Philosophy of Control For Complex Logics

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CHAPTER # 4
PHILOSOPHY OF CONTROL
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TABLE OF CONTENT
1.0
PREFACE............................................................................................................4
Scope................................................................................................................................ 4
Legend.............................................................................................................................. 4
2.0
OVERALL PLANT CONTROL PHILOSOPHY...................................................5
3.0
COMPLEX CONTROL SYSTEMS.....................................................................11

3.1
Feed Surge Drum (99-D-02) Pressure Control (PIC-1204).................................11
3.2
Feed Surge Drum Level Control (LIC-1205, HS-1206).......................................13
3.3
Make-up Gas Compressor (99-C-01A) Suction Pressure Control (PIC-1402/

1328/PY-1328).......................................................................................................15
3.4
Make-up Gas Compressor (99-C-01B) Suction Pressure Control (PIC-1602/

1527/PY-1527).......................................................................................................18
3.5
HDT Reactor Effluent Stripper Feed Temperature Control (TIC-1710).............21
3.6
HDF Reactor Effluent Temperature Control (TIC-1702).....................................24
3.7
HDT Reactor Charge Heater Outlet Temperature Control (TIC-1807)..............26
3.8
HDT Reactor Temperature Control (TIC-2019/2012/2014/2016)........................28
3.9
MSDW Feed Differential Pressure Control (PDIC-2102)....................................31
3.10 Reactor Loop Pressure Control (PIC-3208/HS-3212/FIC-3202/FIC-2106).........32

3.11 Lean Amine Temperature Control (DTIC-2308)..................................................35
3.12 Wash Water Surge Drum (99-D-13) Pressure Control (PIC-2401).....................37
3.13 HDF Feed Temperature Control (TIC-2502)........................................................39
3.14 MSDW Charge Heater Outlet Temperature Control (TIC-2607).........................41
3.15 MSDW Reactor Temperature Control (TIC-2808/2811/2814).............................43
3.16 HDF Reactor Temperature Control (TIC-2903/2902)..........................................46
3.17 HTS OVHD/Recycle Gas Exchanger (99-E-07), Recycle Gas Outlet
Temperature Control (TIC-3002).........................................................................49
3.18 HTS Liquid/Frac. Bottom Exchanger (99-E-14A/B), Product Stripper Feed
3.19 Product Stripper level Control/Flow Control to Vac. Frac. Charge Heater 99-F03 LIC-3303/FIC-3302/FIC-3304)..........................................................................53
3.20 Vac. Frac. Charge Heater Outlet Temperature Control (TIC-3505)...................55
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3.21 Feed/Frac. Bottom Exchanger (99-E-01A/B), Raffinate Feed Temperature

Control (TIC-4103)...............................................................................................58
3.22 Warm Feed/Frac. Bottom Exchanger (99-E-17A/B), Dewaxed Oil Outlet
3.23 Vacuum Frac. Pumparound Return Temperature Control (TIC-4201)..............62
3.24 Amine Degassing Drum (99-D-14) Pressure Control (PIC-4709)......................64
3.25 Sour Water Degassing Drum (99-D-15) Pressure Control (PIC-4704)..............66
3.26 Heater (99-F-01) Damper Control (PIC-1805/HIC-1805/HS-1810)......................68
3.27 Dewaxed Oil Product Cooler (99-AFC-06) Temperature Control (TIC-4104)....71
3.28 Product Stripper Overhead Accumulator (99-D-10) Level Control (LIC3410/FIC-3404A/FIC-3404B)................................................................................73
3.29 Vacuum Frac. Overhead Accumulator (99-D-11) Level Control (LIC-3902/FIC4104A/FIC-4104B)................................................................................................75
1
3.30 Vacuum Frac. Overhead Temp Control (99-T-05), Reflux Control (TIC-3702/FIC3703)..................................................................................................................... 78
3.31 Heavy Distillate Stripper (99-T-07) Level Control (LIC-3801)............................80

3.32 LPG Vaporizer (99-D-26) Level Control (LIC-5901) / Pressure control (PIC-
1
1
1
4.0
5904)..................................................................................................................... 82
3.33 Sour Water Degassing Drum (99-D-15) Level Control (LIC-4701)....................84
3.34 Wash Water Flow Control (FIC-2401 / FIC-2101) for Wash water Column (99-T03) and Hot Stripper OVHD Cooler (99-AFC-01)................................................86
PUMP AUTO START/STOP CONTROL SYSTEM............................................89

4.1
Auto Start /Stop System (I-49) for Closed Blowdown System Pump (99-P18A/B)................................................................................................................... 90
4.2
Auto Start /Stop System (I-201) for Backwash Effluent Transfer Pump (99-P40A/B)................................................................................................................... 92
5.0
4.3
Auto start /stop system (I-209) for Condensate transfer pump 99-P-21 A/B...94
CASE WISE ALARM & TRIP SUMMARY

Refer Attachment-1
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1.0 PREFACE
Scope
This narrative describes the plant control systems by instrumentation.
The purposes of this document are as follows:
(1) To explain control systems to those who are not familiar with instrumentation
symbols or functional logic diagrams.
(2) To define purpose and algorithm of each control system.
Complex control include split range control, cascade control and dual range control.
This document does not cover simple control loops.
Legend
DCS
Distributed Control System
PV
Process Value (Input) to DCS controller
SP
Set Point of Controller
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OVERALL PLANT CONTROL PHILOSOPHY

Oil Charge and Feed Surge Drum
Oil charge is received at the battery limits from tankage. An off-site pump provides
sufficient pressure to pass through low temperature heat exchanger (99-E-01A/B),
filtration (99-FIL-01), Coalescer (99-D-20), and enter the Feed Surge Drum (99-D-01).
Oil charge flow to the unit is controlled by 99-D-01 level which is cascaded to a flow
controller. A handswitch (HS-1206) is provided to allow selection of flow control to either
the normal unit charge controller (FIC-1201) or the special start-up feed (wetting and
sulfiding stock) control valve (LV-1205).
From the Feed Surge Drum, the feed is
boosted to high pressure by the Booster pump (99-P-43A/B) Feed Charge Pump (99-P02A/B) and sent to the Warm Feed / Fractionator Bottom Exchanger (99-E-17A/B), and
the Feed / HDT Reactor Effluent Exchangers (99-E-03A/B/C). The oil charge to the
HDT is on straight flow control.
Make-up Gas Compression
The Make-Up Hydrogen Gas to the unit is taken from a common refinery hydrogen
header and compressed in the Make-up Gas Compressor (99-C-01 A/B). Hydrogen is
available at unit B/L at 20-22 kg/cm2g. Compressor suction pressure is controlled at 20
kg/cm2g by means of PV-1381. The Make-Up Gas is then sent to the HDT Reactor
Effluent Stripper (99-T-01), where it is used to strip H2S and NH3 from the HDT effluent
stream. The Make-Up Gas to 99-T-01 is under flow control. If the supply gas rate
exceeds the set point on the flow controller to the HDT Effluent Stripper, a bypass valve
opens to pass additional hydrogen around the tower - diverted to inlet of the HDT
Stripper Overhead/Treat Gas Exchangers (99-E-04A/B). Recycle Gas is also used for
stripping the HDT Effluent in 99-T-01, which is on a separate flow controller.
HDT Reactor Temperature Control
The HDT Reactor temperature is controlled by the Charge Heater firing rate, and by the
inlet and inter-bed quench flow rates. The HDT Reactor consists of four beds of catalyst,
to limit the overall exotherm in the HDT. Two thirds of the expected exotherm is
eliminated by means of quench to the outlet of the first, second, and third beds. The
quench gas enters on flow control reset by bed inlet and/or outlet temperature. An
additional quench gas connection is provided to the inlet of the reactor for fast trim
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temperature control, if required during an upset condition, and for use in controlling the
wetting exotherm on startup. Both Treat Gas and Quench Gas to the HDT Reactor is
supplied from the Recycle Gas Compressor (99-C-02A/B).
HDT Effluent Stripper
The HDT Effluent Stripper (99-T-01) removes H2S and NH3 from the HDT effluent
stream with fresh incoming make-up hydrogen. The stripper can function through a
reasonable temperature range but will operate close to 180-190C. Control of the inlet
temperature is accomplished by bypassing feed oil around the Feed / HDT Reactor
Effluent Exchangers (99-E-03A/B/C). Stripped, hydrotreated liquid from the 99-T-01 is
normally sent on flow control (reset by level) to the MSDW Reactor Feed/ HDF Effluent
Exchangers (99E-02A/B/C). The HDT Effluent Stripper contains a large liquid inventory
to ensure stable operation of the MSDW Charge Heater and Reactor.
The overhead gas phase from the Hydrogen Stripper is exchanged with Treated Gas in
99-E-04A/B, further cooled in 99-AFC-01 and 99-E-05 before being flashed in the HDT
Low Temperature Separator (99-D-02). The vapors from this vessel are then scrubbed
(cleaned) of H2S (99-T-02) and NH3 (99-T-03), and sent to 99-E-04A/B as Treated Gas
to the MSDW/HDF Reactors.
Gas Scrubbing
Hydrogen-rich gas from the Hydrogen Stripper is cooled (99-E-04A/B / 99-AFC-01 / 99E-05), and gas-liquid separation occurs at the HDT Low Temperature Separator (99-D02). The vapor phase leaving 99-D-02 is sent to HP Amine Absorber KO Drum (99-D23), then scrubbed in the HP Amine Absorber Tower (99-T-02) and then to an HP Amine
KO Drum (99-D-03) and to the Water Wash Tower (99-T-03) to remove H2S and NH3.
The sour hydrogen gas should be cooled below the incoming lean amine and wash
water temperatures to reduce the possibility of condensing hydrocarbons in the amine
solution (rich amine); and should be no higher than 50C leaving 99-T-03 to keep the
water partial pressure in the Treated Gas below the allowable limit. Small, steam heater
(99-E-16) is provided to heat the entering lean amine. Wash water is basically a clean
condensate received from OSBL under level control. It is cooled down in BFW cooler
(99-E-18) and then pumped by HP wash water pump (99-P-10 A/B). Wash water
temperature to wash water tower is maintained at or below 40C by wash water cooler
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(99-E-39). Lean amine and wash water flow rates to their respective towers are both on
simple flow control.
MSDW and HDF Reactor Temperature Control
The control philosophy for the MSDW Reactor is identical to that of the HDT Reactor.
The MSDW reactor temperature is controlled by adjusting the furnace firing rate. The
MSDW Reactor (99-R-02) consists of three bed of catalyst, to control the overall
exotherm. The majority of the expected (gross) exotherm is eliminated by means of
Recycle Gas quench to the outlet of the first and second beds. The quench gas enters
on flow control (reset by bed inlet / outlet temperature). An additional quench gas
connection is provided to the inlet of the reactor for fast trim temperature control during
an upset condition and for use in controlling the wetting exotherm on start-up.
The HDF Reactor (99-R-03) exotherm is expected to be negligible in normal operation.
The HDF inlet temperature is controlled through bypassing of MSDW Feed around the
99-E-06A/B/C. The HDF Reactor consists of two beds of catalyst. The inlet to each bed
is equipped with hydrogen quench connections. The quench hydrogen to the first bed
enters the reactor inlet line on flow control (reset by either reactor inlet temperature) and
provides trim temperature control and for the bed wetting exotherm during the initial
start-up. An additional quench injection point is provided at the inlet to the second bed
for similar reasons.
Product Separator Temperature Control
HDF Reactor effluent is sent to the MSDW Reactor Feed/HDF Effluent Exchanger (99E-02A/B/C). This exchanger will be in use during end-of-run (EOR) conditions; but at
start-of-run (SOR), the duty is expected to be near zero. The HDF Reactor effluent
temperature leaving the exchanger is controlled by bypassing oil feed around the
exchanger. The intent of this is to provide a controlled temperature to the High
Temperature Separator [HTS] (99-D-04). Separator liquid product is discharged on flow
control reset by drum level to the HTS Liquid / Fractionator Bottoms Exchanger (99-E14A/B) and then to the Product Stripper tower (99-T-04). HTS vapor is cooled by
exchange with the Treated Gas (99-E-07), then air-cooled (99-AFC-02), then watercooled (99-E-08) and sent to the Low temperature Separator (99-D-05). There is no
temperature control on the 99-D-05 inlet, as maximum cooling is desired to for Recycle
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Gas purity. An additional amount of light hydrocarbon will be condensed in this drum,
which is sent on flow control reset by level where it combines with the light
hydrocarbons condensed in the HDT Low Temperature separator (99-D-02) and the
combined stream is heated by exchange with Dewaxed Lube Product (99-E-15), before
entering 99-T-04.
In order to protect against a high-pressure blowthrough of gas from the separators to
the fractionation section, both 99-D-04 and 99-D-05 separators are equipped with lowlevel switch interlocks. These interlocks operate a chopper valve and act to close the
product flow control valves by means of air-activated solenoids located on the air supply
to the valves.
Recycle Gas and Unit Pressure Control
Make-Up Hydrogen Gas is injected into the unit at the HDT Effluent Stripper as
described above. In order to maintain Recycle Gas hydrogen purity, it is necessary to
continuously purge a small portion of gas from the unit. The purge gas stream is taken
from the Recycle Compressor Suction KO Drum (99-D-06) overhead line. The unit
pressure controller is also located on the Recycle Compressor Suction KO Drum. The
pressure control signal from PIC-3208 goes to a hand switch (99-HS-3212) to control
either the Make-Up Gas rate or the unit purge gas rate. Once selected, the other
remains left on straight flow control. The unit was designed with a purge allowance of
2% of the Recycle Gas Rate. The make-up hydrogen requirements are minimized when
setting the purge gas rate at some minimum value. This allows the pressure controller to
bring in make-up hydrogen as required to maintain unit pressure.
For stable operation of MSDW reactor it is necessary to have stable HDT effluent
stripper operation. Hence it is preferred to have constant make-up as flow rate to 99-T01 and reactor section pressure is controlled by varying purge rate.
HP Stripper Section
The High Pressure Stripper is a steam stripped column designed to remove naphtha
and lighter boiling components from the liquid product stream. There is no external heat
source for this column. Vapor traffic is generated solely from the sensible heat of the
feed. Stripping steam is introduced on flow control to the bottom of the HP Stripper.
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The amount of naphtha product produced is small. The endpoint of the naphtha is
controlled by the tower top temperature, which resets the reflux rate. Pressure control
of the tower is accomplished by throttling the vapor product, which is sent to Refinery
Fuel Gas Header. The amount of reflux can be controlled somewhat by regulating the
High Temperature Separator Temperature as described earlier. The Naphtha endpoint
and degree of stripping will in turn influence the flashpoint of the distillate product in the
Vacuum Fractionator.
Stripped liquid product from the bottom of the HP Stripper is sent on flow control (reset
by level) to the Vacuum Fractionator Charge Heater (99-F-03). The stripper contains a
large liquid inventory to ensure stable operation of the Heater. As 99-F-03 is two pass
furnace, flow is equally divided between two passes by individual flow controllers, which
are reset by column level.
Vacuum Fractionation Section
The Vacuum Fractionation Section consists of four vessels, the Vacuum Fractionator
(99-T-05), the Dewaxed Oil Vacuum Dryer (99-T-06), the Heavy Distillate Stripper (99-T07) and the Heavy Distillate Vacuum Dryer (99-T-08). The Vaccum Fractionator and
Dewaxed Oil Vacuum Dryer are stacked vessels, as are the Heavy Distillate Stripper
and Heavy Distillate Vacuum Dryer. Bottoms product from the HP Stripper is sent on
flow control (reset by level) to the Vacuum Fractionator Charge Heater (99-F-03). The
feed is brought to the desired temperature on heater outlet temperature control, which
resets the fuel gas pressure to the burners, and is sent to the Post-Vacuum Fractionator
flash zone.
High-Pressure stripping steam is introduced on flow control to the bottom of the Vacuum
Fractionator. There are four packed sections in the tower. The top two beds and the
bottom bed are fractionating beds and the third bed is in pumparound service. Vapor
from the top of the fractionator column is sent to an air-cooler (99-AFC-03A/B/C/D) and
then to the Vacuum Fractionator Overhead Accumulator (99-D-11).
The overhead
vapors from 99-D-11 are sent to the Vacuum System, which is a vendor package
consisting of multiple-stage steam ejectors and water coolers and a Condensate
Receiver. Any non-condensable passing through the ejectors are combined with any
Condensate Receiver vapors and sent to the Off Gas KO Pot (99-D-18) are used as fuel
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for 99-F-03. Any hydrocarbon liquid from the Condensate Receiver is pumped to 99-D11 inlet. Any sour water is pumped to the Sour water Degassing Drum (99-D-15).
The hydrocarbons that have condensed in 99-D-11 are pumped (99-P-09 A/B) under
level control and the stream split into two parts. The first is returned to the Vacuum
Fractionator as top reflux under flow control that is cascaded to overhead temperature.
The second part is water-cooled (99-E-13) and leaves the unit as Light Distillate product
under flow control that is cascaded to the 99-D-11 level.
A heavy distillate product is withdrawn from below the second packed section, and
pressured to the Heavy Distillate Stripper (99-T-07). Flow to 99-T-07 is set by 99-T-07
bottoms level control. The distillate product is steam stripped to remove lighter distillate,
and sent to the Heavy Distillate Vacuum Dryer (99-T-08). Flow to the Dryer is controlled
by Dryer bottoms level control. The dry Heavy Distillate product is then pumped (99-P07 A/B), air-cooled (99-AFC-05A/B/C) on flow control and leaves the unit as Heavy
Distillate Product to storage. In this control scheme, the Heavy Distillate Product is
drawn on flow control, with the stripper and dryer bottom levels controlling the draw rate
from the Vacuum Fractionator. The endpoint of the heavy distillate product will be
determined by the product flow rate. A temperature indicator in the vapor space above
the heavy distillate draw gives an indication of this cutpoint.
Vacuum Fractionator (99-T-05) bottoms is sent on level control to the Dewaxed Oil
Vacuum Dryer (99-T-06), where the product is dried, then pumped (99-P-05 A/B),
exchanged with multiple unit streams (99-E-14, 99-E-15, 99-E-17A/B and 99-E-01A/B),
then air-cooled (99-AFC-06A/B), and sent to product storage on level control. The
cutpoint between the Heavy Distillate and the Dewaxed Oil is set by the draw rate of the
Heavy Distillate product. The front-end of the Heavy Distillate is controlled by the
Medium Distillate draw rate. Start-up lines are provided to allow the Heavy Distillate to
be diverted to the Dewaxed Oil, and the Dewaxed Oil to be recirculated back to the
Charge Surge Drum (99-D-01).
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COMPLEX CONTROL SYSTEMS
3.1
Feed Surge Drum (99-D-02) Pressure Control (PIC-1204)
20/01/2010
This specification should be read in conjunction with the following:

(1)
3.1.1
P&ID No.: 18-3188-D-99-01-1112A
Introduction
Raffinate feed from OSBL will be stored in Feed Surge Drum (99-D-01). Feed Surge
Drum (99-D-01), pressure is controlled by PIC-1204 to maintain positive suction
pressure at Booster pump (99-P-43A/B), which prevent cavitation and damage of these
pumps.
3.1.2 Simplified Block Diagram of Feed Surge Drum Pressure Control (PIC-1204)
Refer FIG. 1 on Sheet No 12.
3.1.3 Description
The pressure of Feed Surge Drum (99-D-01) is maintained at 2.0 kg/cm2g using
push/pull system with Fuel gas. The pressure is controlled by split range controller PIC1204. The output of the controller is split between PV-1204A on Fuel gas line from Fuel
Gas header and PV-1204B on the line to flare. Low pressure is made up by entering FG
through opening of PV-1204A, while high pressure is released by opening PV-1204B to
flare. The split range controller PIC-1204 is provided with a dead band of 5%
(adjustable), i.e. between 47.5% & 52.5% both valves would remain closed. This is done
to allow for normal fluctuations around the set point of pressure controller without
opening any of the valves thereby avoid the wastage of FG & reducing wear & tear of
control valves.
In addition to that, pressure controller will give low alarm (PAL-1204), as applicable, on
DCS.
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FROM 99-D-20
FEED
SPLIT RANGE
PIC
1204
Feed Surge Drum Level Control (LIC-1205, HS-1206)

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CONTROL (PIC-1204)
0%
TO 99-E-17
VIA 99-P-43A/B &99-P-02A/B
FEED
TO FLARE
FEED SURGE DRUM (99-D-01) PRESSURE
FIG.-1
SIMPLIFIED BLOCK DIAGRAM
99-D-01
PAL
F0
CONTROL VALVE OPENING %
FC
PIC-1204
PRESSURE INCREASE
CONTROLLER OUTPUT %
47.5% 50% 52.5%
FROM HEADER
FUEL GAS
04
PV
1204B
(52.5-100%)
- 12
PV
1204A
(0-47.5%)
100%
- SPLIT RANGE CONFIGURATION -
B
04
- 12
PV
PV
3.2
100%
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(1)
P&ID No.: 18-3188-D-99-01-1112
(2)
P&ID No.: 18-3188-D-99-01-1112A
3.2.1 Introduction
Raffinate feed from OSBL will be stored in Feed Surge Drum (99-D-01). Feed Surge
Drum (99-D-01), level is controlled by LIC-1205.
3.2.2 Simplified Block Diagram of Feed Surge Drum Level Control (LIC-1205, HS-1206)
3.2.3 Description
Feed to Feed Surge Drum (99-D-01) is controlled via the feedback set point from the
Surge Drum level Control LIC-1205. This signal then determines the opening of the
control valve FV-1201 during normal operation. During Presulfiding Operation, the Hand
Switch HS-1206 is utilized to switch the destination of the output set point to LV-1205, to
allow Presulfiding Liquid (start-up) oil flow to be controlled.
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FROM STORAGE
FLUSHING OIL &

PRESULFIDING
LIQUID
FROM STORAGE
FEED
LV
1205
FC
FT
1201
FIC
FC
1201
99-E-01A/B 99-FIL-01
FV
1201
FAL
SP
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99-D-01
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FEED SURGE DRUM (99-D-01) LEVEL

CONTROL (LIC-1205,HS-1206)
FIG-2
99-D-20
NORMAL OPERATION
START-UP
LIC
1205
LAL
LAH
HS
TO 99-E-17
VIA 99-P-43A/B
& 99-P-02A/B
FEED
1206
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3.3
Make-up Gas Compressor (99-C-01A) Suction Pressure Control (PIC-1402/
1328/PY-1328)
(1)
P&ID No.: 18-3188-D-99-01-1113
(2)
P&ID No.: 18-3188-D-99-01-1114
3.3.1 Introduction
The Make-up Hydrogen Gas to the unit is taken from a common refinery hydrogen
header and compressed in the Make-up Gas Compressor (99-C-01A/B). It is desirable
to maintain compressor suction pressure 20 kg/cm2g. Since B/L pressure can vary from
20-22 kg/cm2g, pressure controller PIC-1381 is provided at B/L to maintain pressure at
20 kg/cm2g. This is required as set pressure of PSV at compressor suction is 22
kg/cm2g which otherwise would lead to loss of Hydrogen to flare if B/L pressure goes to
22 kg/cm2g. A spillback stream from the compressor third stage discharge to the first
stage suction, with cooling in the Makeup Compressor Spillback Cooler (99-E-11A), is
provided to control the hydrogen makeup rate to the unit. Make-up hydrogen to reactor
is drawn on flow control and the demand was change with capacity. Make-up
compressor is provided with step capacity control. The mismatch between MUG
capacity and reactor demand is met by spill back.
3.3.2 Simplified Block Diagram of Make-up Gas Compressor (99-C-01A) Suction Pressure
Control (PIC-1402/PIC-1328/PY-1328)
3.3.3 Description
The output of the controllers PIC-1402 (discharge pressure controller) and PIC-1328
(suction pressure controller) shall be used by computation block (PY-1328), which is
nothing but a low selector switch to calculate amount spillback stream from the
compressor third stage discharge to the first stage suction.
In this scheme both discharge (PIC-1402) and suction (PIC-1328) outputs of controllers
are used. Priority is given to the lower value of PIC-1402 and PIC-1328 is used to
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control spill back flow. This configuration always ensures suction pressure at the
compressor & thereby avoid serious trips, while ensuring constant discharge pressure.
In addition to that, pressure controller will give high/low alarm (PAH-1328/PAL-1328), as
applicable, on DCS.
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PREPARED BY
RMB
MAKE UP GAS FROM OSBL
PV
1381
PAL
PAH
99-D-07A
PIC
1328
PIC
1381
CHECKED BY
RHD
NC
1STSTAGE
99-C-01A
SWS
SWR
SWS
SWR
99-D-08A
99-E-09A
99-E-11A
NC
PV
1402
PY
FO
1328
2NDSTAGE
99-D-09A
99-E-10A
NC
99-C-01A
Chapter # 4
Page 17 of 95
PIC
1402
TO 99-T-01
MAKE-UP GAS COMPRESSOR (99-C-01A) SUCTION

PRESSURE CONTROL (PIC-1402/1328/PY-1328)
FIG.3
RD
3 STAGE
99-C-01A
SWS
SWR
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3.4
Make-up Gas Compressor (99-C-01B) Suction Pressure Control (PIC-1602/
1527/PY-1527)
(1)
P&ID No.: 18-3188-D-99-01-1115
(2)
P&ID No.: 18-3188-D-99-01-1116
3.4.1 Introduction
The Make-up Hydrogen Gas to the unit is taken from a common refinery hydrogen
header and compressed in the Make-up Gas Compressor (99-C-01A/B). It is desirable
to maintain compressor suction pressure 20 kg/cm2g. Since B/L pressure can vary from
20-22 kg/cm2g, pressure controller PIC-1381 is provided at B/L to maintain pressure at
20 kg/cm2g. This is required as set pressure of PSV at compressor suction is 22
kg/cm2g which otherwise would lead to loss of Hydrogen to flare if B/L pressure goes to
22 kg/cm2g. A spillback stream from the compressor third stage discharge to the first
stage suction, with cooling in the Makeup Compressor Spillback Cooler (99-E-11B), is
provided to control the hydrogen makeup rate to the unit. Make-up hydrogen to reactor
is drawn on flow control and the demand was change with capacity. Make-up
compressor is provided with step capacity control. The mismatch between MUG
capacity and reactor demand is met by spill back.
3.4.2 Simplified Block Diagram of Make-up Gas Compressor (99-C-01B) Suction Pressure
Control (PIC-1602/1527/PY-1527)
3.4.3 Description
The output of the controllers PIC-1602 (discharge pressure controller) and PIC-1527
(suction pressure controller) shall be used by computation block (PY-1527) , which is
nothing but a low selector switch to calculate amount spillback stream from the
compressor third stage discharge to the first stage suction.
In this scheme both discharge (PIC-1602) and suction (PIC-1527) outputs of
controllers are used. Priority is given to the lower value of PIC-1602 and PIC-1527 is
used to control spill back flow. This configuration always ensures suction pressure at
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the compressor & thereby avoid serious trips, while ensuring constant discharge
pressure.
In addition to that, pressure controller will give high/low alarm (PAH-1527/PAL-1527),
as applicable, on DCS.
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PREPARED BY
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MAKE UP GAS FROM OSBL
PV
1381
PAH
PAL
99-D-07B
PIC
1527
PIC
1381
CHECKED BY
RHD
M
NC
1STSTAGE
99-C-01B
SWS
SWR
SWS
SWR
99-D-08B
99-E-09B
99-E-11B
NC
PV
1602
PY
FO
1527
2NDSTAGE
99-D-09B
99-E-10B
NC
PIC
1602
TO 99-T-01
MAKE-UP GAS COMPRESSOR (99-C-01B) SUCTION

PRESSURE CONTROL (PIC-1602/1527/PY-1527)
FIG.4
RD
3 STAGE
99-C-01B
99-C-01B
SWS
SWR
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Chapter # 4
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3.5
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HDT Reactor Effluent Stripper Feed Temperature Control (TIC-1710)

(1)
P&ID No.: 18-3188-D-99-01-1117
3.5.1 Introduction
The HDT Reactor Effluent is cooled against the combined oil feed plus recycle gas in
the Feed / HDT Reactor Effluent Exchanger (99-E-03A/B/C). The partially cooled
effluent stream is phase-separated in HDT Reactor Effluent Stripper (99-T-01).
Temperature control of the stripper is maintained by bypassing oil and treat gas on the
feed side of the Feed / HDT Reactor Effluent Exchanger (99-E-03A/B/C). HDT Reactor
Effluent Stripper Feed temperature is controlled by TIC-1710.
3.5.2 Simplified Block Diagram of HDT Reactor Effluent Stripper Feed Temperature
Control (TIC-1710)
3.5.3 Description
HDT Reactor Effluent Stripper Feed temperature controller TIC-1710 is split range
controller. The output of the controller is split between TV-1710A/B (0-50%) located on
Feed inlet and bypass line around the exchanger (99-E-03A/B/C) respectively and TV1710C/D (50-100%) located on recycle gas at the feed inlet and outlet line around the
exchanger (99-E-03A/B/C) respectively.
In 0-50% range, the control is obtained by adjusting feed flow to exchanger. With
increase in effluent temperature, the bypass valve TV-1710B will start to close & the
inlet valve TV-1710A will start to open allowing more oil flow to pass through the
exchanger thereby increasing heat transfer. Feed valve TV-1710A is provided with
mechanical min. stop (40%) to avoid exchanger running dry & thereby preventing
damage to it. In this range recycle gas valve TV-1710D is fully open allowing the max.
gas to be bypassed.
In 50-100% output range, the control is obtained by adjusting recycle gas flow to
exchanger. With increase in effluent temperature, the bypass valve TV-1710D will start
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to close & the inlet valve TV-1710C will start to open allowing more recycle gas flow to
pass through the exchanger thereby increasing heat transfer. Inlet valve TV-1710C is
provided with mechanical min. stop (40%) to avoid exchanger running dry & thereby
preventing damage to it. In this range oil feed valve TV-1710A is fully open allowing the
max. oil flow through the exchanger & no bypass is there.
In addition to that, temperature controller will give high alarm (TAH-1710), as applicable,
on DCS.
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Chapter # 4
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HOT IN
TO 99-T-01
HOT OUT
HDT REACTOR EFFLUENT
FROM 99-R-01
HDT REACTOR EFFLUENT
1710
TIC
TAH
TV
1710A
TV
1710B
FO
FC
MIN.
STOP
TV
1710C
Chapter # 4
Page 23 of 95
FC
TEMPERATURE CONTROL (TIC-1710)
HDT REACTOR EFFLUENT STRIPPER FEED
FIG. 5
FO
MIN.
STOP
TV
1710D
DUAL ACTING
(50-100%)
(0-50%)
COLD IN
99-E-03A/B/C
COLD OUT
DUAL ACTING
0%
GAS
FROM 99-E-07
RECYCLE GAS
FROM 99-E-17A/B
FEED
TO 99-F-01
FEED
TEMPERATURE INCREASE
50%
CONTROLLER OUTPUT %
B
10
OIL
TIC-1710
D
10
-17
TV
MIN. STOP
(40%)
100%
TV
-17
10
C
100%
71
0A
TV
-1
-17
TV
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3.6
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HDF Reactor Effluent Temperature Control (TIC-1702)

(1)
3.6.1
P&ID No.: 18-3188-D-99-01-1117
Introduction
HDF Reactor effluent is sent to the MSDW Reactor Feed/HDF Reactor Effluent
Exchanger (99-E-02A/B/C).
The HDF Reactor effluent temperature leaving the
exchanger is controlled by TIC-1702 by bypassing oil feed around the exchanger. The
intent of this is to provide a controlled temperature to the High Temperature Separator
(99-D-04), which set the feed temperature to the fractionation section.
3.6.2
Simplified Block Diagram of HDF Reactor Effluent Temperature Control (TIC-1702)

3.6.3
Description
HDF outlet temperature controller TIC-1702 is dual acting controller. TIC-1702 controls
HDF outlet temperature from 99-E-02A/B/C through control valves TV-1702A and TV1702B by controlling the relative flows through exchanger 99-E-02A/B/C and its bypass.
When the HDF outlet temperature from 99-E-02A/B/C increases than the set point, TIC1702 will pass more flow through the 99-E-02A/B/C, i.e. bypass valve TV-1702B starts
to close and Inlet valve TV-1702A will start to open. Reverse action will be followed
when the HDF outlet temperature from 99-E-02A/B/C decreases, i. e. start to open 99E-02A/B/C bypass valve TV-1702B and start to close the valve TV-1702A. In addition to
that feed valve TV-1702A is provided with mechanical min. stop.
on DCS.
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HOT IN
TO 99-D-04
HOT OUT
HDF REACTOR EFFLUENT
FROM 99-R-03
TIC
1702
DUAL ACTING
TAH
TV
1702A
FO
MIN.
STOP
TV
1702B
Chapter # 4
Page 25 of 95
FC
FIG. 6
COLD IN
99-E-02A/B/C
COLD OUT
FROM 99-T-01
STRIPPER MSDW FEED
TO 99-E-06A/B/C
STRIPPER MSDW FEED
0%
MIN. STOP
(40%)
100%
2A
70
-1
TV
CONTROLLER OUTPUT %
TV
-1
70
2B
TIC-1702
- DUAL RANGE CONFIGURATION -
100%
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3.7
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HDT Reactor Charge Heater Outlet Temperature Control (TIC-1807)

(1)
P&ID No.: 18-3188-D-99-01-1118
(2)
P&ID No.: 18-3188-D-99-01-1119
3.7.1 Introduction
HDT Reactor Charge Heater (99-F-01) is fired by Fuel gas/LPG to heat the feed. The
flow of Fuel gas/LPG to furnace is controlled by Furnace Feed outlet temperature
controller TIC-1807 (located at the outlet of furnace 99-F-01) through pressure controller
PIC-1901 (located on fuel gas supply line before furnace).
3.7.2 Simplified Block Diagram of HDT Reactor Charge heater Outlet Temperature
Control (TIC-1807)
3.7.3 Description
Furnace Feed outlet temperature controller TIC-1807 (located at the outlet of furnace
99-F-01) works in cascade with pressure controller PIC-1901 (located on fuel gas
supply line to furnace). If the outlet temperature of Furnace decreases, TIC-1807 will
increase the set point of PIC-1901, resulting in more opening of PV-1901 &
corresponding high flow of fuel gas to the burner. If the outlet temperature increases, the
actions will be vice versa.
In addition to that, temperature controller will give high and low temperature alarm (TAH1807 & TAL-1807) and pressure controller will give high and low flow alarm (PAH-1902
& PAL-1902), as applicable, on DCS.
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FROM 99-D-12
FUEL GAS
TO 99-R-01
FEED
1901
PV
FC
SP
1901
PIC
PAL
PAH
TIC
TAL
TAH
FURNACE OUTLET
Chapter # 4
Page 27 of 95
HDT REACTOR CHARGE HEATER OUTLET

FIG. 7
1807
99-F-01
BURNER
99-F-01
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3.8
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HDT Reactor Temperature Control (TIC-2019/2012/2014/2016)

(1)
3.8.1
P&ID No.: 18-3188-D-99-01-1120
Introduction
In the HDT Reactor (99-R-01), most of the sulfur and nitrogen contaminants in the oil
feed are converted, in the presence of hydrogen in the recycle gas, to hydrogen sulfide
and ammonia and also saturates most of the unsaturates. This hydrotreating step aims
at preparing the feed for the dewaxing reaction stage as well as meeting product
specifications. Temperature required to carry out the hydrotreating reactions, which
increases gradually throughout the run as the catalyst ages, is controlled by adjusting
99-R-01 feed inlet temperature through manipulation of 99-F-01 firing rate, and by the
inlet and inter bed quench flow rates. The HDT Reactor consists of four beds of catalyst.
To limit the overall exotherm in the HDT, two thirds of the expected exotherm is
eliminated by means of quench to the outlet of the first, second, and third beds. The
quench gas enters on flow control reset by averaged bed inlet and averaged bed outlet
temperature. An additional quench gas connection is provided to the inlet of the reactor
for fast trim temperature control, if required during an upset condition, and for use in
controlling the wetting exotherm on startup.
Reactor temperature control is vital to good catalyst performance and should be
controlled to + / - 0.50C. Depending upon the age of the catalyst, feed quality, feed rate
and the desired denitrogenation, desulphurization and conversion, a target Weighted
Average Bed Temperature (WABT) must be maintained for each bed.
Further, the
temperature rise across each bed must be kept below a set target; this is especially
important during runaway reaction.
3.8.2
Simplified Block Diagram

2019/2012/2014/2016)
of
HDT
Reactor
Temperature
Control
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(TIC-
3.8.3
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Description
For each catalyst bed, inlet (A-H eight thermocouples in total) and outlet (A-H eight
thermocouples in total) temperatures are measured. Bed Inlet (except top bed) and
Outlet (except bottom bed) Tis are averaged in a calculation (TY) block. The target bed
outlet temperature is entered by operator based on the operating case and catalyst run
length. Averaged out bed outlet temperature is compared to the operator entered set
point and this difference is used to reset the bed inlet target temperature with a time
delay of 5 min. (adjustable). The bed inlet target temperature is compared to the actual
average inlet temperature (every 1 min., adjustable). The difference between these two
values is used to reset quench flow.
For top bed reactor inlet temperature (TI-2019) is used instead of bed top temperature
(TI-2010 A-H). For bottom bed the reactor outlet temperature (TI-2018) is used for
control purpose instead of bed bottom temperatures (TI-2017 A-H).
3.8.4
Definitions
For the HDT Reactor 99-R-01, there are 4 quench gas flows:
Bed
Inlet
Bed
Temp.
Average
Calculation
Outlet Bed
Temp.
Average
Calculation
TI-2010
(A-H)
TI-2012
(A-H)
TI-2014
(A-H)
TI-2016
(A-H)
--
TI-2011 (AH)
TI-2013
(A-H)
TI-2015
(A-H)
TI-2017
(A-H)
2
3
4
TY-2012
TY-2014
TY-2016
Bed
Inlet
Temp.
Controller
TIC-2019
Flow
Controller
TY-2011
Bed
Outlet
Temp.
Controller
TIC-2011
TY-2013
TIC-2013
TIC-2012
FIC-2002
TY-2015
TIC-2015
TIC-2014
FIC-2003
--
TIC-2018
TIC-2016
FIC-2004
Feed to reactor: TI-2019

Reactor Effluents: TI-2018
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FIC-2001
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SP
FIC
2001
FV
FT
2001
FO
TAHH
PV
TI
TAH
TIC
2019
2019
2010
FROM 99-F-01
TAHH
TAH
TAL
TO 99-F-01
/F-02 TRIP
A-H
TIC
2011
BED-1
PV
FIC
TAHH
TAH
TI
2011
SP
2002
/n
TY
2011
A-H
BED BOTTOM
FT
2002
FV
2002
99-R-01
FO
BED TOP
TI
BED-2
2012
TAHH
TAH
A-H
/n
PV
TY
2012
TIC
2012
TAHH
TAH
TAL
FIC
TO 99-F-01
/F-02 TRIP
BED
BOTTOM
TI
2013
TAHH
TAH
A-H
SP
2003
/n
PV
TY
2013
FV
TIC
2003
FT
FIG.8
TI
BED TOP
HDT REACTOR (99-R-01)TEMPERATURE

CONTROL (TIC-2019/2012/2014/2016)
2001
2003A/B
2013
FO
BED TOP
TI
BED-3
2014
TAHH
TAH
A-H
/n
PV
TY
2014
TIC
TAHH
TAH
2014
TAL
FIC
SP
2004
I
TO 99-F-01
/F-02 TRIP
BED
BOTTOM
TI
2015
TAHH
TAH
A-H
/n
PV
TY
2015
FV
TIC
2004
2015
FT
2004
FO
BED TOP
TI
BED-4
2016
A-H
TO 99-F-01
/F-02 TRIP
TI
2017
PV
TY
2016
3
BED
BOTTOM
TI
/n
TAHH
TAH
TAHH
TAH
PV
A-H
TIC
TIC
2018
2016
TAL
TAHH
TAH
2018
FROM 99-C-02A/B
TO 99-E-03 A/B/C
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3.9
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MSDW Feed Differential Pressure Control (PDIC-2102)

(1)
P&ID No.: 18-3188-D-99-01-1121
3.9.1 Introduction
The HDT Reactor Effluent Stripper (99-T-01) strips H2S and NH3 from the HDT effluent
stream by striping with hydrogen makeup gas from the Make-up Gas Compressor (99C-01A/B) and additional recycle gas from Recycle Gas Compressor (99-C-02A/B). The
liquid stream from 99-T-01 is heated in 99-E-02A/B/C and then combined with treat gas
from 99-T-03 (at the upstream of 99-E-06A/B/C) which is heated against MSDW reactor
effluent in the MSDW Feed / Effluent Exchanger (99-E-06A/B/C).
The Pressure Differential Controller is required to maintain a high enough differential
pressure between 99-T-01 and treated recycle hydrogen from the wash water tower (99T-03) to ensure that liquid flows to 99-E-06A/B/C.
3.9.2 Simplified Block Diagram of MSDW Feed Differential Pressure Control (PDIC-2102)
3.9.3 Description
The Pressure Differential Controller, PDIC-2102 receives signal from PT-2102A which
measure pressure of 99-T-01 Overhead. This signal is then compared with signal from
PT-2102B which measures the pressure of treated gas from wash water tower (99-T-03)
to upstream of shell side inlet of HDT stripper Overhead/Treat Gas Exchanger (99-E04A/B). Based on these values, the controller will then act to manipulate the control
valve located at the treated gas stream to ensure a pressure gradient is maintained
between 99-T-01 and 99-E-06A/B/C. By maintaining this, the bottoms stream will be
able to flow to 99-E-06A/B/C and MSDW Reactor (99-R-02).
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3.10
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Reactor Loop Pressure Control (PIC-3208/HS-3212/FIC-3202/FIC-2106)

(1)
P&ID No.: 18-3188-D-99-01-1121
(2)
P&ID No.: 18-3188-D-99-01-1132
3.10.1 Introduction
Reaction loop is a closed loop system and the system pressure is maintained at single
location i.e. at recycle gas suction by means of PIC-3208. In the reaction, hydrogen is
consumed & thereby system pressure will drop down. To maintain reaction pressure
fresh make-up H2 is required which is supplied by means of Make-up Gas Compressor
(99-C-01A/B). Also it is essential to maintain purity of recirculation gas. To maintain this
a purge steam is taken from FV-3202 located at recycle gas compressor suction.
The reaction can be controlled in two ways
1)
Constant H2 make-up & variable purge
2)
Variable H2 make-up & constant purge
For stable operation of MSDW reactor it is necessary to have stable HDT effluent
stripper operation. Hence it is preferred to have constant make-up as flow rate to 99-T01 and reactor section pressure is controlled by varying purge rate.
3.10.2 Simplified Block Diagram of Reactor Loop Pressure Control (PIC-3208/HS3212/FIC-3202/FIC-2106)
3.10.3 Description
HS-3212 allows Reactor Loop Pressure Control as follow:
Fixed Make-up Gas (FIC-2106 set by operator) and variable Purge Gas (FIC3202 cascade with PIC-3208):
DCS operator shall select the destination of the signal from PIC-3208 to FIC-3202
with the help of Hand Switch HS-3212. The target Make-up Gas rate is selected
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by operator and the Pressure Controller, PIC-3208 controls the flow of purge gas
out of the unit via cascade control of FIC-3202/FV-3202.
Fixed Purge Gas (FIC-3202 set by operator) and variable Make-up Gas (PIC3208 cascade with FIC-2106):
DCS operator shall select the destination of the signal from PIC-3208 to FIC-2106
with the help of Hand Switch HS-3212.The output of the controller FIC-2106 shall
be used by computation block (FY-2102 and FY-2106) to give the set point to the
flow controllers (FIC-2102 and FV-2106 respectively). In 0-50% output range all
the make-up H2 is directed towards 99-T-01 & used as stripping gas. If the
requirement of H2 is higher (i.e. FIC-2106 output is >= 50%) to maintain reaction
operating pressure, then bypass valves FV-2106 will be opened. This is done to
avoid overloading of the stripper. The stripping Hydrogen valve is provided with a
soft higher limiter to limit opening of valve & avoid excess stripping H2 in 99-T-01.
Also the bypass valve FV-2106 is provided with low limiter (2% adjustable) to
keep the system live with small H2 flow through bypass loop. Recycle Gas can
also be used for stripping the HDT Effluent in 99-T-01, which is on a separate flow
controller FIC-2110. The output of the controller FIC-2102 and FIC-2110 shall be
used by computation block (FY-2110) to calculate the total amount of stripping gas
flow to the stripper (FI-2120).
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MAKE-UP H2
FROM 99-D-01
CHECKED BY
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FY
2106
99-C-01A/B
2102
FY
50-100%
FT
2106
2105
FI
99-P-02
2106
FIC
SP
0-50%
FT
2102
FV-2106
FT
1203
FIC
99-C-02A/B
FV-2102
PV 2102
FIC
99-E-17 A/B
SP
FV-1203
1203
FT
2110
99-E-07
TV-1710A
2120
FI
RECYCLE GAS
99-T-01
FT
2104
LT
2102
FIC
FV-2104
2104
SP
PDV-2102
99-E-02 A/B/C
99-D-03/T-03
99-D-23/T-02
99-E-05 (SS)
99-AFC-01
99-E-04 A/B (TS)
Chapter # 4
Page 34 of 95
99-E-08
99-D-05
99-AFC-02
99-E-07
99-D-04
99-R-03
99-E-02 A/B/C (TS)
99-E-06 A/B/C (TS)
99-R-02
99-F-02
99-E-06 A/B/C (SS)
50%
PT
3208
FT
3202
3208
PIC
FIC
3202
SP
3212
HS
PRESSURE INCREASE
CONTROLLER OUTPUT %
PURGE GAS
0%
FV-3202
LOW LIMITER
(2%)
FIC-2106
FV
-21
06
REACTOR LOOP PRESSURE

CONTROL (PIC-3208/HS-3212/FIC-3202/FIC-2106)
FIG.-9
PT
2102B
99-E-04 A/B
QUENCH ON
INDIVIDUAL FLOW CONTROL
FV-2110
2110
FIC
2110
FY
TOTAL
STRIPPING
GAS FLOW
99-E-03 A/B/C (TS)
99-R-01
99-F-01
99-E-03 A/B/C (SS)
PT
2102A
PDIC
2102
HIGH LIMITER
(X%)
FV
-21
02
100%
100%
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3.11
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Lean Amine Temperature Control (DTIC-2308)

(1)
P&ID No.: 18-3188-D-99-01-1123A
3.11.1 Introduction
HDT LTS OVHD vapor from 99-D-02 is routed to the HP Amine Absorber (99-T-02) and
then to the Water Wash Tower (99-T-03) for H2S and NH3 removal for recycle gas
purification. Lean Amine to the HP Amine Absorber is supplied from OSBL (ARU).
Cooler amine to HP Amine Absorber (99-T-02) lead to condensation of HC from gas
may cause foaming in absorber and hotter amine may cause increased water content in
OVHD vapors from HP Amine Absorber (99-T-02) to Water Wash Tower (99-T-03),
hence it is preferable that constant differential temperature is maintained between
amine and LTS OVHD vapor. Control of the Lean Amine temperature is accomplished
by Differential temperature controller DTIC-2308.
3.11.2 Simplified Block Diagram of Lean Amine Temperature Control (DTIC-2308)
3.11.3 Description
DTIC-2308 is a differential temperature controller. DTIC-2308 calculate the difference
between HDT LTS OVHD vapor temperature and HP Lean Amine Pump (99-P-11A/B)
discharge temperature. This differential temperature is used to reset the flow of LP
steam to Lean Amine heater (99-E-16) through control valve TV-2308.
When the differential temperature is more than desired differential temperature, DTIC2308 will pass less LP flow through the 99-E-16, i.e. valve TV-2308 starts to close.
Reverse action will be followed when the differential temperature is less than desired
differential temperature i. e. valve TV-2308 starts to open.
In addition to that, differential temperature controller will give low alarm (DTAL-2308), as
applicable, on DCS.
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HDT LTS OVHD VAPOUR

FROM 99-D-02
LEAN AMINE FROM ARU
LP CONDENSATE
LP STEAM
TV
2308
FC
99-E-16
TI
2321
TT
2308A
2308
DTIC
DTAL
TI
2302
TAL
TAH
99-D-23
20
99-T-02
Chapter # 4
Page 36 of 95
CONTROL (DTIC-2308)
LEAN AMINE TEMPERATURE
FIG.10
TAL
TAH
99-P-11A/B
TT
2308
TO T-04
TO 99-D-14
TO 99-D-03
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3.12
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Wash Water Surge Drum (99-D-13) Pressure Control (PIC-2401)

(1)
P&ID No.: 18-3188-D-99-01-1124A
3.12.1 Introduction
Wash water from OSBL will be stored in Wash Water Surge Drum (99-D-13) via BFW
Cooler(99-E-18). Wash Water Surge Drum (99-D-13), pressure is controlled by PIC2401 to maintain positive suction pressure of HP wash water pump (99-P-10A/B), which
prevent cavitation and damage of these pumps.
3.12.2 Simplified Block Diagram of Wash Water Surge Drum Pressure Control (PIC-2401)
3.12.3 Description
The pressure of Wash Water Surge Drum (99-D-13) is maintained at 2.0 kg/cm2g using
push/pull system with Fuel gas. The pressure is controlled by split range controller PIC2401. The output of the controller is split between PV-2401B on Fuel gas line from Fuel
Gas header and PV-2401A on the line to flare. Low pressure is made up by entering FG
through opening of PV-2401B, while high pressure is released by opening PV-2401A to
control valves.
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PREPARED BY
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FROM 99-E-18
BFW
PIC
CHECKED BY
RHD
TO 99-T-03
VIA 99-P-10A/B
WASH WATER
Chapter # 4
Page 38 of 95
PRESSURE CONTROL (PIC-2401)
WASH WATER SURGE DRUM (99-D-13)
FIG.-11
99-D-13
TO FLARE
0%
2401
F0
PIC-2401
PRESSURE INCREASE
CONTROLLER OUTPUT %
47.5% 50% 52.5%
SPLIT RANGE
FC
PV
2401A
(52.5-100%)
01
FROM HEADER
FUEL GAS
PV
2401B
(0-47.5%)
100%
- 24
PV
PV
- 24
01
100%
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3.13
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HDF Feed Temperature Control (TIC-2502)

(1)
P&ID No.: 18-3188-D-99-01-1125
3.13.1 Introduction
The effluent MSDW Reactor is sent to the HDF Reactor (99-R-03). It is first cooled
against MSDW Feed in MSDW Reactor Feed/Effluent Exchanger (99-E-06A/B/C).
Control of the HDF inlet temperature is accomplished by TIC-2502 by bypassing oil feed
around the exchanger.
3.13.2 Simplified Block Diagram of MSDW Reactor Effluent Temperature Control (TIC2502)
3.13.3 Description
HDF Feed temperature controller TIC-2502 is dual acting controller. TIC-2502 controls
HDF Feed temperature from 99-E-06A/B/C through control valves TV-2502A and TV2502B by controlling the relative flows through exchanger 99-E-06A/B/C and its bypass.
When the HDF Feed temperature from 99-E-06A/B/C increases than the set point, TIC2502 will pass more flow through the 99-E-06A/B/C, i.e. bypass valve TV-2502B starts
to close and Inlet valve TV-2502A will start to open. Reverse action will be followed
when the HDF Feed temperature from 99-E-06A/B/C decreases, i. e. start to open 99-E06A/B/C bypass valve TV-2502B and start to close the valve TV-2502A. In addition to
that feed valve TV-2502A is provided with mechanical min. stop.
In addition to that, temperature controller will give high alarm (TAH-2502), as applicable, on
DCS.
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Chapter # 4
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HOT IN
TO 99-R-03
HOT OUT
MSDW REACTOR EFFLUENT
FROM 99-R-02
MSDW REACTOR EFFLUENT
TIC
2502
DUAL ACTING
TAH
TV
2502A
FO
MIN.
STOP
TV
2502B
Chapter # 4
Page 40 of 95
CONTROL (TIC-2502)
HDF FEEDTEMPERATURE
FIG. 12
COLD IN
99-E-06A/B/C
COLD OUT
FC
FROM 99-E-02A/B/C
MSDW REACTOR LIQ. FEED
TO 99-F-02
MSDW REACTOR CHARGE
0%
MIN. STOP
(40%)
100%
2A
50
-2
TV
CONTROLLER OUTPUT %
TV
-2
50
2B
TIC-2502
100%
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3.14
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MSDW Charge Heater Outlet Temperature Control (TIC-2607)

(1)
P&ID No.: 18-3188-D-99-01-1126
(2)
P&ID No.: 18-3188-D-99-01-1127
3.14.1 Introduction
The MSDW Charge Heater (99-F-02) is fired by Fuel gas/LPG to heat the feed. The flow
of Fuel gas/LPG to furnace is controlled by Furnace Feed outlet temperature controller
TIC-2607 (located at the outlet of furnace 99-F-02) through pressure controller PIC2703 (located on fuel gas supply line before furnace).
3.14.2 Simplified Block Diagram of MSDW Charge Heater Outlet Temperature Control
(TIC-2607)
3.14.3 Description
Furnace Feed outlet temperature controller TIC-2607 (located at the outlet of furnace
99-F-02) works in cascade with pressure controller PIC-2703 (located on fuel gas
supply line to furnace). If the outlet temperature of Furnace decreases, TIC-2607 will
increase the set point of PIC-2703, resulting in more opening of PV-2703 &
corresponding high flow of fuel gas to the burner. If the outlet temperature increases, the
actions will be vice versa.
In addition to that, temperature controller will give high and low temperature alarm (TAH2607 & TAL-2607) and pressure controller will give high and low flow alarm (PAH-2703
& PAL-2703), as applicable, on DCS.
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Chapter # 4
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PREPARED BY
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CHECKED BY
RHD
FROM 99-D-12
FUEL GAS
TO 99-R-02
MSDW REACTOR
CHARGE
2703
PV
FC
SP
2703
PIC
PAL
PAH
TIC
TAL
TAH
FURNACE OUTLET
BURNER
99-F-02
99-F-02
Chapter # 4
Page 42 of 95
CONTROL (TIC-2607)
MSDW CHARGE HEATER OUTLET TEMPERATURE
FIG. 13
2607
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3.15
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MSDW Reactor Temperature Control (TIC-2808/2811/2814)

(1)
P&ID No.: 18-3188-D-99-01-1128
3.15.1 Introduction
In the MSDW Reactor (99-R-02), the paraffins in the waxy oil feed are selectively
cracked and isomerized, in the presence of hydrogen and the MSDW catalyst, to
improve the feed cold flow properties. As in the HDT reactor case, the dewaxing
reactions are exothermic and require inter-bed quenching. Temperature required to
carry out the dewaxing reactions, which increases gradually throughout the run as the
catalyst ages, is controlled by adjusting 99-R-02 feed inlet temperature through
manipulation of 99-F-02 firing rate, and by the inlet and inter bed quench flow rates. The
MSDW Reactor consists of three beds of catalyst. To limit the overall exotherm in the
MSDW, two thirds of the expected exotherm is eliminated by means of quench to the
outlet of the first and second, beds. The quench gas enters on flow control reset by
averaged bed inlet and averaged bed outlet temperature. An additional quench gas
connection is provided to the inlet of the reactor for fast trim temperature control, if
required during an upset condition, and for use in controlling the wetting exotherm on
startup.
Reactor temperature control is vital to good catalyst performance and should be
controlled to + / - 0.50C. Depending upon the age of the catalyst, feed quality, feed rate
and the desired conversion, a target Weighted Average Bed Temperature (WABT) must
be maintained for each bed. Further, the temperature rise across each bed must be
kept below a set target; this is especially important during runaway reaction.
3.15.2 Simplified Block Diagram of MSDW Reactor
2808/2811/2814)
Temperature Control (TIC-

3.15.3 Description
thermocouples in total) temperatures are measured. Bed Inlet (except top bed) and
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Outlet (except bottom bed) Tis are averaged in a calculation (TY) block. The target bed
outlet temperature is entered by operator based on the operating case and catalyst run
length. Averaged out bed outlet temperature is compared to the operator entered set
point and this difference is used to reset the bed inlet target temperature with a time
delay of 5 min. (adjustable). The bed inlet target temperature is compared to the actual
average inlet temperature (every 1 min., adjustable). The difference between these two
values is used to reset quench flow.
For top bed reactor inlet temperature (TI-2808) is used instead of bed top temperature
(TI-2820 A-H). For bottom bed the reactor outlet temperature (TI-2815) is used for
control purpose instead of bed bottom temperatures (TI-2812 A-H).
3.15.4 Definitions
For the MSDW Reactor 99-R-02, there are 3 quench gas flows:
Bed
Inlet
Bed
Temp.
Average
Calculation
Outlet
Bed
Temp.
Average
Calculation
TI-2820
(A-H)
TI-2811
(A-H)
TI-2814
(A-H)
--
TI-2807
(A-H)
TI-2803
(A-H)
TI-2812
(A-H)
2
3
TY-2811
TY-2814
Bed
Inlet
Temp.
Controller
TIC-2808
Flow
Controller
TY-2807
Bed
Outlet
Temp.
Controller
TIC-2807
TY-2803
TIC-2803
TIC-2811
FIC-2802
--
TIC-2815
TIC-2814
FIC-2803
FIC-2801
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SP
FIC
2801
FV
2801
FO
PV
TI
TAHH
TAH
TIC
2808
2808
2820
A-H
I
8
TIC
2807
PV
BED-1
/n
TAHH
TAH
TI
FIC
TY
2807
A-H
BED BOTTOM
SP
2802
2807
FT
2802A/B
FV
2802
99-R-02
FO
BED TOP
TI
BED-2
2811
TAHH
TAH
/n
TY
PV
2811
A-H
TIC
2811
TAHH
TAH
TAL
FIC
I
8
BED
BOTTOM
TI
2803
TO 99-F-01
/F-02 TRIP
TAHH
TAH
2803
/n
PV
TY
2803
A-H
FV
2803
TIC
2803
FT
2803
SP
FIG.14
TI
FROM 99-F-02
TAL
TO 99-F-01
TAHH /F-02 TRIP
TAH
BED TOP
MSDW REACTOR (99-R-02) TEMPERATURE

CONTROL (TIC-2808/2811/2814)
FT
2801
FO
BED TOP TAHH

TAH
TI
BED-3
2814
2814
A-H
I
8
BED
BOTTOM
TI
2812
TIC
PV
TI
2815
/n
TY
TO 99-F-01
/F-02 TRIP
TAHH
TAH
A-H
PV
TIC
2814
TAL
TAHH
TAH
2815
FROM 99-C-02A/B
TO 99-E-06 A/B/C
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3.16
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HDF Reactor Temperature Control (TIC-2903/2902)

(1)
P&ID No.: 18-3188-D-99-01-1129
3.16.1 Introduction
In the HDF Reactor (99-R-03), contaminants in the oil feed such as color bodies, polar
compounds, etc. are removed and most of the olefins are saturated to improve product
quality and stability. The HDF reactions are mildly exothermic and provisions for interbed quenching are provided. However, due to the small temperature rise there is
normally no quench flow to the HDF Reactor. The HDF Reactor consists of two beds of
catalyst. The HDF Reactor (99-R-03) exotherm is expected to be negligible in normal
operation. The HDF inlet temperature is controlled through bypassing of MSDW Feed
around the 99-E-06. The quench gas enters on flow control reset by averaged bed inlet
temperature. An additional quench gas connection is provided to the inlet of the reactor
for fast trim temperature control, if required during an upset condition, and for use in
controlling the wetting exotherm on startup.
3.16.2 Simplified Block Diagram of HDF Reactor Temperature Control (TIC-2903/2902)
3.16.3 Description
thermocouples in total) temperatures are measured. Bottom Bed Inlet Tis are averaged
in a calculation (TY) block. Averaged out bed inlet temperature is used to rest quench
flow.
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3.16.4 Definitions
For the MSDW Reactor 99-R-03, there are 2 quench gas flows:
Bed
Inlet
Bed
Temp.
Average
Calculation
Outlet
Bed
Temp.
Average
Calculation
TI-2913
(A-H)
TI-2902
(A-H)
--
TI-2908
(A-H)
TI-2905
(A-H)
TY-2902
Bed
Inlet
Temp.
Controller
TIC-2903
Flow
Controller
--
Bed
Outlet
Temp.
Controller
TIC-2807
--
TIC-2803
TIC-2902
FIC-2901
FIC-2902

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FT
2902
FO
TIC
2903 TAL
FROM 99-E-06 A/B/C
BED-1
BED TOP
TAHH
TI TAH
2913 A-H
I
9
99-R-03
FIC SP
2901
TO 99-F-01
/F-02 TRIP
BED
BOTTOM
TAHH
TI TAH
2908
A-H
FV
2901
FT
2901
FO
BED-2
BED TOP TAHH

TAH
TI
2902
A-H
I
9
FIG.15
TI
2903
TAHH
TAH
PV
HDF REACTOR (99-R-03) TEMPERATURE

CONTROL (TIC-2903/2902)
SP
FIC
2902
FV
2902
20/01/2010
/n
TY
2902
PV
TIC
2902 TAL
TO 99-F-01
/F-02 TRIP
BED
BOTTOM
TAHH
TI TAH
2905
A-H
TAHH
TI TAH
2901
FROM 99-C-02A/B
TO 99-E-02 A/B/C
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3.17 HTS OVHD/Recycle Gas Exchanger (99-E-07), Recycle Gas Outlet Temperature
Control (TIC-3002)
(1)
P&ID No.: 18-3188-D-99-01-1130
3.17.1 Introduction
HDF reactor effluent is cooled against the liquid from 99-T-01 in the Exchanger (99-E02A/B/C) then flashed in the High Temperature Separator (99-D-04). Vapor from 99-D04 is cooled against recycle gas in the High Temperature Separator Overhead / Recycle
Gas Exchanger (99-E-07). Control of the Recycle Gas outlet temperature is
accomplished by TIC-3002 by bypassing Recycle Gas around the exchanger.
3.17.2 Simplified Block Diagram of HTS OVHD/Recycle Gas Exchanger (99-E-07),
Recycle Gas Outlet Temperature Control (TIC-3002)
3.17.3 Description
Recycle Gas outlet temperature controller TIC-3002 is dual acting controller. TIC-3002
controls Recycle Gas outlet temperature from 99-E-07 through control valves TV-3002A
and TV-3002B by controlling the relative flows through exchanger 99-E-07 and its
bypass.
When the Recycle Gas outlet temperature from 99-E-07 increases than the set point,
TIC-3002 will pass less flow through the 99-E-07, i.e. bypass valve TV-3002B starts to
open and Inlet valve TV-3002A will start to close. Reverse action will be followed when
the Recycle Gas outlet temperature from 99-E-07 decreases, i. e. start to close 99-E-07
bypass valve TV-3002B and start to open the inlet valve TV-3002A. In addition inlet
valve TV-3002A is provided with min. stop to prevent exchanger running dry.
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Chapter # 4
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PREPARED BY
RMB
CHECKED BY
RHD
TO 99-AFC-02
HOT OUT
HTS SEPARATOR OVHD
HOT IN
MIN.
STOP
TV
3002A
FO
FC
TV
3002B
Chapter # 4
Page 50 of 95
FROM 99-C-02A/B
RECYCLE GAS
TO 99-E-03A/B/C
RECYCLE GAS
2B
00
-3
TV
CONTROLLER OUTPUT %
TV
-3
00
2A
TIC-3002
RECYCLE GAS OUTLET TEMPERATURE CONTROL (TIC-3002)
HTS OVHD/RECYCLE GAS EXCHANGER (99-E-07),
FIG. 16
COLD IN
99-E-07
COLD OUT
TIC
3002
0%
FROM 99-D-04
HTS SEPARATOR OVHD
DUAL ACTING
MIN. STOP
40%
100%
100%
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3.18 HTS Liquid/Frac. Bottom Exchanger (99-E-14A/B), Product Stripper Feed

Temperature Control (TIC-3001)
(1)
P&ID No.: 18-3188-D-99-01-1130
3.18.1 Introduction
HDF reactor effluent is cooled against the liquid from 99-T-01 in the Exchanger (99-E02A/B/C) then flashed in the High Temperature Separator (99-D-04). The condensed
liquid from 99-D-04 exchange heat with Dewaxed Oil from Vacuum Dryer (99-T-06) in
HTS Liquid/Frac. Bottom Exchanger (99-E-14A/B) and then routed to the Product
Stripper (99-T-04). Control of the Product stripper feed temperature is accomplished by
TIC-3001 by bypassing Dewaxed Oil around the exchanger.
3.18.2 Simplified Block Diagram of HTS Liquid/Frac. Bottom Exchanger (99-E-14A/B),
HTS Liquid Outlet Temperature Control (TIC-3001)
3.18.3 Description
Product stripper feed temperature controller TIC-3001 is dual acting controller. TIC-3001
controls Product stripper feed temperature from 99-E-14A/B through control valves TV3001A and TV-3001B by controlling the relative flows through exchanger 99-E-14A/B
and its bypass.
When the Product stripper feed temperature from 99-E-14A/B increases than the set
point, TIC-3001 will pass less flow through the 99-E-14A/B, i.e. bypass valve TV-3001B
starts to open and Inlet valve TV-3001A will start to close. Reverse action will be
followed when the Product stripper feed temperature from 99-E-14A/B decreases, i. e.
start to close 99-E-14A/B bypass valve TV-3001B and start to open the inlet valve TV3001A.
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HTS LIQUID
COLD OUT
COLD IN
TIC
3001
DUAL ACTING
TAH
TV
3001A
FO
TV
3001B
Chapter # 4
Page 52 of 95
FC
FROM 99-P-05A/B
DEWAXED OIL
TO 99-E-15A/B
1B
00
-3
TV
CONTROLLER OUTPUT %
TV
-3
00
1A
TIC-3001
PRODUCT STRIPPER FEED TEMPERATURE CONTROL (TIC-3001)
HTS LIQUID/FRAC. BOTTOM EXCHANGER,
FIG. 17
HOT IN
99-E-14A/B
HOT OUT
DEWAXED OIL
0%
FROM 99-D-04
HTS LIQUID
100%
100%
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3.19
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Product Stripper level Control/Flow Control to Vac. Frac. Charge Heater 99-F-03
LIC-3303/FIC-3302/FIC-3304)
(1)
P&ID No.: 18-3188-D-99-01-1133
3.19.1 Introduction
Stripped liquid product from the bottom of the Product Stripper (99-T-04) is sent to the
Vac. Frac. Charge Heater (99-F-03) before introduction to the Vac. Frac. (99-T-05).
Feed is split in two by (LIC-3303/FIC-3302/FIC-3304) prior to entering 99-F-03.
3.19.2 Simplified Block Diagram of Product Stripper level Control/Flow Control to Vac.
Frac. Charge Heater 99-F-03 (LIC-3303/FIC-3302/FIC-3304)
3.19.3 Description
During operation, 99-T-04 level controller LIC-3303 give set point to FIC-3302 and FIC3304, located on the spilt streams, to the Vac. Frac. Charge Heater (99-F-03) passes.
These controllers (FIC-3302 & FIC-3304) compare level signal with middle value of
individual FTs (FT-3302 A/B/C and FT-3304 A/B/C), and manipulates control valve FV3302 and FV-3304 respectively to ensure equal flow to both passes of heater. The
middle value of FT-3302 A/B/C and FT-3304 A/B/C shall be used by computation block
(FY-3302) to calculate the total amount stripped liquid product flow to the Vac. Frac.
Charge Heater (99-F-03). Also the middle value of above FTs shall be used by
computation block (FY-3304) to calculate the difference between two flows and it will
give high difference alarm (FDAH) as applicable, on DCS.
In addition to that, level controller will give high/low alarm (LAH-3303/LAL-3303), as
applicable, on DCS.
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LIQUID FROM 99-D-23,

99-E-14, 99-E-15
99-T-04
LT
3303
PREPARED BY
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CHECKED BY
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I
37
MIDDLE
VALUE
PV
FIC
3304
FAL
FAH
SET PT
FIC
3302
FAL
FAH
SET PT
FC
FC
FV
3304
FV
3302
TO VACUUM FRACTIONATOR
CHARGE HEATER 99-F-03
CHARGE HEATER 99-F-03
CHARGE HEATER SHUTDOWN
99-F-03
Chapter # 4
Page 54 of 95
FRAC. CHARGE HEATER 99-F-03 (LIC-3303/FIC-3302/FIC-3304)
PRODUCT STRIPPER LEVEL CONTROL/FLOW CONTROL TO VAC.
FIG.18
2oo3
PV
MIDDLE VALUE
FY
3302
FY
3304
I
37
FI
3305
FDI
3304
2oo3
FDAH
FT
A,B,C 3302
LAL
LAH
FT
A,B,C 3304
LIC
3303
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3.20
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Vac. Frac. Charge Heater Outlet Temperature Control (TIC-3505)

(1)
P&ID No.: 18-3188-D-99-01-1135
(2)
P&ID No.: 18-3188-D-99-01-1136
3.20.1 Introduction
The Vac. Frac. Charge Heater (99-F-03) is a dual fired heater. It can be fired by Fuel
gas/LPG or Fuel Oil or combination of both Fuel Gas & Fuel Oil to heat the bottoms
product from Product Stripper (99-T-04). The flow of Fuel gas/LPG and Fuel Oil to
furnace is controlled by Vac. Frac. Charge Heater outlet temperature controller TIC3505 (located at the outlet of furnace 99-F-03) through pressure controller PIC-3601
(located on fuel gas supply line before furnace) and flow controller FIC-3601 (located on
fuel oil supply line before furnace).
3.20.2 Simplified Block Diagram of Vac. Frac. Charge Heater Outlet Temperature Control
(TIC-3605)
3.20.3 Description
HS-3601 will be on Fuel Gas mode if furnace is running with 100% Fuel Gas:
Vac. Frac. Charge Heater outlet temperature controller TIC-3505 (located at the
outlet of furnace 99-F-03) works in cascaded with pressure controller PIC-3601
(located on fuel gas supply line before furnace). If the outlet temperature of
Furnace decreases, TIC-3505 will increase the set point of PIC-3601, resulting in
more opening of PV-3601 & corresponding high flow of fuel gas to the burner. If
the outlet temperature increases, the actions will be vice versa.
HS-3601 will be on Fuel Oil mode if furnace is running with 100% Fuel Oil:
Vac. Frac. Charge Heater outlet temperature controller TIC-3505 (located at the
outlet of furnace 99-F-03) works in cascaded with flow controller FIC-3601
(located on fuel oil supply line before furnace). If the outlet temperature of
Furnace decreases, TIC-3505 will increase the set point of FIC-3601, resulting in
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more opening of FV-3601 & corresponding high flow of fuel oil to the burner. If the
outlet temperature increases, the actions will be vice versa.
HS-3601 will be on Fuel Gas mode controlling fuel gas flow rate with Fixed Fuel
Oil Flow rate to maintain the furnace outlet temperature, when furnace is run in
dual fired mode:
In addition to that, temperature controller will give high and low temperature alarm (TAH3505 & TAL-3505), pressure controller will give high and low flow alarm (PAH-3601 &
PAL-3601) and flow controller will give high and low flow alarm (FAH-3601 & FAL-3601)
as applicable, on DCS.
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Chapter # 4
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PREPARED BY
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FROM OSBL
FUEL OIL
FUEL GAS
FROM 99-D-12
FUEL GAS
TO 99-T-05
FEED
PV
3601
FV
3601
FC
FC
PIC
3601
FIC
3601
FAL
FAH
PAL
PAH
3601
HS
SP
TAL
TAH
FURNACE OUTLET
Chapter # 4
Page 57 of 95
VAC. FRAC. CHARGE HEATER OUTLET

FIG. 19
SELECT
FUEL OIL
SELECT
FUEL GAS
TIC
3505
99-F-03
BURNER
99-F-03
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3.21 Feed/Frac. Bottom Exchanger (99-E-01A/B), Raffinate Feed Temperature Control

(TIC-4103)
(1)
P&ID No.: 18-3188-D-99-01-1141
3.21.1 Introduction
Raffinate feed is pumped from storage and preheated first against dewaxed oil in the
Cold Feed / Fractionator Bottoms Exchanger (99-E-01A/B). Control of the Raffinate feed
temperature is accomplished by TIC-4103 by bypassing Dewaxed Oil around the
exchanger.
3.21.2 Simplified Block Diagram of Feed/Frac. Bottom Exchanger (99-E-01A/B), Raffinate
Feed Temperature Control (TIC-4103)
3.21.3 Description
Raffinate feed temperature controller TIC-4103 is dual acting controller. TIC-4103
controls Raffinate feed temperature from 99-E-01A/B through control valves TV-4103A
and TV-4103B by controlling the relative flows through exchanger 99-E-01A/B and its
bypass.
When the Raffinate feed temperature from 99-E-01A/B increases than the set point,
TIC-4103 will pass less flow through the 99-E-01A/B, i.e. bypass valve TV-4103B starts
to open and outlet valve TV-4103A will start to close. Reverse action will be followed
when the Raffinate feed temperature from 99-E-01A/B decreases, i. e. start to close 99E-01A/B bypass valve TV-4103B and start to open the outlet valve TV-4103A.
on DCS.
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TO 99-FIL-01
UNIT FEED
COLD OUT
COLD IN
TIC
4103
DUAL ACTING
TAH
FO
TV
4103B
Chapter # 4
Page 59 of 95
FC
FROM 99-E-17A/B
DEWAXED OIL
TO 99-AFC-06A/B
DEWAXED OIL
3B
10
-4
TV
CONTROLLER OUTPUT %
TV
-4
10
3A
TIC-4103
RAFFINATE FEED TEMPERATURE CONTROL (TIC-4103)
FEED/FRAC. BOTTOM EXCHANGER (99-E-01A/B),
FIG. 20
HOT IN
99-E-01A/B
HOT OUT
TV
4103A
0%
FROM STORAGE
UNIT FEED
100%
100%
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3.22 Warm Feed/Frac. Bottom

Temperature Control (TIC-4101)
Exchanger
(99-E-17A/B),
20/01/2010
Dewaxed
Oil
Outlet

(1)
P&ID No.: 18-3188-D-99-01-1141A
3.22.1 Introduction
The Dewaxed Oil from 99-T-06 is pumped with Pump (99-P-05A/B), exchanged heat
with multiple unit streams (99-E-14, 99-E-15, 99-E-17A/B and 99-E-01A/B), then aircooled (99-AFC-06), and sent to product storage on level control. Dewaxed Oil
exchanged heat with warm feed in Warm Feed/Frac. Bottom Exchanger (99-E-17A/B).
Control of Dewaxed Oil outlet temperature is accomplished by TIC-4101 by bypassing
Dewaxed Oil around the exchanger (99-E-17A/B).
3.22.2 Simplified Block Diagram of Warm Feed/Frac. Bottom Exchanger (99-E-17A/B),
Dewaxed Oil Outlet Temperature Control (TIC-4101)
3.22.3 Description
Dewaxed Oil outlet temperature controller TIC-4101 is dual acting controller. TIC-4101
controls Dewaxed Oil outlet temperature from 99-E-17A/B through control valves TV4101A and TV-4101B by controlling the relative flows through exchanger 99-E-17A/B
and its bypass.
When the Dewaxed Oil outlet temperature from 99-E-17A/B increases than the set
point, TIC-4101 will pass more flow through the 99-E-17A/B, i.e. bypass valve TV-4101B
starts to close and inlet valve TV-4101A will start to open. Reverse action will be
followed when the Dewaxed Oil outlet temperature from 99-E-17A/B decreases, i. e.
start to open 99-E-17A/B bypass valve TV-4101B and start to close the inlet valve TV4101A.
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PREPARED BY
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TO 99-E-03 A/B/C
FEED
COLD OUT
COLD IN
TV
4101A
FO
FC
TV
4101B
Chapter # 4
Page 61 of 95
FROM 99-E-15A/B
DEWAXED OIL
TO 99-E-01A/B
DEWAXED OIL
1A
10
-4
TV
CONTROLLER OUTPUT %
TV
-4
10
1B
TIC-4101
DEWAXED OIL OUTLET TEMPERATURE CONTROL (TIC-3002)
WARM FEED/FRAC. BOTTOM EXCHANGER (99-E-17A/B),
FIG. 21
HOT IN
99-E-17A/B
HOT OUT
TIC
4101
0%
FROM 99-P-02A/B
FEED
DUAL ACTING
100%
100%
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3.23
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Vacuum Frac. Pumparound Return Temperature Control (TIC-4201)

(1)
P&ID No.: 18-3188-D-99-01-1142
3.23.1 Introduction
The Vacuum Fractionator (99-T-05) includes three packed sections and separates light
distillate and heavy distillate from the dewaxed basestock product. The middle packed
bed of the Fractionator serves as a pumparound section with the heavy distillate product
taken from the pumparound circuit. This part is feed back to 99-T-05 as a pumparound
return by Vacuum Frac. PA Pump (99-P-06A/B) via Vacuum Fractionator PA Cooler (99AFC-04) and Strainer (99-STR-01). Control of pumparound return temperature is
accomplished by TIC-4201 by bypassing pumparound return around the Vacuum
Fractionator PA Cooler (99-AFC-04).
3.23.2 Simplified Block Diagram of Vacuum Frac. Pumparound Return Temperature
Control (TIC-4201)
3.23.3 Description
Pumparound return temperature controller TIC-4201 is dual acting controller. TIC-4201
controls pumparound return temperature from 99-AFC-04 through control valves TV4201A and TV-4201B by controlling the relative flows through cooler 99-AFC-04 and its
bypass.
When the pumparound return temperature from 99-AFC-04 increases than the set point,
TIC-4201 will pass more flow through the 99-AFC-04, i.e. bypass valve TV-4201B starts
to close and outlet valve TV-4201A will start to open. Reverse action will be followed
when the pumparound return temperature from 99-AFC-04, decreases, i. e. start to
open 99-AFC-04, bypass valve TV-4201B and start to close the outlet valve TV-4201A.
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FROM PA PUMP 99-P-06A/B
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TV
4201A
FO
TIC
4201
Chapter # 4
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DUAL ACTING
TO 99-T-05
VACUUM FRAC. PUMPAROUND RETURN
FIG. 22
FC
0%
99-AFC-04
TV
4201B
100%
1A
20
-4
TV
CONTROLLER OUTPUT %
TV
-4
20
1B
TIC-4201
100%
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3.24
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Amine Degassing Drum (99-D-14) Pressure Control (PIC-4709)

(1)
P&ID No.: 18-3188-D-99-01-1147
3.24.1 Introduction
The Amine Degassing Drum (99-D-14) collects Rich Amine from Amine KO Drum (99-D03), HP Amine Absorber (99-T-02) and Lean Amine from HP Lean Amine Pump (99-P11A/B) minimum flow line. Amine Degassing Drum (99-D-14), pressure is controlled by
PIC-4709 to maintain positive suction pressure of Rich Amine Degassing Pump (99-P15A/B), which prevent cavitation and damage of the pump.
3.24.2 Simplified Block Diagram of Amine Degassing Drum Pressure Control (PIC-4709)
3.24.3 Description
The pressure of Amine Degassing Drum (99-D-14) is maintained at 2.0 kg/cm2g using
push/pull system with Fuel gas. The pressure is controlled by split range controller PIC4709. The output of the controller is split between PV-4709A on Fuel gas line from Fuel
Gas header and PV-709B on the line to flare. Low pressure is made up by entering FG
through opening of PV-4709A, while high pressure is released by opening PV-4709B to
control valves.
In addition to that, pressure controller will give high and low alarm (PAH-4709 and PAL4709), as applicable, on DCS.
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PREPARED BY
RMB
FROM 99-D-03,
99-T-02,
99-P-11
AMINE
SPLIT RANGE
PIC
4709
99-D-14
PAL
PAH
CHECKED BY
RHD
TO ARU
VIA 99-P-15A/B
RICH AMINE
TO FLARE
Chapter # 4
Page 65 of 95
0%
AMINE DEGASSING DRUM (99-D-14) PRESSURE

CONTROL (PIC-4709)
FIG.-23
F0
FC
PV
4709B
(52.5-100%)
47.5% 50% 52.5%
PIC-4709
PRESSURE INCREASE
CONTROLLER OUTPUT %
09A
-47
PV
FROM HEADER
FUEL GAS
PV
4709A
(0-47.5%)
100%
PV
-47
0
9B
100%
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3.25
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Sour Water Degassing Drum (99-D-15) Pressure Control (PIC-4704)

(1)
P&ID No.: 18-3188-D-99-01-1147
3.25.1 Introduction
The Sour Water Degassing Drum (99-D-15) collects Sour Water from Wash water
Column (99-T-03), HDT Low Temp. Separator (99-D-02), Vac. Frac. OVHD Accumulator
(99-D-11) and Vac. Frac. Condensate Receiver (99-D-42). Sour Water Degassing Drum
(99-D-14), pressure is controlled by PIC-4704 to maintain positive suction pressure of
Slop oil Pump (99-P-20A/B) and Sour water Transfer Pump (99-P-19A/B), which prevent
cavitation and damage of the pumps.
3.25.2 Simplified Block Diagram of Sour Water Degassing Drum Pressure Control (PIC4704)
3.25.3 Description
The pressure of Sour Water Degassing Drum (99-D-15) is maintained at 1.8 kg/cm2g
using push/pull system with Fuel gas.
The pressure is controlled by split range
controller PIC-4704. The output of the controller is split between PV-4704A on Fuel gas
line from Fuel Gas header and PV-704B on the line to flare. Low pressure is made up by
entering FG through opening of PV-4704A, while high pressure is released by opening
PV-4704B to flare. The split range controller PIC-4704 is provided with a dead band of
5% (adjustable), i.e. between 47.5% & 52.5% both valves would remain closed. This is
done to allow for normal fluctuations around the set point of pressure controller without
control valves.
In addition to that, pressure controller will give high and low alarm (PAH-4704 and PAL4704), as applicable, on DCS.
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PREPARED BY
RMB
CHECKED BY
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TO GFEC
VIA 99-P-19A/B
SOUR WATER
FROM 99-T-03,
99-D-02,99-D-11,
99-D-42
SOUR WATER
SPLIT RANGE
PIC
4704
99-D-15
PAL
PAH
TO STORAGE
VIA 99-P-20A/B
SLOP OIL
TO FLARE
0%
SOUR WATER DEGASSING DRUM (99-D-15)

PRESSURE CONTROL (PIC-4704)
FIG.-24
F0
FC
PV
4704B
(52.5-100%)
47.5% 50% 52.5%
PIC-4704
PRESSURE INCREASE
CONTROLLER OUTPUT %
04A
-47
PV
FROM HEADER
FUEL GAS
PV
4704A
(0-47.5%)
100%
PV
-47
0
4B
100%
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Chapter # 4
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3.26
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Heater (99-F-01) Damper Control (PIC-1805/HIC-1805/HS-1810)

(1) P&ID No.: 18-3188-D-99-01-1118
3.26.1 Introduction
The hot flue gases inside the firebox and stack are lighter than the cold ambient air
outside. This result in the creation of a slightly negative pressure inside the furnace.
Combustion air is drawn into the burners and the hot gas flows out of the stack due to
this pressure differential.
The draft in the furnace is controlled by means of stack
damper (PV-1805). The arch of the heater or inlet to the convection section is the point
of having the highest pressure and thus has been used as point of control. A typical draft
value of -2.54mm WC is maintained at the arch. A high draft will lead to more
combustion air being drawn in the firebox. Conversely insufficient draft may lead to
positive pressure inside the firebox leading to flue gas leakage from the openings.
3.26.2 Simplified Block Diagram of Heater Damper Control (PIC-1805/HIC-1805/HS-1810)
3.26.3 Description
During Normal operation stack damper PV-1805 is controlled by means of pressure
controller (PIC-1805) placed at the arch. When the draft pressure is more than the set
point (i.e. draft is decreasing) PIC-1805 start to open the stack damper. Reverse action
will be followed when draft pressure is less than the set point (i.e. draft is increasing)
PIC-1805 start to close the stack damper. The stack damper PV-1805 have the
capability of being operated at intermediate opening between 10% (Min. Stop) to 100%
(Full Open) from the control room and provided with mechanical position indicator (at
damper level and ground level). Selector Switch HS-1805 is provided for selection
between PIC-1805 and local HIC-1805. HIC-1805 is provided for operating damper from
grade during start-up/shut down. Hand switch HS-1810 is provided for selection
between actuator mode and manual winch pulley mode. Position of damper is
continuously available in control room by ZI-1805.
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In addition to that, pressure controller will give high alarm (PAH-1805), as applicable, on
DCS.
**Note: Damper control scheme for (99-F-02) Heater (PIC-2601/HIC-2601/HS-2610)
and (99-F-03) Heater (PIC-3506/HIC-3506/HS-3510) is same as above.
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Chapter # 4
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PREPARED BY
RMB
FO
MIN.
STOP
99-F-01
PV
1805
ZSO
1805
PT
1805
CHECKED BY
RHD
P AH
VENT
XY
1801
HIC
1805
S
OPEN
DAMP ER
PS
1805
Chapter # 4
Page 70 of 95
AI
I
P ROCESS TRIP S
HS
1810
CONTROL (PIC-1805/HIC-1805/HS-1810)
HEATER (99-F-01) DAMPER

FIG.25
1805
PI
1805
P IC
HS
1805
ZI
1805
ZLO
1805
I
215
PY
1805
I
271
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3.27
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PROJECT
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Dewaxed Oil Product Cooler (99-AFC-06) Temperature Control (TIC-4104)

(1)
P&ID No.: 18-3188-D-99-01-1141
3.27.1 Introduction
The dewaxed base stock product from the bottom of 99-T-05 is vacuum dried in the
Dewaxed Oil Vacuum Dryer (99-T-06). The dewaxed oil product is pumped by the
Dewaxed Oil Product Pump (99-P-05A/B) to the HTS Liquid / Fractionator Bottoms
Exchanger (99-E-14), Frac Bottoms / LTS Liquids Exchanger (99-E-15) where it heats
the stripper feed streams. The stream is then used to preheat the raffinate feed to the
unit in Warm Feed /Frac. Bottoms Exchanger (99-E-17A/B) and Cold Feed / Frac
Bottoms Exchanger (99-E-01A/B). The stream is further cooled in the Dewaxed Oil
Product Cooler (99-AFC-06) before rundown to storage. The temperature of Dewaxed
Oil Product is controlled by TIC-4104 by controlling Fan pitch.
3.27.2 Simplified Block Diagram of Dewaxed Oil Product Cooler Temperature Control
(TIC-4104)
3.27.3 Description
The Dewaxed Oil Product temperature controller TIC-4104 controls the outlet
temperature of 99-AFC-06 by controlling Fan pitch.
When the Dewaxed Oil Product temperature from 99-AFC-06 increases than the set
point, TIC-4401 will increase fan pitch thereby increasing air flow across AFC. Reverse
action will be followed when the temperature from 99-AFC-06, decreases, i. e. TIC-4401
will decrease fan pitch thereby decreasing air flow across AFC. Only 50% of fans are on
auto variable pitch control. In addition to that, temperature controller will give high and low
alarm (TAH-4104 and TAL-4104), as applicable, in DCS.

**Note: Heavy Distillate Product Cooler (99-AFC-05) Temperature Control (TIC- 4112)
scheme is same as above.
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DEWAXED PRODUCT OIL
TAL
TAH
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DEWAXED OIL PRODUCT COOLER
FIG. 26
99-AFC-06
TIC
4104
TO STORAGE
DEWAXED PRODUCT OIL
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3.28
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Product Stripper Overhead Accumulator (99-D-10) Level Control (LIC-3410/FIC3404A/FIC-3404B)

(1)
P&ID No.: 18-3188-D-99-01-1134
3.28.1 Introduction
Overhead vapor from product stripper column (99-T-04) top is condensed by product
stripper ovhd. Condenser (99-E-12). The condensed liquid then transfer to product
stripper ovhd. accumulator (99-D-10). Unstabilized naphtha, sour gas and sour water
are separated in the 99-D-10. Unstabilized naphtha from 99-D-10 is pumped to storage
by product stripper ovhd pumps (99-P-04 A/B). Product stripper ovhd accumulator level
is control by LIC-3410 cascade with FIC-3404A & FIC-3404B.
3.28.2 Simplified block diagram of Product Stripper Overhead Accumulator (99-D-10)
Level Control (LIC-3410/FIC-3404A /FIC-3404B)
3.28.3 Description
Product stripper ovhd. accumulator level controller LIC-3410 controls the accumulator
level by controlling the flow through FV-3404A or FV-3404B.
When the level in product stripper ovhd. accumulator is increased then LIC-3410 will
increase the set point (in terms of flow) to the FX-3404.
If the set point (in terms of flow) is up to 0.5 m3/hr then the set point will be passed to
FIC-3404A, which will increase the opening of FV-3404A to control the level. Till this
time set point of FIC-3404B shall be equal to zero and FV-3404B is in closed condition.
If the set point (in terms of flow) is goes beyond 0.5 m3/hr then set of FIC-3404A shall
be clamped at 0.5 m3/hr & the set point (in terms of flow between 0.5 m3/hr to 4.5
m3/hr) will be passed to FIC-3404B, which will increase the opening of FV-3404B to
control the level.
Reverse action will be followed when level in product stripper ovhd. accumulator is
decreasing. I.e. LIC-3410 will decrease the set point (in terms of flow) to FX-3404 and
FIC-3404A will close the valve FV-3404A if the set point is less then 0.5 m3/hr or FIC3404B will close the valve FV-3404B if the set point is beyond 0.5 m3/hr (Between 0.5
m3/hr and 4.5 m3/hr). In addition to this LIC-3410 will high and low level alarm, LAH3410 and LAL-3410 as applicable in DCS.
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FROM 99-E-12
CHECKED BY
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99-P-04A/B
LAL
LAH
SP
FV
3404A
FV
3404B
LIC
3410
FC
FC
FIC
3410B
FV
3404A
FV
3404B
FAL
SP
FIC
3410A
0 - 0.5 m3/hr
FAL
PRODUCT STRIPPER OVHD ACCUMULATOR (99-D-10)

LEVEL CONTROL (LIC-3410/FIC-3404A/FIC-3404B)
FIG.-27
SP
FX
3410
99-D-10
0.5 - 4.5 m3/hr
HP STRIPPER
OVHD PRODUCT
TO OSBL
UNSTABILIZED
NAPTHA
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3.29
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20/01/2010
Vacuum Frac. Overhead Accumulator (99-D-11) Level Control (LIC-3902/FIC4104A/FIC-4104B)

(1)
P&ID No.: 18-3188-D-99-01-1139
(2)
(2) P&ID No.: 18-3188-D-99-01-1141A
3.29.1 Introduction
Overhead vapor from vacuum fractionator column (99-T-05) top is condensed by
vacuum fractionator ovhd. condenser (99-AFC-03 A/B/C/D). The condensed liquid then
transfer to vacuum fractionator ovhd. accumulator (99-D-11). Light Distillate Product,
non-condensable vapor and sour water are separated in the 99-D-11. Light Distillate
Product from 99-D-11 is pumped to storage by vacuum fractionator ovhd pumps (99-P08 A/B) through Light Distillate Cooler (99-E-13). Vacuum Fractionator ovhd.
accumulator level is control by LIC-3902 cascade with FIC-4104A & FIC-4104B.
3.29.2 Simplified block diagram of Vacuum Frac. Overhead Accumulator (99-D-11) Level
Control (LIC-3902/FIC-4104A/FIC-4104B)
3.29.3 Description
Vacuum fractionator accumulator level controller LIC-3902 is controls the accumulator
level by controlling the flow through FV-4104A or FV-4104B.
When the level in vacuum fractionator ovhd. accumulator is increase, then LIC-3902 will
increase the set point (in terms of flow) to the FX-4104.
If the set point (in terms of flow) is up to 8.0 m3/hr then the set point will be passed to
FIC-4104A, which will increase the opening of FV-4104A to control the level. Till this
time set point of FIC-4104B shall be equal to zero and FV-4104B is in closed condition.
If the set point (in terms of flow) is goes beyond 8.0 m3/hr then set of FIC-4104A shall
be clamped at 8.0 m3/hr & the set point (in terms of flow between 8.0 m3/hr to 26.75
m3/hr) will be passed to FIC-4104B, which will increase the opening of FV-4104B to
control the level.
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Reverse action will be followed when level in vacuum fractionator ovhd. accumulator is
decrease. I.e. LIC-3902 will decrease the set point (in terms of flow) to FX-4104 and
FIC-4104A will close the valve FV-4104A if the set point is less then 8.0 m3/hr or FIC4104B will close the valve FV-4104B if the set point is beyond 8.0 m3/hr (Between 8.0
m3/hr and 26.75 m3/hr). In addition to this LIC-3902 will give high and low level alarm,
LAH-3902 and LAL-3902 as applicable in DCS.
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FROM 99-AFC-03A/B/C/D
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99-P-04A/B
99-E-13
LAL
LAH
SP
FV
4104A
FV
4104B
LIC
3902
FC
FC
FIC
4104B
FV
4104A
FV
4104B
FAL
FAH
SP
FIC
4104A
0 8.0 m3/hr
FAL
FAH
VAC. FRAC. OVHD ACCUMULATOR (99-D-11)

LEVEL CONTROL (LIC-3902/FIC-4104A/FIC-4104B)
FIG.-28
SP
FX
4104
99-D-11
8 - 26.75 m3/hr
VAC. FRAC.
OVHD VAPOR
TO STORAGE
LIGHT
DISTILLATE
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3.30
1
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Vacuum Frac. Overhead Temp Control (99-T-05), Reflux Control (TIC-3702/FIC3703)

(1)
P&ID No.: 18-3188-D-99-01-1137
(2)
P&ID No.: 18-3188-D-99-01-1139
3.30.1 Introduction
Overhead vapor from vacuum fractionator column (99-T-05) top is condensed by
vacuum fractionator ovhd. condenser (99-AFC-03 A/B/C/D). The condensed liquid then
transfer to vacuum fractionator ovhd. accumulator (99-D-11). The hydrocarbons that
have collected in 99-D-11 are pumped (99-P-09 A/B) under level control and the stream
split into two parts. The first is returned to the Vacuum Fractionator as top reflux under
flow control that is cascaded to overhead temperature of 99-T-05. The second part is
water-cooled (99-E-13) and leaves the unit as Light Distillate product. Vacuum
fractionator top reflux flow rate is control by TIC-3702 cascade with FIC-3703 and that
adjust the opening of FV-3703.
3.30.2 Simplified block diagram of Vacuum Frac. Overhead Temp Control (99-T-05),
Reflux Control (TIC-3702/FIC-3703)
3.30.3 Description
Vacuum fractionator overhead temperature controller TIC-3702 (located at the outlet of
column overhead 99-T-05) works in cascade with flow controller FIC-3703 (located at
reflux line to column 99-T-05). If the outlet temperature of Vacuum Fractionator increase,
TIC-3702 will increase the set point of FIC-3703, resulting in more opening of FV-3703
& corresponding high flow of reflux to the Vacuum fractionator. If the outlet temperature
decreases, the actions will be vice versa.
In addition to that, temperature controller will give high and low temperature alarm (TAH3702 & TAL-3702) and Flow controller will give high and low flow alarm (FAH-3703 &
FAL-3703), as applicable, on DCS.
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3.31
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20/01/2010
Heavy Distillate Stripper (99-T-07) Level Control (LIC-3801)

(1)
P&ID No.: 18-3188-D-99-01-1138
3.31.1 Introduction
Feed for Heavy Distillate Stripper (99-T-07) is supplied from Vacuum fractionator (99-T05) draw off nozzle below bed-2. Heavy Distillate Stripper (99-T-07), level is controlled
by LIC-3801.
3.31.2 Simplified Block Diagram of Heavy Distillate Stripper Level Control (LIC-3801)
3.31.3 Description
Feed to Heavy Distillate Stripper (99-T-07) is taken from the draw off nozzle below Bed2 of the 99-T-05. The level in the 99-T-07 is controlled by LIC-3801. Based on the set
point given in the LIC-3801, opening of the control valve LV-3801 is controlled during
normal operation. When level in Heavy Distillate Stripper increases above set point,
then LIC-3801 will give signal to close LV-3801 to reduce the flow. If the level decreases,
the actions will be vice versa.
In addition to that, level controller will give high and low level alarm (LAH-3801 & LAL3801), as applicable, on DCS.
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3.32
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LPG Vaporizer (99-D-26) Level Control (LIC-5901) / Pressure control (PIC-5904)

(1)
P&ID No.: 18-3188-D-99-01-1159
3.32.1 Introduction
LPG is used as alternate fuel in all the fired heaters (99-F-01/02/03). LPG Liquid from
OSBL will be supplied to LPG Vaporizer (99-D-26). LP Steam from header will be
supplied to LPG Vaporizer (99-D-26) to vaporize the liquid LPG. LPG Vaporizer (99-D26), level is controlled by LIC-5901 & pressure is control by PIC-5904.
3.32.2
Simplified Block Diagram of LPG Vaporizer Level Control (LIC-5901) / Pressure

control (PIC-5904)
3.32.3 Description
(i) Level control (LIC-5901)
Feed to LPG Vaporizer (99-D-26) is controlled via the feedback set point from the LPG
Vaporizer level controller LIC-5901. This signal then determines the opening of the
control valve LV-5901 during normal operation. When the level in LPG vaporizer (99-D26) is increases, then LT-5901 will decrease the set point of LIC-5901 then less flow will
pass through LV-5901. If the level decreases, the actions will be vice versa.
(ii) Pressure Control (PIC-5904)
LP Steam flow to LPG Vaporizer (99-D-26) is controlled via the feedback set point from
the LPG Vaporizer pressure controller PIC-5904. This signal then determines the
opening of the control valve PV-5904 during normal operation. When the pressure in
LPG Vaporizer is increases, then PT-5904 will decrease the set point of PIC-5904 then
less steam flow will pass through PV-5904. If the pressure decreases, the actions will be
vice versa.
In addition to that, Pressure controller will give high and low level alarm (PAH-5904 &
PAL-5904), as applicable, on DCS.
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3.33
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Sour Water Degassing Drum (99-D-15) Level Control (LIC-4701)

(1)
P&ID No.: 18-3188-D-99-01-1147
3.33.1 Introduction
Sour water in Sour Water Degassing Drum (99-D-15) is pumped through (99-P-19 A/B)
under level control and leaves the unit to OSBL to GFEC. Sour Water Degassing Drum
Level is control by LIC-4701.
3.33.2 Simplified Block Diagram of Heavy Distillate Stripper Level Control (LIC-3801)
3.33.3 Description
The Sour Water Degassing Drum level controller LIC-4701 controls the level of Sour
Water Degassing Drum (99-D-15) by controlling LV-4701 valve opening which is located
on the common pump discharge line. When the level in Sour Water Degassing Drum is
increases, then LT-4701 will increase the set point of the LIC-4701, resulting in more
opening of LV-4701 & corresponding high flow through LV-4701 to OSBL. If the level
decreases, the actions will be vice versa.
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3.34 Wash Water Flow Control (FIC-2401 / FIC-2101) for Wash water Column (99-T-03)
and Hot Stripper OVHD Cooler (99-AFC-01)
(1)
P&ID No.: 18-3188-D-99-01-1124A
(2)
P&ID No.: 18-3188-D-99-01-1124
(3)
P&ID No.: 18-3188-D-99-01-1121A
3.34.1 Introduction
Wash water from OSBL will be stored in Wash Water Surge Drum (99-D-13) via BFW
Cooler (99-E-18). HP Wash Water Pump (99-P-10 A/B) is provided for pumping the
Wash Water from wash water Surge Drum (99-D-13) to Wash Water Column (99-T-03)
and Hot Stripper OVHD Cooler (99-AFC-01) through HP Wash Water Cooler (99-E-39).
Wash Water flow through FV-2401 and FV-2101 is control by FIC-2401 & FIC-2101
respectively.
3.34.2 Simplified Block Diagram of Wash Water Flow Control (FIC-2401 / FIC-2101) for
Wash Water Column (99-T-03) and Hot Stripper OVHD Cooler (99-AFC-01)
3.34.3 Description
(A) Wash water Flow Control (FIC-2401) for 99-T-03
Wash water flow to wash water column (99-T-03) is controlled through FIC-2401 by
controlling the FV-2401 valve opening. A set point is given in FIC-2401 which in turn
controls the opening of FV-2401. If wash water flow to 99-T-03 is higher than the set
point, then FIC-2401 will give signal to close the FV-2401. If flow decreases, then action
will be reverse.
When the low low level (LALL-2410A) is detected in Wash Water surge Drum (99-D-13),
Interlock (I-35) overrides the signals to FIC-2401. In this event, FIC-2401 will come to
manual mode with output set to 0% and FV-2401 will be closed.
In addition to that, Flow controller will give low flow alarm (FAL-2401), as applicable, on
DCS.
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(B) Wash water Flow Control (FIC-2101) for 99-AFC-01

Wash water flow controller FIC-2101 controls the wash water flow to Hot Stripper OVHD
Cooler (99-AFC-01), by controlling the FV-2101 valve opening. A set point is given in
FIC-2101 which in turn controls the opening of FV-2101. If wash water flow to 99-AFC01 is higher than the set point, then FIC-2101 will give signal to close the FV-2101. If
flow decreases, then action will be reverse.
When the low low level (LALL-2410A) is detected in Wash Water surge Drum (99-D-13),
Interlock (I-35) overrides the signals to FIC-2101. In this event, FIC-2101 will come to
manual mode with output set to 0% and FV-2101 will be closed.
In addition to that, Flow controller will give high and low flow alarm (FAH-2101 FAL2401), as applicable, on DCS.
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PUMP AUTO START/STOP CONTROL SYSTEM

Pump auto start systems are provided for the pumps, which operate based on level
ON/OFF control philosophy.
Each pump with Auto start/Stop has a HAND/OFF/AUTO selection switch provided in
field to facilitate Manual start of Pump from Field.
During normal operation, running pump is in AUTO mode. In the event of high Level of
vessel (LAH), Interlock (I**) will auto start the Pump. When level goes low (LAL),
Interlock (I**) will shutdown the Pump. Pump can be started from local (field) by
operator by taking switch in Hand mode. This will facilitate to start pump for local even
though LAH has not reached. During maintenance of pump, switch to be put in OFF
position.
HAND/OFF/AUTO selection switches for motor driven pumps are connected to the
motor control centre. The system sends auto-start requests to the motor control centre.
The feedback of HAND/OFF/AUTO is available in the DCS to alert DCS operator.
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Auto Start /Stop System (I-49) for Closed Blowdown System Pump (99-P-18A/B)
(1)
P&ID No.: 18-3188-D-99-01-1143
4.1.1 Introduction
Closed Blow Down handles the Hydrocarbon drain of LOUP plant. Hydrocarbon from
Closed Blow Down Drum (99-D-22) will be pumped to SLOP tank (OSBL). Closed Blow
Down Sump Pump (99-P-18A) is provided for pumping the hydrocarbon liquid from
Closed Blow down Drum (99-D-22) to OSBL.
4.1.2 Simplified Block Diagram of Auto Start/Stop System (I-49) for Closed Blow Down
System Pump (99-P-18A/B)
4.1.3 Description
In the event of Hydrocarbon level in 99-D-22 going High (LAH-4303), Interlock (I-49) will
auto start Pump 99-P-18A. When hydrocarbon level goes low (LAL-4303), Interlock (I49) will stop the Closed Blowdown Pump 99-P-18A. Hand/Off/Auto Switch (HOA- 4301)
has been provided in field to facilitate Manual start of the Pump from Field also. High
and Low alarm (LAH-4303/ LAL-4303) is available in control room. Also feedback of
HOA is available in DCS to alert DCS operator.
**Note: Auto Start System for Closed Amine Sump Pump (99-P-17A/B) and OWS Oily
Slop Pump (99-P-39A/B) is same as above also refer Interlock / Cause and Effect
Description (Doc. No. 18-3188-L-99-01-4408) for the same.
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Auto Start /Stop System (I-201) for Backwash Effluent Transfer Pump (99-P-40A/B)
(1)
P&ID No.: 18-3188-D-99-01-1148
4.2.1 Introduction
Raffinate Feed from OSBL will pass through Feed Filter (99-FIL-01) and Feed
Coalescer (99-D-20) before it enters into Feed Surge Drum (99-D-01). Feed Filter is
auto backwash type cartridge filter. Backwash effluent generated from Feed Filter will
be routed to Backwash Effluent Transfer Vessel (99-D-45). Backwash effluent from 99D-45 will be pumped to Slop header by Backwash Effluent Transfer Pump (99-P-40
A/B).
4.2.2 Simplified Block Diagram of Auto Start/Stop System (I-201) for Backwash Effluent
Transfer Pump (99-P-40A/B)
4.2.3 Description
In the event of Effluent Level in 99-D-45 going High (LAH-4803), Interlock (I-201) will
auto start Pump 99-P-40A/B.When Effluent level in 99-D-45 goes low (LAL-4803),
Interlock (I-201) will shutdown the Pump 99-P-40A/B. Hand/Off/ Auto Switch (HOA
4801/HOA 4802) has been provided in field to facilitate Manual start of Pump from Field
also. DCS operator can select the pump by pressing HS-4810 (DCS) selector switch.
High and Low alarm (LAH-4803/ LAL-4803) is available in control room. Also feedback
of HOA is available in DCS to alert DCS operator.
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Chapter # 4
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4.3
1
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Auto start /stop system (I-209) for Condensate transfer pump 99-P-21 A/B
(1)
4.3.1
P&ID No.: 18-3188-D-99-01-1152
Introduction
Condensate Transfer Pump Auto Start / Stop on Level High / Low of Condensate Flash
Drum (99-D-24) (LAH5201 / LAL5201). Individual Hand/Off/Auto Switch (HOA-5202 &
HOA-5203) has been provided in field to facilitate Manual start of the pump from field
also. DCS operator can select the pump (99-P-21 A or 99-P-21 B) by through HS-5201
(DCS) selector switch.
4.3.2
Simplified Block Diagram of Condensate Pump Level Control (Start / Stop)

4.3.3
Trip Description
In the event of Condensate Level in 99-D-24 going High (LAH-5201), Interlock (I-209)
will auto start Pump 99-P-21A/B.When Condensate level in 99-D-24 goes low (LAL5201), Interlock (I-209) will shutdown the Pump 99-P-21A/B. Hand/Off/ Auto Switch
(HOA 4801/HOA 4802) has been provided in field to facilitate Manual start of Pump from
Field also. DCS operator can select the pump by pressing HS-5201 (DCS) selector
switch. High and Low alarm (LAH-5201 / LAL-5201) is available in control room. Also
feedback of HOA is available in DCS to alert DCS operator.
**Note: Auto Start System for Slop Oil Pump (99-P-20A/B) and Vac. Frac. Condensate
receiver Slop Oil Pump (99-P-41A/B) is same as above and also refer Interlock / Cause
and Effect Description (Doc. No. 18-3188-L-99-01-4408) for the same.
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5. CASEWISE ALARM & TRIP SUMMARY

Refer Attachment-1
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Philosophy of Control For Complex Logics

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LOBS QUALITY UPGRADATION

Doc. No. 18-3188-M-99-01-4400

LOBS QUALITY UPGRADATION

Doc. No. 18-3188-M-99-01-4400

OVERALL PLANT CONTROL PHILOSOPHY...................................................5

COMPLEX CONTROL SYSTEMS.....................................................................11

Feed Surge Drum (99-D-02) Pressure Control (PIC-1204).................................11

Feed Surge Drum Level Control (LIC-1205, HS-1206).......................................13

Make-up Gas Compressor (99-C-01A) Suction Pressure Control (PIC-1402/

Make-up Gas Compressor (99-C-01B) Suction Pressure Control (PIC-1602/

HDT Reactor Effluent Stripper Feed Temperature Control (TIC-1710).............21

HDF Reactor Effluent Temperature Control (TIC-1702).....................................24

HDT Reactor Charge Heater Outlet Temperature Control (TIC-1807)..............26

HDT Reactor Temperature Control (TIC-2019/2012/2014/2016)........................28

MSDW Feed Differential Pressure Control (PDIC-2102)....................................31

3.10 Reactor Loop Pressure Control (PIC-3208/HS-3212/FIC-3202/FIC-2106).........32

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3.21 Feed/Frac. Bottom Exchanger (99-E-01A/B), Raffinate Feed Temperature

3.31 Heavy Distillate Stripper (99-T-07) Level Control (LIC-3801)............................80

PUMP AUTO START/STOP CONTROL SYSTEM............................................89

CASE WISE ALARM & TRIP SUMMARY

LOBS QUALITY UPGRADATION

Doc. No. 18-3188-M-99-01-4400

Distributed Control System

Process Value (Input) to DCS controller

Set Point of Controller

LOBS QUALITY UPGRADATION

Doc. No. 18-3188-M-99-01-4400

OVERALL PLANT CONTROL PHILOSOPHY

From the Feed Surge Drum, the feed is

LOBS QUALITY UPGRADATION

Doc. No. 18-3188-M-99-01-4400

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LOBS QUALITY UPGRADATION

Doc. No. 18-3188-M-99-01-4400

LOBS QUALITY UPGRADATION

Doc. No. 18-3188-M-99-01-4400

LOBS QUALITY UPGRADATION

Doc. No. 18-3188-M-99-01-4400

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Doc. No. 18-3188-M-99-01-4400

COMPLEX CONTROL SYSTEMS

Feed Surge Drum (99-D-02) Pressure Control (PIC-1204)

This specification should be read in conjunction with the following:

P&ID No.: 18-3188-D-99-01-1112A

Feed Surge Drum Level Control (LIC-1205, HS-1206)

FEED SURGE DRUM (99-D-01) PRESSURE

SIMPLIFIED BLOCK DIAGRAM

CONTROL VALVE OPENING %

47.5% 50% 52.5%

- SPLIT RANGE CONFIGURATION -

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Doc. No. 18-3188-M-99-01-4400

This specification should be read in conjunction with the following:

P&ID No.: 18-3188-D-99-01-1112

P&ID No.: 18-3188-D-99-01-1112A

FLUSHING OIL &

FEED SURGE DRUM (99-D-01) LEVEL

SIMPLIFIED BLOCK DIAGRAM