Continue unloading the Regenerators, normally the Second Regenerator empty first.
When the Second Regenerator is empty, open the regenerated catalyst slide valve and empty the
withdrawal well and standpipe.
When the regenerated catalyst slide valve differential pressure reaches 0.1 kg/cm2, close the slide
valve.
Equalise the pressure on the Disengager and on the Second Regenerator.
Empty the Stripper to the First Regenerator through the spent catalyst slide valve.
Continue unloading the First Regenerator.
15 After all the catalyst has been unloaded, reduce the regenerator pressures to a minimum to reduce
the blower discharge temperature for refractory cooling.
16 Block in the dispersion and stabilisation steam. Continue cooling the Disengager/Stripper with
stripping steam until a temperature of 200 C is reached.
17 Stop steam flow on steam rings and admit air via the temporary plant air lines.
18 Replace nitrogen purges by air purges.
19 Continue cooling the regenerators with Blower air until the dilute phase temperatures are within 15
C of the Air Blower discharge temperature.
20 When the UNIT is cooled , shut down the Air Blower as per VENDORs instructions.
21 Check for residual hydrocarbons.
22 Release the plant for maintenance under a Permit to Work
8.2.3 Summary of Shutdown on Fractionator and Gas Recovery Section
1 Inform all concerned of the time of the shutdown.
2 As feed to the reactor is reduced, gradually reduce the HCO, LCO and Heavy Naphtha pumparound
duties.
3 Maintain slurry pumparound flow at normal rate to the grid to avoid coking.
4 Bring the Wet Gas compressor speed to minimum, operate on spill back to maintain control.
5 Bring fuel gas or nitrogen into the Main Fractionator Reflux Drum.
6 Stop pumparound pumps, reflux pump and product pumps as levels are lost.
7 Continue slurry oil pumparound to the bottom of the Fractionator.
8 Bring in cold LCO to the Main Fractionator from the feed section to allow flushing of the slurry
circuit. Rundown via the clarified oil circuit to the clarified oil storage or to slops.
9 Shutdown and isolate the Wet Gas Compressor when catalyst circulation in the reaction section of
the RFCC has stopped.
10 Isolate the compressor stages by closing the suction and discharge valves and the spillback valves.
11 Stop water wash to the inter-cooler and pump out the liquid from the 2nd stage suction drum to the
HP separator. Depressurise the compressor stages to fuel gas and then to flare.
12 Close MOV-001 for segregation of the Main Fractionator and the reactor section.
13 The Gas Recovery section shutdown must be closely co-ordinated with the Main Fractionator shut
down.
14 Stop the lean oil pump while the Main Fractionator is being shutdown. Pressurise the liquid from the
Secondary Absorber back to the Main Fractionator.
15 When there is no longer flow of liquid from the Fractionator reflux drum to the Primary Absorber,
drain remaining liquid to the HP separator.

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16 Pump the hydrocarbon liquid from the HP Separator to the Stripper and pressurise water to the Sour
Water Stripper.
17 Pressurise hydrocarbon liquid from the Stripper to the Debutaniser.
18 Depressure the Absorbers and Stripper to fuel gas and then to flare.
19 Pressurise liquid from the bottom of the Debutaniser to off-spec storage or slops. Pump LPG from
the Debutaniser Reflux Drum to the LPG Treating Unit (Unit 16) and then off-spec LPG storage.
Depressure the Debutaniser to flare.
20 Drain remaining liquids in the unit to the closed drain or to the oily water sewer. Purge the Wet Gas
Compressor to flare with nitrogen and then to atmosphere. Leave the compressor under a slight
nitrogen pressure until it is opened for maintenance.

8.3 Shut Down Procedure


8.3.1

Catalyst inventory reduction

a) Prior to shutdown, the spent catalyst hopper should be checked and provision made for adequate
room to hold the unit catalyst inventory. Activate hopper steam ejector and pull vacuum on the
spent catalyst hopper.
b) Approximately 8 hours prior to reducing feed, begin to lower the catalyst levels in all three
vessels to their minimum operating levels. Withdraw catalyst slowly using X-1501, catalyst
with-draw package, by resetting draw-off rate, taking acount to avoid upsets and avoid
overheating the spent catalyst hopper (400C maximum).
c) Never throttle catalyst withdrawal flow with the valve next to the regenerator vessel. Use the
next valve downstream to avoid erosion damage to primary vessel isolating valve.
8.3.2

Feed reduction

a)

Close recycle to the MTC injectors. Keep dispersion steam of MTC injectors in operation at
normal flow rate. This will clean MTC injectors.

b)

Reduce the feed by 5% increments to 60% of normal operating flow. Reduce air rates and
stripping steam rate, generally in the same proportion to feed, while observing regenerator
temperature profiles. Accordingly adjust air rate to the regenerators and keep an excess of
oxygen in flue gas of second regenerator in the range of 1 to 3% volume to keep a good
regeneration of the catalyst. During the feed rate reduction adjust steam generation system and
watch carefully levels in the steam drums.

c) Observe the position of air lift control valve during the changes in air rates and adjust FIC-161
and PV-311 on the first regenerator combustion air lines as necessary to maintain good control
above the minimum air lift rate.
d) As feed is decreased, the disengager pressure will fall. Adjust the regenerator pressures as
necessary to maintain adequate pressure differential across the spent catalyst slide valve.
e) Maintain the feed rate at 60% of capacity for one hour, decrease the disengager temperature to
510C and prepare to inject fuel-gas in the fractionator reflux drum to keep the control of the
disengager pressure.
f) Reduce the LCO production to make the slurry oil lighter. Maintain products on specifications
by keeping drawoff-tray temperatures, adjusting pumparounds and reflux.

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g) As coke make decreases, regenerator temperatures will have a tendency to decrease. Light air
heater to keep a minimum of 650C in the regenerators. Keep catalyst circulation for at least 15
minutes to regenerate the whole batch of catalyst with a temperature in the regenerators of
around 600/650C. Avoid to use torch oil. Watch carefully the main air blower to avoid surging.
Stop the burners in CO Boiler or incinerator and apply Manufacturer instructions to stop the
boiler.
h) Shutdown passivator injection and isolate the chemical injection from the feed line.
8.3.3

Oil out of riser

a)

From 60% feed rate, reduce the feed to 10 to 20% as quickly as possible. Be sure to maintain
stabilization and dispersion steam at operating flow rates to keep the riser lift. Reduce the air
rates to about 50% of the normal operating flow, while observing regenerator temperature
profiles.

b)

At 10 to 20% of capacity, activate the reaction section bypass and block in oil feed to the riser
feed injectors. Admit LCO from storage to the feed surge drum, and then flush feed lines and
torch oil lines with light feed to dedicated HSO connection. Adjust vessel pressure as necessary
to maintain pressure differentials. Reduce regenerator pressures and increase the main
fractionator pressure as necessary while maintaining adequate catalyst slide valves differential
pressure. Continue catalyst circulation on steam with dispersion and stabilization steam.

c)

Switch fuel gas purges to nitrogen purges on disengager stripper section.

d)

The isolation valve MOV-001 can be closed at this stage, after opening of the disengager vent
line.

8.3.4

Coke burn-off

a) Place regenerated and spent catalyst slide valves on manual control as the regenerators begin to
cool. Using manual control, lower the level of catalyst stripper as low as possible without losing
the spent slide valve differential pressure.
b) Continue catalyst circulation until there is no appreciable temperature difference between the
first and second regenerator dense phases.
c) Begin unloading catalyst when dense phases cool down to 400C.
8.3.5

Stop catalyst circulation


a) When no temperature rise exists between the first and second regenerator dense phases close the
regenerated slide valve and stop the catalyst circulation. Close the plug valve on manual
hydraulic control.
b) Lower the stripper level until the pressure differential across the spent slide valve reaches
0.1 kg/cm2. The first regenerator pressure may be reduced to 0.1 kg/cm2 less than the
disengager pressure to facilitate this transfer. At this point the disengager pressure should be
maintained 0.1 kg/cm2 higher than the first stage regenerator to prevent air flow through the
spent slide valve from the regenerator to the disengager. Close the spent slide valve and
prevent from reopening except to dump any additional catalyst that may collect in the stripper.
If the first regenerator dilute phase or flue gas temperature increases this could indicate that gas

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is flowing from the disengager to the regenerator. If this occurs, adjust the disengager and first
regenerator pressure to the same value.
c) Control pressures on both regenerators to the same value, between 0.7 and 0.9 kg/cm2g.
Continue to unload the catalyst.
8.3.6
a).

Closing of MOV-001 at main fractionator inlet


Blind hydrocarbon sources to the feed system and to the riser. Switch the fuel gas purges on
the stripper/disengager to nitrogen.

b). Cool the main fractionator bottom. Stop reflux and pumparound flows. Empty the main
fractionator bottom level. Depressure the main fractionator. Start steam injection from the
bottom of the main fractionator to purge out hydrocarbon vapors.
c).

Reduce the dispersion steam flow rate and stripping steam flow rate to about 50 % of the
normal operating flow. Steam out to atmosphere through the vent for 15 minutes.

d). Reduce the steam flow in the main fractionator, feed, MTC, stabilization injectors, and put
stripping steam to minimum. Open vent valve to SL-1501 upstream of MOV-001 on the
transfer line, to prevent forming a vacuum in the vessels when steam flow is stopped.
e).

Following plant safety procedures and using precaution so that employees are not exposed to
sour gas and/or super-heated steam, close MOV-001 at the main fractionator inlet.

f).

Be sure that the purge HPS to MOV-001 is closed prior MOV-001 operation.

g). After closing MOV-001 at the main fractionator inlet, the shutdown operation in the main
fractionator and gas recovery sections may proceed independently.
h). Re-establish dispersion steam flow at about 50 % of the normal flow rate and stripping steam at
30%. If necessary, throttle the disengager vent to equalize the disengager pressure to the same
value as the regenerators.
8.3.7

Catalyst removal

a) Continue unloading the regenerators. Normally the second regenerator will empty first.
b) When the second regenerator is empty, open slightly the regenerated slide valve and empty the
withdrawal well and regenerated catalyst standpipe. Lift this catalyst up through the riser into the
stripper with dispersion steam. Dispersion steam rate, second regenerator pressure, and
disengager vent may have to be adjusted to accomplish this transfer.
c) When the regenerated catalyst slide valve differential reaches 0.1 kg/cm2 close the slide valve.
d) Equalize the pressure on the disengager and on the second regenerator.
e) Open the spent catalyst slide valve and empty the stripper to the first regenerator. Close the spent
catalyst slide valve.
f) Continue unloading the first stage regenerator until no more catalyst can be unloaded.
g) Be aware of the disengager temperatures during the unloading procedure as an increase in
temperature may indicate burning of coke adhered to the vessel dome or walls. If this occurs,
increase the disengager pressure to be slightly higher than regenerator pressure.

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8.3.8

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Unit cooldown
a) After all the catalyst has been unloaded, reduce the regenerator pressures to minimum to reduce
the blower discharge temperature for refractory cooling.
b) Block in the dispersion and stabilization steam and continue to cool the disengager/stripper with
stripping steam. When the disengager temperature has fallen below 200C, the steam flow can
be stopped on steam rings and air admitted via the temporarily plant air line. Nitrogen purges on
the reaction section can be replaced by air purges.
Caution : When this is done, disengager/stripper temperatures should be monitored very
closely to observe any sign of burning. Stop air flow and re-admit steam at any sign of
temperatures rise which would indicator coke burning.

c) Continue cooling the regenerators with blower air until the dilute phase temperatures are within
15C of the blower discharge temperature.
d) When the unit is cool, the blower may be shutdown in accordance with the Manufacturers
instructions.
Note: Before any vessel entry or hot work is permitted, the proper safety requirements must be
met. Personnel must be aware of the possibility of pockets of hydrocarbon or H2S which may
be present.

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8.4 Short period shutdown


If the shutdown is foreseen to last a short period it is not necessary to unload the catalyst as long as the
catalyst does not cool down too much. If necessary, use torch oil to keep at least 600C in the
regenerators. Cut off the feed by following the above procedure from scheduled shutdown and keep
catalyst in circulation with steam in the riser.

8.5 Automatic emergency shutdown (ES)


Automatic emergency shutdown can be carried out through the various safety sequences described below.
However operators must carefully analyze the initiating events and their possible causes in order to
prevent, whenever possible, the emergency shutdown.
Anytime an emergency shutdown is necessary, other units affected by the shutdown must be notified as
soon as possible. The object of an emergency shutdown procedure is first to make the unit safe for
personnel and equipment and second to have the unit in condition for a prompt start-up when the
emergency conditions have passed.
In most emergency shutdowns, the first action is to take the feed out of the unit and simultaneously
increase dispersion steam to clear the riser. The disengager/stripper is then segregated from the
regenerators by closing the regenerated catalyst slide valve and the spent catalyst slide valve. After
these steps are taken, other variables can be adjusted to prepare the unit for re-start. The first
steps in an emergency shutdown should be committed to memory by all operating personnel.
No written procedure can encompass all of the possible symptoms and difficulties encountered during an
emergency condition. The following scenarios are supplied as representing some of the major reasons in
an emergency shutdown of the RFCC. Changes in process conditions can occur rapidly during an
emergency condition and require intelligent and safe judgement. This can only be attained through
classroom and on-the-job training and operating experience.
The emergency shutdown sequences are designed to put the unit in a safe condition for some of the
known conditions, such as loss of air blower or loss of feed. The unit operator should verify that the
control valves have moved to their fail-safe position when they are activated and must confirm that feed
to the riser is shut-off by checking that the riser air operated valve is closed and that the valve on the
return to feed surge drum is open.
The main fractionator pressure must be watched carefully and fuel gas must be brought in as required to
hold the disengager pressure. If feed can be re-established quickly, raise the feed circulation to 60% of
capacity and proceed with restart after having at least 510C in the disengager.
Notes: 1. Avoid return of air in the riser and stripper section by adjusting the pressure of the
disengager 0.1 kg/cm2 higher than the pressure of the first regenerator.
2. When injecting torch oil to keep the catalyst temperature, always check that there is an
excess of oxygen in the flue gas.
8.6 Injectors Inspection and Maintenance
Typically the feed, MTC, steam and backwash injectors should be inspected for wear at normal unit
turnarounds. They usually require minimal maintenance. If erosion occurs, the concerned part is the
injection tip.
8.6.1

Inspection

Injector tips can be inspected visually from inside the riser, it is not necessary to remove the injector for
inspection. If erosion and tip damage is noticed it can be necessary to remove the injector for
maintenance.

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8.6.2
A)

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Maintenance
Principle

Injector tip is made of high strength alloy coated with stellite hard facing. Due to the stellite it is not
recommended to attempt repair in the field.
Consequently, it is recommended to have a complete set(1) of feed, MTC, steam, and backwash injectors
as spare in the warehouse.
Note: Spare injectors are covered in the 2 years spare list.
(1) Complete set: Junction flange, venturi, tip, threated rod, nuts, and gaskets for each type of injector.
B)

Replacement operation

In case of damage, remove piping and mixing chamber from riser nozzle flange.
Injector should be replaced in the same sleeve from which it was taken by a new complete set of injector,
or by the same injector after a tip replacement (injector flanges and riser flanges are matched marked at
original installation).
C)

Tip replacement

The injector tip should be replaced as a unit with the warehouse spare tip. Remove the injector from the
vessel sleeve and take it to the maintenance shop. After confirming the integrity of venturi orifice.
1. Measure the new tip length and mark the injector venturi for cutting at this length. The new tip is
sized to place the new weld outside of the present weld zone (about 20 mm).
2. Verify that the overall length of the injector will remain the same when tip assembly is mounted at
the marked cut line.
3. Match mark the injector venturi upstream of the cut line to ensure proper injector slot orientation
when the new tip assembly is installed.
4. Saw cut the old assembly and remove it from the venturi.
5. Prepare the saw cut end of the feed injector venturi for welding. This bevel should approximate the
bevel provided on the new tip assembly.
Note: Grinding discs shall be compatible with stainless steel to avoid contamination of the base
metal.
6. Align the new tip assembly to the existing feed injector venturi. Tack weld injector tip assembly to
the injector venturti using the Gas Tungsten Arc Welding (GTAW) process. Welding procedure and
filler material shall be provided by Injector Vendor.
7. Weld the root pass using the GTAW process between the injector tip assembly and the venturi with
weld filler metal. Clean the weld upon completion with a stainless steel brush or compatible grinding
disc; all slag, scale and impurities must be removed prior to the next weld pass.
Note: All welding shall be full penetration.
8. Continue welding the injector tip assembly to the venturi cleaning between weld passes using the
GTAW process until the weld thickness equals the injectors venturi thickness.

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9. Remove the purge and visually examine the weld. The root pass visible through the injector tip
assembly shall be clean and free of concavity and convexity. The exposed surface shall be free of
slag, inclusions, cracks, etc.
10. Perform a dye penetrant examination on the weld and correct any finding.
11. Upon successful completion of inspection, the feed injector is ready for reinstallation.
12. Verify the injectors are clean for operation.
D)

Injector reinstallation

The injector is then reinstalled in the riser in the proper orientation.


Pack the annular space between the injector and internal refractory sleeve with kaowool or
ceramic paper.
Reconnect piping and mixing chamber for operation.

8.7 Shutdown of the Fractionator Section


8.7.1 Normal shutdown
This section describes the normal planned shutdown of the unit, as for scheduled maintenance. The
procedure outlines the general philosophy.
This procedure must be elaborated in detail by operating personnel for each shutdown circuit at the time
of shutdown.
8.7.2 Feed reduction and removal
As feed to the reactor is reduced, gradually reduce the HCO, LCO and heavy naphtha pumparound duties,
with the aim of keeping products on specification. As the shutdown proceeds, send products to slops.
The duty of the slurry pumparound is also reduced. Keep the flowrate to the grid at normal flowrate to
avoid coking while feed temperature is still high. Keep the quench rate high to keep the bottom
temperature at or below 340C. By reducing the bottom temperature, flowrates through the slurry
exchangers can be maintained high as duties are reduced.
As gas production is reduced, reduce compressor speed. Bring the compressor speed to a minimum and
operate the compressor on spill-back to maintain control. Bring fuel gas or nitrogen into the line from the
fractionator reflux drum as necessary.
A.
Upper section fractionator (LCO section to overhead section)
When feed to the riser has been cut proceed as follows:
- Stop corrosion inhibitor injection, if not already stopped.
- Pump out sour water to the sour water stripper and stop the overhead sour water pumps.
- Stop the reflux pump.
- Pump out as much hydrocarbon liquid as possible from the overhead drum to the absorber-stripper
and then stop the overhead liquid pump.
- Cool down the heavy naphtha and LCO pumparounds and stop the pumps.
- Stop reboiling and pump out the heavy naphtha stripper to slops and stop the product pump.
- Stop the LCO stripping steam. Pump out the LCO stripper to slops.

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B.
Lower section of Fractionator (HCO and slurry sections)
When feed to the riser has been cut proceed as follows:
- Continue operation of the HCO pumparound.
- Continue operation of the slurry circuit to cool down the bottom of the fractionator.
- Bring feed in from the feed section to the bottom of the fractionator. Run down via the clarified oil
circuit while continuing to circulate the slurry pumparound.
- Reduce the level of feed in the feed surge drum to a minimum, then bring in LCO to the drum.
- Bring in LCO to the bottom of the fractionator to flush out the slurry product section and slurry
pumparound circuits while running LCO to clarified oil storage or to slops.
- Bring LCO into the HCO circuit to flush the HCO pumparound and HCO circuits. The LCO can be
brought in via the connection on the LCO pumparound and overflowed down the column.
- Stop HCO stripping steam and pump out as much hydrocarbon liquid as possible from the HCO
stripper to the HCO flushing oil drum. Ensure that LCO is also available for flushing oil to the HCO
flushing oil drum.
8.7.3 Main Fractionator MOV-001 closing
Closing operation of MOV-001 between the main fractionator and the reactor must be coordinated
between the two sections.
Stop feed of LCO to the fractionator if this has not already been stopped. Stop circulation of the HCO
and slurry pumparounds. Reduce the fractionator level below the steam out connection and depressurize
the main fractionator section to flare. Start steaming out the fractionator via the bottom steam out
connection.
Steam out the main fractionator for a minimum of one hour to remove any hydrocarbon . Reduce steam
flows to the main fractionator and the reactor to a minimum, allowing both sides of MOV-001. Close
MOV-001, slowly. After closing MOV-001, steam flows to the reactor and main fractionator may be
restarted. Shutdown operations in the fractionation and vapor recovery sections can proceed
independently of the reaction section.
8.7.4 Fractionation section hydrocarbon removal
At this stage, all vessels should have been pumped out to minimum levels.
Shut-off all flushing connections to the fractionation section.
Drain all remaining liquids to the closed drain system. Steam out all vessels to flare to remove the bulk of
the hydrocarbon vapors. After steam out to flare, open vents and drains and steam out to atmosphere.
Drain condensate from low points. When steam flow is stopped, ensure that vents are open to prevent
vacuum conditions.
Following plant safety rules, install blinds and open vessels as required. Personnel must be aware that
there may be pockets of hydrocarbon or H2S.
8.8 Gas recovery section shutdown
8.8.1 Shut-down Procedure of gas Recovery Section
The shutdown of this section must be closely coordinated with the fractionation section shutdown.
As feed to the unit is reduced, the overhead liquid distillate and wet gas from the fractionation section
reduces. Reduce the stripper and debutanizer reboiler duties gradually, with the aim of keeping gasoline

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and LPG on specification. As the shutdown proceeds send light gasoline to slops and LPG to offspecification storage.
- When gas flow from the fractionator has stopped and catalyst circulation has stopped (and the
catalyst slide valves are closed) stop the compressor.
- Stop the water wash to the intercooler and isolate the compressor stages by closing suction and
discharge valves.
-

Depressurize the compressor sections to fuel gas and then to flare.


While the fractionation section is being shutdown stop the lean oil pump. Pressurize the liquid in the
secondary absorber back to the fractionator. Also pressurize any liquid in the fuel gas absorber feed
knock-out drum back to the fractionator.
Pump out as much liquid as possible from the compressor interstage drum to the HP separator drum.
When there is no longer a flow of liquid distillate from the fractionation section to the primary
absorber, drain remaining liquid from the primary absorber to the HP separator.
Pump the hydrocarbon liquid from the HP separator to the stripper and pressurize sour water to the
sour water stripper section.
Pressurize liquid from the stripper to the debutanizer.
Pressurize amine from the fuel gas absorber column and outlet KO drum to the amine unit.
Depressurize the stripper, primary and secondary absorbers and fuel gas absorber to fuel gas and then
to flare.
Pressurize liquid from the bottom of the debutanizer to light slops.
Pump out LPG from the debutanizer reflux drum to the LPG amine absorber. As this LPG may be
off-specification, it should be sent to off-specification storage after the LPG treating unit. Stop flow
of lean amine.
Pressurize sour water from the boot of the debutanizer reflux drum.
Isolate the debutanizer section and depressurize to flare.
The recovery of LPG from the LPG amine absorber and coalescer should be maximized by manually
increasing the amine /LPG interface.
Pressurize amine to the amine unit from the column and from the coalescer. The vessels should be
pressurized with nitrogen to avoid freezing as the pressure decreases. Drain remaining liquid to the
amine drain and depressurize the vessels to flare.

8.8.2 Gas recovery section hydrocarbon removal


At this stage, all vessels should have been pumped out, or pressurized, to minimum levels and all sections
depressurized to flare.
Drain any remaining hydrocarbon liquids to the closed drain and any amine to the amine drain.
The compressor stages suction and discharge valves are closed and the two compressor stages have been
depressurized. Purge the compressor stages with nitrogen to flare and then to atmosphere.
Steam out all vessels to flare to remove the bulk of the hydrocarbon vapors.
After steam out to the flare, open vents and drains and steam out to atmosphere. Drain condensate from
low points. When steam flow is stopped ensure that vents are open to prevent vacuum conditions.
Following plant safety rules, install blinds and open vessels as required. Personnel must be aware that
there may be pockets of hydrocarbon or H2S.

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EMERGENCY SHUTDOWN PROCEDURE

9.1 Emergency sequences Summary


Emergency shutdown systems operate automatically upon the occurrence of the undesirable events but
can also be activated by operators.
This covers the following emergency sequences:
UX-001 (ES1) Feed Outage
UX-002 (ES2) Catalyst Circulation Failure
UX-003 (ES3) First Regenerator Air heater trip
UX-004 (ES4) Second Regenerator Air heater trip
UX-005 (ES5) Air Blower Failure
UX-907 (ES7) COB/WHB Failure (by COB/WHB Vendor)
UX-901- COB Combustion failure (by COB/WHB Vendor)
UX-008 (ES8) COB/WHB First Regenerator Flue Gas Bypass Valve
UX-009 (ES9) Electrostatic Precipitator Trip
UX-010 (ES10) COB/WHB Second Regenerator Flue Gas Bypass Valve
UX-013 (ES13) Economiser Bypass Operation
(ES14) DeSOx Unit (Future)
Note: ES-XX in ( ) shows original Axenss ES numbers.
Operators must be thoroughly familiar with these sequences and able to perform the emergency sequence
step by step, should the automatic system fail.
For the right understanding of what follows, operators must refer to the emergency systems Cause and
Effect Table and the relevant PID's.
Note: Restart of the unit
For restarting the unit after a maintenance shutdown or an emergency shutdown, the normal start-up
instructions should be followed.
In case of air blower shutdown during an emergency shutdown, specific care must be taken to restart the
air blower (refer to air blower failure).

9.2 Detail Description of Emergency Trip System


9.2.1

Emergency Shut-down System

Refer to Cause & Effect Chart 8474L-015-DW-1514-602, in detail function.


Note: ES-XX in ( ) shows original Axenss ES numbers.
UX-001(ES1): FEED OUTAGE (Reaction Stop)
Initiators:

Hand switch in control room. (UXHS-001)

Signal from UX-002(ES2)

Signal from Feed Flow Stop (FALL-405).

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Actions:

Close valve XV-002 to stop feed to injectors I-1501A - F

Open valve FV-001 to send feed oil to surge drum D-1513

Close valve XV-003 to stop MTC to injectors I-1502A-D .

Close valve XV-004 to backwash recycle oil to injector I-1504.

Stops metal passivator injection pump P-1502AB in feed line.

Stop MTC injection pump P-1512AB.

Stop backflush oil recycle pumps P-1508AB.

Stop HCO recycle pumps P-1507AB to riser .

Open valves on steam injection FV-005A - F of feed injectors to fully admit dispersion
steam to riser.

Open valves on stabilization steam injectors FV-007A - D to fully admit stabilization steam
to riser.
UX-002(ES2): CATALYST CIRCULATION STOP
Initiators:

Hand switch in control room (UXHS-002)

Low low D-1501 Disengager/Stripper level by PDXALL-064

Low low pressure drop across the spent catalyst slide valve SV-1502 by PDXALL-104

Low low withdrawal well level by LXALL-010

Low low pressure drop across the regenerated catalyst slide valve SV-1501 by PDXALL242

Low low air flow rate to air lift by FXAL-172, first regenerator by FXAL-170, second
regenerator by FXAL-171.

Air Blower trip UX-005 (ES5).

Signal from low MP steam pressure on MPS supply sub-header to Reactor, by PXAL-363.

Actions:

Close the spent catalyst slide valve, SV-1502

Close the regenerated catalyst slide valve, SV-1501

Close the plug valve, PV-1501

Activate UX-001(ES1), feed outage

Activate UX-008 (ES8) to open First Regenerator Flue Gas by-pass of COB/WHB

Activate UX-010 (ES10) to open Second Regenerator Flue gas by-pas of COB/WHB.
UX-003(ES3): FIRST AIR PREHEATER TRIP
Initiators:

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Hand switch in control room, UXHA-003A

Pilot flame detector, BXAL-003

Main flame detector, BXAL-004

Low low air flow rate to heater, FALL-170

Low low fuel gas pressure, PXALL-321

High high temperature air heater H-1501 outlet, TXAHH-069

Air blower trip, UX-801 (ES5)

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Actions:

Close the valve on fuel gas XV-016 and XV-017 to First Regenerator Air Heater, H-1501.

Open vent valve XV-019 between XV-016 and XV-017


UX-004 (ES4): SECOND AIR PREHEATER TRIP
Initiators:

Hand switch in control room, UXHA-004A

Pilot flame detector, BXAL-001

Main flame detector, BXAL-002

Low low air flow rate to heater, FALL-171

Low low fuel gas pressure, PXALL-321

High high temperature air heater H-1501 outlet.TXAHH-072

Air blower trip, UX-801 (ES5)

Actions:

Closes the valve on fuel gas XV-014 and XV-015 to Second Regenerator Air Heater, H1502

Open vent valve XV-020 between XV-014 and XV-015


UX-005 (ES5): AIR BLOWER TRIP
Initiators:

Hand Switch for Air Blower Trip, UXHS-005

Shut down signals from Air Blower Protection (from UX-801).

Actions:

Open the blower discharge to atmosphere by UX-802

Closes the assisted check valves CV-1501, CV-1502, CV-1503, and CV-1504 on air blower
discharge lines.

Actuates UX-002 (ES2), catalyst circulation


UX-907 (ES7): CO BOILER Steam Drum Level FAILURE
Initiators:

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Hand switch in control room (UXHS-907)

High high liquid level in steam drum (LXA-901)

Low low liquid level in steam drum (LXA-902)

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Actions:

Open the First Regenerator Flue Gas COB/WHB by-pass valves, BV-1501B and Close the
valves to COB/WHB, BV-1501A (Interlocking)

Open BFW injection valves, XV-058A / XV-058B and Atomizing MPS XV-059

Open COB/WHB flue gas bypass valves BV-1502A and close flue gas block valve BV1502A (interlocks)

Opens BFW valves XV-056A and XV-056B to bypass sprayers and opens MP steam valve
XV-057 to bypass valves sprayers.

Shut-down fuel gas and fuel oil to all burners

Close damper at FD fan and open LP steam purge


UX-901: COB Combustion Control Failure
Initiators:

Hand switch in control room (UXHS-901)

Pilot fuel gas low low pressure (PXA-908)

Pilot fuel gas high high pressure (PXA-908)

Fuel gas low low pressure (PXA-913)

Fuel gas high high pressure (PXA-913)

Fuel Oil Pressure low low (PXA-921)

Fuel Oil pressure high high (PXA-921)

Atomizing steam/Fuel oil diffential pressure low low (PDXA-915)

Combustion air flow low flow (FXA-932)

Flame failure detector (4 out of 5 burners)

Actions:

Close pilot gas valves (all burners)

Close fuel gas valves (all burners), activates by upset fuel gas pressure

Close fuel oil valves (all burners), activated by upset fuel oil pressure

Close FD fan discharge valve

Open LP steam purge at FD fan discharge


UX-008 (ES8): First Regenerator flue gas COB/WHB BY-PASS
Initiators:

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High high flue gas temperature in CO Boiler bypass line TXAHH-089A/B

COB/WHB Trip signal by UX-907

Activates by UX-002 (ES2), catalyst circulation.

Actions:

Opens MP Steam valve XV-059 to bypass valve sprayers (two signals).


Open BFW injection valves, XV-058A / XV-058B

Open the First Regenerator Flue Gas COB/WHB by-pass valves, BV-1501B and closes the
valves to COB/WHB, BV-1501A (interlocking)
UX-009 (ES9): ELECTROSTATIC PRECIPITATOR
Initiators:

Hand switch in control room, UXHS-650

by Vendor.

Actions:
by Vendor.
UX-010 (ES10): Second Regenerator Flue Gas By-Pass of COB/WHB
Initiators:

Hand switch in control room, UXHS-010

High high flue gas temperature in WHB bypass line (two signals), TXAHH-082AB

COB/WHB Trip signal by UX-907

Activates by UX-002 (ES2), catalyst circulation.

Actions:

Opens COB/WHB flue gas bypass valves BV-1502B and closes flue gas block valve BV1502A (interlocks).

Opens BFW valves XV-056A and XV-056B to bypass sprayers

Opens MP steam valve XV-057 to bypass valves sprayers.

UX-013 (ES13): Economizer Bypass


Initiators:

Hand switch in control room, UXHS-906

High high flue gas temperature in Economizer outlet line TXAHH-098AB

Economizer By-pass signal by UX-906 (by Vendor), activated by low low HPBFW flow to
Economizer

Actions:

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Open ROV-005 (by-pass open)

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Open BFW valves XV-060A and XV-060B to bypass sprayers.

Open MP steam XV-061 to bypass sprayers.


(ES14): DESOx Unit Bypass (Future)
The following ESD are anticipated, but to be reviewed and develop in future.
Initiators:

Hand switch in control room.

by Vendor.

Actions:

9.2.2

Open the DeSOx bypass valve.

Close the inlet valve to DeSOx unit.

Inventory Isolation and Equipment Protection

Refer to Cause & Effect Chart 8474L-015-DW-1514-602, in detail function. The following are list
of the inventory isolation, equipment protection, and depressuring system.
UX-421
D-1513 OVERFILLING PROTECTION
UX-422
P-1501A/B PROTECTION
UX-423
T-1501 & P-1507A/B INVENTORY ISOLATION
UX-424
T-1501 & P-1508A/B INVENTORY ISOLATION
UX-425
SLURRY PUMPS P-1519A/B/C PROTECTION
UX-426
T-1501 & P-1519A/B/C INVENTORY ISOLATION
UX-427
T-1504 & P-1509A/B INVENTORY ISOLATION
UX-428
P-1515A/B PROTECTION
UX-429
P-1511A/B PROTECTION
UX-430
D-1514, P-1516A/B & P-1518A/B INVENTORY
ISOLATION
UX-431
D-1524, P-1517A/B INVENTORY ISOLATION
UX-432
D-1515 OVERFILLING PROTECTION
UX-433
P-1504A/B PROTECTION
UX-434
P-1506A/B PROTECTION
UX-435
D-1517 OVERFILLING PROTECTION
UX-436
P-1505A/B PROTECTION
UX-437
D-1516 OVERFILLING PROTECTION
UX-438
P-1521A/B PROTECTION
UX-439
P-1522A/B PROTECTION
UX-440
D-1522 OVERFILLING PROTECTION
UX-441
P-1526A/B PROTECTION
UX-442
D-1523 OVERFILLING PROTECTION
UX-443
P-1527A/B PROTECTION
UX-444
P-1528A/B PROTECTION
UX-705
C-1551 ISOLATION & PROTECTION
UX-706
P-1551A/B PROTECTION
UX-707
D-1553 INTERFACE ISOLATION
UX-708
D-1553 INVENTORY ISOLATION

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UX-709
UX-710
UX-712
UX-713
UX-714
UX-715
UX-716
UX-717
UX-718
UX-719

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D-1556 INTERFACE ISOLATION


T-1555 INTERFACE ISOLATION
T-1554 INVENTORY ISOLATION
D-1554 INTERFACE ISOLATION
D-1554 INVENTORY ISOLATION
T-1556 INTERFACE ISOLATION
D-1555 INTERFACE ISOLATION
T-1556 DEPRESSURIZATION
D-1559 INTERFACE ISOLATION
D-1553 DEPRESSURIZATION

9.3 Emergency shutdown by operators


9.3.1

General

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, who can anticipate the automatic
action.
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 (ES1). 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.
9.3.2

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 at refinery wide power failure. Instrument
indications and controls should not be affected by UPS system.
The consequences and emergency sequences to be followed will depend on the localized power failure or
refinery wide power failure.

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Note that Air Blower and Wet Gas Compressor will also stopped at power failure, since sea water to the
turbines surface condensers will be stopped during power failure as 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
SCSV differential pressure will fall
Cooling water supply temperature will increase as fans are inoperative.
The following actions should be taken immediately:
a) Activate ES1, block in all oil feed to riser. Place RCSV, SCSV, 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.
9.3.3 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. 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.
a) Activate UX-001(ES1) to bypass feed and recycles from the riser, 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.

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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:

1. The major problem will come from the air blower which can surge or choke during
transient operations. Snort valves will fail close 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.
Possibility to run the air blower in these conditions must be checked with the machine
manufacturer.

9.3.4

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(ES 1) to bypass the riser, block in the oil feed and adjust the dispersion
steam at the rate of 50% operating conditions.
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.

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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. The tap should be checked for pluggage 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:

1.

9.3.5

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.

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(ES1), bypass the riser, block in all oil feeds to the riser, and shut down the
passivator injection system.
b) Close the RCSV (SV-1502) 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 SCSV (SV-1501) 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 SCSV (SV-1501)
e) Transfer as much as possible 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 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
converter 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 assure that steam headers are dry all the way up to

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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.
9.3.6

Boiler feed water failure

Loss of boiler feed water (BFW) will require a shutdown of the RFCC unit. Actuate UX-001(ES1).
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), and maintain water circulation through the tubes as long as possible to
maintain cooling on the tubes. It must be checked that the sprayers have been automatically started. 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.
9.3.7

Cooling water failure

Loss of cooling to the fractionation and Gas Concentration section will require the shutdown of the
RFCC unit. Loss of lube oil cooler of the air blower also require to trip Air Blower.
Actuate UX-001(ES1), bypass the riser, block in all oil injectors feeds, and adjust the fresh feed
dispersion steam rate for 50% operating condition. Place the RCSV, SCSV, 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.

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Sea water failure

Sea water is used for coolant of the surface condenser of the air blower. Therefore, failure of sea water
will automatically trip of air blower, as turbine is not work properly. Follow operation procedure of Air
Blower failure.
9.3.9

Air blower failure

In case of air blower failure, the unit will be shut down by UX-005(ES5), which will actuate UX002(ES2) and UX-001(ES1) systems. The pressure in the regenerators will fall rapidly resulting in
possible flow reversal at the RCSV 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. Place the RCSV and SCSV 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 re-establishing air flow.
Normally the following actions are required to re-established air flow to the unit when restarting the
blower:
Close the control valves on the line to the first stage regenerator air rings.
Open the plant air into the catalyst lift line between the first regenerator and second regenerator.
The uppermost blast point should be started first, then open the lower blast points stepwise down
the lift line. With all blast points open, slowly begin lift air from the air blower and then reduce
plant air to minimum purge rates.
Before to start 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.
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.
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.
After clearing of the air lines, the air blower can be restart following the manufacturer
instructions.
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.
When all air flows are re-established, the unit may be started as in the normal start-up procedure.

Notes:

1.

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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 fluidised bed to slump. As a result, not all catalyst is
regenerated and more is 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 temperature in the regenerators imperatively below 300C everywhere into
the regenerators before starting the unloading, 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.
9.3.10 Feed pump failure as loss of feed
Loss of feed will activate emergency shutdown system, activate UX-001(ES1) 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 vessel pressure will fall. Adjust the pressure balance to
maintain a positive pressure differential between the disengager and the regenerators.

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.

9.3.11 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.
9.3.12 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 fuel gas

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from R-1 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. Shut-down of COB will seriously affect to the overall steam balance of
the refinery, including Air 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 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.
9.3.13 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(ES1) 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 unsteady pressure
balance, (temperatures in regenerators), actuate UX-002 (ES2) to shut-down the unit.
2. In addition, instrument purge systems on the disengager side use treated gas from the Gas
Concentration 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.

When the WGC is ready for restarting follow vendors procedures and restart the unit following normal
start-up procedure.
Notes:

1.

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Loss of the WGC by serious mechanical failure due to long duration problem, will
necessity 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 prim 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.

9.3.14 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 R-1 catalyst level with the R-1/R-2
differential pressure. Is stable control cannot be demonstrated quickly, the unit should be shutdown.
a) If stable control cannot be achieved activate UX-001(ES1) to stop feed and recycles to the riser,
block in all oil feeds, and shutdown passivator injection.
b) Close the RCSV on manual or with the handwheel. If the RCSV 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:

1.

If catalyst valve is blocked in closed position, check that UX-001(ES1) and UX002(ES2) have been activated.

2.

If catalyst slide valve is blocked in open position activate UX-001(ES1) 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, circulation which will be
dictated by the opening of the failed valve.

3.

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.

9.3.15 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 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 demonstrated quickly, the unit should be shutdown.
If stable control cannot be achieved, activate UX-001 (ES1) to stop feed and recycles to the riser, block
in all oil feeds, and shutdown passivator injection. Hold the disengager pressure 0.15 kg/cm2 above the
regenerator pressure.

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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.

9.3.16 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(ES1) and UX-002(ES2).
9.3.17 Oil reversal
This situation can occur when oil injected in the riser comes 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(ES2) and UX-001(ES1) 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 of oil reversal is explained and corrected.

Note:

1.

In R2R process regenerated catalyst is withdrawn into an external withdrawal stand


pipe. This proven system ensures an efficient seal against oil reversal.

9.3.18 Low riser outlet temperature


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(ES1). The catalyst circulation can continue on automatic control, however, the
operator may have to temporarily help the instruments by manually slowing the catalyst circulation rates.
Feed-in can be achieved when an acceptable Riser Outlet Temperature for start-up (510-530C) is
obtained.
9.3.19 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 as actuate UX-001(ES1) before unplugging the
catalyst.
a) In case of plugging in the air lift, blast connections are provided along the air lift to help to
refluidize 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 deplug 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

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line plugging (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.
9.3.20 Downstream unit failure
Depending upon the nature of the downstream equipment failure, the RFCC may operate at reduced
throughput. If unable 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.
9.3.21 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 as activate UX-001(ES1). 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 reactional section and the unit should be maintained in a hot condition using torch oil.
As required the catalyst circulation may be shut down as activate UX-002(ES2) until the emergency
situation is under control.
When the fire emergency is over, the unit can be restarted following the normal start-up procedure.

9.4 Emergency shutdown of Fractionator and Gas Concentration Section


9.4.1 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.
9.4.2

Utility failure

A. Steam failure
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 steam turbine driven and
these also will be lost.

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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. Shutoff stripping steam to the HCO and LCO strippers.
When steam becomes available, start the slurry pumps and start slurry circulation. 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.
B. Instrument air failure
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 service. Restart the unit following the normal start-up procedure.
C. Boiler feed water failure
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.
D. Fuel gas failure
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.
E. Electrical power failure
Electrical power failure will require a shutdown of the unit. There is a possibility that steam failure will
subsequently anticipated, soon after refinery wide power failure.
Wet gas compressor will be shut-down, automatically, as sea water is not available at 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, by 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.

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LP steam to T-1503

- LP steam to T-1504
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.
F. Cooling water failure
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.
G. Sea water failure
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.
9.4.3 Wet gas compressor failure
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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10 SAFETY EQUIPMENT AND PROCEDURES


10.1 Pressure Safety Devices
The following is RFCC flare discharge summary as attached:
8474L-015-NM-0006-701: RFCC Flare Discharge Summary
Refer to specification of safety relief valves (8474L-400-SP-1545-001).
10.2 Alarm Setting
Refer to the attached Alarm Setting List
10.3 Trip Setting
Refer to the attached Trip Setting List
10.4 Trip System Chart
Refer to Cause and Effect Table (8474L-015-DW-1514-602) as attached.
10.5 Hazardous and Toxic Materials
10.5.1 General considerations
Safety is a wide field covering a large variety of subjects including safety during start-up, shutdown,
emergencies, normal operation, fire fighting, maintenance, handling or toxic materials, turn-around.
It is the responsibility of the refinery staff to make sure that the procedure used during the various
operations are in accordance with the government regulations, guidelines from the professional groups
and the general safety policy of the refinery.
Training of the operators to improve their knowledge of the RFCC process and of the equipment,
together with good communication and good coordination between groups involved in the unit operation
plus regular safety practice exercises are very important to ensure a good level of safety.
It is not in the scope of this operating instructions manual to describe fire fighting nor vessels entry
methods. Hereunder will be given some recommendations concerning handling of hazardous materials
and vessel entry.
Materials in an RFCC unit are not dangerous as long as they are handled according to the normal
procedure. Some are dangerous if they are allowed to leak in the atmosphere or if someone attempts to
enter a vessel which is not sufficiently purged out. Therefore sampling and vessels entry methods should
be adhered to and cautiously elaborated.
10.5.2 Vessel entry
Before opening the disengager or the stripper manholes or nozzles, make sure that the vessels are cooled
down below 200C to avoid auto-ignition or coke deposits.
Among other precautions make sure that before entering any vessel :
The vessel is isolated by blind flanges from other vessels, steam injections, nitrogen injections,
fuel gas injections.
Breathable atmosphere is obtained especially in the low points. Check for O2, CO content,
hydrocarbons, explosivity.
Separate air supply independent from electric power system should be available for immediate
transfer to people working in the vessels,
Supply fresh air continuously by an air mover.

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UNIT RFCC (015)

February 2007
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10.5.3 Hazardous and Toxic Materials


These substances are:
Catalyst and additives,
Flue gases,
Cracked hydrocarbons.
Detailed data regarding the hazard and toxicity of these compounds can be found in the following
documents:
OSHA Regulated Hazardous Substances published by the Occupational Safety and Health
Organization - US Department of labor.
Fiches toxicologiques published by:
Institut National de Recherche et de Scurit
30, rue Olivier Noyer
75680 PARIS CEDEX.
The Unit Owner is advised to request the relevant data sheets from the above organizations.
Concerning catalysts and additives supplied under a trade mark, the relevant updated Material Safety data
sheets must be acquired from the manufacturers.
a). Catalyst
RFCC catalyst is able to cause eyes and lungs irritations. When working with catalyst (sampling taking,
catalyst containers loading and unloading) face shields or goggles and a dust mask should be worn.
Hot catalyst will burn skin. During catalyst sampling the whole body should be protected by adequate
clothing. One should be careful with pile of hot catalyst spillage which can be cold externally but very
hot inside.
b). 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.
c). Chemical and hazardous properties of carbon monoxide (CO)
Poisonous 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.
Autoignition temperature: 650C.
Mixtures of CO and air in certain proportions are flammable.
Detection of CO
Should be detected only by a reliable detector such as ORSAT apparatus or DRAEGER tube.
Personnel protection
Always wear an autonomous oxygen mask when entering in an area or vessel suspected to contain CO.
First aid
Move victim to fresh air.
If recovery is slow, bring resuscitator and give oxygen.

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UNIT RFCC (015)

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If the breathing has stopped, practice artificial respiration until the doctor arrives.
d). 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.
10.5.4 Material Safety Data Sheet (MSDS)
MSDS of the following chemical are attached.
Nickel Passivator EC9192
Corrosion Inhibitor CHIMEC 1430
Anti foam Chemical CHIMEC 8045
Phosphate NALCO 7208
10.6 HAZOP Recommendation for Operation Instruction
The following are list of HAZOP Follow-up action, relating the operation manual. See the relevant
section for the detail procedures to cover the Hazop review requirement during design review.
HAZOP Follow-up Action in Operation Manual
Action Description
Follow-up Description by TPC
Action
No
4003
Ensure
operating
manual
and Operation manual will cover the following.
procedures includes actions to be At event of Atomizing steam low flow of either
taken if steam supply fails.
FI-005 A to F, check the site condition of FV005 A to F, while manual by-passing of the
relevant control valve.
4009
Consider provision of temporary A temporary Strainer on the feed line will be
strainer and relevant operating provided for the initial start up, and procedure
instruction.
will be covered in the operation manual.
4015
Ensure that the operating procedure Operating Manual will cover the detail
indicates the opening and closing of Procedures for:
valves and blinds of the PSV-002
- opening of AOV-001
- closing isolation valve of PSV-002
- during normal operation, isolation valve of
PSV-002 shall keep closing
4019
Ensure operating manual has an Operation manual will instruct appropriate
appropriate instruction.
procedure to avoid solidification of feed oil
system as following.
- Routine checking that steam trace is working
properly.
4023
Ensure that the operating guideline Operation manual will cover that the reactor
should include reference to need for temperature control is the prime concerns to
correct process condition.
promote coke formation.
4026
4036

See
Section
7.9.2
See
Section
7.9.3

See
Section
7.9.4

See
Section
7.9.5 and
7.3.1
Ensure operating procedure cover this Operation manual will cover that MPS injection See
aspect.
shall be maintained while no MTC injection.
Section
7.9.6
Ensure that the operating procedure Operation procedure will cover that venting line See
includes reference to possibility of shall never closed while steam out operation to Section
creating a vacuum.
7.9.7
create vacuum condition.

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Section
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VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

Action Description
Action
No
4040
Confirm arrangements to ensure that
isolation valve on the PSV is not
blocked before putting the PSV in
service.
4041
Operating procedures should describe
that overflow vent valve should be
open during drum filling and close
during normal operation
4048
Ensure procedures provide for
positive valve isolation.
4050

4058
4067

4080
4082
4092
4097
4144

4320
4345

4381

Follow-up Description by TPC

Referen
ce Sect
See Action No. 4015, that operation manual See
will cover the procedure for isolation of PSV- Section
002.
7.9.3
Operation manual will cover that valve of See
overflow should be opened during filling, and Section
be closed during operation.
7.9.8

Operation manual to cover that PDT-103


should be commissioned properly that LP side
shall never left open condition
Confirm sampling operation can be Operation procedure will be cover sampling of
carried out safely with equipment hot catalyst from the reactor.
provided and that instructions to
operators are appropriate.
Confirm operators guideline for Operation manual to cover the procedures when
action on HH temperature.
high high temperature of the regenerator

See
Section
7.9.9
See
Section
7.9.10

See
Section
7.9.20
Confirm sampling operation can be Operation manual to cover sampling procedure See
carried out safely with equipment of hot catalyst.
Section
provided and that instructions to
7.9.10
operators are appropriate.
Confirm procedures and arrangements It will be confirmed when vendors data is See
for setting and operating SV1503-VO- available, and will be described in the operation Section
01/02.
manual, if any.
7.9.11
Operating procedure should include Operation manual will cover that combustion See
corrective actions.
air to the 1st regenerator should be adjusted to Section
control CO in the flue gas.
7.9.12
Confirm procedures and arrangements Operation manual by vendor will cover the See
for setting and operating SV1504-VO. procedures and arrangements for setting and Section
operation.
7.9.11
Operating procedure should include Operation manual to cover that combustion air See
corrective actions.
to the 2nd regenerator should be properly Section
control to attain complete combustion of CO.
7.8.13
Operating procedure to ensure flue gas Operation manual will cover that flue gas See
temperature is above the dew point by temperature should be always 50deg C higher Section
at 50 degree C (minimum).
than its dew point ( 160-190 deg C), i.e.240 deg 7.9.14
C.
Confirm operating procedure include Operation procedure will cover flush out is See
need to flush out slurry exchangers required while not in service of slurry Section
not in service.
exchangers.
7.9.15
Investigate arrangement for bringing A check valve will be added on BFW supply, See
steam generated back into service downstream of isolation valve, respectively to Section
after outage and start up.
secure filling BFW operation on the idling 7.9.16
exchanger. Operation manual will cover the
switch over operation to the stand-by
exchanger.
Lock open inlet and outlet valves on It will be covered in the operation manual.
See
water side of E-1511 and ensure this is
Section
covered by operating procedure.
7.9.17

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Action Description
Action
Follow-up Description by TPC
No
4601
Ensure that adequate operating (Rev.0 on 11-APR-2006)
instructions provided for on/off pumps
Operation manual will cover that vessel D-1551
P-1552.
is normally empty and ensure that pump P-1551
A or B shall never operate while vessel empty.
(Rev.1 on 21-JUL-2006)
See Action No. 4600, appropriate operation is
required when activating low alarm on LA-701
to avoid pump P-1552A or B to operate lose
suction condition.
4697
Contractor to identify depressurization Design temperature of T-1556 covers the
mode for failure of solenoid or open situation self refrigeration (- 25 deg C).
circuit and consider provision of
Operation manual will cover, specifically, that
upstream isolation valve
depressuring operation of LPG vessel shall be
activated during external fire, only.
There is a substantial time for operators
intervention to check the realistic situation at
the case of operation fault, and to reach
complete frozen condition of T-1556.
4449
Contractor to check for this condition (Rev.2 on 11-SEP-2006)
4468
where fuel gas via the following PCVs
The split range control with purge gas and
4482
without causing PIC low alarm.
4488
- PIC-483 for PCV-483A & B venting to flare is commonly applied for
at D-1518
pressure control of the surge drum. Intelligent
- PIC-489 for PCV-489A & B assessment confirms that the frequency of
at D-1519
driven open of PCV to flare is quite rare. As the
- PIC-505 for PCV-505 A & B relevant drum is designed for full vacuum
at D-1522
condition, and even if operation pressure is
- PIC-510 for PCV-510 A & B balanced to the flare pressure, there is no
at D-1523
concerning of safety and operability.
In order to close out this issue, TPC will
describe in the operation manual that operation
condition of these control valves should be
checked, time to time, whether both PCVs are
opened or not, and check local PG for
confirmation of proper function of PIC.
(Rev.3 on 17-NOV-2006 for 4468)
Please be informed that PV-489A and PV-489B
are close in normal operation and one (not
both) of them will be open dependent on
input signal as split range control. There is no
change that both PV-489A and PV-489B are
open at a time as shown on the P&ID. With this
split range control and the system availability
as per project specifications, there is no
considerable loss of fuel gas to the flare.

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See
Section
7.9.18

See
Section
7.9.19

See
Section
7.9.21

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

Action Description
Action
No
2070
Provide operating procedures which
require rapid communication of FG
treater problem to FG customers so
that they can initiate appropriate
safety measures.

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Follow-up Description by TPC

Referen
ce Sect
See
YOC will develop this procedure in the
Section
Operation manual for RFCC Unit.
7.9.22
NOTE: This action is highlighted in HAZOP
Action of Unit 12 for the failure situation of the
fuel gas absorber T-1555 that H2S in fuel gas
will be higher than normal, and special
attention for handling is required for the
relating unit, using treated fuel gas.

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


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11 INSTRUEMNT DATA
11.1 Control Valves and Instruments
Refer to following control valve and flow instrument data sheets:
8474L-015-SP-1541-101: Data Sheets for Control Valves (Unit 15)
8474L-015-SP-1541-102: Data Sheets for Control Valves (Slurry Service) (Unit 15)
8474L-015-SP-1542-103: Data Sheets for Self Actuated Control Valves (Unit 15)
8474L-015-SP-1543-201: Data Sheets for Actuated On-off Valves (Unit 15)
8474L-015-SP-1543-202: Data Sheets for Actuated On-off Valves (Slurry Service) (Unit 15)
8474L-015-SP-1553-101: Data Sheets for Electronic Diff. Pressure Type Flow Transmitter (Unit 15)
8474L-015-SP-1547-002: Data Sheets for Rotormeters (Unit 15)
8474L-015-SP-1547-016: Data Sheets for Ultrasonic Flowmeters (Unit 15)
11.2 Orifice Plates
Refer to following orifice plates and restriction orifice data sheets:
8474L-015-SP-1546-002: Data Sheets for Orifice Plates (Unit 15)
8474L-400-SP-1546-001: Instrument Specification Restriction Orifice

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OPERATING MANUAL
UNIT RFCC (015)

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12 SUMMARY OF MAJOR EQUIPMENT


12.1 Equipment List
Refer to RFCC Equipment List (8474L-410-EL-001) as attached.
12.2 Large Rotating Equipment
12.2.1 Air Blower, C-1501
Air Blower 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.
The major operating conditions are as follows:
C-1501 Process Condition
Mix MG
Mix MD
BH MG
BH MD
Ope Case
Unit
Design
Flowrate
NM3/hr
340,432
309,483
254,808
213,247
195,748
Suct Press
kg/cm2A
1.008
1.008
1.008
1.008
1.008
Suct Temp
Deg C
36
36
36
36
36
Disch Press
kg/cm2A
4.66
4.26
4.26
4.26
4.26
Disch Temp
Deg C
227
210
223
232
238
The following are design data of turbine of C-1501:
- First critical speed of C-1501: 2011 RPM
- First critical speed of turbine: 2604 RPM (HOLD)
- Normal speed: 4,400 RPM
- Rated speed: 4,661RPM (100 %)
- Minimum continuous speed: 3,263 RPM (70 %)
- Maximum continuous speed: 4,894 RPM (105 %)
- Trip speed : 5,383 RPM (115.5 %)
Refer to the attached expected Q-H curves for C-1501.
12.2.2 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 Concentration Section. The
machine consists two stages compressor, with external cooling. 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.
Mixed Crude Max
Bach Ho Max
C-1551 process Condition
Gasoline
Gasoline
Unit
Normal
Design
Normal
Design
Ope Case
First Stage
Flowrate
NM3/hr
65326
75127
67578
77715
Wt Flow
Kg/hr
138964
159809
139263
160152
MW
47.68
47.68
46.19
46.19
Suct Press
kg/cm2A
1.33
1.33
1.33
1.33
Suct Temp
Deg C
41.9
41.9
41.9
41.9
Disch Press
kg/cm2A
5.13
5.09
5.2
5.19
Disch Temp
Deg C
96.5
97
98.7
99.5

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DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

C-1551 process Condition

Bach Ho Max
Gasoline
Normal
Design

Unit
Ope Case
Second Stage
Flowrate
NM3/hr
43794
Wt Flow
Kg/hr
80749
MW
41.33
Suct Press
kg/cm2A
4.43
Suct Temp
Deg C
41.9
Disch Press
kg/cm2A
17.1
Disch Temp
Deg C
111.3
The following are design data of turbine of C-1551
- Normal speed: 5,134 RPM
- Rated Speed: 5,458 RPM
- Maximum continuous speed: 5,731 RPM
- Trip Speed: 6,304 RPM
- First Critical speed: 2,600 - 2,700 RPM
- Second Critical Speed: 11,000 RPM
Refer to the attached expected Q-H curves for C-1551.

50363
92861
41.33
4.39
41.9
17.1
112

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Mixed Crude Max


Gasoline
Normal
Design
48195
86739
40.34
4.5
41.9
17.1
112

55424
99750
40.34
4.49
41.9
17.1
112.6

12.3 Major Special Packages


12.3.1 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 facilities consist of two parallel precipitators and ash
handling facilities. The principle of operation is to provide high voltage electric for collection of dust by
corona effect.
12.3.2 COB/WHB Package, H-1503
The COB/WHB Package is provided to incinerate CO rich flue gas from the first regenerator, steam
generation from COB and flue gas from the second regenerator. The package consists of COB, WHB,
and Economizer sections. The auxiliary firing of COB is designed to generate 205 ton/hr of HPS at all
operation cases. The imported saturated HPS and MPS are also superheated in WHB. This package
contributes a production of major HPS generation for the users in the Refinery.
12.3.3 Slurry Separator, X-1504
The Slurry Separator is provided to decrease catalyst fine in the Fractionator Bottom and produce
Clarified Oil for fuel oil production. 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 back-washing facilities by
flushing oil.

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UNIT RFCC (015)

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13 ANALYSIS
13.1 Sampling and Testing Method Schedule
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.
Feed Oil
ANALYSIS

METHOD

FREQUENCY

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

D 5863 / D 5708 /D 5185

Weekly

ASTM D 611

Weekly

METHOD

FREQUENCY

Paramagnetic type analyzer

Daily (continuous)

Specific Gravity

Metals
Aniline point
Flue gas
ANALYSIS
1st flue gas

O2

2nd flue gas

CO, O2

Infrared photometry

Daily (continuous)

SOx, NOx

Chemiluminescence

Weekly or at request

Particulates

Isokinetic sampling

At request

METHOD

FREQUENCY

Catalyst
ANALYSIS
Spent catalyst

Carbon

Element analyzer

Daily

1st regen. catalyst

Carbon

ASTM D 3178 or equiv.

Daily

2nd regen. catalyst

Carbon

ASTM D 3178 or equiv.

Daily

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Particle size

by catalyst vendor

MAT Activity

by catalyst vendor

Surface area

by catalyst vendor

Pore volume

by catalyst vendor

Bulk density

by catalyst vendor

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

ANALYSIS

Fresh catalyst

METHOD

Metals

by catalyst vendor

Rare earths

by catalyst vendor

MAT
activity

by catalyst vendor/
R2R MAT

Particle size

by catalyst vendor

Surface area

by catalyst vendor

Pore volume

by catalyst vendor

Bulk density

by catalyst vendor

Metals

by catalyst vendor

Rare earths

by catalyst vendor

FREQUENCY

Light cycle oil


Property
Specific gravity
Distillation
Sulfur
Nitrogen
Color
Flash point
Cloud point
Water
Viscosity at 50C
Pour point

Method
ASTM D1298 / D4052
ASTM D86
ASTM D4294
ASTM 4629
ASTM D1500
ASTM D93
ASTM D2500
ASTM D4377 / E0203
ASTM D445
ASTM D97

Frequency
Daily
Daily
Daily
Daily
Daily
Daily
Daily
Daily
Daily
Daily

Heavy cycle oil


Property
Specific gravity
Distillation
Viscosity
Sulfur

Method
ASTM D1298 / D4052
ASTM D86 / D1160
ASTM D445
ASTM D4294

Frequency
At request
At request
At request
At request

Method
ASTM D1298 / D4052
ASTM D1160
ASTM D445
ASTM D97
ASTM D93
ASTM D4294
ASTM D1796
ASTM D482

Frequency
Daily
At request
At request
Daily
At request
Daily
Daily
Daily

Clarified oil
Property
Specific gravity
Distillation
Viscosity at 100C
Pour point
Flash point
Sulfur
Water & sediment
Catalyst loading (Ash)
Slurry

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OPERATING MANUAL
UNIT RFCC (015)

Property
Catalyst loading (Ash)
Absorber gas
Property
Composition
H2S

Method
ASTM D482

Frequency
Daily

Method

Frequency
Daily

Gas chromatograph
Draeger tube

Daily

Method
ASTM D1298 / D4052
ASTM D86
ASTM D4294
ASTM D2699
ASTM D2700

Frequency
Daily
Daily
Daily
Daily
Daily

Debutanizer bottoms / Gasoline product


Property
Method
Specific gravity
ASTM D1298 / D4052
Distillation
ASTM D86
Sulfur
ASTM D4294
RON
ASTM D2699
MON
ASTM D2700
RVP
ASTM D323

Frequency
Daily
Daily
Daily
Daily
Daily
Daily

Heavy Naphtha
Property
Specific gravity
Distillation
Sulfur
RON
MON

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LPG
Property
Composition
C5, mol%
C2, mol%

Specific gravity

Method

Gas chromatograph

Frequency
Daily

ASTM D2163
ASTM D2163
ASTM D1657

Daily
Daily
As required

Method
ASTM D1293
ASTM D1688
ASTM D1068
ASTM D1783
ASTM D4282
ASTM D4658
ASTM D1426
ASTM D3921

Frequency
At request
At request
At request
At request
At request
At request
At request
At request

Sour water
Property
pH
Copper
Iron
Phenols
Cyanides
Sulfides
Ammonia
Hydrocarbons

13.2 Catalyst sampling method


See attached drawing and P&I diagrams of spent catalyst line, regenerated catalyst line and first
regenerator.
When sampling is not in operation, valve 3 is opened to purge the nozzles with nitrogen and valves 1,
2 and 4 are closed.

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_
__ RA|
D __|
N
I
||___
0

8474L-015-ML-001-A
07
R-20
7-MA

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
Rev.
:A
Chapter : 13
Page
:225/230

At the time of catalyst sampling, close valve 3 to get catalyst in the sampling line. Then open valves
1 and 2 to allow the sampling in the buffer. When the buffer is full, close 2 and open 4 to backflush the sampling line. Finally open 3 and close valves 1 and 4.

_
_
_
__ RA|
D __|
N
I
||___
0

8474L-015-ML-001-A
07
R-20
7-MA

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

_
_
_
__ RA|
D __|
N
I
||___
0

8474L-015-ML-001-A
07
R-20
7-MA

February 2007
Rev.
:A
Chapter : 13
Page
:226/230

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

13.3 On-Line Analyzer


Refer to RFCC Analyzer Process Data Sheet (8474L-015-PDS-AE-401).

_
_
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__ RA|
D __|
N
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0

8474L-015-ML-001-A
07
R-20
7-MA

February 2007
Rev.
:A
Chapter : 13
Page
:227/230

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

14 PROCESS CONTROL
14.1 Distributed System Control (DCS)
LATER.

_
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_
__ RA|
D __|
N
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0

8474L-015-ML-001-A
07
R-20
7-MA

February 2007
Rev.
:A
Chapter : 14
Page
:228/230

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
Rev.
:A
Chapter : 15
Page
:229/230

15 DRAWINGS
15.1 Plot Plans
Refer to the attached RFCC Plot Plan (8474L-015-DW-0051-001) and Area Classification (8474L-015DW-1920-001).
15.2 Process Flow Diagram
Refer to the attached RFCC Process Flow Diagrams and Material Selection Diagram.

15.3 Piping and Instrumentation Diagram


Refer to the attached RFCC Piping and Instrumentation Diagrams.

15.4 Other Drawings


Refer to the attached following drawings for RFCC unit.
- Substation SS8A Single Line Diagram
- Civil Installation Works Underground Plan
- Fire Fighting Water Distribution Diagram

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_
__ RA|
D __|
N
I
||___
0

8474L-015-ML-001-A
07
R-20
7-MA

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)


DUNG QUAT REFINERY
OPERATING MANUAL
UNIT RFCC (015)

February 2007
Rev.
:A
Chapter : 16
Page
:230/230

16 ATTACHMENT
Description

Spec No.
8474L-015-CN-0003-511

Estimated Utility Consumption Bach Ho MG Normal

8474L-015-CN-0003-512

Estimated Utility Consumption Bach Ho MD Normal

8474L-015-CN-0003-513

Estimated Utility Consumption Mixed Crude MG Normal

8474L-015-CN-0003-514

Estimated Utility Consumption Mixed Crude MD Normal

8474L-015-CN-0003-521

Estimated Utility Consumption Bach Ho MG Design

8474L-015-CN-0003-522

Estimated Utility Consumption Bach Ho MD Design

8474L-015-CN-0003-523

Estimated Utility Consumption Mixed Crude MG Design

8474L-015-CN-0003-524

Estimated Utility Consumption Mixed Crude MD Design

8474L-015-NM-0006-701

RFCC Flare Discharge Summary

---

Alarm Setting List

---

Trip Setting List

8474L-015-DW-1514-602
---

MSDS for Nickel Passivator EC9192

---

MSDS for Corrosion Inhibitor CHIMEC 1430

---

MSDS for Anti foam Chemical CHIMEC 8045

---

MSDS for Phosphate NALCO 7208

8474L-410-EL-001

RFCC Equipment List

8474L-015-A1002-1040-001-035

C-1501 Q-H Curves

8474L-015-A1002-1010-001-009

C-1551 Q-H Curves

8474L-015-DW-0051-001

RFCC Plot Plan

8474L-015-DW-1920-001

RFCC Hazardous Area Classification

8474L-015-PFD-0010-101-117

RFCC Process Flow Diagram

8474L-015-MSD-0011-501-505

RFCC Material Selection Diagram

8474L-015-PID-0021-101-662

RFCC Piping and Instrumentation Diagram

8474L-001-DW-1652-108

Substation SS8A Single Line Diagram

8474L-015-DW-1452-001-019

Civil Installation Works Underground Plan

8474L-015-PID-1931-601-603

RFCC Fire Fighting Water Distribution Diagram

_
_
_
__ RA|
D __|
N
I
||___

8474L-015-ML-001-A
07
R-20
7-MA

Cause and Effect Chart

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


DOCUMENT CLASS
CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

Pages modified under revision 1 :

REVISION
69,700 BPSD
-

7
2-20007
FEABR0273-M

Code

Serial N

Rev. index

CN

00 03

511

Op. Center JOB No.

0-3952-20-0000

Op. Center Doc. No.

S-015-1223-511

FEED Doc. No.

23-MAY-06

01-FEB-07

23-FEB-07

WRITTEN BY

T. Tsuchiya

T. Tsuchiya

T. Tsuchiya

Bach Ho Max Gasoline

CHECKED BY

M. Okada

M. Okada

M. Okada

- Normal Case

APPROVED BY

M. Okada

M. Okada

M. Okada

DESCRIPTION

Issue for Review

For Construction

For Construction

2,4,10

Bach Ho MG - Normal

S-015-1223-511-1.xls

Doc. type

8474L 015

DATE

GENERAL NOTES:

_
_
_
__ RA|
D __|
N
I
||___

Project N - Unit

6960-015-DS-0711

SHEET

OF

10

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

-0.3

-0.3

-585.0

-597.0

HP
STM

MP
STM

219.9

0.5

COB / WHB PACKAGE


FORCED DRAFT AIR FAN

C-1502 B

FORCED DRAFT AIR FAN

(-18.0)

C-1502B HOT STAND-BY

-1.4

1230

BFW HEATER
AIR BLOWER

-3.0

-3.0

P-1529 A

C-1501 TURBINE CONDENSATE PUMP

55

-39.0

-43.3

P-1529 B

C-1501 TURBINE CONDENSATE PUMP

55

(-39.0)

(-43.3)

E-1531

SURFACE CONDENSER
37

-18.5

-20.6

15

-15.0

-15.0

C-1501 LUBE OIL PUMP (Main)


C-1501 LUBE OIL PUMP (Spare)

TURNING GEAR MOTOR

C-1551

WET GAS COMPRESSOR

-1.5

-1.5

C-1551 TURBINE CONDENSATE PUMP

18.5

-13.9

-14.8

P-1559 B

C-1551 TURBINE CONDENSATE PUMP

18.5

(-13.9)

(-14.8)

E-1567

TURBINE CONDENSER
30

-16.0

-17.8

C-1551 LUBE OIL PUMP (Main)

C-1551 LUBE OIL PUMP (Spare)

Serial N

Rev. index

8474L 015

CN

00 03

511

HP
COND

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

-68.7

-30.4

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

BFW
T/h
HP
BFW

LP
BFW

-226.1

-0.5

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

REMARKS

1.4

-0.3

9.0
-0.1

0.1

68.7

0.3

30.4

0.4

(2.6)

-0.4

(-2.1)

(2.1)

-34.7

34.7

DISENGAGER / STRIPPER

COB/WHB LP BLOWDOWN DRUM

0.5

-0.5

D-1527

LP BLOWDOWN DRUM

0.1

-0.1

T-1503

LCO STRIPPER

-3.0

3.0

T-1504

HCO STRIPPER

-0.5

0.5

PAGE TOTAL

1462

-692.2

-713.3

119.4

-43.9

-3.0

0.0

9.0

0.1

99.1

-226.1

-0.5

0.0

0.0

45.9

GENERAL TOTAL

1462

-692.2

-713.3

119.4

-43.9

-3.0

0.0

9.0

0.1

99.1

-226.1

-0.5

0.0

0.0

45.9

NOTES

S-015-1223-511-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

REV

6.2

D-1501

_
_
_
__ RA|
D __|
N
I
||___

10

APPROVED BY

(18.0)

(-2.6)

P-1559 A

LP
STM

-9.0

E-1534

Code

Included in H-1503

C-1501

69,700 BPSD
Bach Ho Max Gasoline
- Normal Case
STEAM
T/h

H-1503

ECONOMIZER

Doc. type

REVISION

C-1502 A

E-1525

Project N - Unit

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

511

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

1462

-692.2

-713.3

P-1501 A

FEED PUMP

600

-476.0

-500.5

P-1501 B

FEED PUMP

600

(-476.0)

(-500.5)

P-1504 A

SLURRY PRODUCT PUMP

55

-42.7

-45.1

P-1504 B

SLURRY PRODUCT PUMP

55

(-42.7)

(-45.1)

P-1505 A

BACKFLUSH OIL PUMP

22

-15.0

-16.5

P-1505 B

BACKFLUSH OIL PUMP

22

(-15.0)

(-16.5)

P-1506 A

BACKFLUSH OIL RECYCLE PUMP

11

-7.4

-8.4

P-1506 B

BACKFLUSH OIL RECYCLE PUMP

11

(-7.4)

(-8.4)

P-1507 A

HCO RECYCLE PUMP

150

0.0

0.0

P-1507 B

HCO RECYCLE PUMP

150

(0.0)

(0.0)

69,700 BPSD
Bach Ho Max Gasoline
- Normal Case
STEAM
T/h

DATE

SHEET

WRITTEN BY
3

CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW
-226.1

-0.5

0.0

0.0

45.9

HP
STM

MP
STM

LP
STM

HP
COND

119.4

-43.9

-3.0

0.0

9.0

0.1

99.1

BFW
T/h

P-1508 A

HCO PUMPAROUND PUMP

220

-179.4

-188.4

P-1508 B

HCO PUMPAROUND PUMP

220

(-179.4)

(-188.4)

P-1509 A

HCO PRODUCT PUMP

15

-9.1

-10.1

P-1509 B

HCO PRODUCT PUMP

15

(-9.1)

(-10.1)

P-1510 A

LCO PUMPAROUND PUMP

335

-303.0

-316.0

P-1510 B

LCO PUMPAROUND PUMP

335

(-303.0)

(-316.0)

P-1511 A

LCO STRIPPER PUMP

90

-73.4

-76.9

P-1511 B

LCO STRIPPER PUMP

90

(-73.4)

(-76.9)

P-1512 A

MTC RECYCLE PUMP

75

0.0

0.0

P-1512 B

MTC RECYCLE PUMP

75

(0.0)

(0.0)

P-1513 A

LEAN OIL PUMP

75

-55.0

-58.1

P-1513 B

LEAN OIL PUMP

75

(-55.0)

(-58.1)

P-1514 A

NAPHTHA PUMPAROUND PUMP

225

-203.0

-213.9

P-1514 B

NAPHTHA PUMPAROUND PUMP

225

(-203.0)

(-213.9)

PAGE TOTAL

3746

-1364.0

-1433.9

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

GENERAL TOTAL

5208

-2056.2

-2147.2

119.4

-43.9

-3.0

0.0

9.0

0.1

99.1

-226.1

-0.5

0.0

0.0

45.9

REMARKS

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-511-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

511

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

5208

-2056.2

-2147.2

P-1515 A

HEAVY NAPHTHA PRODUCT PUMP

55

-39.4

-41.6

P-1515 B

HEAVY NAPHTHA PRODUCT PUMP

55

(-39.4)

(-41.6)

P-1516 A

FRACTIONATOR REFLUX PUMP

110

-96.0

-101.3
(-101.3)

69,700 BPSD
Bach Ho Max Gasoline
- Normal Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

119.4

-43.9

-3.0

0.0

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
LP
MP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

0.1

-226.1

-0.5

0.0

0.0

45.9

9.0

99.1

BFW
T/h

P-1516 B

FRACTIONATOR REFLUX PUMP

110

(-96.0)

P-1517 A

OVERHEAD SOUR WATER PUMP

30

-25.5

-27.6

P-1517 B

OVERHEAD SOUR WATER PUMP

30

(-25.5)

(-27.6)

P-1518 A

OVERHEAD LIQUID PUMP

250

-206.0

-228.9

P-1518 B

OVERHEAD LIQUID PUMP

250

(-206.0)

(-228.9)

P-1519 A

SLURRY PUMPAROUND PUMP

-10.3

P-1519 B

SLURRY PUMPAROUND PUMP

-10.3

10.3

P-1519 C

SLURRY PUMPAROUND PUMP

(-10.3)

(10.3)

P-1519C HOT STAND-BY

-0.8

P-1521 A

HCO FLUSHING OIL PUMP

-3.7

P-1521 B

HCO FLUSHING OIL PUMP

110

(-80.9)

P-1522 A

LCO FLUSHING OIL PUMP

30

-18.4

-19.9

P-1522 B

LCO FLUSHING OIL PUMP

30

(-18.4)

(-19.9)

P-1526 A

LIGHT SLOPS PUMP

37

-26.1

-27.9

P-1526 B

LIGHT SLOPS PUMP

37

(-26.1)

(-27.9)

P-1527 A

HEAVY SLOPS PUMP

37

-27.9

-29.8

P-1527 B

HEAVY SLOPS PUMP

37

(-27.9)

(-29.8)

P-1528 A

TEMPERED WATER PUMP

15

-10.5

-11.7

P-1528 B

TEMPERED WATER PUMP

15

(-10.5)

(-11.7)

PAGE TOTAL

1238

-449.8

-488.7

-25.1

0.0

24.3

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.8

GENERAL TOTAL

6446

-2506.0

-2635.8

94.3

-43.9

21.3

0.0

9.0

0.1

99.1

-226.1

-0.5

0.0

0.0

46.7

REMARKS

S-015-1223-511-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

0.8
3.7

(-84.4)

+ INDICATES QUANTITY PRODUCED

REV

10.3

NOTES

_
_
_
__ RA|
D __|
N
I
||___

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

511

REVISION

MOTOR
LOAD/
RATING

69,700 BPSD
Bach Ho Max Gasoline
- Normal Case
STEAM
T/h

DATE

CHECKED BY

DESCRIPTION
CONDENSATE
T/h
MP
COLD
LP
COND
COND
COND

HP
STM

MP
STM

LP
STM

HP
COND

94.3

-43.9

21.3

0.0

9.0

0.1

TOTAL PREVIOUS PAGES

6446

-2506.0

-2635.8

INTERSTAGE DRUM PUMP

150

-134.0

-142.3

P-1551 B

INTERSTAGE DRUM PUMP

150

(-134.0)

(-142.3)

P-1552 A

KO DRUM LIQUID PUMP

-1.2

-1.4

P-1552 B

KO DRUM LIQUID PUMP

(-1.2)

(-1.4)

P-1553 A

STRIPPER FEED PUMP

132

-112.0

-117.9

P-1553 B

STRIPPER FEED PUMP

132

(-112.0)

(-117.9)

P-1554 A

GASOLINE RECYCLE PUMP

55

0.0

0.0

P-1554 B

GASOLINE RECYCLE PUMP

55

(0.0)

(0.0)

OF

99.1

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

BFW
T/h

-226.1

-0.5

0.0

0.0

46.7

P-1556 A

DEBUTANIZER OVERHEAD PUMP

225

-185.0

-194.9

P-1556 B

DEBUTANIZER OVERHEAD PUMP

225

(-185.0)

(-194.9)

P-1560 A

RFCC CLOSED DRAIN PUMP

22

(-16.5)

(-18.1)

P-1560 B

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)

PAGE TOTAL

1214

-432.2

-456.5

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

GENERAL TOTAL

7660

-2938.2

-3092.3

94.3

-43.9

21.3

0.0

9.0

0.1

99.1

-226.1

-0.5

0.0

0.0

46.7

REMARKS

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-511-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

P-1551 A

SHEET

WRITTEN BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

511

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

7660

-2938.2

-3092.3

E-1514

LCO AIR COOLER

120

-97.6

-106.2

E-1517

HEAVY NAPHTHA AIR COOLER

33

-20.4

-23.1

E-1519

OVERHEAD AIR CONDENSER

960

-736.0

-800.9

E-1521

HEAVY NAPHTHA 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

69,700 BPSD
Bach Ho Max Gasoline
- Normal Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

94.3

-43.9

21.3

0.0

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND
9.0

0.1

99.1

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW
-226.1

-0.5

0.0

0.0

46.7

BFW
T/h

E-1553

HP CONDENSER

180

-134.4

-146.2

E-1558

GASOLINE AIR COOLER

120

-92.8

-101.0

E-1503

SLURRY HP STEAM GENERATOR

0.0

0.0

E-1504

SLURRY HP STEAM GENERATOR

10.3

-10.6

E-1505

SLURRY MP STEAM GENERATOR

E-1506

SLURRY LP STEAM GENERATOR

E-1508

HCO RECYCLE MP STEAM GENERATOR

E-1510

8.0

0.2

1.3

-1.4

0.1

0.0

0.0

HCO LP STEAM GENERATOR

2.1

-2.2

0.1

E-1513

LCO PRODUCT LP STEAM GENERATOR

2.2

-2.2

0.0

E-1518

HEAVY NAPHTHA TRIM COOLER

0.0

REMARKS

0.3

-8.2

PAGE TOTAL

1796

-1386.2

-1510.8

10.3

8.0

5.6

0.0

0.0

0.0

0.0

-10.6

-14.0

0.0

0.0

0.7

GENERAL TOTAL

9455

-4324.4

-4603.1

104.6

-35.9

26.9

0.0

9.0

0.1

99.1

-236.7

-14.5

0.0

0.0

47.4

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-511-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

TOTAL PREVIOUS PAGES


E-1520 A-H

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

511

REVISION

MOTOR
LOAD/
RATING
9455

69,700 BPSD
Bach Ho Max Gasoline
- Normal Case
STEAM
T/h

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

HP
STM

MP
STM

LP
STM

HP
COND

-4603.1

104.6

-35.9

26.9

0.0

-4324.4

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
LP
MP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

0.1

-236.7

-14.5

0.0

0.0

47.4

9.0

99.1

BFW
T/h

REMARKS

OVERHEAD TRIM CONDENSER

E-1522

MP STEAM FEED HEATER

-8.7

E-1523

HCO PUMPAROUND MP STEAM GENERATOR

0.7

E-1524

HP STEAM FEED HEATER

E-1532

BLOWDOWN COOLER

E-1552 A/B

WET GAS COMPRESSOR TRIM COOLER

E-1554 A-D

STRIPPER CONDENSER

E-1559

GASOLINE COOLER

E-1561 A/B

DEBUTANIZER CONDENSER

E-1562

LPG COOLER

E-1564

LEAN OIL COOLER

8.7

Cold Feed Case: -18.7 t/h MPS


0.0

-0.7

-13.5

Cold Feed Case: -22.8 t/h HPS

13.5

E-1565

FUEL GAS COOLER

E-1566

LEAN AMINE COOLER

I-1501

FEED INJECTOR

Included in D-1501

I-1502

MTC INJECTOR

Included in D-1501

I-1503

STABILIZATION INJECTOR

Included in D-1501

I-1504

BACK FLUSH OIL INJECTOR

SPR-1501

FIRST REGENERATOR TORCH OIL SPRAYER

(-0.3)

Included in D-1501
(0.3)

SPR-1502

SECOND REGENERATOR TORCH OIL SPRAYER

(-0.3)

SPR-1503

WATER SPRAY FOR D-1502 FLUE GAS BYPASS

(-1.5)

(-25.7)

(-27.2)

SPR-1504

WATER SPRAY FOR D-1503 FLUE GAS BYPASS

(-1.5)

(-15.8)

(-17.3)

SPR-1505

WATER SPRAY FOR ECONOMIZER BYPASS

(-1.5)

(-18.5)

(-20.0)

(0.3)

PAGE TOTAL

0.0

0.0

-13.5

-8.0

0.0

13.5

8.7

0.0

0.0

0.0

-0.7

0.0

0.0

0.0

GENERAL TOTAL

9455

-4324.4

-4603.1

91.1

-43.9

26.9

13.5

17.7

0.1

99.1

-236.7

-15.2

0.0

0.0

47.4

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-511-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

TOTAL PREVIOUS PAGES


X-1504

SLURRY SEPARATOR

X-1505

CORROSION INHIBITOR INJECTION PACKAGE

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

9455

-4324.4

-4603.1

-230.0

-230.0

CORROSION INHIBITOR PUMP

0.55

-0.40

-0.44

X-1507

ELECTROSTATIC PRECIPITATOR

491

-379.0

-379.0

88

(-53)

(-53)

(-270.0)

(-300.0)

X-1509

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

511

REVISION

P-1520

X-1508

Project N - Unit

DESOX UNIT(FUTURE)

69,700 BPSD
Bach Ho Max Gasoline
- Normal Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

91.1

-43.9

26.9

13.5

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

0.1

-236.7

-15.2

0.0

0.0

47.4

17.7

99.1

BFW
T/h

-0.3

REMARKS

0.3
Intermittent Users in X-1507

METAL PASSIVATOR INJECTION PACKAGE

P-1502 A

METAL PASSIVATION PUMP

0.55

0.00

0.00

P-1502 B

METAL PASSIVATION PUMP

0.55

(0.00)

(0.00)

X-1510

PHOSPHATE INJECTION PACKAGE

6.05

-4.36

-4.84

X-1551

ANTI-FOAM INJECTION PACKAGE

P-1557

ANTI-FOAMING PUMP

0.55

(-0.40)

(-0.44)

P-1558

ANTI-FOAMING PUMP

0.55

(-0.40)

(-0.44)

-3.3

EJ-1501

CATALYST HOPPERS STEAM EJECTOR

SV-1501

REGENERATED CATALYST SLIDE VALVE

4.0

-3.0

SV-1502

SPENT CATALYST SLIDE VALVE

4.0

-3.0

-3.3

SV-1503

FIRST REGENERATOR FLUE GAS SLIDE VALVE

4.0

-3.0

-3.3

SV-1504

SECOND 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

---

STEAM TRACE

(0.9)

(-0.9)

0.1

-0.1

-2.0

2.0

PAGE TOTAL

611

-631.5

-633.7

0.0

0.0

-2.4

0.0

0.0

2.0

0.0

0.0

0.0

0.0

0.0

0.4

GENERAL TOTAL (excl. Future DeSOx)

10066

-4955.9

-5236.8

91.1

-43.9

24.5

13.5

17.7

2.1

99.1

-236.7

-15.2

0.0

0.0

47.8

GENERAL TOTAL (incl. Future DeSOx)

10066

-5225.9

-5536.8

91.1

-43.9

24.5

13.5

17.7

2.1

99.1

-236.7

-15.2

0.0

0.0

47.8

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-511-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION

CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

511

REVISION

COOLING WATER

DESCRIPTION

T
C

m3/h

E-1518

HEAVY NAPHTHA TRIM COOLER

6.0

-19

E-1520 A-H

OVERHEAD TRIM CONDENSER

8.0

-1882

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

-255

E-1554 A-D

STRIPPER CONDENSER

6.0

-820

E-1559

GASOLINE COOLER

6.0

-160

E-1561 A/B

DEBUTANIZER CONDENSER

12.0

-1353

E-1562

LPG COOLER

6.0

-64

E-1564

LEAN OIL COOLER

6.0

-177

E-1565

FUEL GAS COOLER

6.0

-9

E-1566

LEAN AMINE COOLER

6.0

-72

E-1567

TURBINE CONDENSER

69,700 BPSD
Bach Ho Max Gasoline
- Normal Case
SEA WATER
T
C

m3/h

8.8

-7285

8.8

-2300

FRESH
WATER
T/h

DATE

SHEET

WRITTEN BY
CHECKED BY

DESCRIPTION
PLANT AIR
INST.
Nm3/h
AIR
Nm3/h
CONTIN
INTERMIT

NITROGEN
Nm3/h

S-015-1223-511-1.xls

7
2-20007
FEABR0273-M

CONTIN

INTERMIT

Efficiency
%

FUEL FIRED
MW

PUMP / COMP COOLING

-95

PAGE TOTAL

-4945

-9585

0.0

0.0

0.0

GENERAL TOTAL

-4945

-9585

0.0

0.0

0.0

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

FURNACES & BOILERS


DUTY
MW

NOTES

_
_
_
__ RA|
D __|
N
I
||___

OF

APPROVED BY

- INDICATES QUANTITY CONSUMED

REMARKS

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION

CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

511

REVISION

DESCRIPTION

COOLING WATER
T
C

m3/h
-4945

TOTAL PREVIOUS PAGES

69,700 BPSD
Bach Ho Max Gasoline
- Normal Case
SEA WATER
T
C

m3/h

FRESH
WATER
T/h

DATE

SHEET

WRITTEN BY
10

CHECKED BY

DESCRIPTION
INST.
PLANT AIR
AIR
Nm3/h
Nm3/h
CONTIN
INTERMIT

H-1502

SECOND REGENERATOR HEATER

H-1503

COB/WHB PACKAGE

NITROGEN
Nm3/h
CONTIN

FURNACES & BOILERS

INTERMIT

DUTY
MW

X-1507
X-1504

X-1502

FRESH CATALYST FEEDER

X-1503

AUXILIARY CATALYST FEEDER

C-1501

AIR BLOWER

-22

-3

-50

(-125)

ELECTROSTATIC PRECIPITATOR

-26

-8

(-85)

SLURRY SEPARATOR

-1

OIL MIST GENERATOR

-165
-3

-60

(-40)

(-3)

(-60)

(-40)

GLAND CONDENSER

-76

OIL COOLER

-32
-6

MAIN OIL COOLER

6.0

-60

GLAND CONDENSER

6.0

-50

PV-1501

PLUG VALVE

SV-1501

REGENERATED CATALYST SLIDE VALVE

SV-1502

SPENT CATALYST SLIDE VALVE

SV-1504

SECOND REGENERATOR FLUE GAS SLIDE VALVE

-134

PRIMARY PLANT AIR FOR REGEN SECTION

-4230

REV

(-280)

-611
-84
-36

(2)

(-2320)
-340

-160

(-560)

PAGE TOTAL

-221

-5658

-118

-351

0.0

0.0

-113.7

GENERAL TOTAL

-5166

-9585

-5658

-118

-351

0.0

0.0

-113.7

MISCELLANEOUS USERS

-13.7

NOTES
1. FUEL GAS RATES DURING START-UP FOR BOTH REGENERATOR AIR HEATERS (APPROX. 4.5 T/h)
2. PLANT AIR FROM INSTRUMENT AIR HEADER FOR PRIMARY USERS.

) INTERMITTENT PRODUCER/CONSUMER

REMARKS

-100.0

-71

SECONDARY PLANT AIR FOR REGEN SECTION

7
2-20007
FEABR0273-M

FUEL FIRED
MW

(1)
15.0

WET GAS COMPRESSOR

S-015-1223-511-1.xls

Efficiency
%

(1)

-120

10

-9585

FIRST REGENERATOR AIR HEATER

_
_
_
__ RA|
D __|
N
I
||___

OF

APPROVED BY

H-1501

C-1551

Project N - Unit

+ INDICATES QUANTITY PRODUCED

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


DOCUMENT CLASS
CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

Pages modified under revision 1 :

REVISION
69,700 BPSD
-

7
2-20007
FEABR0273-M

Code

Serial N

Rev. index

CN

00 03

512

Op. Center JOB No.

0-3952-20-0000

Op. Center Doc. No.

S-015-1223-512

FEED Doc. No.

23-MAY-06

01-FEB-07

23-FEB-07

WRITTEN BY

T. Tsuchiya

T. Tsuchiya

T. Tsuchiya

Bach Ho Max Distillate

CHECKED BY

M. Okada

M. Okada

M. Okada

- Normal Case

APPROVED BY

M. Okada

M. Okada

M. Okada

DESCRIPTION

Issue for Review

For Construction

For Construction

2,4,10

Bach Ho MD - Normal

S-015-1223-512-1.xls

Doc. type

8474L 015

DATE

GENERAL NOTES:

_
_
_
__ RA|
D __|
N
I
||___

Project N - Unit

6960-015-DS-0711

SHEET

OF

10

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

HP
STM

MP
STM

219.3

0.7

COB / WHB PACKAGE


FORCED DRAFT AIR FAN

C-1502 B

FORCED DRAFT AIR FAN

(-21.0)

C-1502B HOT STAND-BY

-1.7

1230

-0.3

-0.3

-683.0

-697.0

E-1534

BFW HEATER
AIR BLOWER

-3.0

-3.0

P-1529 A

C-1501 TURBINE CONDENSATE PUMP

55

-39.0

-43.3

P-1529 B

C-1501 TURBINE CONDENSATE PUMP

55

(-39.0)

(-43.3)

E-1531

SURFACE CONDENSER
37

-18.5

-20.6

15

-15.0

-15.0

C-1501 LUBE OIL PUMP (Main)

C-1501 LUBE OIL PUMP (Spare)

TURNING GEAR MOTOR

WET GAS COMPRESSOR

-1.5

-1.5

C-1551 TURBINE CONDENSATE PUMP

18.5

-13.9

-14.8

P-1559 B

C-1551 TURBINE CONDENSATE PUMP

18.5

(-13.9)

(-14.8)

E-1567

TURBINE CONDENSER
30

-16.0

-17.8

C-1551 LUBE OIL PUMP (Main)


C-1551 LUBE OIL PUMP (Spare)

Serial N

Rev. index

8474L 015

CN

00 03

512

HP
COND

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

-68.7

-30.4

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

BFW
T/h
HP
BFW

LP
BFW

-225.5

-0.7

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

REMARKS

1.7

-0.3

7.0
-0.1

0.1

68.7

0.3

30.4

0.4

(2.6)

-0.4

(-2.1)

(2.1)

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

34.7

-34.7

PAGE TOTAL

1462

-790.2

-813.3

118.5

-41.7

-2.9

0.0

7.0

0.1

99.1

-225.5

-0.7

0.0

0.0

46.1

GENERAL TOTAL

1462

-790.2

-813.3

118.5

-41.7

-2.9

0.0

7.0

0.1

99.1

-225.5

-0.7

0.0

0.0

46.1

NOTES

S-015-1223-512-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

REV

6.2

D-1501

_
_
_
__ RA|
D __|
N
I
||___

10

APPROVED BY

(21.0)

(-2.6)

C-1551

LP
STM

-7.0

P-1559 A

Code

Included in H-1503

C-1501

69,700 BPSD
Bach Ho Max Distillate
- Normal Case
STEAM
T/h

H-1503

ECONOMIZER

Doc. type

REVISION

C-1502 A

E-1525

Project N - Unit

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

512

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

1462

-790.2

-813.3

P-1501 A

FEED PUMP

600

-476.0

-500.5

P-1501 B

FEED PUMP

600

(-476.0)

(-500.5)

69,700 BPSD
Bach Ho Max Distillate
- Normal Case
STEAM
T/h

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

HP
STM

MP
STM

LP
STM

HP
COND

118.5

-41.7

-2.9

0.0

7.0

0.1

99.1

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW
-225.5

-0.7

0.0

0.0

46.1

BFW
T/h

P-1504 A

SLURRY PRODUCT PUMP

55

-42.7

-45.1

P-1504 B

SLURRY PRODUCT PUMP

55

(-42.7)

(-45.1)

P-1505 A

BACKFLUSH OIL PUMP

22

-15.0

-16.5

P-1505 B

BACKFLUSH OIL PUMP

22

(-15.0)

(-16.5)

P-1506 A

BACKFLUSH OIL RECYCLE PUMP

11

-7.4

-8.4

P-1506 B

BACKFLUSH OIL RECYCLE PUMP

11

(-7.4)

(-8.4)

P-1507 A

HCO RECYCLE PUMP

150

-128.0

-142.2

P-1507 B

HCO RECYCLE PUMP

150

(-128.0)

(-142.2)

P-1508 A

HCO PUMPAROUND PUMP

220

-179.4

-188.4

P-1508 B

HCO PUMPAROUND PUMP

220

(-179.4)

(-188.4)

P-1509 A

HCO PRODUCT PUMP

15

-9.1

-10.1

P-1509 B

HCO PRODUCT PUMP

15

(-9.1)

(-10.1)

P-1510 A

LCO PUMPAROUND PUMP

335

-303.0

-316.0

P-1510 B

LCO PUMPAROUND PUMP

335

(-303.0)

(-316.0)

P-1511 A

LCO STRIPPER PUMP

90

-73.4

-76.9

P-1511 B

LCO STRIPPER PUMP

90

(-73.4)

(-76.9)

P-1512 A

MTC RECYCLE PUMP

75

0.0

0.0

P-1512 B

MTC RECYCLE PUMP

75

(0.0)

(0.0)

P-1513 A

LEAN OIL PUMP

75

-55.0

-58.1

P-1513 B

LEAN OIL PUMP

75

(-55.0)

(-58.1)

P-1514 A

NAPHTHA PUMPAROUND PUMP

225

-203.0

-213.9

P-1514 B

NAPHTHA PUMPAROUND PUMP

225

(-203.0)

(-213.9)

PAGE TOTAL

3746

-1492.0

-1576.1

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

GENERAL TOTAL

5208

-2282.2

-2389.4

118.5

-41.7

-2.9

0.0

7.0

0.1

99.1

-225.5

-0.7

0.0

0.0

46.1

REMARKS

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-512-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

512

REVISION

MOTOR
LOAD/
RATING

69,700 BPSD
Bach Ho Max Distillate
- Normal Case
STEAM
T/h

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

HP
STM

MP
STM

LP
STM

HP
COND

118.5

-41.7

-2.9

0.0

TOTAL PREVIOUS PAGES

5208

-2282.2

-2389.4

P-1515 A

HEAVY NAPHTHA PRODUCT PUMP

55

-39.4

-41.6

P-1515 B

HEAVY NAPHTHA PRODUCT PUMP

55

(-39.4)

(-41.6)

P-1516 A

FRACTIONATOR REFLUX PUMP

110

-96.0

-101.3

P-1516 B

FRACTIONATOR REFLUX PUMP

110

(-96.0)

(-101.3)

P-1517 A

OVERHEAD SOUR WATER PUMP

30

-25.5

-27.6

P-1517 B

OVERHEAD SOUR WATER PUMP

30

(-25.5)

(-27.6)

P-1518 A

OVERHEAD LIQUID PUMP

250

-206.0

-228.9

P-1518 B

OVERHEAD LIQUID PUMP

250

(-206.0)

(-228.9)

P-1519 A

SLURRY PUMPAROUND PUMP

-10.3

P-1519 B

SLURRY PUMPAROUND PUMP

-10.3

10.3

P-1519 C

SLURRY PUMPAROUND PUMP

(-10.3)

(10.3)

P-1519C HOT STAND-BY

-0.8

P-1521 A

HCO FLUSHING OIL PUMP

-3.7

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
COLD
LP
COND
COND
COND
7.0

0.1

99.1

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

BFW
T/h

-225.5

-0.7

0.0

0.0

46.1

REMARKS

0.8
3.7

P-1521 B

HCO FLUSHING OIL PUMP

110

(-80.9)

LCO FLUSHING OIL PUMP

30

-18.4

-19.9

P-1522 B

LCO FLUSHING OIL PUMP

30

(-18.4)

(-19.9)

P-1526 A

LIGHT SLOPS PUMP

37

-26.1

-27.9

P-1526 B

LIGHT SLOPS PUMP

37

(-26.1)

(-27.9)

P-1527 A

HEAVY SLOPS PUMP

37

-27.9

-29.8

P-1527 B

HEAVY SLOPS PUMP

37

(-27.9)

(-29.8)

P-1528 A

TEMPERED WATER PUMP

15

-10.5

-11.7

P-1528 B

TEMPERED WATER PUMP

15

(-10.5)

(-11.7)

PAGE TOTAL

1238

-449.8

-488.7

-25.1

0.0

24.3

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.8

GENERAL TOTAL

6446

-2732.0

-2878.1

93.4

-41.7

21.4

0.0

7.0

0.1

99.1

-225.5

-0.7

0.0

0.0

46.9

(-84.4)

NOTES

S-015-1223-512-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

REV

10.3

P-1522 A

_
_
_
__ RA|
D __|
N
I
||___

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

512

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

6446

-2732.0

-2878.1

P-1551 A

INTERSTAGE DRUM PUMP

150

-134.0

-142.3

P-1551 B

INTERSTAGE DRUM PUMP

150

(-134.0)

(-142.3)

P-1552 A

KO DRUM LIQUID PUMP

-1.2

-1.4

P-1552 B

KO DRUM LIQUID PUMP

(-1.2)

(-1.4)

P-1553 A

STRIPPER FEED PUMP

132

-112.0

-117.9

P-1553 B

STRIPPER FEED PUMP

132

(-112.0)

(-117.9)

P-1554 A

GASOLINE RECYCLE PUMP

55

-44.0

-47.7

P-1554 B

GASOLINE RECYCLE PUMP

55

(-44.0)

(-47.7)

P-1556 A

DEBUTANIZER OVERHEAD PUMP

225

-185.0

-194.9

P-1556 B

DEBUTANIZER OVERHEAD PUMP

225

(-185.0)

(-194.9)

69,700 BPSD
Bach Ho Max Distillate
- Normal Case
STEAM
T/h

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
LP
MP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW
-225.5

-0.7

0.0

0.0

46.9

HP
STM

MP
STM

LP
STM

HP
COND

93.4

-41.7

21.4

0.0

7.0

0.1

99.1

BFW
T/h

P-1560 A

RFCC CLOSED DRAIN PUMP

22

(-16.5)

(-18.1)

P-1560 B

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)

PAGE TOTAL

1214

-476.2

-504.2

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

GENERAL TOTAL

7660

-3208.2

-3382.3

93.4

-41.7

21.4

0.0

7.0

0.1

99.1

-225.5

-0.7

0.0

0.0

46.9

REMARKS

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-512-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

512

REVISION

MOTOR
LOAD/
RATING

69,700 BPSD
Bach Ho Max Distillate
- Normal Case
STEAM
T/h

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

HP
STM

MP
STM

LP
STM

HP
COND

93.4

-41.7

21.4

0.0

TOTAL PREVIOUS PAGES

7660

-3208.2

-3382.3

E-1514

LCO AIR COOLER

120

-97.6

-106.2

E-1517

HEAVY NAPHTHA AIR COOLER

33

-20.4

-23.1

E-1519

OVERHEAD AIR CONDENSER

960

-736.0

-800.9

E-1521

HEAVY NAPHTHA 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

DATE

SHEET

WRITTEN BY
6

CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND
7.0

0.1

99.1

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW
-225.5

-0.7

0.0

0.0

46.9

BFW
T/h

E-1553

HP CONDENSER

180

-134.4

-146.2

E-1558

GASOLINE AIR COOLER

120

-92.8

-101.0

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

0.4

1.3

-1.4

0.1

-6.7

0.2

HCO LP STEAM GENERATOR

2.9

-3.0

0.1

E-1513

LCO PRODUCT LP STEAM GENERATOR

8.6

-8.9

0.3

E-1518

HEAVY NAPHTHA TRIM COOLER

13.8

6.5

REMARKS

0.5

-14.2

PAGE TOTAL

1796

-1386.2

-1510.8

18.0

20.3

12.8

0.0

0.0

0.0

0.0

-18.5

-34.2

0.0

0.0

1.6

GENERAL TOTAL

9455

-4594.4

-4893.1

111.4

-21.4

34.2

0.0

7.0

0.1

99.1

-244.0

-34.9

0.0

0.0

48.5

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-512-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

TOTAL PREVIOUS PAGES

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

512

REVISION

MOTOR
LOAD/
RATING
9455

69,700 BPSD
Bach Ho Max Distillate
- Normal Case
STEAM
T/h

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

HP
STM

MP
STM

LP
STM

HP
COND

-4893.1

111.4

-21.4

34.2

0.0

-4594.4

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
LP
MP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

0.1

-244.0

-34.9

0.0

0.0

48.5

7.0

99.1

BFW
T/h

REMARKS

OVERHEAD TRIM CONDENSER

E-1520 A-H
E-1522

MP STEAM FEED HEATER

-6.5

E-1523

HCO PUMPAROUND MP STEAM GENERATOR

7.3

E-1524

HP STEAM FEED HEATER

E-1532

BLOWDOWN COOLER

E-1552 A/B

WET GAS COMPRESSOR TRIM COOLER

E-1554 A-D

STRIPPER CONDENSER

E-1559

GASOLINE COOLER

E-1561 A/B

DEBUTANIZER CONDENSER

E-1562

LPG COOLER

E-1564

LEAN OIL COOLER

6.5

Cold Feed Case: -16.4 t/h MPS


-7.5

-11.3

0.2

11.3

Cold Feed Case: -20.7 t/h HPS

E-1565

FUEL GAS COOLER

E-1566

LEAN AMINE COOLER

I-1501

FEED INJECTOR

Included in D-1501

I-1502

MTC INJECTOR

Included in D-1501

I-1503

STABILIZATION INJECTOR

Included in D-1501

I-1504

BACK FLUSH OIL INJECTOR

SPR-1501

FIRST REGENERATOR TORCH OIL SPRAYER

(-0.3)

SPR-1502

SECOND REGENERATOR TORCH OIL SPRAYER

(-0.3)

SPR-1503

WATER SPRAY FOR D-1502 FLUE GAS BYPASS

(-1.5)

(-22.8)

(-24.3)

SPR-1504

WATER SPRAY FOR D-1503 FLUE GAS BYPASS

(-1.5)

(-14.0)

(-15.5)

SPR-1505

WATER SPRAY FOR ECONOMIZER BYPASS

(-1.5)

(-5.2)

(-6.7)

Included in D-1501
(0.3)
(0.3)

PAGE TOTAL

0.0

0.0

-11.3

0.8

0.0

11.3

6.5

0.0

0.0

0.0

-7.5

0.0

0.0

0.2

GENERAL TOTAL

9455

-4594.4

-4893.1

100.1

-20.6

34.2

11.3

13.5

0.1

99.1

-244.0

-42.4

0.0

0.0

48.7

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-512-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

TOTAL PREVIOUS PAGES


X-1504

SLURRY SEPARATOR

X-1505

CORROSION INHIBITOR INJECTION PACKAGE

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

512

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

9455

-4594.4

-4893.1

-230.0

-230.0

P-1520

CORROSION INHIBITOR PUMP

0.55

-0.40

-0.44

X-1507

ELECTROSTATIC PRECIPITATOR

491

-379.0

-379.0

88

(-53)

(-53)

(-270.0)

(-300.0)

X-1508

Project N - Unit

DESOX UNIT(FUTURE)

X-1509

METAL PASSIVATOR INJECTION PACKAGE

P-1502 A

METAL PASSIVATION PUMP

0.55

0.00

0.00

P-1502 B

METAL PASSIVATION PUMP

0.55

(0.00)

(0.00)

X-1510

PHOSPHATE INJECTION PACKAGE

6.05

-4.36

-4.84

X-1551

ANTI-FOAM INJECTION PACKAGE

P-1557

ANTI-FOAMING PUMP

0.55

(-0.40)

(-0.44)

P-1558

ANTI-FOAMING PUMP

0.55

(-0.40)

(-0.44)

-3.3

69,700 BPSD
Bach Ho Max Distillate
- Normal Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

100.1

-20.6

34.2

11.3

DATE

SHEET

WRITTEN BY
8

CHECKED BY

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND
13.5

0.1

99.1

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW
-244.0

-42.4

0.0

0.0

48.7

BFW
T/h

-0.3

CATALYST HOPPERS STEAM EJECTOR


REGENERATED CATALYST SLIDE VALVE

4.0

-3.0

SV-1502

SPENT CATALYST SLIDE VALVE

4.0

-3.0

-3.3

SV-1503

FIRST REGENERATOR FLUE GAS SLIDE VALVE

4.0

-3.0

-3.3

SV-1504

SECOND 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

---

STEAM TRACE

REMARKS

0.3
Intermittent Users in X-1507

(-0.9)

EJ-1501
SV-1501

OF

(0.9)

-0.1

0.1

-2.0

2.0

PAGE TOTAL

611

-631.5

-633.7

0.0

0.0

-2.4

0.0

0.0

2.0

0.0

0.0

0.0

0.0

0.0

0.4

GENERAL TOTAL (excl. Future DeSOx)

10066

-5225.9

-5526.7

100.1

-20.6

31.8

11.3

13.5

2.1

99.1

-244.0

-42.4

0.0

0.0

49.1

GENERAL TOTAL (incl. Future DeSOx)

10066

-5495.9

-5826.7

100.1

-20.6

31.8

11.3

13.5

2.1

99.1

-244.0

-42.4

0.0

0.0

49.1

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-512-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION

CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

512

REVISION

COOLING WATER

DESCRIPTION

T
C

m3/h

E-1518

HEAVY NAPHTHA 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

69,700 BPSD
Bach Ho Max Distillate
- Normal Case
SEA WATER
T
C

m3/h

8.8

-7285

8.8

-2300

FRESH
WATER
T/h

DATE

SHEET

WRITTEN BY
CHECKED BY

DESCRIPTION
PLANT AIR
INST.
Nm3/h
AIR
Nm3/h
CONTIN
INTERMIT

NITROGEN
Nm3/h

S-015-1223-512-1.xls

7
2-20007
FEABR0273-M

CONTIN

INTERMIT

Efficiency
%

FUEL FIRED
MW

PUMP / COMP COOLING

-95

PAGE TOTAL

-4373

-9585

0.0

0.0

0.0

GENERAL TOTAL

-4373

-9585

0.0

0.0

0.0

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

FURNACES & BOILERS


DUTY
MW

NOTES

_
_
_
__ RA|
D __|
N
I
||___

OF

APPROVED BY

- INDICATES QUANTITY CONSUMED

REMARKS

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION

CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

512

REVISION

DESCRIPTION

COOLING WATER
T
C

TOTAL PREVIOUS PAGES

m3/h
-4373

69,700 BPSD
Bach Ho Max Distillate
- Normal Case
SEA WATER
T
C

m3/h

FRESH
WATER
T/h

DATE

SHEET

WRITTEN BY
CHECKED BY

10

DESCRIPTION
PLANT AIR
INST.
Nm3/h
AIR
Nm3/h
CONTIN
INTERMIT

H-1502

SECOND REGENERATOR HEATER

H-1503

COB/WHB PACKAGE

NITROGEN
Nm3/h
CONTIN

FURNACES & BOILERS

INTERMIT

DUTY
MW

X-1507
X-1504

X-1502

FRESH CATALYST FEEDER

X-1503

AUXILIARY CATALYST FEEDER

C-1501

AIR BLOWER

-22

(-125)

ELECTROSTATIC PRECIPITATOR

-26

-8

(-85)

SLURRY SEPARATOR

-1

OIL MIST GENERATOR

-165
-3

-60

(-40)

(-3)

(-60)

(-40)

-3

GLAND CONDENSER

-76

OIL COOLER

-32
-6

MAIN OIL COOLER

6.0

-60

GLAND CONDENSER

6.0

-50

PV-1501

PLUG VALVE

SV-1501

REGENERATED CATALYST SLIDE VALVE

SV-1502

SPENT CATALYST SLIDE VALVE

SV-1504

SECOND REGENERATOR FLUE GAS SLIDE VALVE

-134

PRIMARY PLANT AIR FOR REGEN SECTION

-4230

REV

(-280)

-611
-84
-36

(2)

(-2320)
-340

-160

(-560)

PAGE TOTAL

-221

-5658

-118

-351

0.0

0.0

-123.7

GENERAL TOTAL

-4594

-9585

-5658

-118

-351

0.0

0.0

-123.7

MISCELLANEOUS USERS

-13.7

NOTES
1. FUEL GAS RATES DURING START-UP FOR BOTH REGENERATOR AIR HEATERS (APPROX. 4.5 T/h)
2. PLANT AIR FROM INSTRUMENT AIR HEADER FOR PRIMARY USERS.

) INTERMITTENT PRODUCER/CONSUMER

REMARKS

-110.0

-71

SECONDARY PLANT AIR FOR REGEN SECTION

7
2-20007
FEABR0273-M

FUEL FIRED
MW

(1)
-50

15.0

WET GAS COMPRESSOR

S-015-1223-512-1.xls

Efficiency
%

(1)

-120

10

-9585

FIRST REGENERATOR AIR HEATER

_
_
_
__ RA|
D __|
N
I
||___

OF

APPROVED BY

H-1501

C-1551

Project N - Unit

+ INDICATES QUANTITY PRODUCED

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


DOCUMENT CLASS
CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

Pages modified under revision 1 :

REVISION
69,700 BPSD
-

7
2-20007
FEABR0273-M

Code

Serial N

Rev. index

CN

00 03

513

Op. Center JOB No.

0-3952-20-0000

Op. Center Doc. No.

S-015-1223-513

FEED Doc. No.

23-MAY-06

01-FEB-07

23-FEB-07

WRITTEN BY

T. Tsuchiya

T. Tsuchiya

T. Tsuchiya

Mixed Crude Max Gasoline

CHECKED BY

M. Okada

M. Okada

M. Okada

- Normal Case

APPROVED BY

M. Okada

M. Okada

M. Okada

DESCRIPTION

Issue for Review

For Construction

For Construction

2,4,10

Mixed Crude MG - Normal

S-015-1223-513-1.xls

Doc. type

8474L 015

DATE

GENERAL NOTES:

_
_
_
__ RA|
D __|
N
I
||___

Project N - Unit

6960-015-DS-0711

SHEET

OF

10

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

-0.3

-0.3

-352.0

-363.0

HP
STM

MP
STM

214.0

0.7

COB / WHB PACKAGE


FORCED DRAFT AIR FAN

C-1502 B

FORCED DRAFT AIR FAN

(-11.0)

C-1502B HOT STAND-BY

-0.9

1230

BFW HEATER
AIR BLOWER

-3.0

-3.0

P-1529 A

C-1501 TURBINE CONDENSATE PUMP

55

-39.0

-43.3

P-1529 B

C-1501 TURBINE CONDENSATE PUMP

55

(-39.0)

(-43.3)

E-1531

SURFACE CONDENSER
37

-18.5

-20.6

15

-15.0

-15.0

C-1501 LUBE OIL PUMP (Main)


C-1501 LUBE OIL PUMP (Spare)

TURNING GEAR MOTOR

C-1551

WET GAS COMPRESSOR

-1.5

-1.5

C-1551 TURBINE CONDENSATE PUMP

18.5

-13.9

-14.8

P-1559 B

C-1551 TURBINE CONDENSATE PUMP

18.5

(-13.9)

(-14.8)

E-1567

TURBINE CONDENSER
30

-16.0

-17.8

C-1551 LUBE OIL PUMP (Main)

C-1551 LUBE OIL PUMP (Spare)

Serial N

Rev. index

8474L 015

CN

00 03

513

HP
COND

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

-94.0

-32.2

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

BFW
T/h
HP
BFW

LP
BFW

-220.2

-0.7

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

REMARKS

0.9

-0.3

10.0
-0.1

0.1

94.0

0.3

32.2

0.4

(2.6)

-0.4

(-2.1)

(2.1)

DISENGAGER / STRIPPER

COB/WHB LP BLOWDOWN DRUM

0.5

-0.5

D-1527

LP BLOWDOWN DRUM

0.5

-0.5

T-1503

LCO STRIPPER

-3.0

3.0

T-1504

HCO STRIPPER

-0.5

0.5

-34.7

34.7

PAGE TOTAL

1462

-459.2

-479.3

86.9

-44.7

-2.6

0.0

10.0

0.1

126.2

-220.2

-0.7

0.0

0.0

45.0

GENERAL TOTAL

1462

-459.2

-479.3

86.9

-44.7

-2.6

0.0

10.0

0.1

126.2

-220.2

-0.7

0.0

0.0

45.0

NOTES

S-015-1223-513-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

REV

6.2

D-1501

_
_
_
__ RA|
D __|
N
I
||___

10

APPROVED BY

(11.0)

(-2.6)

P-1559 A

LP
STM

-10.0

E-1534

Code

Included in H-1503

C-1501

69,700 BPSD
Mixed Crude Max Gasoline
- Normal Case
STEAM
T/h

H-1503

ECONOMIZER

Doc. type

REVISION

C-1502 A

E-1525

Project N - Unit

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

513

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

1462

-459.2

-479.3

P-1501 A

FEED PUMP

600

-476.0

-500.5

P-1501 B

FEED PUMP

600

(-476.0)

(-500.5)

69,700 BPSD
Mixed Crude Max Gasoline
- Normal Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

86.9

-44.7

-2.6

0.0

DATE

SHEET

WRITTEN BY
3

CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

10.0

0.1

-220.2

-0.7

0.0

0.0

45.0

126.2

BFW
T/h

P-1504 A

SLURRY PRODUCT PUMP

55

-42.7

-45.1

P-1504 B

SLURRY PRODUCT PUMP

55

(-42.7)

(-45.1)

P-1505 A

BACKFLUSH OIL PUMP

22

-15.0

-16.5

P-1505 B

BACKFLUSH OIL PUMP

22

(-15.0)

(-16.5)

P-1506 A

BACKFLUSH OIL RECYCLE PUMP

11

-7.4

-8.4

P-1506 B

BACKFLUSH OIL RECYCLE PUMP

11

(-7.4)

(-8.4)

P-1507 A

HCO RECYCLE PUMP

150

0.0

0.0

P-1507 B

HCO RECYCLE PUMP

150

(0.0)

(0.0)

P-1508 A

HCO PUMPAROUND PUMP

220

-179.4

-188.4

P-1508 B

HCO PUMPAROUND PUMP

220

(-179.4)

(-188.4)

P-1509 A

HCO PRODUCT PUMP

15

-9.1

-10.1

P-1509 B

HCO PRODUCT PUMP

15

(-9.1)

(-10.1)

P-1510 A

LCO PUMPAROUND PUMP

335

-303.0

-316.0

P-1510 B

LCO PUMPAROUND PUMP

335

(-303.0)

(-316.0)

P-1511 A

LCO STRIPPER PUMP

90

-73.4

-76.9

P-1511 B

LCO STRIPPER PUMP

90

(-73.4)

(-76.9)

P-1512 A

MTC RECYCLE PUMP

75

-67.0

-72.0

P-1512 B

MTC RECYCLE PUMP

75

(-67.0)

(-72.0)

P-1513 A

LEAN OIL PUMP

75

-55.0

-58.1

P-1513 B

LEAN OIL PUMP

75

(-55.0)

(-58.1)

P-1514 A

NAPHTHA PUMPAROUND PUMP

225

-203.0

-213.9

P-1514 B

NAPHTHA PUMPAROUND PUMP

225

(-203.0)

(-213.9)

PAGE TOTAL

3746

-1431.0

-1505.9

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

GENERAL TOTAL

5208

-1890.2

-1985.2

86.9

-44.7

-2.6

0.0

10.0

0.1

126.2

-220.2

-0.7

0.0

0.0

45.0

REMARKS

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-513-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

513

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

5208

-1890.2

-1985.2

P-1515 A

HEAVY NAPHTHA PRODUCT PUMP

55

-39.4

-41.6

P-1515 B

HEAVY NAPHTHA PRODUCT PUMP

55

(-39.4)

(-41.6)

P-1516 A

FRACTIONATOR REFLUX PUMP

110

-96.0

-101.3
(-101.3)

69,700 BPSD
Mixed Crude Max Gasoline
- Normal Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

86.9

-44.7

-2.6

0.0

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
LP
MP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

0.1

-220.2

-0.7

0.0

0.0

45.0

10.0

126.2

BFW
T/h

P-1516 B

FRACTIONATOR REFLUX PUMP

110

(-96.0)

P-1517 A

OVERHEAD SOUR WATER PUMP

30

-25.5

-27.6

P-1517 B

OVERHEAD SOUR WATER PUMP

30

(-25.5)

(-27.6)

P-1518 A

OVERHEAD LIQUID PUMP

250

-206.0

-228.9

P-1518 B

OVERHEAD LIQUID PUMP

250

(-206.0)

(-228.9)

P-1519 A

SLURRY PUMPAROUND PUMP

-10.3

P-1519 B

SLURRY PUMPAROUND PUMP

-10.3

10.3

P-1519 C

SLURRY PUMPAROUND PUMP

(-10.3)

(10.3)

P-1519C HOT STAND-BY

-0.8

P-1521 A

HCO FLUSHING OIL PUMP

-3.7

P-1521 B

HCO FLUSHING OIL PUMP

110

(-80.9)

P-1522 A

LCO FLUSHING OIL PUMP

30

-18.4

-19.9

P-1522 B

LCO FLUSHING OIL PUMP

30

(-18.4)

(-19.9)

P-1526 A

LIGHT SLOPS PUMP

37

-26.1

-27.9

P-1526 B

LIGHT SLOPS PUMP

37

(-26.1)

(-27.9)

P-1527 A

HEAVY SLOPS PUMP

37

-27.9

-29.8

P-1527 B

HEAVY SLOPS PUMP

37

(-27.9)

(-29.8)

P-1528 A

TEMPERED WATER PUMP

15

-10.5

-11.7

P-1528 B

TEMPERED WATER PUMP

15

(-10.5)

(-11.7)

PAGE TOTAL

1238

-449.8

-488.7

-25.1

0.0

24.3

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.8

GENERAL TOTAL

6446

-2340.0

-2473.8

61.8

-44.7

21.7

0.0

10.0

0.1

126.2

-220.2

-0.7

0.0

0.0

45.8

REMARKS

S-015-1223-513-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

0.8
3.7

(-84.4)

+ INDICATES QUANTITY PRODUCED

REV

10.3

NOTES

_
_
_
__ RA|
D __|
N
I
||___

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

513

REVISION

MOTOR
LOAD/
RATING

69,700 BPSD
Mixed Crude Max Gasoline
- Normal Case
STEAM
T/h

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

HP
STM

MP
STM

LP
STM

HP
COND

61.8

-44.7

21.7

0.0

TOTAL PREVIOUS PAGES

6446

-2340.0

-2473.8

P-1551 A

INTERSTAGE DRUM PUMP

150

-134.0

-142.3

P-1551 B

INTERSTAGE DRUM PUMP

150

(-134.0)

(-142.3)

P-1552 A

KO DRUM LIQUID PUMP

-1.2

-1.4

P-1552 B

KO DRUM LIQUID PUMP

(-1.2)

(-1.4)

P-1553 A

STRIPPER FEED PUMP

132

-112.0

-117.9

P-1553 B

STRIPPER FEED PUMP

132

(-112.0)

(-117.9)

P-1554 A

GASOLINE RECYCLE PUMP

55

-44.0

-47.7

P-1554 B

GASOLINE RECYCLE PUMP

55

(-44.0)

(-47.7)

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
COLD
LP
COND
COND
COND
10.0

0.1

126.2

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

BFW
T/h

-220.2

-0.7

0.0

0.0

45.8

P-1556 A

DEBUTANIZER OVERHEAD PUMP

225

-185.0

-194.9

P-1556 B

DEBUTANIZER OVERHEAD PUMP

225

(-185.0)

(-194.9)

P-1560 A

RFCC CLOSED DRAIN PUMP

22

(-16.5)

(-18.1)

P-1560 B

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)

PAGE TOTAL

1214

-476.2

-504.2

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

GENERAL TOTAL

7660

-2816.2

-2978.0

61.8

-44.7

21.7

0.0

10.0

0.1

126.2

-220.2

-0.7

0.0

0.0

45.8

REMARKS

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-513-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

513

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

7660

-2816.2

-2978.0

E-1514

LCO AIR COOLER

120

-97.6

-106.2

E-1517

HEAVY NAPHTHA AIR COOLER

33

-20.4

-23.1

E-1519

OVERHEAD AIR CONDENSER

960

-736.0

-800.9

E-1521

HEAVY NAPHTHA 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

69,700 BPSD
Mixed Crude Max Gasoline
- Normal Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

61.8

-44.7

21.7

0.0

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND
10.0

0.1

126.2

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW
-220.2

-0.7

0.0

0.0

45.8

BFW
T/h

E-1553

HP CONDENSER

180

-134.4

-146.2

E-1558

GASOLINE AIR COOLER

120

-92.8

-101.0

E-1503

SLURRY HP STEAM GENERATOR

43.1

-44.4

1.3

E-1504

SLURRY HP STEAM GENERATOR

18.5

-19.1

0.6

E-1505

SLURRY MP STEAM GENERATOR

E-1506

SLURRY LP STEAM GENERATOR

E-1508

HCO RECYCLE MP STEAM GENERATOR

E-1510

13.8

-14.2

0.4

1.2

-1.2

0.0

HCO LP STEAM GENERATOR

1.9

-2.0

0.1

E-1513

LCO PRODUCT LP STEAM GENERATOR

2.6

-2.7

0.1

E-1518

HEAVY NAPHTHA TRIM COOLER

REMARKS

0.0

0.0

PAGE TOTAL

1796

-1386.2

-1510.8

61.6

13.8

5.7

0.0

0.0

0.0

0.0

-63.5

-20.1

0.0

0.0

2.5

GENERAL TOTAL

9455

-4202.4

-4488.8

123.4

-30.9

27.4

0.0

10.0

0.1

126.2

-283.7

-20.8

0.0

0.0

48.3

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-513-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

TOTAL PREVIOUS PAGES


E-1520 A-H

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

513

REVISION

MOTOR
LOAD/
RATING
9455

69,700 BPSD
Mixed Crude Max Gasoline
- Normal Case
STEAM
T/h

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

HP
STM

MP
STM

LP
STM

HP
COND

-4488.8

123.4

-30.9

27.4

0.0

-4202.4

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
LP
MP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

0.1

-283.7

-20.8

0.0

0.0

48.3

10.0

126.2

BFW
T/h

REMARKS

OVERHEAD TRIM CONDENSER

E-1522

MP STEAM FEED HEATER

(-17.2)

E-1523

HCO PUMPAROUND MP STEAM GENERATOR

0.9

E-1524

HP STEAM FEED HEATER

E-1532

BLOWDOWN COOLER

E-1552 A/B

WET GAS COMPRESSOR TRIM COOLER

E-1554 A-D

STRIPPER CONDENSER

E-1559

GASOLINE COOLER

E-1561 A/B

DEBUTANIZER CONDENSER

E-1562

LPG COOLER

E-1564

LEAN OIL COOLER

(17.2)

Cold Feed Case Only


0.1

-1.0

0.0

0.0

E-1565

FUEL GAS COOLER

E-1566

LEAN AMINE COOLER

I-1501

FEED INJECTOR

Included in D-1501

I-1502

MTC INJECTOR

Included in D-1501

I-1503

STABILIZATION INJECTOR

Included in D-1501

I-1504

BACK FLUSH OIL INJECTOR

SPR-1501

FIRST REGENERATOR TORCH OIL SPRAYER

(-0.3)

Included in D-1501
(0.3)

SPR-1502

SECOND REGENERATOR TORCH OIL SPRAYER

(-0.3)

SPR-1503

WATER SPRAY FOR D-1502 FLUE GAS BYPASS

(-1.4)

(-42.0)

(-43.4)

SPR-1504

WATER SPRAY FOR D-1503 FLUE GAS BYPASS

(-1.4)

(-25.5)

(-26.9)

SPR-1505

WATER SPRAY FOR ECONOMIZER BYPASS

(-1.4)

(-10.5)

(-11.9)

(0.3)

PAGE TOTAL

0.0

0.0

0.0

0.9

0.0

0.0

0.0

0.0

0.0

0.0

-1.0

0.0

0.0

0.1

GENERAL TOTAL

9455

-4202.4

-4488.8

123.4

-30.0

27.4

0.0

10.0

0.1

126.2

-283.7

-21.8

0.0

0.0

48.4

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-513-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

TOTAL PREVIOUS PAGES


X-1504

SLURRY SEPARATOR

X-1505

CORROSION INHIBITOR INJECTION PACKAGE

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

9455

-4202.4

-4488.8

-230.0

-230.0

CORROSION INHIBITOR PUMP

0.55

-0.40

-0.44

X-1507

ELECTROSTATIC PRECIPITATOR

491

-379.0

-379.0

88

(-53)

(-53)

(-270.0)

(-300.0)

X-1509

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

513

REVISION

P-1520

X-1508

Project N - Unit

DESOX UNIT(FUTURE)

69,700 BPSD
Mixed Crude Max Gasoline
- Normal Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

123.4

-30.0

27.4

0.0

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

0.1

-283.7

-21.8

0.0

0.0

48.4

10.0

126.2

BFW
T/h

-0.3

REMARKS

0.3
Intermittent Users in X-1507

METAL PASSIVATOR INJECTION PACKAGE

P-1502 A

METAL PASSIVATION PUMP

0.55

-0.40

-0.44

P-1502 B

METAL PASSIVATION PUMP

0.55

(-0.40)

(-0.44)

X-1510

PHOSPHATE INJECTION PACKAGE

6.05

-4.36

-4.84

X-1551

ANTI-FOAM INJECTION PACKAGE

P-1557

ANTI-FOAMING PUMP

0.55

(-0.40)

(-0.44)

P-1558

ANTI-FOAMING PUMP

0.55

(-0.40)

(-0.44)

-3.3

EJ-1501

CATALYST HOPPERS STEAM EJECTOR

SV-1501

REGENERATED CATALYST SLIDE VALVE

4.0

-3.0

SV-1502

SPENT CATALYST SLIDE VALVE

4.0

-3.0

-3.3

SV-1503

FIRST REGENERATOR FLUE GAS SLIDE VALVE

4.0

-3.0

-3.3

SV-1504

SECOND 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

---

STEAM TRACE

(0.9)

(-0.9)

0.1

-0.1

-2.0

2.0

PAGE TOTAL

611

-631.9

-634.1

0.0

0.0

-2.4

0.0

0.0

2.0

0.0

0.0

0.0

0.0

0.0

0.4

GENERAL TOTAL (excl. Future DeSOx)

10066

-4834.3

-5123.0

123.4

-30.0

25.0

0.0

10.0

2.1

126.2

-283.7

-21.8

0.0

0.0

48.8

GENERAL TOTAL (incl. Future DeSOx)

10066

-5104.3

-5423.0

123.4

-30.0

25.0

0.0

10.0

2.1

126.2

-283.7

-21.8

0.0

0.0

48.8

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-513-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION

CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

513

REVISION

COOLING WATER

DESCRIPTION

T
C

m3/h

E-1518

HEAVY NAPHTHA TRIM COOLER

6.0

-19

E-1520 A-H

OVERHEAD TRIM CONDENSER

8.0

-1786

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

-245

E-1554 A-D

STRIPPER CONDENSER

6.0

-863

E-1559

GASOLINE COOLER

6.0

-156

E-1561 A/B

DEBUTANIZER CONDENSER

12.0

-1319

E-1562

LPG COOLER

6.0

-54

E-1564

LEAN OIL COOLER

6.0

-182

E-1565

FUEL GAS COOLER

6.0

-16

E-1566

LEAN AMINE COOLER

6.0

-72

E-1567

TURBINE CONDENSER

69,700 BPSD
Mixed Crude Max Gasoline
- Normal Case
SEA WATER
T
C

m3/h

8.8

-7285

8.8

-2300

FRESH
WATER
T/h

DATE

SHEET

WRITTEN BY
CHECKED BY

DESCRIPTION
PLANT AIR
INST.
Nm3/h
AIR
Nm3/h
CONTIN
INTERMIT

NITROGEN
Nm3/h

S-015-1223-513-1.xls

7
2-20007
FEABR0273-M

CONTIN

INTERMIT

Efficiency
%

FUEL FIRED
MW

PUMP / COMP COOLING

-95

PAGE TOTAL

-4846

-9585

0.0

0.0

0.0

GENERAL TOTAL

-4846

-9585

0.0

0.0

0.0

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

FURNACES & BOILERS


DUTY
MW

NOTES

_
_
_
__ RA|
D __|
N
I
||___

OF

APPROVED BY

- INDICATES QUANTITY CONSUMED

REMARKS

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION

CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

513

REVISION

DESCRIPTION

COOLING WATER
T
C

m3/h
-4846

TOTAL PREVIOUS PAGES

69,700 BPSD
Mixed Crude Max Gasoline
- Normal Case
SEA WATER
T
C

m3/h

FRESH
WATER
T/h

DATE

SHEET

WRITTEN BY
10

CHECKED BY

DESCRIPTION
INST.
PLANT AIR
AIR
Nm3/h
Nm3/h
CONTIN
INTERMIT

H-1502

SECOND REGENERATOR HEATER

H-1503

COB/WHB PACKAGE

NITROGEN
Nm3/h
CONTIN

FURNACES & BOILERS

INTERMIT

DUTY
MW

X-1507
X-1504

X-1502

FRESH CATALYST FEEDER

X-1503

AUXILIARY CATALYST FEEDER

C-1501

AIR BLOWER

-22

-3

-50

(-125)

ELECTROSTATIC PRECIPITATOR

-26

-8

(-85)

SLURRY SEPARATOR

-1

OIL MIST GENERATOR

-165
-3

-60

(-40)

(-3)

(-60)

(-40)

GLAND CONDENSER

-76

OIL COOLER

-32
-6

MAIN OIL COOLER

6.0

-60

GLAND CONDENSER

6.0

-50

PV-1501

PLUG VALVE

SV-1501

REGENERATED CATALYST SLIDE VALVE

SV-1502

SPENT CATALYST SLIDE VALVE

SV-1504

SECOND REGENERATOR FLUE GAS SLIDE VALVE

-134

PRIMARY PLANT AIR FOR REGEN SECTION

-4230

REV

(-280)

-611
-84
-36

(2)

(-2320)
-340

-160

(-560)

PAGE TOTAL

-221

-5658

-118

-351

0.0

0.0

-63.6

GENERAL TOTAL

-5067

-9585

-5658

-118

-351

0.0

0.0

-63.6

MISCELLANEOUS USERS

-13.7

NOTES
1. FUEL GAS RATES DURING START-UP FOR BOTH REGENERATOR AIR HEATERS (APPROX. 4.5 T/h)
2. PLANT AIR FROM INSTRUMENT AIR HEADER FOR PRIMARY USERS.

) INTERMITTENT PRODUCER/CONSUMER

REMARKS

-49.9

-71

SECONDARY PLANT AIR FOR REGEN SECTION

7
2-20007
FEABR0273-M

FUEL FIRED
MW

(1)
15.0

WET GAS COMPRESSOR

S-015-1223-513-1.xls

Efficiency
%

(1)

-120

10

-9585

FIRST REGENERATOR AIR HEATER

_
_
_
__ RA|
D __|
N
I
||___

OF

APPROVED BY

H-1501

C-1551

Project N - Unit

+ INDICATES QUANTITY PRODUCED

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


DOCUMENT CLASS
CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

Pages modified under revision 1 :

REVISION
69,700 BPSD
-

7
2-20007
FEABR0273-M

Code

Serial N

Rev. index

CN

00 03

514

Op. Center JOB No.

0-3952-20-0000

Op. Center Doc. No.

S-015-1223-514

FEED Doc. No.

23-MAY-06

01-FEB-07

23-FEB-07

WRITTEN BY

T. Tsuchiya

T. Tsuchiya

T. Tsuchiya

Mixed Crude Max Distillate

CHECKED BY

M. Okada

M. Okada

M. Okada

- Normal Case

APPROVED BY

M. Okada

M. Okada

M. Okada

DESCRIPTION

Issue for Review

For Construction

For Construction

2,4,10

Mixed Crude MD - Normal

S-015-1223-514-1.xls

Doc. type

8474L 015

DATE

GENERAL NOTES:

_
_
_
__ RA|
D __|
N
I
||___

Project N - Unit

6960-015-DS-0711

SHEET

OF

10

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

-0.3

-0.3

-443.0

-457.0

HP
STM

MP
STM

214.8

0.5

COB / WHB PACKAGE


FORCED DRAFT AIR FAN

C-1502 B

FORCED DRAFT AIR FAN

(-13.8)

C-1502B HOT STAND-BY

-1.1

1230

BFW HEATER
AIR BLOWER

-3.0

-3.0

P-1529 A

C-1501 TURBINE CONDENSATE PUMP

55

-39.0

-43.3

P-1529 B

C-1501 TURBINE CONDENSATE PUMP

55

(-39.0)

(-43.3)

E-1531

SURFACE CONDENSER
37

-18.5

-20.6

15

-15.0

-15.0

C-1501 LUBE OIL PUMP (Main)


C-1501 LUBE OIL PUMP (Spare)

TURNING GEAR MOTOR

C-1551

WET GAS COMPRESSOR

-1.5

-1.5

C-1551 TURBINE CONDENSATE PUMP

18.5

-13.9

-14.8

P-1559 B

C-1551 TURBINE CONDENSATE PUMP

18.5

(-13.9)

(-14.8)

E-1567

TURBINE CONDENSER
30

-16.0

-17.8

C-1551 LUBE OIL PUMP (Main)

C-1551 LUBE OIL PUMP (Spare)

Serial N

Rev. index

8474L 015

CN

00 03

514

HP
COND

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

-77.9

-32.2

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

BFW
T/h
HP
BFW

LP
BFW

-221.0

-0.5

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

REMARKS

1.1

-0.3

10.0
-0.1

0.1

77.9

0.3

32.2

0.4

(2.6)

-0.4

(-2.1)

(2.1)

DISENGAGER / STRIPPER

COB/WHB LP BLOWDOWN DRUM

0.5

-0.5

D-1527

LP BLOWDOWN DRUM

0.5

-0.5

T-1503

LCO STRIPPER

-3.0

3.0

T-1504

HCO STRIPPER

-0.5

0.5

-34.7

34.7

PAGE TOTAL

1462

-550.2

-573.3

103.6

-44.9

-2.6

0.0

10.0

0.1

110.1

-221.0

-0.5

0.0

0.0

45.2

GENERAL TOTAL

1462

-550.2

-573.3

103.6

-44.9

-2.6

0.0

10.0

0.1

110.1

-221.0

-0.5

0.0

0.0

45.2

NOTES

S-015-1223-514-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

REV

6.2

D-1501

_
_
_
__ RA|
D __|
N
I
||___

10

APPROVED BY

(13.8)

(-2.6)

P-1559 A

LP
STM

-10.0

E-1534

Code

Included in H-1503

C-1501

69,700 BPSD
Mixed Crude Max Distillate
- Normal Case
STEAM
T/h

H-1503

ECONOMIZER

Doc. type

REVISION

C-1502 A

E-1525

Project N - Unit

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

514

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

1462

-550.2

-573.3

P-1501 A

FEED PUMP

600

-476.0

-500.5

P-1501 B

FEED PUMP

600

(-476.0)

(-500.5)

P-1504 A

SLURRY PRODUCT PUMP

55

-42.7

-45.1

P-1504 B

SLURRY PRODUCT PUMP

55

(-42.7)

(-45.1)

P-1505 A

BACKFLUSH OIL PUMP

22

-15.0

-16.5

P-1505 B

BACKFLUSH OIL PUMP

22

(-15.0)

(-16.5)

P-1506 A

BACKFLUSH OIL RECYCLE PUMP

11

-7.4

-8.4

P-1506 B

BACKFLUSH OIL RECYCLE PUMP

11

(-7.4)

(-8.4)

P-1507 A

HCO RECYCLE PUMP

150

-128.0

-142.2

P-1507 B

HCO RECYCLE PUMP

150

(-128.0)

(-142.2)

69,700 BPSD
Mixed Crude Max Distillate
- Normal Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

103.6

-44.9

-2.6

0.0

DATE

SHEET

WRITTEN BY
3

CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

10.0

0.1

-221.0

-0.5

0.0

0.0

45.2

110.1

BFW
T/h

P-1508 A

HCO PUMPAROUND PUMP

220

-179.4

-188.4

P-1508 B

HCO PUMPAROUND PUMP

220

(-179.4)

(-188.4)

P-1509 A

HCO PRODUCT PUMP

15

-9.1

-10.1

P-1509 B

HCO PRODUCT PUMP

15

(-9.1)

(-10.1)

P-1510 A

LCO PUMPAROUND PUMP

335

-303.0

-316.0

P-1510 B

LCO PUMPAROUND PUMP

335

(-303.0)

(-316.0)

P-1511 A

LCO STRIPPER PUMP

90

-73.4

-76.9

P-1511 B

LCO STRIPPER PUMP

90

(-73.4)

(-76.9)

P-1512 A

MTC RECYCLE PUMP

75

0.0

0.0

P-1512 B

MTC RECYCLE PUMP

75

(0.0)

(0.0)

P-1513 A

LEAN OIL PUMP

75

-55.0

-58.1

P-1513 B

LEAN OIL PUMP

75

(-55.0)

(-58.1)

P-1514 A

NAPHTHA PUMPAROUND PUMP

225

-203.0

-213.9

P-1514 B

NAPHTHA PUMPAROUND PUMP

225

(-203.0)

(-213.9)

PAGE TOTAL

3746

-1492.0

-1576.1

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

GENERAL TOTAL

5208

-2042.2

-2149.4

103.6

-44.9

-2.6

0.0

10.0

0.1

110.1

-221.0

-0.5

0.0

0.0

45.2

REMARKS

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-514-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

514

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

5208

-2042.2

-2149.4

P-1515 A

HEAVY NAPHTHA PRODUCT PUMP

55

-39.4

-41.6

P-1515 B

HEAVY NAPHTHA PRODUCT PUMP

55

(-39.4)

(-41.6)

P-1516 A

FRACTIONATOR REFLUX PUMP

110

-96.0

-101.3
(-101.3)

69,700 BPSD
Mixed Crude Max Distillate
- Normal Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

103.6

-44.9

-2.6

0.0

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
LP
MP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

0.1

-221.0

-0.5

0.0

0.0

45.2

10.0

110.1

BFW
T/h

P-1516 B

FRACTIONATOR REFLUX PUMP

110

(-96.0)

P-1517 A

OVERHEAD SOUR WATER PUMP

30

-25.5

-27.6

P-1517 B

OVERHEAD SOUR WATER PUMP

30

(-25.5)

(-27.6)

P-1518 A

OVERHEAD LIQUID PUMP

250

-206.0

-228.9

P-1518 B

OVERHEAD LIQUID PUMP

250

(-206.0)

(-228.9)

P-1519 A

SLURRY PUMPAROUND PUMP

-10.3

P-1519 B

SLURRY PUMPAROUND PUMP

-10.3

10.3

P-1519 C

SLURRY PUMPAROUND PUMP

(-10.3)

(10.3)

P-1519C HOT STAND-BY

-0.8

P-1521 A

HCO FLUSHING OIL PUMP

-3.7

P-1521 B

HCO FLUSHING OIL PUMP

110

(-80.9)

P-1522 A

LCO FLUSHING OIL PUMP

30

-18.4

-19.9

P-1522 B

LCO FLUSHING OIL PUMP

30

(-18.4)

(-19.9)

P-1526 A

LIGHT SLOPS PUMP

37

-26.1

-27.9

P-1526 B

LIGHT SLOPS PUMP

37

(-26.1)

(-27.9)

P-1527 A

HEAVY SLOPS PUMP

37

-27.9

-29.8

P-1527 B

HEAVY SLOPS PUMP

37

(-27.9)

(-29.8)

P-1528 A

TEMPERED WATER PUMP

15

-10.5

-11.7

P-1528 B

TEMPERED WATER PUMP

15

(-10.5)

(-11.7)

PAGE TOTAL

1238

-449.8

-488.7

-25.1

0.0

24.3

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.8

GENERAL TOTAL

6446

-2492.0

-2638.1

78.5

-44.9

21.7

0.0

10.0

0.1

110.1

-221.0

-0.5

0.0

0.0

46.0

REMARKS

S-015-1223-514-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

0.8
3.7

(-84.4)

+ INDICATES QUANTITY PRODUCED

REV

10.3

NOTES

_
_
_
__ RA|
D __|
N
I
||___

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

514

REVISION

MOTOR
LOAD/
RATING

69,700 BPSD
Mixed Crude Max Distillate
- Normal Case
STEAM
T/h

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

HP
STM

MP
STM

LP
STM

HP
COND

78.5

-44.9

21.7

0.0

TOTAL PREVIOUS PAGES

6446

-2492.0

-2638.1

P-1551 A

INTERSTAGE DRUM PUMP

150

-134.0

-142.3

P-1551 B

INTERSTAGE DRUM PUMP

150

(-134.0)

(-142.3)

P-1552 A

KO DRUM LIQUID PUMP

-1.2

-1.4

P-1552 B

KO DRUM LIQUID PUMP

(-1.2)

(-1.4)

P-1553 A

STRIPPER FEED PUMP

132

-112.0

-117.9

P-1553 B

STRIPPER FEED PUMP

132

(-112.0)

(-117.9)

P-1554 A

GASOLINE RECYCLE PUMP

55

-44.0

-47.7

P-1554 B

GASOLINE RECYCLE PUMP

55

(-44.0)

(-47.7)

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
COLD
LP
COND
COND
COND
10.0

0.1

110.1

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

BFW
T/h

-221.0

-0.5

0.0

0.0

46.0

P-1556 A

DEBUTANIZER OVERHEAD PUMP

225

-185.0

-194.9

P-1556 B

DEBUTANIZER OVERHEAD PUMP

225

(-185.0)

(-194.9)

P-1560 A

RFCC CLOSED DRAIN PUMP

22

(-16.5)

(-18.1)

P-1560 B

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)

PAGE TOTAL

1214

-476.2

-504.2

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

GENERAL TOTAL

7660

-2968.2

-3142.3

78.5

-44.9

21.7

0.0

10.0

0.1

110.1

-221.0

-0.5

0.0

0.0

46.0

REMARKS

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-514-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

514

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

7660

-2968.2

-3142.3

E-1514

LCO AIR COOLER

120

-97.6

-106.2

E-1517

HEAVY NAPHTHA AIR COOLER

33

-20.4

-23.1

E-1519

OVERHEAD AIR CONDENSER

960

-736.0

-800.9

E-1521

HEAVY NAPHTHA 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

69,700 BPSD
Mixed Crude Max Distillate
- Normal Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

78.5

-44.9

21.7

0.0

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND
10.0

0.1

110.1

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW
-221.0

-0.5

0.0

0.0

46.0

BFW
T/h

E-1553

HP CONDENSER

180

-134.4

-146.2

E-1558

GASOLINE AIR COOLER

120

-92.8

-101.0

E-1503

SLURRY HP STEAM GENERATOR

35.0

-36.1

1.1

E-1504

SLURRY HP STEAM GENERATOR

21.4

-22.1

0.7

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

2.8

E-1513

LCO PRODUCT LP STEAM GENERATOR

8.5

E-1518

HEAVY NAPHTHA TRIM COOLER

16.1

1.2

14.4

-16.6

0.5

-1.2

0.0

-14.9

0.5

-2.8

0.0

-8.8

0.3

PAGE TOTAL

1796

-1386.2

-1510.8

56.4

30.5

12.5

0.0

0.0

0.0

0.0

-58.2

-44.3

0.0

0.0

3.1

GENERAL TOTAL

9455

-4354.4

-4653.1

134.9

-14.4

34.2

0.0

10.0

0.1

110.1

-279.2

-44.8

0.0

0.0

49.1

REMARKS

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-514-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

TOTAL PREVIOUS PAGES


E-1520 A-H

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

514

REVISION

MOTOR
LOAD/
RATING
9455

69,700 BPSD
Mixed Crude Max Distillate
- Normal Case
STEAM
T/h

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

HP
STM

MP
STM

LP
STM

HP
COND

-4653.1

134.9

-14.4

34.2

0.0

-4354.4

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
LP
MP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

0.1

-279.2

-44.8

0.0

0.0

49.1

10.0

110.1

BFW
T/h

REMARKS

OVERHEAD TRIM CONDENSER

E-1522

MP STEAM FEED HEATER

(-17.1)

E-1523

HCO PUMPAROUND MP STEAM GENERATOR

6.8

E-1524

HP STEAM FEED HEATER

E-1532

BLOWDOWN COOLER

E-1552 A/B

WET GAS COMPRESSOR TRIM COOLER

E-1554 A-D

STRIPPER CONDENSER

E-1559

GASOLINE COOLER

E-1561 A/B

DEBUTANIZER CONDENSER

E-1562

LPG COOLER

E-1564

LEAN OIL COOLER

(17.1)

Cold Feed Case Only


0.2

-7.0

0.0

0.0

E-1565

FUEL GAS COOLER

E-1566

LEAN AMINE COOLER

I-1501

FEED INJECTOR

Included in D-1501

I-1502

MTC INJECTOR

Included in D-1501

I-1503

STABILIZATION INJECTOR

Included in D-1501

I-1504

BACK FLUSH OIL INJECTOR

SPR-1501

FIRST REGENERATOR TORCH OIL SPRAYER

(-0.3)

Included in D-1501
(0.3)

SPR-1502

SECOND REGENERATOR TORCH OIL SPRAYER

(-0.3)

SPR-1503

WATER SPRAY FOR D-1502 FLUE GAS BYPASS

(-1.5)

(-31.1)

(-32.6)

SPR-1504

WATER SPRAY FOR D-1503 FLUE GAS BYPASS

(-1.5)

(-19.2)

(-20.7)

SPR-1505

WATER SPRAY FOR ECONOMIZER BYPASS

(-1.5)

(-9.7)

(-11.2)

(0.3)

PAGE TOTAL

0.0

0.0

0.0

6.8

0.0

0.0

0.0

0.0

0.0

0.0

-7.0

0.0

0.0

0.2

GENERAL TOTAL

9455

-4354.4

-4653.1

134.9

-7.6

34.2

0.0

10.0

0.1

110.1

-279.2

-51.8

0.0

0.0

49.3

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-514-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

TOTAL PREVIOUS PAGES


X-1504

SLURRY SEPARATOR

X-1505

CORROSION INHIBITOR INJECTION PACKAGE

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

9455

-4354.4

-4653.1

-230.0

-230.0

CORROSION INHIBITOR PUMP

0.55

-0.40

-0.44

X-1507

ELECTROSTATIC PRECIPITATOR

491

-379.0

-379.0

88

(-53)

(-53)

(-270.0)

(-300.0)

X-1509

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

514

REVISION

P-1520

X-1508

Project N - Unit

DESOX UNIT(FUTURE)

69,700 BPSD
Mixed Crude Max Distillate
- Normal Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

134.9

-7.6

34.2

0.0

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

0.1

-279.2

-51.8

0.0

0.0

49.3

10.0

110.1

BFW
T/h

-0.3

REMARKS

0.3
Intermittent Users in X-1507

METAL PASSIVATOR INJECTION PACKAGE

P-1502 A

METAL PASSIVATION PUMP

0.55

0.00

0.00

P-1502 B

METAL PASSIVATION PUMP

0.55

(0.00)

(0.00)

X-1510

PHOSPHATE INJECTION PACKAGE

6.05

-4.36

-4.84

X-1551

ANTI-FOAM INJECTION PACKAGE

P-1557

ANTI-FOAMING PUMP

0.55

(-0.40)

(-0.44)

P-1558

ANTI-FOAMING PUMP

0.55

(-0.40)

(-0.44)

-3.3

EJ-1501

CATALYST HOPPERS STEAM EJECTOR

SV-1501

REGENERATED CATALYST SLIDE VALVE

4.0

-3.0

SV-1502

SPENT CATALYST SLIDE VALVE

4.0

-3.0

-3.3

SV-1503

FIRST REGENERATOR FLUE GAS SLIDE VALVE

4.0

-3.0

-3.3

SV-1504

SECOND 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

---

STEAM TRACE

(0.9)

(-0.9)

0.1

-0.1

-2.0

2.0

PAGE TOTAL

611

-631.5

-633.7

0.0

0.0

-2.4

0.0

0.0

2.0

0.0

0.0

0.0

0.0

0.0

0.4

GENERAL TOTAL (excl. Future DeSOx)

10066

-4985.9

-5286.7

134.9

-7.6

31.8

0.0

10.0

2.1

110.1

-279.2

-51.8

0.0

0.0

49.7

GENERAL TOTAL (incl. Future DeSOx)

10066

-5255.9

-5586.7

134.9

-7.6

31.8

0.0

10.0

2.1

110.1

-279.2

-51.8

0.0

0.0

49.7

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-514-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION

CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

514

REVISION

COOLING WATER

DESCRIPTION

T
C

m3/h

E-1518

HEAVY NAPHTHA TRIM COOLER

6.0

-19

E-1520 A-H

OVERHEAD TRIM CONDENSER

8.0

-1675

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

-219

E-1554 A-D

STRIPPER CONDENSER

6.0

-684

E-1559

GASOLINE COOLER

6.0

-134

E-1561 A/B

DEBUTANIZER CONDENSER

12.0

-1154

E-1562

LPG COOLER

6.0

-43

E-1564

LEAN OIL COOLER

6.0

-195

E-1565

FUEL GAS COOLER

6.0

-8

E-1566

LEAN AMINE COOLER

6.0

-56

E-1567

TURBINE CONDENSER

69,700 BPSD
Mixed Crude Max Distillate
- Normal Case
SEA WATER
T
C

m3/h

8.8

-7285

8.8

-2300

FRESH
WATER
T/h

DATE

SHEET

WRITTEN BY
CHECKED BY

DESCRIPTION
PLANT AIR
INST.
Nm3/h
AIR
Nm3/h
CONTIN
INTERMIT

NITROGEN
Nm3/h

S-015-1223-514-1.xls

7
2-20007
FEABR0273-M

CONTIN

INTERMIT

Efficiency
%

FUEL FIRED
MW

PUMP / COMP COOLING

-95

PAGE TOTAL

-4321

-9585

0.0

0.0

0.0

GENERAL TOTAL

-4321

-9585

0.0

0.0

0.0

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

FURNACES & BOILERS


DUTY
MW

NOTES

_
_
_
__ RA|
D __|
N
I
||___

OF

APPROVED BY

- INDICATES QUANTITY CONSUMED

REMARKS

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION

CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

514

REVISION

DESCRIPTION

COOLING WATER
T
C

m3/h
-4321

TOTAL PREVIOUS PAGES

69,700 BPSD
Mixed Crude Max Distillate
- Normal Case
SEA WATER
T
C

m3/h

FRESH
WATER
T/h

DATE

SHEET

WRITTEN BY
10

CHECKED BY

DESCRIPTION
INST.
PLANT AIR
AIR
Nm3/h
Nm3/h
CONTIN
INTERMIT

H-1502

SECOND REGENERATOR HEATER

H-1503

COB/WHB PACKAGE

NITROGEN
Nm3/h
CONTIN

FURNACES & BOILERS

INTERMIT

DUTY
MW

X-1507
X-1504

X-1502

FRESH CATALYST FEEDER

X-1503

AUXILIARY CATALYST FEEDER

C-1501

AIR BLOWER

-22

-3

-50

(-125)

ELECTROSTATIC PRECIPITATOR

-26

-8

(-85)

SLURRY SEPARATOR

-1

OIL MIST GENERATOR

-165
-3

-60

(-40)

(-3)

(-60)

(-40)

GLAND CONDENSER

-76

OIL COOLER

-32
-6

MAIN OIL COOLER

6.0

-60

GLAND CONDENSER

6.0

-50

PV-1501

PLUG VALVE

SV-1501

REGENERATED CATALYST SLIDE VALVE

SV-1502

SPENT CATALYST SLIDE VALVE

SV-1504

SECOND REGENERATOR FLUE GAS SLIDE VALVE

-134

PRIMARY PLANT AIR FOR REGEN SECTION

-4230

REV

(-280)

-611
-84
-36

(2)

(-2320)
-340

-160

(-560)

PAGE TOTAL

-221

-5658

-118

-351

0.0

0.0

-92.6

GENERAL TOTAL

-4542

-9585

-5658

-118

-351

0.0

0.0

-92.6

MISCELLANEOUS USERS

-13.7

NOTES
1. FUEL GAS RATES DURING START-UP FOR BOTH REGENERATOR AIR HEATERS (APPROX. 4.5 T/h)
2. PLANT AIR FROM INSTRUMENT AIR HEADER FOR PRIMARY USERS.

) INTERMITTENT PRODUCER/CONSUMER

REMARKS

-78.9

-71

SECONDARY PLANT AIR FOR REGEN SECTION

7
2-20007
FEABR0273-M

FUEL FIRED
MW

(1)
15.0

WET GAS COMPRESSOR

S-015-1223-514-1.xls

Efficiency
%

(1)

-120

10

-9585

FIRST REGENERATOR AIR HEATER

_
_
_
__ RA|
D __|
N
I
||___

OF

APPROVED BY

H-1501

C-1551

Project N - Unit

+ INDICATES QUANTITY PRODUCED

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


DOCUMENT CLASS
CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

Pages modified under revision 1 :

REVISION
69,700 BPSD
-

7
2-20007
FEABR0273-M

Code

Serial N

Rev. index

CN

00 03

521

Op. Center JOB No.

0-3952-20-0000

Op. Center Doc. No.

S-015-1223-521

FEED Doc. No.

23-MAY-06

01-FEB-07

23-FEB-07

WRITTEN BY

T. Tsuchiya

T. Tsuchiya

T. Tsuchiya

Bach Ho Max Gasoline

CHECKED BY

M. Okada

M. Okada

M. Okada

- Design Case

APPROVED BY

M. Okada

M. Okada

M. Okada

DESCRIPTION

Issue for Review

For Construction

For Construction

2,4,10

Bach Ho MG - Design

S-015-1223-521-1.xls

Doc. type

8474L 015

DATE

GENERAL NOTES:

_
_
_
__ RA|
D __|
N
I
||___

Project N - Unit

6960-015-DS-0711

SHEET

OF

10

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

-0.3

-0.3

-585.0

-597.0

HP
STM

MP
STM

219.9

0.5

COB / WHB PACKAGE


FORCED DRAFT AIR FAN

C-1502 B

FORCED DRAFT AIR FAN

(-18.0)

C-1502B HOT STAND-BY

-1.4

1230

BFW HEATER
AIR BLOWER

-3.0

-3.0

P-1529 A

C-1501 TURBINE CONDENSATE PUMP

55

-39.0

-43.3

P-1529 B

C-1501 TURBINE CONDENSATE PUMP

55

(-39.0)

(-43.3)

E-1531

SURFACE CONDENSER
37

-18.5

-20.6

15

-15.0

-15.0

C-1501 LUBE OIL PUMP (Main)


C-1501 LUBE OIL PUMP (Spare)

TURNING GEAR MOTOR

C-1551

WET GAS COMPRESSOR

-1.5

-1.5

C-1551 TURBINE CONDENSATE PUMP

18.5

-13.9

-14.8

P-1559 B

C-1551 TURBINE CONDENSATE PUMP

18.5

(-13.9)

(-14.8)

E-1567

TURBINE CONDENSER
30

-16.0

-17.8

C-1551 LUBE OIL PUMP (Main)

C-1551 LUBE OIL PUMP (Spare)

Serial N

Rev. index

8474L 015

CN

00 03

521

HP
COND

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

-68.7

-30.4

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

BFW
T/h
HP
BFW

LP
BFW

-226.1

-0.5

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

REMARKS

1.4

-0.3

21.1
-0.1

0.1

68.7

0.3

30.4

0.4

(2.6)

-0.4

(-2.1)

(2.1)

DISENGAGER / STRIPPER

COB/WHB LP BLOWDOWN DRUM

0.5

-0.5

D-1527

LP BLOWDOWN DRUM

0.1

-0.1

T-1503

LCO STRIPPER

-3.0

3.0

T-1504

HCO STRIPPER

-0.5

0.5

-34.7

34.7

PAGE TOTAL

1462

-692.2

-713.3

119.4

-56.0

-3.0

0.0

21.1

0.1

99.1

-226.1

-0.5

0.0

0.0

45.9

GENERAL TOTAL

1462

-692.2

-713.3

119.4

-56.0

-3.0

0.0

21.1

0.1

99.1

-226.1

-0.5

0.0

0.0

45.9

NOTES

S-015-1223-521-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

REV

6.2

D-1501

_
_
_
__ RA|
D __|
N
I
||___

10

APPROVED BY

(18.0)

(-2.6)

P-1559 A

LP
STM

-21.1

E-1534

Code

Included in H-1503

C-1501

69,700 BPSD
Bach Ho Max Gasoline
- Design Case
STEAM
T/h

H-1503

ECONOMIZER

Doc. type

REVISION

C-1502 A

E-1525

Project N - Unit

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

521

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

1462

-692.2

-713.3

P-1501 A

FEED PUMP

600

-476.0

-500.5

P-1501 B

FEED PUMP

600

(-476.0)

(-500.5)

P-1504 A

SLURRY PRODUCT PUMP

55

-42.7

-45.1

P-1504 B

SLURRY PRODUCT PUMP

55

(-42.7)

(-45.1)

P-1505 A

BACKFLUSH OIL PUMP

22

-15.0

-16.5

P-1505 B

BACKFLUSH OIL PUMP

22

(-15.0)

(-16.5)

P-1506 A

BACKFLUSH OIL RECYCLE PUMP

11

-7.4

-8.4

P-1506 B

BACKFLUSH OIL RECYCLE PUMP

11

(-7.4)

(-8.4)

P-1507 A

HCO RECYCLE PUMP

150

0.0

0.0

P-1507 B

HCO RECYCLE PUMP

150

(0.0)

(0.0)

69,700 BPSD
Bach Ho Max Gasoline
- Design Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

119.4

-56.0

-3.0

0.0

DATE

SHEET

WRITTEN BY
3

CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

21.1

0.1

-226.1

-0.5

0.0

0.0

45.9

99.1

BFW
T/h

P-1508 A

HCO PUMPAROUND PUMP

220

-179.4

-188.4

P-1508 B

HCO PUMPAROUND PUMP

220

(-179.4)

(-188.4)

P-1509 A

HCO PRODUCT PUMP

15

-9.1

-10.1

P-1509 B

HCO PRODUCT PUMP

15

(-9.1)

(-10.1)

P-1510 A

LCO PUMPAROUND PUMP

335

-303.0

-316.0

P-1510 B

LCO PUMPAROUND PUMP

335

(-303.0)

(-316.0)

P-1511 A

LCO STRIPPER PUMP

90

-73.4

-76.9

P-1511 B

LCO STRIPPER PUMP

90

(-73.4)

(-76.9)

P-1512 A

MTC RECYCLE PUMP

75

0.0

0.0

P-1512 B

MTC RECYCLE PUMP

75

(0.0)

(0.0)

P-1513 A

LEAN OIL PUMP

75

-55.0

-58.1

P-1513 B

LEAN OIL PUMP

75

(-55.0)

(-58.1)

P-1514 A

NAPHTHA PUMPAROUND PUMP

225

-203.0

-213.9

P-1514 B

NAPHTHA PUMPAROUND PUMP

225

(-203.0)

(-213.9)

PAGE TOTAL

3746

-1364.0

-1433.9

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

GENERAL TOTAL

5208

-2056.2

-2147.2

119.4

-56.0

-3.0

0.0

21.1

0.1

99.1

-226.1

-0.5

0.0

0.0

45.9

REMARKS

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-521-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

521

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

5208

-2056.2

-2147.2

P-1515 A

HEAVY NAPHTHA PRODUCT PUMP

55

-39.4

-41.6

P-1515 B

HEAVY NAPHTHA PRODUCT PUMP

55

(-39.4)

(-41.6)

P-1516 A

FRACTIONATOR REFLUX PUMP

110

-96.0

-101.3
(-101.3)

69,700 BPSD
Bach Ho Max Gasoline
- Design Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

119.4

-56.0

-3.0

0.0

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
LP
MP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

0.1

-226.1

-0.5

0.0

0.0

45.9

21.1

99.1

BFW
T/h

P-1516 B

FRACTIONATOR REFLUX PUMP

110

(-96.0)

P-1517 A

OVERHEAD SOUR WATER PUMP

30

-25.5

-27.6

P-1517 B

OVERHEAD SOUR WATER PUMP

30

(-25.5)

(-27.6)

P-1518 A

OVERHEAD LIQUID PUMP

250

-206.0

-228.9

P-1518 B

OVERHEAD LIQUID PUMP

250

(-206.0)

(-228.9)

P-1519 A

SLURRY PUMPAROUND PUMP

-10.3

P-1519 B

SLURRY PUMPAROUND PUMP

-10.3

10.3

P-1519 C

SLURRY PUMPAROUND PUMP

(-10.3)

(10.3)

P-1519C HOT STAND-BY

-0.8

P-1521 A

HCO FLUSHING OIL PUMP

-3.7

P-1521 B

HCO FLUSHING OIL PUMP

110

(-80.9)

P-1522 A

LCO FLUSHING OIL PUMP

30

-18.4

-19.9

P-1522 B

LCO FLUSHING OIL PUMP

30

(-18.4)

(-19.9)

P-1526 A

LIGHT SLOPS PUMP

37

-26.1

-27.9

P-1526 B

LIGHT SLOPS PUMP

37

(-26.1)

(-27.9)

P-1527 A

HEAVY SLOPS PUMP

37

-27.9

-29.8

P-1527 B

HEAVY SLOPS PUMP

37

(-27.9)

(-29.8)

P-1528 A

TEMPERED WATER PUMP

15

-10.5

-11.7

P-1528 B

TEMPERED WATER PUMP

15

(-10.5)

(-11.7)

PAGE TOTAL

1238

-449.8

-488.7

-25.1

0.0

24.3

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.8

GENERAL TOTAL

6446

-2506.0

-2635.8

94.3

-56.0

21.3

0.0

21.1

0.1

99.1

-226.1

-0.5

0.0

0.0

46.7

REMARKS

S-015-1223-521-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

0.8
3.7

(-84.4)

+ INDICATES QUANTITY PRODUCED

REV

10.3

NOTES

_
_
_
__ RA|
D __|
N
I
||___

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

521

REVISION

MOTOR
LOAD/
RATING

69,700 BPSD
Bach Ho Max Gasoline
- Design Case
STEAM
T/h

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

HP
STM

MP
STM

LP
STM

HP
COND

94.3

-56.0

21.3

0.0

TOTAL PREVIOUS PAGES

6446

-2506.0

-2635.8

P-1551 A

INTERSTAGE DRUM PUMP

150

-134.0

-142.3

P-1551 B

INTERSTAGE DRUM PUMP

150

(-134.0)

(-142.3)

P-1552 A

KO DRUM LIQUID PUMP

-1.2

-1.4

P-1552 B

KO DRUM LIQUID PUMP

(-1.2)

(-1.4)

P-1553 A

STRIPPER FEED PUMP

132

-112.0

-117.9

P-1553 B

STRIPPER FEED PUMP

132

(-112.0)

(-117.9)

P-1554 A

GASOLINE RECYCLE PUMP

55

0.0

0.0

P-1554 B

GASOLINE RECYCLE PUMP

55

(0.0)

(0.0)

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
COLD
LP
COND
COND
COND
21.1

0.1

99.1

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

BFW
T/h

-226.1

-0.5

0.0

0.0

46.7

P-1556 A

DEBUTANIZER OVERHEAD PUMP

225

-185.0

-194.9

P-1556 B

DEBUTANIZER OVERHEAD PUMP

225

(-185.0)

(-194.9)

P-1560 A

RFCC CLOSED DRAIN PUMP

22

(-16.5)

(-18.1)

P-1560 B

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)

PAGE TOTAL

1214

-432.2

-456.5

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

GENERAL TOTAL

7660

-2938.2

-3092.3

94.3

-56.0

21.3

0.0

21.1

0.1

99.1

-226.1

-0.5

0.0

0.0

46.7

REMARKS

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-521-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

521

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

7660

-2938.2

-3092.3

E-1514

LCO AIR COOLER

120

-97.6

-106.2

E-1517

HEAVY NAPHTHA AIR COOLER

33

-20.4

-23.1

E-1519

OVERHEAD AIR CONDENSER

960

-736.0

-800.9

E-1521

HEAVY NAPHTHA 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

69,700 BPSD
Bach Ho Max Gasoline
- Design Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

94.3

-56.0

21.3

0.0

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND
21.1

0.1

99.1

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW
-226.1

-0.5

0.0

0.0

46.7

BFW
T/h

E-1553

HP CONDENSER

180

-134.4

-146.2

E-1558

GASOLINE AIR COOLER

120

-92.8

-101.0

E-1503

SLURRY HP STEAM GENERATOR

0.0

0.0

E-1504

SLURRY HP STEAM GENERATOR

10.3

-10.6

E-1505

SLURRY MP STEAM GENERATOR

E-1506

SLURRY LP STEAM GENERATOR

E-1508

HCO RECYCLE MP STEAM GENERATOR

E-1510

8.0

0.2

1.3

-1.4

0.1

0.0

0.0

HCO LP STEAM GENERATOR

2.1

-2.2

0.1

E-1513

LCO PRODUCT LP STEAM GENERATOR

2.2

-2.2

0.0

E-1518

HEAVY NAPHTHA TRIM COOLER

0.0

REMARKS

0.3

-8.2

PAGE TOTAL

1796

-1386.2

-1510.8

10.3

8.0

5.6

0.0

0.0

0.0

0.0

-10.6

-14.0

0.0

0.0

0.7

GENERAL TOTAL

9455

-4324.4

-4603.1

104.6

-48.0

26.9

0.0

21.1

0.1

99.1

-236.7

-14.5

0.0

0.0

47.4

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-521-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

TOTAL PREVIOUS PAGES


E-1520 A-H

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

521

REVISION

MOTOR
LOAD/
RATING
9455

69,700 BPSD
Bach Ho Max Gasoline
- Design Case
STEAM
T/h

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

HP
STM

MP
STM

LP
STM

HP
COND

-4603.1

104.6

-48.0

26.9

0.0

-4324.4

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
LP
MP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

0.1

-236.7

-14.5

0.0

0.0

47.4

21.1

99.1

BFW
T/h

REMARKS

OVERHEAD TRIM CONDENSER

E-1522

MP STEAM FEED HEATER

-8.7

E-1523

HCO PUMPAROUND MP STEAM GENERATOR

0.7

E-1524

HP STEAM FEED HEATER

E-1532

BLOWDOWN COOLER

E-1552 A/B

WET GAS COMPRESSOR TRIM COOLER

E-1554 A-D

STRIPPER CONDENSER

E-1559

GASOLINE COOLER

E-1561 A/B

DEBUTANIZER CONDENSER

E-1562

LPG COOLER

E-1564

LEAN OIL COOLER

8.7

Cold Feed Case: -18.7 t/h MPS


0.0

-0.7

-13.5

Cold Feed Case: -22.8 t/h HPS

13.5

E-1565

FUEL GAS COOLER

E-1566

LEAN AMINE COOLER

I-1501

FEED INJECTOR

Included in D-1501

I-1502

MTC INJECTOR

Included in D-1501

I-1503

STABILIZATION INJECTOR

Included in D-1501

I-1504

BACK FLUSH OIL INJECTOR

SPR-1501

FIRST REGENERATOR TORCH OIL SPRAYER

(-0.3)

Included in D-1501
(0.3)

SPR-1502

SECOND REGENERATOR TORCH OIL SPRAYER

(-0.3)

SPR-1503

WATER SPRAY FOR D-1502 FLUE GAS BYPASS

(-1.5)

(-25.7)

(-27.2)

SPR-1504

WATER SPRAY FOR D-1503 FLUE GAS BYPASS

(-1.5)

(-15.8)

(-17.3)

SPR-1505

WATER SPRAY FOR ECONOMIZER BYPASS

(-1.5)

(-18.5)

(-20.0)

(0.3)

PAGE TOTAL

0.0

0.0

-13.5

-8.0

0.0

13.5

8.7

0.0

0.0

0.0

-0.7

0.0

0.0

0.0

GENERAL TOTAL

9455

-4324.4

-4603.1

91.1

-56.0

26.9

13.5

29.8

0.1

99.1

-236.7

-15.2

0.0

0.0

47.4

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-521-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

TOTAL PREVIOUS PAGES


X-1504

SLURRY SEPARATOR

X-1505

CORROSION INHIBITOR INJECTION PACKAGE

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

9455

-4324.4

-4603.1

-230.0

-230.0

CORROSION INHIBITOR PUMP

0.55

-0.40

-0.44

X-1507

ELECTROSTATIC PRECIPITATOR

491

-379.0

-379.0

88

(-53)

(-53)

(-270.0)

(-300.0)

X-1509

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

521

REVISION

P-1520

X-1508

Project N - Unit

DESOX UNIT(FUTURE)

69,700 BPSD
Bach Ho Max Gasoline
- Design Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

91.1

-56.0

26.9

13.5

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

0.1

-236.7

-15.2

0.0

0.0

47.4

29.8

99.1

BFW
T/h

-0.3

REMARKS

0.3
Intermittent Users in X-1507

METAL PASSIVATOR INJECTION PACKAGE

P-1502 A

METAL PASSIVATION PUMP

0.55

0.00

0.00

P-1502 B

METAL PASSIVATION PUMP

0.55

(0.00)

(0.00)

X-1510

PHOSPHATE INJECTION PACKAGE

6.05

-4.36

-4.84

X-1551

ANTI-FOAM INJECTION PACKAGE

P-1557

ANTI-FOAMING PUMP

0.55

(-0.40)

(-0.44)

P-1558

ANTI-FOAMING PUMP

0.55

(-0.40)

(-0.44)

-3.3

EJ-1501

CATALYST HOPPERS STEAM EJECTOR

SV-1501

REGENERATED CATALYST SLIDE VALVE

4.0

-3.0

SV-1502

SPENT CATALYST SLIDE VALVE

4.0

-3.0

-3.3

SV-1503

FIRST REGENERATOR FLUE GAS SLIDE VALVE

4.0

-3.0

-3.3

SV-1504

SECOND 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

---

STEAM TRACE

(0.9)

(-0.9)

0.1

-0.1

-2.0

2.0

PAGE TOTAL

611

-631.5

-633.7

0.0

0.0

-2.4

0.0

0.0

2.0

0.0

0.0

0.0

0.0

0.0

0.4

GENERAL TOTAL (excl. Future DeSOx)

10066

-4955.9

-5236.8

91.1

-56.0

24.5

13.5

29.8

2.1

99.1

-236.7

-15.2

0.0

0.0

47.8

GENERAL TOTAL (incl. Future DeSOx)

10066

-5225.9

-5536.8

91.1

-56.0

24.5

13.5

29.8

2.1

99.1

-236.7

-15.2

0.0

0.0

47.8

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-521-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION

CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

521

REVISION

COOLING WATER

DESCRIPTION

T
C

m3/h

E-1518

HEAVY NAPHTHA TRIM COOLER

6.0

-19

E-1520 A-H

OVERHEAD TRIM CONDENSER

8.0

-1882

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

-255

E-1554 A-D

STRIPPER CONDENSER

6.0

-820

E-1559

GASOLINE COOLER

6.0

-160

E-1561 A/B

DEBUTANIZER CONDENSER

12.0

-1353

E-1562

LPG COOLER

6.0

-64

E-1564

LEAN OIL COOLER

6.0

-177

E-1565

FUEL GAS COOLER

6.0

-9

E-1566

LEAN AMINE COOLER

6.0

-72

E-1567

TURBINE CONDENSER

69,700 BPSD
Bach Ho Max Gasoline
- Design Case
SEA WATER
T
C

m3/h

8.8

-7285

8.8

-2300

FRESH
WATER
T/h

DATE

SHEET

WRITTEN BY
CHECKED BY

DESCRIPTION
PLANT AIR
INST.
Nm3/h
AIR
Nm3/h
CONTIN
INTERMIT

NITROGEN
Nm3/h

S-015-1223-521-1.xls

7
2-20007
FEABR0273-M

CONTIN

INTERMIT

Efficiency
%

FUEL FIRED
MW

PUMP / COMP COOLING

-95

PAGE TOTAL

-4945

-9585

0.0

0.0

0.0

GENERAL TOTAL

-4945

-9585

0.0

0.0

0.0

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

FURNACES & BOILERS


DUTY
MW

NOTES

_
_
_
__ RA|
D __|
N
I
||___

OF

APPROVED BY

- INDICATES QUANTITY CONSUMED

REMARKS

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION

CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

521

REVISION

DESCRIPTION

COOLING WATER
T
C

m3/h
-4945

TOTAL PREVIOUS PAGES

69,700 BPSD
Bach Ho Max Gasoline
- Design Case
SEA WATER
T
C

m3/h

FRESH
WATER
T/h

DATE

SHEET

WRITTEN BY
10

CHECKED BY

DESCRIPTION
INST.
PLANT AIR
AIR
Nm3/h
Nm3/h
CONTIN
INTERMIT

H-1502

SECOND REGENERATOR HEATER

H-1503

COB/WHB PACKAGE

NITROGEN
Nm3/h
CONTIN

FURNACES & BOILERS

INTERMIT

DUTY
MW

X-1507
X-1504

X-1502

FRESH CATALYST FEEDER

X-1503

AUXILIARY CATALYST FEEDER

C-1501

AIR BLOWER

-22

-3

-50

(-125)

ELECTROSTATIC PRECIPITATOR

-26

-8

(-85)

SLURRY SEPARATOR

-1

OIL MIST GENERATOR

-165
-3

-60

(-40)

(-3)

(-60)

(-40)

GLAND CONDENSER

-76

OIL COOLER

-32
-6

MAIN OIL COOLER

6.0

-60

GLAND CONDENSER

6.0

-50

PV-1501

PLUG VALVE

SV-1501

REGENERATED CATALYST SLIDE VALVE

SV-1502

SPENT CATALYST SLIDE VALVE

SV-1504

SECOND REGENERATOR FLUE GAS SLIDE VALVE

-134

PRIMARY PLANT AIR FOR REGEN SECTION

-4230

REV

(-280)

-611
-84
-36

(2)

(-2320)
-340

-160

(-560)

PAGE TOTAL

-221

-5658

-118

-351

0.0

0.0

-113.7

GENERAL TOTAL

-5166

-9585

-5658

-118

-351

0.0

0.0

-113.7

MISCELLANEOUS USERS

-13.7

NOTES
1. FUEL GAS RATES DURING START-UP FOR BOTH REGENERATOR AIR HEATERS (APPROX. 4.5 T/h)
2. PLANT AIR FROM INSTRUMENT AIR HEADER FOR PRIMARY USERS.

) INTERMITTENT PRODUCER/CONSUMER

REMARKS

-100.0

-71

SECONDARY PLANT AIR FOR REGEN SECTION

7
2-20007
FEABR0273-M

FUEL FIRED
MW

(1)
15.0

WET GAS COMPRESSOR

S-015-1223-521-1.xls

Efficiency
%

(1)

-120

10

-9585

FIRST REGENERATOR AIR HEATER

_
_
_
__ RA|
D __|
N
I
||___

OF

APPROVED BY

H-1501

C-1551

Project N - Unit

+ INDICATES QUANTITY PRODUCED

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


DOCUMENT CLASS
CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

Pages modified under revision 1 :

REVISION
69,700 BPSD
-

7
2-20007
FEABR0273-M

Code

Serial N

Rev. index

CN

00 03

522

Op. Center JOB No.

0-3952-20-0000

Op. Center Doc. No.

S-015-1223-522

FEED Doc. No.

23-MAY-06

01-FEB-07

23-FEB-07

WRITTEN BY

T. Tsuchiya

T. Tsuchiya

T. Tsuchiya

Bach Ho Max Distillate

CHECKED BY

M. Okada

M. Okada

M. Okada

- Design Case

APPROVED BY

M. Okada

M. Okada

M. Okada

DESCRIPTION

Issue for Review

For Construction

For Construction

2,4,10

Bach Ho MD - Design

S-015-1223-522-1.xls

Doc. type

8474L 015

DATE

GENERAL NOTES:

_
_
_
__ RA|
D __|
N
I
||___

Project N - Unit

6960-015-DS-0711

SHEET

OF

10

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

-0.3

-0.3

-683.0

-697.0

HP
STM

MP
STM

219.3

0.7

COB / WHB PACKAGE


FORCED DRAFT AIR FAN

C-1502 B

FORCED DRAFT AIR FAN

(-21.0)

C-1502B HOT STAND-BY

-1.7

1230

BFW HEATER
AIR BLOWER

-3.0

-3.0

P-1529 A

C-1501 TURBINE CONDENSATE PUMP

55

-39.0

-43.3

P-1529 B

C-1501 TURBINE CONDENSATE PUMP

55

(-39.0)

(-43.3)

E-1531

SURFACE CONDENSER
37

-18.5

-20.6

15

-15.0

-15.0

C-1501 LUBE OIL PUMP (Main)


C-1501 LUBE OIL PUMP (Spare)

TURNING GEAR MOTOR

C-1551

WET GAS COMPRESSOR

-1.5

-1.5

C-1551 TURBINE CONDENSATE PUMP

18.5

-13.9

-14.8

P-1559 B

C-1551 TURBINE CONDENSATE PUMP

18.5

(-13.9)

(-14.8)

E-1567

TURBINE CONDENSER
30

-16.0

-17.8

C-1551 LUBE OIL PUMP (Main)

C-1551 LUBE OIL PUMP (Spare)

Serial N

Rev. index

8474L 015

CN

00 03

522

HP
COND

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

-68.7

-30.4

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

BFW
T/h
HP
BFW

LP
BFW

-225.5

-0.7

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

REMARKS

1.7

-0.3

18.5
0.1

-0.1

68.7

0.3

30.4

0.4

(2.6)

-0.4

(2.1)

(-2.1)

-34.7

34.7

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

PAGE TOTAL

1462

-790.2

-813.3

118.5

-53.2

-2.9

0.0

18.5

0.1

99.1

-225.5

-0.7

0.0

0.0

46.1

GENERAL TOTAL

1462

-790.2

-813.3

118.5

-53.2

-2.9

0.0

18.5

0.1

99.1

-225.5

-0.7

0.0

0.0

46.1

NOTES

S-015-1223-522-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

REV

6.2

D-1501

_
_
_
__ RA|
D __|
N
I
||___

10

APPROVED BY

(21.0)

(-2.6)

P-1559 A

LP
STM

-18.5

E-1534

Code

Included in H-1503

C-1501

69,700 BPSD
Bach Ho Max Distillate
- Design Case
STEAM
T/h

H-1503

ECONOMIZER

Doc. type

REVISION

C-1502 A

E-1525

Project N - Unit

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

522

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

1462

-790.2

-813.3

P-1501 A

FEED PUMP

600

-476.0

-500.5

P-1501 B

FEED PUMP

600

(-476.0)

(-500.5)

P-1504 A

SLURRY PRODUCT PUMP

55

-42.7

-45.1

P-1504 B

SLURRY PRODUCT PUMP

55

(-42.7)

(-45.1)

P-1505 A

BACKFLUSH OIL PUMP

22

-15.0

-16.5

P-1505 B

BACKFLUSH OIL PUMP

22

(-15.0)

(-16.5)

P-1506 A

BACKFLUSH OIL RECYCLE PUMP

11

-7.4

-8.4

P-1506 B

BACKFLUSH OIL RECYCLE PUMP

11

(-7.4)

(-8.4)

P-1507 A

HCO RECYCLE PUMP

150

-128.0

-142.2

P-1507 B

HCO RECYCLE PUMP

150

(-128.0)

(-142.2)

69,700 BPSD
Bach Ho Max Distillate
- Design Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

118.5

-53.2

-2.9

0.0

DATE

SHEET

WRITTEN BY
3

CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

18.5

0.1

-225.5

-0.7

0.0

0.0

46.1

99.1

BFW
T/h

P-1508 A

HCO PUMPAROUND PUMP

220

-179.4

-188.4

P-1508 B

HCO PUMPAROUND PUMP

220

(-179.4)

(-188.4)

P-1509 A

HCO PRODUCT PUMP

15

-9.1

-10.1

P-1509 B

HCO PRODUCT PUMP

15

(-9.1)

(-10.1)

P-1510 A

LCO PUMPAROUND PUMP

335

-303.0

-316.0

P-1510 B

LCO PUMPAROUND PUMP

335

(-303.0)

(-316.0)

P-1511 A

LCO STRIPPER PUMP

90

-73.4

-76.9

P-1511 B

LCO STRIPPER PUMP

90

(-73.4)

(-76.9)

P-1512 A

MTC RECYCLE PUMP

75

0.0

0.0

P-1512 B

MTC RECYCLE PUMP

75

(0.0)

(0.0)

P-1513 A

LEAN OIL PUMP

75

-55.0

-58.1

P-1513 B

LEAN OIL PUMP

75

(-55.0)

(-58.1)

P-1514 A

NAPHTHA PUMPAROUND PUMP

225

-203.0

-213.9

P-1514 B

NAPHTHA PUMPAROUND PUMP

225

(-203.0)

(-213.9)

PAGE TOTAL

3746

-1492.0

-1576.1

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

GENERAL TOTAL

5208

-2282.2

-2389.4

118.5

-53.2

-2.9

0.0

18.5

0.1

99.1

-225.5

-0.7

0.0

0.0

46.1

REMARKS

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-522-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

522

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

5208

-2282.2

-2389.4

P-1515 A

HEAVY NAPHTHA PRODUCT PUMP

55

-39.4

-41.6

P-1515 B

HEAVY NAPHTHA PRODUCT PUMP

55

(-39.4)

(-41.6)

P-1516 A

FRACTIONATOR REFLUX PUMP

110

-96.0

-101.3
(-101.3)

69,700 BPSD
Bach Ho Max Distillate
- Design Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

118.5

-53.2

-2.9

0.0

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
COLD
LP
COND
COND
COND
18.5

0.1

99.1

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

BFW
T/h

-225.5

-0.7

0.0

0.0

46.1

P-1516 B

FRACTIONATOR REFLUX PUMP

110

(-96.0)

P-1517 A

OVERHEAD SOUR WATER PUMP

30

-25.5

-27.6

P-1517 B

OVERHEAD SOUR WATER PUMP

30

(-25.5)

(-27.6)

P-1518 A

OVERHEAD LIQUID PUMP

250

-206.0

-228.9

P-1518 B

OVERHEAD LIQUID PUMP

250

(-206.0)

(-228.9)

P-1519 A

SLURRY PUMPAROUND PUMP

-10.3

P-1519 B

SLURRY PUMPAROUND PUMP

-10.3

10.3

P-1519 C

SLURRY PUMPAROUND PUMP

(-10.3)

(10.3)

P-1519C HOT STAND-BY

-0.8

P-1521 A

HCO FLUSHING OIL PUMP

-3.7

P-1521 B

HCO FLUSHING OIL PUMP

110

(-80.9)

P-1522 A

LCO FLUSHING OIL PUMP

30

-18.4

-19.9

P-1522 B

LCO FLUSHING OIL PUMP

30

(-18.4)

(-19.9)

P-1526 A

LIGHT SLOPS PUMP

37

-26.1

-27.9

P-1526 B

LIGHT SLOPS PUMP

37

(-26.1)

(-27.9)

P-1527 A

HEAVY SLOPS PUMP

37

-27.9

-29.8

P-1527 B

HEAVY SLOPS PUMP

37

(-27.9)

(-29.8)

P-1528 A

TEMPERED WATER PUMP

15

-10.5

-11.7

P-1528 B

TEMPERED WATER PUMP

15

(-10.5)

(-11.7)

PAGE TOTAL

1238

-449.8

-488.7

-25.1

0.0

24.3

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.8

GENERAL TOTAL

6446

-2732.0

-2878.1

93.4

-53.2

21.4

0.0

18.5

0.1

99.1

-225.5

-0.7

0.0

0.0

46.9

REMARKS

S-015-1223-522-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

0.8
3.7

(-84.4)

+ INDICATES QUANTITY PRODUCED

REV

10.3

NOTES

_
_
_
__ RA|
D __|
N
I
||___

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

522

REVISION

MOTOR
LOAD/
RATING

69,700 BPSD
Bach Ho Max Distillate
- Design Case
STEAM
T/h

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

HP
STM

MP
STM

LP
STM

HP
COND

93.4

-53.2

21.4

0.0

TOTAL PREVIOUS PAGES

6446

-2732.0

-2878.1

P-1551 A

INTERSTAGE DRUM PUMP

150

-134.0

-142.3

P-1551 B

INTERSTAGE DRUM PUMP

150

(-134.0)

(-142.3)

P-1552 A

KO DRUM LIQUID PUMP

-1.2

-1.4

P-1552 B

KO DRUM LIQUID PUMP

(-1.2)

(-1.4)

P-1553 A

STRIPPER FEED PUMP

132

-112.0

-117.9

P-1553 B

STRIPPER FEED PUMP

132

(-112.0)

(-117.9)

P-1554 A

GASOLINE RECYCLE PUMP

55

-44.0

-47.7

P-1554 B

GASOLINE RECYCLE PUMP

55

(-44.0)

(-47.7)

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
COLD
LP
COND
COND
COND
18.5

0.1

99.1

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

BFW
T/h

-225.5

-0.7

0.0

0.0

46.9

P-1556 A

DEBUTANIZER OVERHEAD PUMP

225

-185.0

-194.9

P-1556 B

DEBUTANIZER OVERHEAD PUMP

225

(-185.0)

(-194.9)

P-1560 A

RFCC CLOSED DRAIN PUMP

22

(-16.5)

(-18.1)

P-1560 B

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)

PAGE TOTAL

1214

-476.2

-504.2

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

GENERAL TOTAL

7660

-3208.2

-3382.3

93.4

-53.2

21.4

0.0

18.5

0.1

99.1

-225.5

-0.7

0.0

0.0

46.9

REMARKS

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-522-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

522

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

7660

-3208.2

-3382.3

E-1514

LCO AIR COOLER

120

-97.6

-106.2

E-1517

HEAVY NAPHTHA AIR COOLER

33

-20.4

-23.1

E-1519

OVERHEAD AIR CONDENSER

960

-736.0

-800.9

E-1521

HEAVY NAPHTHA 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

69,700 BPSD
Bach Ho Max Distillate
- Design Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

93.4

-53.2

21.4

0.0

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND
18.5

0.1

99.1

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW
-225.5

-0.7

0.0

0.0

46.9

BFW
T/h

E-1553

HP CONDENSER

180

-134.4

-146.2

E-1558

GASOLINE AIR COOLER

120

-92.8

-101.0

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

2.9

E-1513

LCO PRODUCT LP STEAM GENERATOR

8.6

E-1518

HEAVY NAPHTHA TRIM COOLER

13.8

1.3

6.5

REMARKS

0.5

-14.2

0.4

-1.4

0.1

-6.7

0.2

-3.0

0.1

-8.9

0.3

PAGE TOTAL

1796

-1386.2

-1510.8

18.0

20.3

12.8

0.0

0.0

0.0

0.0

-18.5

-34.2

0.0

0.0

1.6

GENERAL TOTAL

9455

-4594.4

-4893.1

111.4

-32.9

34.2

0.0

18.5

0.1

99.1

-244.0

-34.9

0.0

0.0

48.5

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-522-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

TOTAL PREVIOUS PAGES


E-1520 A-H

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

522

REVISION

MOTOR
LOAD/
RATING
9455

69,700 BPSD
Bach Ho Max Distillate
- Design Case
STEAM
T/h

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

HP
STM

MP
STM

LP
STM

HP
COND

-4893.1

111.4

-32.9

34.2

0.0

-4594.4

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
LP
MP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

0.1

-244.0

-34.9

0.0

0.0

48.5

18.5

99.1

BFW
T/h

REMARKS

OVERHEAD TRIM CONDENSER

E-1522

MP STEAM FEED HEATER

-6.5

E-1523

HCO PUMPAROUND MP STEAM GENERATOR

7.3

E-1524

HP STEAM FEED HEATER

E-1532

BLOWDOWN COOLER

E-1552 A/B

WET GAS COMPRESSOR TRIM COOLER

E-1554 A-D

STRIPPER CONDENSER

E-1559

GASOLINE COOLER

E-1561 A/B

DEBUTANIZER CONDENSER

E-1562

LPG COOLER

E-1564

LEAN OIL COOLER

6.5

Cold Feed Case: -16.4 t/h MPS


0.2

-7.5

-11.3

Cold Feed Case: -20.7 t/h HPS

11.3

E-1565

FUEL GAS COOLER

E-1566

LEAN AMINE COOLER

I-1501

FEED INJECTOR

Included in D-1501

I-1502

MTC INJECTOR

Included in D-1501

I-1503

STABILIZATION INJECTOR

Included in D-1501

I-1504

BACK FLUSH OIL INJECTOR

SPR-1501

FIRST REGENERATOR TORCH OIL SPRAYER

(-0.3)

Included in D-1501
(0.3)

SPR-1502

SECOND REGENERATOR TORCH OIL SPRAYER

(-0.3)

SPR-1503

WATER SPRAY FOR D-1502 FLUE GAS BYPASS

(-1.5)

(-22.8)

(-24.3)

SPR-1504

WATER SPRAY FOR D-1503 FLUE GAS BYPASS

(-1.5)

(-14.0)

(-15.5)

SPR-1505

WATER SPRAY FOR ECONOMIZER BYPASS

(-1.5)

(-5.2)

(-6.7)

(0.3)

PAGE TOTAL

0.0

0.0

-11.3

0.8

0.0

11.3

6.5

0.0

0.0

0.0

-7.5

0.0

0.0

0.2

GENERAL TOTAL

9455

-4594.4

-4893.1

100.1

-32.1

34.2

11.3

25.0

0.1

99.1

-244.0

-42.4

0.0

0.0

48.7

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-522-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

TOTAL PREVIOUS PAGES


X-1504

SLURRY SEPARATOR

X-1505

CORROSION INHIBITOR INJECTION PACKAGE

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

9455

-4594.4

-4893.1

-230.0

-230.0

CORROSION INHIBITOR PUMP

0.55

-0.40

-0.44

X-1507

ELECTROSTATIC PRECIPITATOR

491

-379.0

-379.0

88

(-53)

(-53)

(-270.0)

(-300.0)

X-1509

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

522

REVISION

P-1520

X-1508

Project N - Unit

DESOX UNIT(FUTURE)

69,700 BPSD
Bach Ho Max Distillate
- Design Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

100.1

-32.1

34.2

11.3

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

0.1

-244.0

-42.4

0.0

0.0

48.7

25.0

99.1

BFW
T/h

-0.3

REMARKS

0.3
Intermittent Users in X-1507

METAL PASSIVATOR INJECTION PACKAGE

P-1502 A

METAL PASSIVATION PUMP

0.55

0.00

0.00

P-1502 B

METAL PASSIVATION PUMP

0.55

(0.00)

(0.00)

X-1510

PHOSPHATE INJECTION PACKAGE

6.05

-4.36

-4.84

X-1551

ANTI-FOAM INJECTION PACKAGE

P-1557

ANTI-FOAMING PUMP

0.55

(-0.40)

(-0.44)

P-1558

ANTI-FOAMING PUMP

0.55

(-0.40)

(-0.44)

-3.3

EJ-1501

CATALYST HOPPERS STEAM EJECTOR

SV-1501

REGENERATED CATALYST SLIDE VALVE

4.0

-3.0

SV-1502

SPENT CATALYST SLIDE VALVE

4.0

-3.0

-3.3

SV-1503

FIRST REGENERATOR FLUE GAS SLIDE VALVE

4.0

-3.0

-3.3

SV-1504

SECOND 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

---

STEAM TRACE

(0.9)

(-0.9)

0.1

-0.1

-2.0

2.0

PAGE TOTAL

611

-631.5

-633.7

0.0

0.0

-2.4

0.0

0.0

2.0

0.0

0.0

0.0

0.0

0.0

0.4

GENERAL TOTAL (excl. Future DeSOx)

10066

-5225.9

-5526.7

100.1

-32.1

31.8

11.3

25.0

2.1

99.1

-244.0

-42.4

0.0

0.0

49.1

GENERAL TOTAL (incl. Future DeSOx)

10066

-5495.9

-5826.7

100.1

-32.1

31.8

11.3

25.0

2.1

99.1

-244.0

-42.4

0.0

0.0

49.1

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-522-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION

CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

522

REVISION

COOLING WATER

DESCRIPTION

T
C

m3/h

E-1518

HEAVY NAPHTHA 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

69,700 BPSD
Bach Ho Max Distillate
- Design Case
SEA WATER
T
C

m3/h

8.8

-7285

8.8

-2300

FRESH
WATER
T/h

DATE

SHEET

WRITTEN BY
CHECKED BY

DESCRIPTION
PLANT AIR
INST.
Nm3/h
AIR
Nm3/h
CONTIN
INTERMIT

NITROGEN
Nm3/h

S-015-1223-522-1.xls

7
2-20007
FEABR0273-M

CONTIN

INTERMIT

Efficiency
%

FUEL FIRED
MW

PUMP / COMP COOLING

-95

PAGE TOTAL

-4373

-9585

0.0

0.0

0.0

GENERAL TOTAL

-4373

-9585

0.0

0.0

0.0

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

FURNACES & BOILERS


DUTY
MW

NOTES

_
_
_
__ RA|
D __|
N
I
||___

OF

APPROVED BY

- INDICATES QUANTITY CONSUMED

REMARKS

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION

CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

522

REVISION

DESCRIPTION

COOLING WATER
T
C

m3/h
-4373

TOTAL PREVIOUS PAGES

69,700 BPSD
Bach Ho Max Distillate
- Design Case
SEA WATER
T
C

m3/h

FRESH
WATER
T/h

DATE

SHEET

WRITTEN BY
10

CHECKED BY

DESCRIPTION
INST.
PLANT AIR
AIR
Nm3/h
Nm3/h
CONTIN
INTERMIT

H-1502

SECOND REGENERATOR HEATER

H-1503

COB/WHB PACKAGE

NITROGEN
Nm3/h
CONTIN

FURNACES & BOILERS

INTERMIT

DUTY
MW

X-1507
X-1504

X-1502

FRESH CATALYST FEEDER

X-1503

AUXILIARY CATALYST FEEDER

C-1501

AIR BLOWER

-22

-3

-50

(-125)

ELECTROSTATIC PRECIPITATOR

-26

-8

(-85)

SLURRY SEPARATOR

-1

OIL MIST GENERATOR

-165
-3

-60

(-40)

(-3)

(-60)

(-40)

GLAND CONDENSER

-76

OIL COOLER

-32
-6

MAIN OIL COOLER

6.0

-60

GLAND CONDENSER

6.0

-50

PV-1501

PLUG VALVE

SV-1501

REGENERATED CATALYST SLIDE VALVE

SV-1502

SPENT CATALYST SLIDE VALVE

SV-1504

SECOND REGENERATOR FLUE GAS SLIDE VALVE

-134

PRIMARY PLANT AIR FOR REGEN SECTION

-4230

REV

(-280)

-611
-84
-36

(2)

(-2320)
-340

-160

(-560)

PAGE TOTAL

-221

-5658

-118

-351

0.0

0.0

-123.7

GENERAL TOTAL

-4594

-9585

-5658

-118

-351

0.0

0.0

-123.7

MISCELLANEOUS USERS

-13.7

NOTES
1. FUEL GAS RATES DURING START-UP FOR BOTH REGENERATOR AIR HEATERS (APPROX. 4.5 T/h)
2. PLANT AIR FROM INSTRUMENT AIR HEADER FOR PRIMARY USERS.

) INTERMITTENT PRODUCER/CONSUMER

REMARKS

-110.0

-71

SECONDARY PLANT AIR FOR REGEN SECTION

7
2-20007
FEABR0273-M

FUEL FIRED
MW

(1)
15.0

WET GAS COMPRESSOR

S-015-1223-522-1.xls

Efficiency
%

(1)

-120

10

-9585

FIRST REGENERATOR AIR HEATER

_
_
_
__ RA|
D __|
N
I
||___

OF

APPROVED BY

H-1501

C-1551

Project N - Unit

+ INDICATES QUANTITY PRODUCED

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


DOCUMENT CLASS
CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

Pages modified under revision 1 :

REVISION
69,700 BPSD
-

7
2-20007
FEABR0273-M

Code

Serial N

Rev. index

CN

00 03

523

Op. Center JOB No.

0-3952-20-0000

Op. Center Doc. No.

S-015-1223-523

FEED Doc. No.

23-MAY-06

01-FEB-07

23-FEB-07

WRITTEN BY

T. Tsuchiya

T. Tsuchiya

T. Tsuchiya

Mixed Crude Max Gasoline

CHECKED BY

M. Okada

M. Okada

M. Okada

- Design Case

APPROVED BY

M. Okada

M. Okada

M. Okada

DESCRIPTION

Issue for Review

For Construction

For Construction

2,4,10

Mixed Crude MG - Design

S-015-1223-523-1.xls

Doc. type

8474L 015

DATE

GENERAL NOTES:

_
_
_
__ RA|
D __|
N
I
||___

Project N - Unit

6960-015-DS-0711

SHEET

OF

10

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

-0.3

-0.3

-352.0

-363.0

HP
STM

MP
STM

214.0

0.7

COB / WHB PACKAGE


FORCED DRAFT AIR FAN

C-1502 B

FORCED DRAFT AIR FAN

(-11.0)

C-1502B HOT STAND-BY

-0.9

1230

BFW HEATER
AIR BLOWER

-3.0

-3.0

P-1529 A

C-1501 TURBINE CONDENSATE PUMP

55

-39.0

-43.3

P-1529 B

C-1501 TURBINE CONDENSATE PUMP

55

(-39.0)

(-43.3)

E-1531

SURFACE CONDENSER
37

-18.5

-20.6

15

-15.0

-15.0

C-1501 LUBE OIL PUMP (Main)


C-1501 LUBE OIL PUMP (Spare)

TURNING GEAR MOTOR

C-1551

WET GAS COMPRESSOR

-1.5

-1.5

C-1551 TURBINE CONDENSATE PUMP

18.5

-13.9

-14.8

P-1559 B

C-1551 TURBINE CONDENSATE PUMP

18.5

(-13.9)

(-14.8)

E-1567

TURBINE CONDENSER
30

-16.0

-17.8

C-1551 LUBE OIL PUMP (Main)

C-1551 LUBE OIL PUMP (Spare)

Serial N

Rev. index

8474L 015

CN

00 03

523

HP
COND

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

-94.0

-32.2

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

BFW
T/h
HP
BFW

LP
BFW

-220.2

-0.7

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

REMARKS

0.9

-0.3

19.8
-0.1

0.1

94.0

0.3

32.2

0.4

(2.6)

-0.4

(-2.1)

(2.1)

DISENGAGER / STRIPPER

COB/WHB LP BLOWDOWN DRUM

0.5

-0.5

D-1527

LP BLOWDOWN DRUM

0.5

-0.5

T-1503

LCO STRIPPER

-3.0

3.0

T-1504

HCO STRIPPER

-0.5

0.5

-34.7

34.7

PAGE TOTAL

1462

-459.2

-479.3

86.9

-54.5

-2.6

0.0

19.8

0.1

126.2

-220.2

-0.7

0.0

0.0

45.0

GENERAL TOTAL

1462

-459.2

-479.3

86.9

-54.5

-2.6

0.0

19.8

0.1

126.2

-220.2

-0.7

0.0

0.0

45.0

NOTES

S-015-1223-523-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

REV

6.2

D-1501

_
_
_
__ RA|
D __|
N
I
||___

10

APPROVED BY

(11.0)

(-2.6)

P-1559 A

LP
STM

-19.8

E-1534

Code

Included in H-1503

C-1501

69,700 BPSD
Mixed Crude Max Gasoline
- Design Case
STEAM
T/h

H-1503

ECONOMIZER

Doc. type

REVISION

C-1502 A

E-1525

Project N - Unit

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

523

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

1462

-459.2

-479.3

P-1501 A

FEED PUMP

600

-476.0

-500.5

P-1501 B

FEED PUMP

600

(-476.0)

(-500.5)

69,700 BPSD
Mixed Crude Max Gasoline
- Design Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

86.9

-54.5

-2.6

0.0

DATE

SHEET

WRITTEN BY
3

CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

19.8

0.1

-220.2

-0.7

0.0

0.0

45.0

126.2

BFW
T/h

P-1504 A

SLURRY PRODUCT PUMP

55

-42.7

-45.1

P-1504 B

SLURRY PRODUCT PUMP

55

(-42.7)

(-45.1)

P-1505 A

BACKFLUSH OIL PUMP

22

-15.0

-16.5

P-1505 B

BACKFLUSH OIL PUMP

22

(-15.0)

(-16.5)

P-1506 A

BACKFLUSH OIL RECYCLE PUMP

11

-7.4

-8.4

P-1506 B

BACKFLUSH OIL RECYCLE PUMP

11

(-7.4)

(-8.4)

P-1507 A

HCO RECYCLE PUMP

150

0.0

0.0

P-1507 B

HCO RECYCLE PUMP

150

(0.0)

(0.0)

P-1508 A

HCO PUMPAROUND PUMP

220

-179.4

-188.4

P-1508 B

HCO PUMPAROUND PUMP

220

(-179.4)

(-188.4)

P-1509 A

HCO PRODUCT PUMP

15

-9.1

-10.1

P-1509 B

HCO PRODUCT PUMP

15

(-9.1)

(-10.1)

P-1510 A

LCO PUMPAROUND PUMP

335

-303.0

-316.0

P-1510 B

LCO PUMPAROUND PUMP

335

(-303.0)

(-316.0)

P-1511 A

LCO STRIPPER PUMP

90

-73.4

-76.9

P-1511 B

LCO STRIPPER PUMP

90

(-73.4)

(-76.9)

P-1512 A

MTC RECYCLE PUMP

75

-67.0

-72.0

P-1512 B

MTC RECYCLE PUMP

75

(-67.0)

(-72.0)

P-1513 A

LEAN OIL PUMP

75

-55.0

-58.1

P-1513 B

LEAN OIL PUMP

75

(-55.0)

(-58.1)

P-1514 A

NAPHTHA PUMPAROUND PUMP

225

-203.0

-213.9

P-1514 B

NAPHTHA PUMPAROUND PUMP

225

(-203.0)

(-213.9)

PAGE TOTAL

3746

-1431.0

-1505.9

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

GENERAL TOTAL

5208

-1890.2

-1985.2

86.9

-54.5

-2.6

0.0

19.8

0.1

126.2

-220.2

-0.7

0.0

0.0

45.0

REMARKS

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-523-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

523

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

5208

-1890.2

-1985.2

P-1515 A

HEAVY NAPHTHA PRODUCT PUMP

55

-39.4

-41.6

P-1515 B

HEAVY NAPHTHA PRODUCT PUMP

55

(-39.4)

(-41.6)

P-1516 A

FRACTIONATOR REFLUX PUMP

110

-96.0

-101.3
(-101.3)

69,700 BPSD
Mixed Crude Max Gasoline
- Design Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

86.9

-54.5

-2.6

0.0

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
LP
MP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

0.1

-220.2

-0.7

0.0

0.0

45.0

19.8

126.2

BFW
T/h

P-1516 B

FRACTIONATOR REFLUX PUMP

110

(-96.0)

P-1517 A

OVERHEAD SOUR WATER PUMP

30

-25.5

-27.6

P-1517 B

OVERHEAD SOUR WATER PUMP

30

(-25.5)

(-27.6)

P-1518 A

OVERHEAD LIQUID PUMP

250

-206.0

-228.9

P-1518 B

OVERHEAD LIQUID PUMP

250

(-206.0)

(-228.9)

P-1519 A

SLURRY PUMPAROUND PUMP

-10.3

P-1519 B

SLURRY PUMPAROUND PUMP

-10.3

10.3

P-1519 C

SLURRY PUMPAROUND PUMP

(-10.3)

(10.3)

P-1519C HOT STAND-BY

-0.8

P-1521 A

HCO FLUSHING OIL PUMP

-3.7

P-1521 B

HCO FLUSHING OIL PUMP

110

(-80.9)

P-1522 A

LCO FLUSHING OIL PUMP

30

-18.4

-19.9

P-1522 B

LCO FLUSHING OIL PUMP

30

(-18.4)

(-19.9)

P-1526 A

LIGHT SLOPS PUMP

37

-26.1

-27.9

P-1526 B

LIGHT SLOPS PUMP

37

(-26.1)

(-27.9)

P-1527 A

HEAVY SLOPS PUMP

37

-27.9

-29.8

P-1527 B

HEAVY SLOPS PUMP

37

(-27.9)

(-29.8)

P-1528 A

TEMPERED WATER PUMP

15

-10.5

-11.7

P-1528 B

TEMPERED WATER PUMP

15

(-10.5)

(-11.7)

PAGE TOTAL

1238

-449.8

-488.7

-25.1

0.0

24.3

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.8

GENERAL TOTAL

6446

-2340.0

-2473.8

61.8

-54.5

21.7

0.0

19.8

0.1

126.2

-220.2

-0.7

0.0

0.0

45.8

REMARKS

S-015-1223-523-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

0.8
3.7

(-84.4)

+ INDICATES QUANTITY PRODUCED

REV

10.3

NOTES

_
_
_
__ RA|
D __|
N
I
||___

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

523

REVISION

MOTOR
LOAD/
RATING

69,700 BPSD
Mixed Crude Max Gasoline
- Design Case
STEAM
T/h

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

HP
STM

MP
STM

LP
STM

HP
COND

61.8

-54.5

21.7

0.0

TOTAL PREVIOUS PAGES

6446

-2340.0

-2473.8

P-1551 A

INTERSTAGE DRUM PUMP

150

-134.0

-142.3

P-1551 B

INTERSTAGE DRUM PUMP

150

(-134.0)

(-142.3)

P-1552 A

KO DRUM LIQUID PUMP

-1.2

-1.4

P-1552 B

KO DRUM LIQUID PUMP

(-1.2)

(-1.4)

P-1553 A

STRIPPER FEED PUMP

132

-112.0

-117.9

P-1553 B

STRIPPER FEED PUMP

132

(-112.0)

(-117.9)

P-1554 A

GASOLINE RECYCLE PUMP

55

-44.0

-47.7

P-1554 B

GASOLINE RECYCLE PUMP

55

(-44.0)

(-47.7)

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
COLD
LP
COND
COND
COND
19.8

0.1

126.2

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

BFW
T/h

-220.2

-0.7

0.0

0.0

45.8

P-1556 A

DEBUTANIZER OVERHEAD PUMP

225

-185.0

-194.9

P-1556 B

DEBUTANIZER OVERHEAD PUMP

225

(-185.0)

(-194.9)

P-1560 A

RFCC CLOSED DRAIN PUMP

22

(-16.5)

(-18.1)

P-1560 B

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)

PAGE TOTAL

1214

-476.2

-504.2

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

GENERAL TOTAL

7660

-2816.2

-2978.0

61.8

-54.5

21.7

0.0

19.8

0.1

126.2

-220.2

-0.7

0.0

0.0

45.8

REMARKS

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-523-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

523

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

7660

-2816.2

-2978.0

E-1514

LCO AIR COOLER

120

-97.6

-106.2

E-1517

HEAVY NAPHTHA AIR COOLER

33

-20.4

-23.1

E-1519

OVERHEAD AIR CONDENSER

960

-736.0

-800.9

E-1521

HEAVY NAPHTHA 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

69,700 BPSD
Mixed Crude Max Gasoline
- Design Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

61.8

-54.5

21.7

0.0

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND
19.8

0.1

126.2

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW
-220.2

-0.7

0.0

0.0

45.8

BFW
T/h

E-1553

HP CONDENSER

180

-134.4

-146.2

E-1558

GASOLINE AIR COOLER

120

-92.8

-101.0

E-1503

SLURRY HP STEAM GENERATOR

43.1

-44.4

1.3

E-1504

SLURRY HP STEAM GENERATOR

18.5

-19.1

0.6

E-1505

SLURRY MP STEAM GENERATOR

E-1506

SLURRY LP STEAM GENERATOR

E-1508

HCO RECYCLE MP STEAM GENERATOR

E-1510

13.8

-14.2

0.4

1.2

-1.2

0.0

HCO LP STEAM GENERATOR

1.9

-2.0

0.1

E-1513

LCO PRODUCT LP STEAM GENERATOR

2.6

-2.7

0.1

E-1518

HEAVY NAPHTHA TRIM COOLER

REMARKS

0.0

0.0

PAGE TOTAL

1796

-1386.2

-1510.8

61.6

13.8

5.7

0.0

0.0

0.0

0.0

-63.5

-20.1

0.0

0.0

2.5

GENERAL TOTAL

9455

-4202.4

-4488.8

123.4

-40.7

27.4

0.0

19.8

0.1

126.2

-283.7

-20.8

0.0

0.0

48.3

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-523-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

TOTAL PREVIOUS PAGES


E-1520 A-H

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

523

REVISION

MOTOR
LOAD/
RATING
9455

69,700 BPSD
Mixed Crude Max Gasoline
- Design Case
STEAM
T/h

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

HP
STM

MP
STM

LP
STM

HP
COND

-4488.8

123.4

-40.7

27.4

0.0

-4202.4

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
LP
MP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

0.1

-283.7

-20.8

0.0

0.0

48.3

19.8

126.2

BFW
T/h

REMARKS

OVERHEAD TRIM CONDENSER

E-1522

MP STEAM FEED HEATER

(-17.2)

E-1523

HCO PUMPAROUND MP STEAM GENERATOR

0.9

E-1524

HP STEAM FEED HEATER

E-1532

BLOWDOWN COOLER

E-1552 A/B

WET GAS COMPRESSOR TRIM COOLER

E-1554 A-D

STRIPPER CONDENSER

E-1559

GASOLINE COOLER

E-1561 A/B

DEBUTANIZER CONDENSER

E-1562

LPG COOLER

E-1564

LEAN OIL COOLER

(17.2)

Cold Feed Case Only


0.1

-1.0

0.0

0.0

E-1565

FUEL GAS COOLER

E-1566

LEAN AMINE COOLER

I-1501

FEED INJECTOR

Included in D-1501

I-1502

MTC INJECTOR

Included in D-1501

I-1503

STABILIZATION INJECTOR

Included in D-1501

I-1504

BACK FLUSH OIL INJECTOR

SPR-1501

FIRST REGENERATOR TORCH OIL SPRAYER

(-0.3)

Included in D-1501
(0.3)

SPR-1502

SECOND REGENERATOR TORCH OIL SPRAYER

(-0.3)

SPR-1503

WATER SPRAY FOR D-1502 FLUE GAS BYPASS

(-1.4)

(-42.0)

(-43.4)

SPR-1504

WATER SPRAY FOR D-1503 FLUE GAS BYPASS

(-1.4)

(-25.5)

(-26.9)

SPR-1505

WATER SPRAY FOR ECONOMIZER BYPASS

(-1.4)

(-10.5)

(-11.9)

(0.3)

PAGE TOTAL

0.0

0.0

0.0

0.9

0.0

0.0

0.0

0.0

0.0

0.0

-1.0

0.0

0.0

0.1

GENERAL TOTAL

9455

-4202.4

-4488.8

123.4

-39.8

27.4

0.0

19.8

0.1

126.2

-283.7

-21.8

0.0

0.0

48.4

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-523-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

TOTAL PREVIOUS PAGES


X-1504

SLURRY SEPARATOR

X-1505

CORROSION INHIBITOR INJECTION PACKAGE

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

9455

-4202.4

-4488.8

-230.0

-230.0

CORROSION INHIBITOR PUMP

0.55

-0.40

-0.44

X-1507

ELECTROSTATIC PRECIPITATOR

491

-379.0

-379.0

88

(-53)

(-53)

(-270.0)

(-300.0)

X-1509

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

523

REVISION

P-1520

X-1508

Project N - Unit

DESOX UNIT(FUTURE)

69,700 BPSD
Mixed Crude Max Gasoline
- Design Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

123.4

-39.8

27.4

0.0

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

0.1

-283.7

-21.8

0.0

0.0

48.4

19.8

126.2

BFW
T/h

-0.3

REMARKS

0.3
Intermittent Users in X-1507

METAL PASSIVATOR INJECTION PACKAGE

P-1502 A

METAL PASSIVATION PUMP

0.55

-0.40

-0.44

P-1502 B

METAL PASSIVATION PUMP

0.55

(-0.40)

(-0.44)

X-1510

PHOSPHATE INJECTION PACKAGE

6.05

-4.36

-4.84

X-1551

ANTI-FOAM INJECTION PACKAGE

P-1557

ANTI-FOAMING PUMP

0.55

(-0.40)

(-0.44)

P-1558

ANTI-FOAMING PUMP

0.55

(-0.40)

(-0.44)

-3.3

EJ-1501

CATALYST HOPPERS STEAM EJECTOR

SV-1501

REGENERATED CATALYST SLIDE VALVE

4.0

-3.0

SV-1502

SPENT CATALYST SLIDE VALVE

4.0

-3.0

-3.3

SV-1503

FIRST REGENERATOR FLUE GAS SLIDE VALVE

4.0

-3.0

-3.3

SV-1504

SECOND 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

---

STEAM TRACE

(0.9)

(-0.9)

0.1

-0.1

-2.0

2.0

PAGE TOTAL

611

-631.9

-634.1

0.0

0.0

-2.4

0.0

0.0

2.0

0.0

0.0

0.0

0.0

0.0

0.4

GENERAL TOTAL (excl. Future DeSOx)

10066

-4834.3

-5123.0

123.4

-39.8

25.0

0.0

19.8

2.1

126.2

-283.7

-21.8

0.0

0.0

48.8

GENERAL TOTAL (incl. Future DeSOx)

10066

-5104.3

-5423.0

123.4

-39.8

25.0

0.0

19.8

2.1

126.2

-283.7

-21.8

0.0

0.0

48.8

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-523-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION

CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

523

REVISION

COOLING WATER

DESCRIPTION

T
C

m3/h

E-1518

HEAVY NAPHTHA TRIM COOLER

6.0

-19

E-1520 A-H

OVERHEAD TRIM CONDENSER

8.0

-1786

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

-245

E-1554 A-D

STRIPPER CONDENSER

6.0

-863

E-1559

GASOLINE COOLER

6.0

-156

E-1561 A/B

DEBUTANIZER CONDENSER

12.0

-1319

E-1562

LPG COOLER

6.0

-54

E-1564

LEAN OIL COOLER

6.0

-182

E-1565

FUEL GAS COOLER

6.0

-16

E-1566

LEAN AMINE COOLER

6.0

-72

E-1567

TURBINE CONDENSER

69,700 BPSD
Mixed Crude Max Gasoline
- Design Case
SEA WATER
T
C

m3/h

8.8

-7285

8.8

-2300

FRESH
WATER
T/h

DATE

SHEET

WRITTEN BY
CHECKED BY

DESCRIPTION
PLANT AIR
INST.
Nm3/h
AIR
Nm3/h
CONTIN
INTERMIT

NITROGEN
Nm3/h

S-015-1223-523-1.xls

7
2-20007
FEABR0273-M

CONTIN

INTERMIT

Efficiency
%

FUEL FIRED
MW

PUMP / COMP COOLING

-95

PAGE TOTAL

-4846

-9585

0.0

0.0

0.0

GENERAL TOTAL

-4846

-9585

0.0

0.0

0.0

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

FURNACES & BOILERS


DUTY
MW

NOTES

_
_
_
__ RA|
D __|
N
I
||___

OF

APPROVED BY

- INDICATES QUANTITY CONSUMED

REMARKS

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION

CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

523

REVISION

DESCRIPTION

COOLING WATER
T
C

m3/h
-4846

TOTAL PREVIOUS PAGES

69,700 BPSD
Mixed Crude Max Gasoline
- Design Case
SEA WATER
T
C

m3/h

FRESH
WATER
T/h

DATE

SHEET

WRITTEN BY
10

CHECKED BY

DESCRIPTION
INST.
PLANT AIR
AIR
Nm3/h
Nm3/h
CONTIN
INTERMIT

H-1502

SECOND REGENERATOR HEATER

H-1503

COB/WHB PACKAGE

NITROGEN
Nm3/h
CONTIN

FURNACES & BOILERS

INTERMIT

DUTY
MW

X-1507
X-1504

X-1502

FRESH CATALYST FEEDER

X-1503

AUXILIARY CATALYST FEEDER

C-1501

AIR BLOWER

-22

-3

-50

(-125)

ELECTROSTATIC PRECIPITATOR

-26

-8

(-85)

SLURRY SEPARATOR

-1

OIL MIST GENERATOR

-165
-3

-60

(-40)

(-3)

(-60)

(-40)

GLAND CONDENSER

-76

OIL COOLER

-32
-6

MAIN OIL COOLER

6.0

-60

GLAND CONDENSER

6.0

-50

PV-1501

PLUG VALVE

SV-1501

REGENERATED CATALYST SLIDE VALVE

SV-1502

SPENT CATALYST SLIDE VALVE

SV-1504

SECOND REGENERATOR FLUE GAS SLIDE VALVE

-134

PRIMARY PLANT AIR FOR REGEN SECTION

-4230

REV

(-280)

-611
-84
-36

(2)

(-2320)
-340

-160

(-560)

PAGE TOTAL

-221

-5658

-118

-351

0.0

0.0

-63.6

GENERAL TOTAL

-5067

-9585

-5658

-118

-351

0.0

0.0

-63.6

MISCELLANEOUS USERS

-13.7

NOTES
1. FUEL GAS RATES DURING START-UP FOR BOTH REGENERATOR AIR HEATERS (APPROX. 4.5 T/h)
2. PLANT AIR FROM INSTRUMENT AIR HEADER FOR PRIMARY USERS.

) INTERMITTENT PRODUCER/CONSUMER

REMARKS

-49.9

-71

SECONDARY PLANT AIR FOR REGEN SECTION

7
2-20007
FEABR0273-M

FUEL FIRED
MW

(1)
15.0

WET GAS COMPRESSOR

S-015-1223-523-1.xls

Efficiency
%

(1)

-120

10

-9585

FIRST REGENERATOR AIR HEATER

_
_
_
__ RA|
D __|
N
I
||___

OF

APPROVED BY

H-1501

C-1551

Project N - Unit

+ INDICATES QUANTITY PRODUCED

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


DOCUMENT CLASS
CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

Pages modified under revision 1 :

REVISION
69,700 BPSD
-

7
2-20007
FEABR0273-M

Code

Serial N

Rev. index

CN

00 03

524

Op. Center JOB No.

0-3952-20-0000

Op. Center Doc. No.

S-015-1223-524

FEED Doc. No.

23-MAY-06

01-FEB-07

23-FEB-07

WRITTEN BY

T. Tsuchiya

T. Tsuchiya

T. Tsuchiya

Mixed Crude Max Distillate

CHECKED BY

M. Okada

M. Okada

M. Okada

- Design Case

APPROVED BY

M. Okada

M. Okada

M. Okada

DESCRIPTION

Issue for Review

For Construction

For Construction

2,4,10

Mixed Crude MD - Design

S-015-1223-524-1.xls

Doc. type

8474L 015

DATE

GENERAL NOTES:

_
_
_
__ RA|
D __|
N
I
||___

Project N - Unit

6960-015-DS-0711

SHEET

OF

10

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

-0.3

-0.3

-443.0

-457.0

HP
STM

MP
STM

214.8

0.5

COB / WHB PACKAGE


FORCED DRAFT AIR FAN

C-1502 B

FORCED DRAFT AIR FAN

(-13.8)

C-1502B HOT STAND-BY

-1.1

1230

BFW HEATER
AIR BLOWER

-3.0

-3.0

P-1529 A

C-1501 TURBINE CONDENSATE PUMP

55

-39.0

-43.3

P-1529 B

C-1501 TURBINE CONDENSATE PUMP

55

(-39.0)

(-43.3)

E-1531

SURFACE CONDENSER
37

-18.5

-20.6

15

-15.0

-15.0

C-1501 LUBE OIL PUMP (Main)


C-1501 LUBE OIL PUMP (Spare)

TURNING GEAR MOTOR

C-1551

WET GAS COMPRESSOR

-1.5

-1.5

C-1551 TURBINE CONDENSATE PUMP

18.5

-13.9

-14.8

P-1559 B

C-1551 TURBINE CONDENSATE PUMP

18.5

(-13.9)

(-14.8)

E-1567

TURBINE CONDENSER
30

-16.0

-17.8

C-1551 LUBE OIL PUMP (Main)

C-1551 LUBE OIL PUMP (Spare)

Serial N

Rev. index

8474L 015

CN

00 03

524

HP
COND

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

-77.9

-32.2

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

BFW
T/h
HP
BFW

LP
BFW

-221.0

-0.5

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

REMARKS

1.1

-0.3

12.2
0.1

-0.1

77.9

0.3

32.2

0.4

(2.6)

-0.4

(2.1)

(-2.1)

-34.7

34.7

DISENGAGER / STRIPPER

COB/WHB LP BLOWDOWN DRUM

0.5

-0.5

D-1527

LP BLOWDOWN DRUM

0.5

-0.5

T-1503

LCO STRIPPER

-3.0

3.0

T-1504

HCO STRIPPER

-0.5

0.5

PAGE TOTAL

1462

-550.2

-573.3

103.6

-47.1

-2.6

0.0

12.2

0.1

110.1

-221.0

-0.5

0.0

0.0

45.2

GENERAL TOTAL

1462

-550.2

-573.3

103.6

-47.1

-2.6

0.0

12.2

0.1

110.1

-221.0

-0.5

0.0

0.0

45.2

NOTES

S-015-1223-524-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

REV

6.2

D-1501

_
_
_
__ RA|
D __|
N
I
||___

10

APPROVED BY

(13.8)

(-2.6)

P-1559 A

LP
STM

-12.2

E-1534

Code

Included in H-1503

C-1501

69,700 BPSD
Mixed Crude Max Distillate
- Design Case
STEAM
T/h

H-1503

ECONOMIZER

Doc. type

REVISION

C-1502 A

E-1525

Project N - Unit

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

524

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

1462

-550.2

-573.3

P-1501 A

FEED PUMP

600

-476.0

-500.5

P-1501 B

FEED PUMP

600

(-476.0)

(-500.5)

P-1504 A

SLURRY PRODUCT PUMP

55

-42.7

-45.1

P-1504 B

SLURRY PRODUCT PUMP

55

(-42.7)

(-45.1)

P-1505 A

BACKFLUSH OIL PUMP

22

-15.0

-16.5

P-1505 B

BACKFLUSH OIL PUMP

22

(-15.0)

(-16.5)

P-1506 A

BACKFLUSH OIL RECYCLE PUMP

11

-7.4

-8.4

P-1506 B

BACKFLUSH OIL RECYCLE PUMP

11

(-7.4)

(-8.4)

P-1507 A

HCO RECYCLE PUMP

150

-128.0

-142.2

P-1507 B

HCO RECYCLE PUMP

150

(-128.0)

(-142.2)

69,700 BPSD
Mixed Crude Max Distillate
- Design Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

103.6

-47.1

-2.6

0.0

DATE

SHEET

WRITTEN BY
3

CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

12.2

0.1

-221.0

-0.5

0.0

0.0

45.2

110.1

BFW
T/h

P-1508 A

HCO PUMPAROUND PUMP

220

-179.4

-188.4

P-1508 B

HCO PUMPAROUND PUMP

220

(-179.4)

(-188.4)

P-1509 A

HCO PRODUCT PUMP

15

-9.1

-10.1

P-1509 B

HCO PRODUCT PUMP

15

(-9.1)

(-10.1)

P-1510 A

LCO PUMPAROUND PUMP

335

-303.0

-316.0

P-1510 B

LCO PUMPAROUND PUMP

335

(-303.0)

(-316.0)

P-1511 A

LCO STRIPPER PUMP

90

-73.4

-76.9

P-1511 B

LCO STRIPPER PUMP

90

(-73.4)

(-76.9)

P-1512 A

MTC RECYCLE PUMP

75

0.0

0.0

P-1512 B

MTC RECYCLE PUMP

75

(0.0)

(0.0)

P-1513 A

LEAN OIL PUMP

75

-55.0

-58.1

P-1513 B

LEAN OIL PUMP

75

(-55.0)

(-58.1)

P-1514 A

NAPHTHA PUMPAROUND PUMP

225

-203.0

-213.9

P-1514 B

NAPHTHA PUMPAROUND PUMP

225

(-203.0)

(-213.9)

PAGE TOTAL

3746

-1492.0

-1576.1

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

GENERAL TOTAL

5208

-2042.2

-2149.4

103.6

-47.1

-2.6

0.0

12.2

0.1

110.1

-221.0

-0.5

0.0

0.0

45.2

REMARKS

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-524-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

524

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

5208

-2042.2

-2149.4

P-1515 A

HEAVY NAPHTHA PRODUCT PUMP

55

-39.4

-41.6

P-1515 B

HEAVY NAPHTHA PRODUCT PUMP

55

(-39.4)

(-41.6)

P-1516 A

FRACTIONATOR REFLUX PUMP

110

-96.0

-101.3
(-101.3)

69,700 BPSD
Mixed Crude Max Distillate
- Design Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

103.6

-47.1

-2.6

0.0

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
LP
MP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

0.1

-221.0

-0.5

0.0

0.0

45.2

12.2

110.1

BFW
T/h

P-1516 B

FRACTIONATOR REFLUX PUMP

110

(-96.0)

P-1517 A

OVERHEAD SOUR WATER PUMP

30

-25.5

-27.6

P-1517 B

OVERHEAD SOUR WATER PUMP

30

(-25.5)

(-27.6)

P-1518 A

OVERHEAD LIQUID PUMP

250

-206.0

-228.9

P-1518 B

OVERHEAD LIQUID PUMP

250

(-206.0)

(-228.9)

P-1519 A

SLURRY PUMPAROUND PUMP

-10.3

P-1519 B

SLURRY PUMPAROUND PUMP

-10.3

10.3

P-1519 C

SLURRY PUMPAROUND PUMP

(-10.3)

(10.3)

P-1519C HOT STAND-BY

-0.8

P-1521 A

HCO FLUSHING OIL PUMP

-3.7

P-1521 B

HCO FLUSHING OIL PUMP

110

(-80.9)

P-1522 A

LCO FLUSHING OIL PUMP

30

-18.4

-19.9

P-1522 B

LCO FLUSHING OIL PUMP

30

(-18.4)

(-19.9)

P-1526 A

LIGHT SLOPS PUMP

37

-26.1

-27.9

P-1526 B

LIGHT SLOPS PUMP

37

(-26.1)

(-27.9)

P-1527 A

HEAVY SLOPS PUMP

37

-27.9

-29.8

P-1527 B

HEAVY SLOPS PUMP

37

(-27.9)

(-29.8)

P-1528 A

TEMPERED WATER PUMP

15

-10.5

-11.7

P-1528 B

TEMPERED WATER PUMP

15

(-10.5)

(-11.7)

PAGE TOTAL

1238

-449.8

-488.7

-25.1

0.0

24.3

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.8

GENERAL TOTAL

6446

-2492.0

-2638.1

78.5

-47.1

21.7

0.0

12.2

0.1

110.1

-221.0

-0.5

0.0

0.0

46.0

REMARKS

S-015-1223-524-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

0.8
3.7

(-84.4)

+ INDICATES QUANTITY PRODUCED

REV

10.3

NOTES

_
_
_
__ RA|
D __|
N
I
||___

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

524

REVISION

MOTOR
LOAD/
RATING

69,700 BPSD
Mixed Crude Max Distillate
- Design Case
STEAM
T/h

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

HP
STM

MP
STM

LP
STM

HP
COND

78.5

-47.1

21.7

0.0

TOTAL PREVIOUS PAGES

6446

-2492.0

-2638.1

P-1551 A

INTERSTAGE DRUM PUMP

150

-134.0

-142.3

P-1551 B

INTERSTAGE DRUM PUMP

150

(-134.0)

(-142.3)

P-1552 A

KO DRUM LIQUID PUMP

-1.2

-1.4

P-1552 B

KO DRUM LIQUID PUMP

(-1.2)

(-1.4)

P-1553 A

STRIPPER FEED PUMP

132

-112.0

-117.9

P-1553 B

STRIPPER FEED PUMP

132

(-112.0)

(-117.9)

P-1554 A

GASOLINE RECYCLE PUMP

55

-44.0

-47.7

P-1554 B

GASOLINE RECYCLE PUMP

55

(-44.0)

(-47.7)

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
COLD
LP
COND
COND
COND
12.2

0.1

110.1

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

BFW
T/h

-221.0

-0.5

0.0

0.0

46.0

P-1556 A

DEBUTANIZER OVERHEAD PUMP

225

-185.0

-194.9

P-1556 B

DEBUTANIZER OVERHEAD PUMP

225

(-185.0)

(-194.9)

P-1560 A

RFCC CLOSED DRAIN PUMP

22

(-16.5)

(-18.1)

P-1560 B

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)

PAGE TOTAL

1214

-476.2

-504.2

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

GENERAL TOTAL

7660

-2968.2

-3142.3

78.5

-47.1

21.7

0.0

12.2

0.1

110.1

-221.0

-0.5

0.0

0.0

46.0

REMARKS

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-524-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

524

REVISION

MOTOR
LOAD/
RATING

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

TOTAL PREVIOUS PAGES

7660

-2968.2

-3142.3

E-1514

LCO AIR COOLER

120

-97.6

-106.2

E-1517

HEAVY NAPHTHA AIR COOLER

33

-20.4

-23.1

E-1519

OVERHEAD AIR CONDENSER

960

-736.0

-800.9

E-1521

HEAVY NAPHTHA 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

69,700 BPSD
Mixed Crude Max Distillate
- Design Case
STEAM
T/h

HP
STM

MP
STM

LP
STM

HP
COND

78.5

-47.1

21.7

0.0

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
MP
LP
COLD
COND
COND
COND
12.2

0.1

110.1

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW
-221.0

-0.5

0.0

0.0

46.0

BFW
T/h

E-1553

HP CONDENSER

180

-134.4

-146.2

E-1558

GASOLINE AIR COOLER

120

-92.8

-101.0

E-1503

SLURRY HP STEAM GENERATOR

35.0

-36.1

1.1

E-1504

SLURRY HP STEAM GENERATOR

21.4

-22.1

0.7

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

2.8

E-1513

LCO PRODUCT LP STEAM GENERATOR

8.5

E-1518

HEAVY NAPHTHA TRIM COOLER

16.1

1.2

14.4

-16.6

0.5

-1.2

0.0

-14.9

0.5

-2.8

0.0

-8.8

0.3

PAGE TOTAL

1796

-1386.2

-1510.8

56.4

30.5

12.5

0.0

0.0

0.0

0.0

-58.2

-44.3

0.0

0.0

3.1

GENERAL TOTAL

9455

-4354.4

-4653.1

134.9

-16.6

34.2

0.0

12.2

0.1

110.1

-279.2

-44.8

0.0

0.0

49.1

REMARKS

NOTES

_
_
_
__ RA|
D __|
N
I
||___
(

S-015-1223-524-1.xls

7
2-20007
FEABR0273-M

) INTERMITTENT PRODUCER/CONSUMER

+ INDICATES QUANTITY PRODUCED

10

APPROVED BY

MOTOR/LOAD RATING:

NAMEPLATE RATING OF MOTOR OR LOAD

MECH. RUNNING LOAD:

MOTOR SHAFT POWER

ELEC. OPERATING LOAD:

POWER ABSORBED BY MOTOR (MECH. LOAD/EFFY)

- INDICATES QUANTITY CONSUMED

REV

ESTIMATED UTILITY CONSUMPTION

ESTIMATED UTILITY CONSUMPTION


CLIENT

PETROVIETNAM

LOCATION

DUNG QUAT

PLANT CAPACITY

VIETNAM

SECTION No.

015 RFCC

CASE

UNIT

ITEM
No.

DESCRIPTION

TOTAL PREVIOUS PAGES


E-1520 A-H

Project N - Unit

Doc. type

Code

Serial N

Rev. index

8474L 015

CN

00 03

524

REVISION

MOTOR
LOAD/
RATING
9455

69,700 BPSD
Mixed Crude Max Distillate
- Design Case
STEAM
T/h

ELECTRIC POWER kW
MECH.
ELEC.
RUNNING
OPER
LOAD
LOAD

HP
STM

MP
STM

LP
STM

HP
COND

-4653.1

134.9

-16.6

34.2

0.0

-4354.4

DATE

SHEET

WRITTEN BY
CHECKED BY

OF

DESCRIPTION
CONDENSATE
T/h
LP
MP
COLD
COND
COND
COND

LP
BFW

COLD
BFW

DW
T/h
DEMIN.
WATER

LOSSES
T/h

HP
BFW

0.1

-279.2

-44.8

0.0

0.0

49.1

12.2

110.1

BFW
T/h

REMARKS

OVERHEAD TRIM CONDENSER

E-1522

MP STEAM FEED HEATER

(-17.1)

E-1523

HCO PUMPAROUND MP STEAM GENERATOR

6.8

E-1524

HP STEAM FEED HEATER

E-1532

BLOWDOWN COOLER

E-1552 A/B

WET GAS COMPRESSOR TRIM COOLER

E-1554 A-D

STRIPPER CONDENSER

E-1559

GASOLINE COOLER

E-1561 A/B

DEBUTANIZER CONDENSER

E-1562

LPG COOLER

E-1564

LEAN OIL COOLER

(17.1)

Cold Feed Case Only


0.2

-7.0

0.0

0.0

E-1565

FUEL GAS COOLER

E-1566

LEAN AMINE COOLER

I-1501

FEED INJECTOR

Included in D-1501

I-1502

MTC INJECTOR

Included in D-1501

I-1503

STABILIZATION INJECTOR

Included in D-1501

I-1504

BACK FLUSH OIL INJECTOR

SPR-1501

FIRST REGENERATOR TORCH OIL SPRAYER

(-0.3)

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