SECTION 3 PROCESS DESCRIPTION 3.

1 HYDROCRACKER UNIT 3000 The hydrocracker unit processes a waxy distillate from High Vacuum Unit 2000 to produce lighter distillates and fuel gas. The hydrocracker capacity is a catalytic process that employs a two-stage reactor system lined up in a series flow-type operation. Due to two reactor trains operating in parallel are re!uired to which is optimi"e e!uipment si"e. The process consumes hydrogen supplied #y dedicated Hydrogen $anufacturing Unit %000. The hydrocracking catalyst is sensiti&e to the presence of organically #ound nitrogen compounds in the feed. The o#'ecti&e of the first reaction stage is to o#tain essentially nitrogen-free hydrocar#ons as feed to the second with reactor. Desulfuri"ation and some and consuming aromatic denitrification together hydrogenation

hydrocracking reactions take place in the first reactor hydrogen and yielding hydrogen sulfide (H 2)* cracked content. products. The resultant employed stream is The catalyst is a fluorided reduced in

ammonia (+H ,*

nickel-moly#denum

formulation on an alumina carrier. The ma'or part of the hydrocracking reaction takes place in the second-stage reactor. $ore hydrogen is consumed and light products are formed. The catalyst used here is a nickel-tungsten formulation on a "eolite carrier. The hydrocracker reactor unit is composed of se&eral

sections. .or con&enience following main systems/ -

sections ha&e #een grouped to form the

.resh .eed and 0ecycle 1i!uid )ystem. 0eactor Trains. 1i!uid and Vapor )eparation. 2ater 2ash )eparation. 0ecycle 3as 4ompression and Distri#ution. Hydrogen Distri#ution.
3/1 April 1997

OM/3000/3100/3200 Rev.1

4ontrol of the Hydrogen )ystem.

,.5.5 .06)H .66D 7+D 0648416 19:U9D )8)T6$ Hot feed from High Vacuum Unit 2000 enters .eed )urge Vessel V-,005 on 1e&el 4ontroller ,0-1047-5. The entering feed passes through catalyst filled filter )-,00; and then filtered in )-,005 7-< to remo&e solid particles. .resh .eed =ump =-,005 takes suction from the surge &essel 0-,005 parallel exchangers The 7-< &ia .eed 6-,0027-< and pumps the feed to .irst )tage 0eactors =reheat The 6xchangers feed splits 6-,00>7-< #efore 6-,00,7-< the preheat

and 6-,0057-<. 7 and < are designations for the two reactor trains. and is flow-controlled to each train. controls while of .resh .eed =ump =-,005 minimi"e The power of

consumption

fulfilling

process

re!uirements.

flow

fresh feed to each train is flow-controlled #y ,0-.047-500-200. The differential pressure across these control &al&es ,0-=D07-500-200 ,0-=D94-@ at > and flow-selected as measured #y #y #y ,0-?-,05 is controlled

#ar(g* #y ad'usting )peed of Tur#ine =T-,005 &ia

,0-)4-A and ,0-H4-55. Uncon&erted column )econd of )tage feedstock 0eactors from the #ottom Unit &ia a of ,500 the is mild &acuum to pumping

Hydrocracker

.ractionation 0-,0027-< li!uid enters

recycled

two-stage

arrangement. The recycle

catalyst filled filter )-

,00A #efore it enters 1i!uid 0ecycle )urge Vessel V-,002 from which it is pumped to an intermediate pressure le&el #y 1i!uid 0ecycle =ump =-,002 which is protected #y minimum-flow #ypass control ,0.947-@. The li!uid enters 1i!uid 0ecycle 9nterstage )urge Vessel V,05@ on le&el control #y ,0-1047-;. 1i!uid 0ecycle <ooster =ump =,00, takes suction from the interstage surge &essel and pumps the recycle li!uid to the second stage reactors. The flow is split e!ually #etween the two trains downstream of =-,00, #y ,0.04)7-502-202. =-,00, is protected #y minimum-flow ,0-.947-B5. #ypass control

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The surge &essels in the feed and recycle li!uid system are #lanketed with hydrogen-rich gas to preclude the entry of air. The pressure in the feed surge &essel and the recycle li!uid surge &essel is maintained #y )plit-0ange 4ontroller ,0-=947-> #y admitting gas from the hydrogen supply line or #y releasing gas to the refinery gas system. <ecause of its higher operating pressure gas from the second-stage discharge of the fresh gas compressors is used to #lanket the interstage &essel in a similar manner #y ,0-=947-%. .acilities are pro&ided to in'ect a fluorine compound into the feed during to normal D.6 keeps operation. (5 the Two pumps =-,00A7-< into #y each are train the pro&ided a train. in'ect D.6 5-difluoroethane* catalyst acti&e

selecti&ely. These pumps operate in parallel The fluorine ,.5.2

each supplying D.6 to replacing

which comes off during the operation.

0674TC0 T079+) The reactor trains consist of .irst )tage 0eactors 6ffluent 0-

,0057-<

)econd )tage

0eactors

0-,0027-<

0eactor

Heat

6xchangers

6-,0057-< through 6-,00B7-<

and 6ffluent 7ir 4oolers

6-,00;7-<. Various streams are used as the cooling medium in the series of effluent heat exchangers. The fresh feedstream is split and goes to the first stage reactors 6-,0027-< gas is at &ia the 6ffluent of Heat 6xchangers 6-,00>7-< To the 6-,00,7-< achie&e recycle ,.5.>.* the gas The and 6-,0057-<. The preheated feed is mixed with recycle inlet #y the first-stage which ()ee reactors. ad'usts the temperature of the mixture su#section

re!uired denitrification (50 ppmw* controlled ,0-T94-50B-20B to the mixing. temperature prior

mixture then enters the first of four catalyst #eds in the firststage reactor.
OM/3000/3100/3200 Rev.1 3/3 April 1997

The reactions that occur in the catalyst #eds are highly exothermic. To limit the temperature rise added upstream of catalyst #eds 2 , and cold recycle gas is @ is regulated #y and and introduced #etween the #eds as a !uench. The amount of !uench gas Temperature 4ontrollers ,0-T047-55>-25> ,0-T047-55%-25%

,0-T047-55B-25B

respecti&ely. :uench gas is pro&ided to limit the

temperature rise o&er each #ed to 2>D4 o&er the first two #eds each catalyst with #ed to monitor the reactor temperature to protect

20D4 o&er the other #eds. )e&eral thermocouples are pro&ided in profile against together emergency instrumentation

temperature runaway. ()ee su#section >.2.* The first-stage reactor effluent is cooled #y heat exchange with fresh feed in 6-,0057-<. 1i!uid recycle is added to the effluent after the heat exchanger. The com#ined effluent and li!uid recycle is mixed with recycle gas at the inlet of the second-stage reactor. The temperature of the mixture is controlled #y ,0-T94-5@B-2@B that ad'usts the recycle gas temperature going to the second-stage reactor. ()ee su#section ,.5.>.* The mixture then enters the first catalyst #ed of the second-stage reactor. The ma'or hydrocracking reactions take place in a series of fixed catalyst #eds in the second-stage reactor. These reactions are also highly exothermic. 4old recycle gas is introduced #etween the 5 2 catalyst , @ > #eds to control the temperature as in the first reactor. The amount of !uench gas added upstream of catalyst #eds and % is regulated #y Temperature 4ontrollers ,0respecti&ely. :uench is pro&ided to o&er the #eds to 50D4 per #ed. also to monitor the reactor #ed rise T047-5>@-2>@ through 5>A-2>A limit the temperature

Thermocouples are pro&ided here and wall temperature profiles. 6ffluent exchange with from fresh the

second-stage as

reactor

is

cooled

#y

heat heat

feed

descri#ed
3/4

a#o&e.

7dditional

OM/3000/3100/3200 Rev.1

April 1997

reco&ery is o#tained #y gas. fans. .inal cooling

preheating #y #y

the

fractionator is

feed

in

6in

,00B7-< and 6-,00@7-<. 6-,00%7-< are used to preheat the recycle controlled 6-,00;7-< ,0-T94-5%B-2%B ad'usting the achie&ed 6ffluent 7ir 4oolers &aria#le pitch

The tu#e wall temperatures on the reactor effluent side of the heat exchangers must #e kept a#o&e 5>0D4 to pre&ent su#limation and deposition of fluorine salts. 7 #ypass of fresh feed around the feed-effluent exchangers is pro&ided to ensure that this precaution can #e met. 6-,00% 7< recycle-gas #y-passes H4-502-202 E 552-252 can also #e used to keep these temperature a#o&e 5>0D4. 2ash water must #e 9n'ected upstream of the air coolers to pre&ent corrosion and plugging #y the deposition of salts as the reactor effluent is cooled. 2ash water in'ection is essential for safe operation of the unit and must #e maintained o&er the entire length of the run. To an alternati&e secure supply of stripped sour water from this end

)our 2ater )tripper Unit >@00 has #een lined up. The wash water must #e cool and free of oxygen. 7fter final cooling in 6-,00;7-< the parallel effluent streams are com#ined to form a single stream. ,.5., 19:U9D 7+D V7=C0 )6=707T9C+ The reactor effluent downstream of 6-,00;7-< consists of a mixture of gas oil and water phases. High-=ressure )eparator of the recycle gas compressor. V-,00, allows the phases to disengage and to separate. The top of the separator ser&es as a F.C. drum

The oil phase in the high-pressure separator is released to 1ow-=ressure )eparator V-,00@ #y 1e&el 4ontroller ,0-194-5% where it is flashed. The offgas produced is sent to 7D9= Treating Unit ,200 for H2) reco&ery. =ressure is maintained in the low-pressure separator separator #y is ,0-=04-55 on . The oil phase from and the is low-pressure pumped &ia ,0-1047-2B le&el control

4oalescer .eed =ump =-,00; through 4oalescer .eed .ilter )-,002 and .ractionator .eed 4oalescer V-,00>. The pump #oosts the pressure to o&ercome system pressure drop and to pre&ent flashing in the

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April 1997

coalescer. The coalescer remo&es free water

which is drained to on

the low-pressure separator or to )our 2ater .lash Vessel V-,00%

interface 1e&el 4ontroller ,0-1947-,5. The oil is then used to cool the reactor effluent as descri#ed a#o&e. The flow splits upstream of 6-,00B exchanges heat with the reactor effluent in each train and then goes to Hydrocracker .ractionation Unit ,500.

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,.5.@

27T60 27)H )8)T6$ 7 water circuit is employed in the separation section to

dissol&e ammonium salts

which can deposit in cooler parts of the together with fluorine which can com#ine to form the salts

plant. H2) and +H, produced in the reactors stripped from the catalyst dissol&e these salts

cause corrosion. 2ash water is in'ected at appropriate points to thus a#ating corrosion and a&oiding plugging. The water circuit is lined up counter-current to the flow of oil. $akeup water enters 2ater in'ection Tank V-,00; on 1e&el 4ontroller ,0-1947-,2. $akeup is either process in'ection water free of oxygen and calcium or as an alternati&e supply stripped

water from the sour water strippers. The water is pumped &ia 2ater in'ection =ump =-,00% on .low 4ontroller ,0-.047-5@ to the lowpressure separator. )ome of the water is used to counter-currently wash the oil mo&ing from the low-pressure separator to the coalescer and after #eing drained from the coalescer to sour

water flash &essel. The ma'or !uantity of water mixes with the oil entering the low pressure separator. 2ater <ooster =ump =-,00B takes suction from the #oot of 1ow-=ressure ,0-1947-,0 ,52 and )eparator and pumps to the V-,00@ water to and the air 9nterface discharge coolers. 1e&el of 4ontroller 2ater #y =-,00>.

4irculation =ump =-,00> takes suction from the upstream of ,0 ?6 pumps effluent .low 4ontrol ,0-.047-52; and 22; there#y splitting the flow to #oth trains. The

effluent and water mixture enters the lower section of the highpressure separator for phase separation. The under Vessel water phase 1e&el from the high-pressure ,0-194-5B to separator )our 2ater flows .lash

interface

4ontroller

V-,00%. The offgas is sent to 7D9= Treating Unit ,200 for

H2) reco&ery. The flash &essel contains #affles to skim oil off the sour water. <oth skimmed oil and sour water are sent to )our 2ater )tripper Unit >@00 for transfer to slops and further treating respecti&ely.

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April 1997

,.5.>

0648416 37) 4C$=06))9C+ 7+D D9)T09<UT9C+ 3as from the top of the high-pressure separator is

circulated through the reactor trains #y 0ecycle 3as 4ompressor F-,002. $akeup hydrogen Goins the recycle gas at the discharge of the recycle gas compressor train. 0ecycle 3as 4ompressor F-,002 is a tur#ine-dri&en control and the flow then splits and goes to the two reactor trains. The distri#ution of gas is the same in each

centrifugal compressor e!uipped with lu#e oil

seal oil

oil systems and an alternate external #uffer gas supply. 0efer to )ection 52 for additional information. The speed of the compressor is ad'usted manually from the control room #y the use of ,0-H4-,05. The compressor is protected against the potentially

dangerous condition Hsurging.H This condition is #asically a shock wa&e through the compressor caused #y insufficient flow forward through the machine. 7nti-surge 4ontrol ,0-?047-,2,-,2@ determines the !uotient of flow (,0-.T-25* di&ided #y pressure difference (,0-=d9-2,* times a constant in ,0-?-,25 operation of the compressor. 0efer to Drawing +os. T-5.@;A.@%2 - @%> for a listing of compressor emergency shutdowns. The #ulk of the recycle gas is preheated #y heat exchange with reactor effluent in 6-,00%7-<. The !uench gas #ypasses the heat exchanger and is in'ected into the reactors as re!uired to limit the temperature increase through the &arious catalyst #eds. 7 second #ypass deli&ers unheated recycle gas to each of the furnaces to maintain operating flexi#ility in the firing of the furnaces. The amount of #ypass to each furnace is ad'usted manually. and acts on )pill#ack

Val&es ,0-H4-2%-2B to pro&ide a minimum &alue to maintain sta#le

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April 1997

=art of the preheated ,0-.047-50%-20% .-,0057-<. The to furnace

recycle rate

gas is flow-controlled 0ecycle ad'usted 3as #y is

#y

.irst-)tage firing

0eactor

.urnaces =ressure

4ontroller =04-50,-20,

which is reset #y the lowest of the outputs

of ,0-T047-50%-20% (furnace exit temperature* or #y the lowest of the inputs of ,0-T04-50B-20B (reactor inlet temperature*. )imilarly )econd )tage 0eactor 0ecycle 3as .urnace .-,0027-< heats the remainder of the recycle gas to the proper temperature for hydrocracking. The reactor effluent descri#ed a#o&e the recycle gas flow cycle. The process temperatures in the furnaces are sufficiently high so that there is a large amount of useful heat in the flue gas. )ome of this heat is reco&ered #y generating high-pressure superheated steam in 4ommon 2aste Heat <oiler .-,00,. The steam is discharged to the refinery high-pressure steam system. High-pressure flow-controlled computer relay Transmitter #y #oiler feedwater with Drum a recei&es to .-,00, economi"er ad'ustment )team is #y .low after heat exchange and cooling as

returns to the high-pressure separator to complete

,0-.04)7-%0 which )team and

setpoint inputs V-,05,

,0-?-,%5

from 1e&el

,0-.T->A

4ontroller

,0-104->2. The #oiler feedwater is heated in the economi"er tu#es and flows to the steam drum. 2aste Heat <oiler 2ater 4irculating =umps =-,0507-< take suction from the steam drum and pump the water through the #oiler shock tu#es and e&aporator section #ack to the steam drum where steam is separated from the water phase. .rom the steam drum the steam flows through the superheater. The final steam temperature is controlled in High-=ressure )team 7ttemperator G-,002 #y ,0-T047-55 and exits to the high-pressure steam system. ,.5.% H8D0C36+ D9)T09<UT9C+ Hydrogen-rich makeup gas is supplied #y Hydrogen

$anufacturing Unit %000. The makeup gas allows for the chemical consumption of hydrogen leakage and solution losses. $akeup gas each is sent to .resh 3as 4ompressors F-,0057-<-4. Two compressors
OM/3000/3100/3200 Rev.1 3/9

April 1997

supplying >0I of design re!uirements while the third is on stand#y.

are normally in operation

The fresh gas compressors can #e considered the nucleus of the hydrogen supply and control system. )ince the hydrocracker is the largest consumer of hydrogen Hydrocracker 0eactor U-,000. Hydrodealkylation U-B>00 the system is handled as part of Cther hydrogen consumers are

Hydrodesulfuri"ation units 5200-5,00-5@00

E 5B00 U1)D ultra low sulfur diesel and =latformer Hydrotreater UB500. 0eference should #e made to manuals for the indi&idual units for further details. The fresh gas compressors are multistage machines e!uipped with common and 9nterstage 9nterstage fourth )uction 4oolers ,00A-,050-,055-,052 and are V-

Vessels

6-,00A-,050-,055.

4ompressed gas from the

stage is fed to the discharge of

0ecycle 3as 4ompressor F-,002. 7 side drawoff is taken from Third)tage )uction Vessel V-,055. =art of this gas is recycled to the hydrogen manufacturing unit under flow control. The other part is fed to the hydrogen header under pressure control. The tie-in to the hydrogen header is located near the #lock limit of Hydrodesulfuri"er Units. Higher controller in purity the feed hydrogen line to enhances Ferosene the operation of

U-5@00. The hydrogen header pressure is controlled #y a pressure supply Hydrodesulfuri"ation Unit 5,00. .eed gas pressure to this unit is the most critical one. Hydrogen production from =latformer Unit B200 also supplies the hydrogen header. The gas is fed to <ooster 4ompressors F-B2027 or < and is compressed into the header. The remaining H 2 consumers are supplied with gas from the H 2 header. ,.5.B 4C+T0C1 C. TH6 H8D0C36+ )8)T6$

OM/3000/3100/3200 Rev.1

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April 1997

The hydrogen pressure is

hydrogen

manufacturing to the

unit

is

capa#le gas

of

producing under

more hydrogen than all of the process units can consume. The excess discharged The refinery flow fuel system control. maximum through the letdown control

&al&e occurs when the hydrocracker is shut down and the hydrogen manufacturing unit is operating at @0I capacity. The recycle of hydrogen production to the hydrogen manufacturing unit fuel gas is then at a maximum. The refinery fuel gas system can a#sor# the hydrogen-rich gas without distur#ing #urner operation. 7dditional excess gas must #e sent to the flare. During 4ompressors consumption pressure normal operation is makeup to gas the first to .resh 3as

F-,0057-<-4 is

e!ui&alent through at the

total two of

hydrogen compressor 3as

consumption. The difference #etween compressor capacity and actual recirculated located the stages. The flow of hydrogen to the hydrocracker is controlled #y a controller suction 0ecycle 4ompressor F-,002. The controller regulates the recycle from Third )tage )uction Vessel V-,055 to .irst )tage )uction Vessel V-,00A.

7 decrease in the hydrocracker recycle gas pressure will close the &al&e in the recirculation line #etween the first two fresh gas compressor stages. 7s a result suction fuel gas pressure will decrease. The the fresh gas compressor controller in the pressure

hydrogen manufacturing unit will stop the flow of excess gas to or the flare. 7ll of the hydrogen production is then directed to consumers. 9f the control &al&e in the third to first stage recycle line is fully closed still too low and the pressure in the recycle gas loop is the &al&e controlling the gas flow to the hydrogen

header will close. The &al&e is actuated #y a low signal selector on the pressure controller at the recycle gas compressor suction. This feature ensures the priority of hydrogen supply to the hydrocracker o&er all other consumers. 7 third signal from a flow controller of hydrogen going to the hydrogen header at any time.
OM/3000/3100/3200 Rev.1 3/11 April 1997

a&aila#le

ena#les the operator to restrict the amount

9f the fresh gas compressor suction pressure goes #elow the minimum setting the pressure controller on the first-stage suction &essel o&errides any other signal to the control &al&e in the third to first-stage recycle line and the &al&e opens. The resulting decrease in pressure at the third-stage suction actuates another control &al&e the which recycles gas from the compressor discharge to suction. the full The compressor from is then in the total gas third-stage accept

recycle mode. The third stage suction &essel and 9nterstage 4ooler cannot recycle two operating fresh compressors. The operator must manually unload the compressors to achie&e a >0I capacity per compressor. =latformer make-gas is another source of hydrogen-rich gas for the hydrogen header. 7 split-range pressure control arrangement recycles gas from the discharge to suction of <ooster 4ompressor F-B202 when the gas make is low. 7ny excess gas is sent to refinery fuel gas. The &arious hydrogen consumers take gas from the hydrogen header either under pressure control or flow control. The controls are located within the respecti&e unit limits. ,.5.; C=607T9+3 V7097<16) The ma'or process &aria#les that affect #oth the

hydrotreating and hydrocracking reactions are/ Temperature. 4harge rate (space &elocity*. Hydrogen recycle rate. Cil recycle ratio. 0eactor pressure. Hydrogen purity. 4harge stock properties. :uality control.

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April 1997

5.

Temperature The temperature at which the reactions are occurring is the primary the &aria#le reaction the a&aila#le rate and to a the lower operator to control the reaction. 7n increase of reactor temperature increases slows temperature is down reaction. 0eactor temperature

controlled #oth #y controlling reactor feed temperatures and #y !uenching (with hydrogen* to maintain internal reactor temperatures.

The

#asic

reaction to

control

is

to

increase percentage 9f the

reactor of $V4 is

temperature from time to time deacti&ation V-,002 rising is not maintain

compensating for catalyst

re!uired

#ottom #leed. The le&el in 1i!uid 0ecycle )urge Vessel directly controlled. le&el the reactors are operating at less than 500I of

re!uired con&ersion. 7n increase of reactor temperature or some other change (such as reduction of feed rate at constant falling re!uired temperature* the reactors con&ersion is are and needed. operating a 9f at the o&er of le&el 500I is of

decrease

reactor

temperature is indicated. .irst-stage reactor temperatures are controlled to

arri&e at the re!uired denitrification (50 ppm wt*. The !uench flow rates are ad'usted to limit temperature rise o&er each #ed. .or the first-stage reactor temperature rise o&er the first two #eds should limited to 2>D4 should #e the #e

and 20D4 o&er the other #eds. .or the the temperature rise o&er each #ed to 50D4. Cperators must stri&e to

second-stage reactor limited

maintain a flat temperature profile. Cutlet temperatures are limited #y the maximum operating temperatures.

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April 1997

To prolong the acti&ity of the catalyst the desired con&ersion rates.

temperatures

should #e kept as low as possi#le while still achie&ing

2.

4harge 0ate ()pace Velocity* 2hen the charge rate is low the space &elocity is said temperature should #e

to #e low. 1ow space &elocity at constant temperature increases con&ersion. 9n general the danger of a runaway reaction. lowered prior to lowering the charge rate to minimi"e

,.

Hydrogen 0ecycle 0ate 9n general the unit should #e run at or near maximum except rate is

design hydrogen recycle rate. The recycle rate is not normally used to control operation of a unit temperature important therefore @. change for the is flow made. regime The in recycle the air that a small change of total recycle rate occurs as a coolersJ

it should not #e reduced #elow design le&el.

Cil 0ecycle 0atio The oil recycle ratio is not generally used as a primary control. (gas 9ncreasing #utane the oil recycle ratio tends to reduce hydrogen consumption and to reduce light product propane etc.* yields in fa&or of hea&ier (naphtha kerosene and gas oil* li!uid product yields.

9ncreasing the oil recycle ratio reduces the fresh feed processing capacity of the unit.

>.

0eactor =ressure

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9n general process

the unit should run at or near the maximum pressure. 0eactor pressure is not except

design

normally used to control operation of the unit stop

that emergency depressuring is used as a way to rapidly a reaction that has gotten out of control (runaway reaction*.

%.

Hydrogen =urity The hydrogen partial pressure promotes the occurring

reactions and reduces coke laydown. Hydrogen purity may #e ad&ersely affected #y upsets in the hydrogen plant causing it to produce a less pure hydrogen )eparator extremely affecting may well #e or hot the #y high which of temperature in the some of turn heat and-or in may High-=ressure #e to caused cool for #y the low fouling V-,00,

weather a#ility to pour #y

exchanger

exchangers

effluent. 2eather permitting lowered the gi&e point

the separator temperature compensation the hea&iest

hydrogen purity. Take care to keep the exit temperature a#o&e effluent The to material. 4aution must #e exercised in trying to o&erpurify a#ility hydrogen of the o&ercooling the separator. compressor centrifugal recycle

circulate the necessary amount of hydrogen is sensiti&e

OM/3000/3100/3200 Rev.1

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April 1997

to the molecular weight of the recycle gas turn is a measure of hydrogen purity. B. 4harge )tock =roperties 4harge stock a properties operators. change an early are in not unit controlla#le their of performance an

which in

#y can

the in #e

hydrocracker recogni"ing important in

Howe&er correction

alertness

undesira#le

charge stock property change. The most pro#a#le pro#lems are associated with high endpoint (high metals content charge* which would deacti&ate the catalyst. 7 noticea#le darkening of the feedstock color should #e treated as suspicious. 4olor 7larm 7naly"er ,0-:07-2 has #een installed to detect any contamination detecta#le #y a change in color.

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April 1997

3.2

HYDROCRACKER FRACTIONATION UNIT 3100 Hydrocracker .ractionation Unit ,500 processes li!uid hydro-

car#on product from Hydrocracker 0eactor Unit ,000 to separate gas oil kerosene naphtha sour 1=3 and sour fuel gas. The unit consists of three main sections/ ,.2.5 $ain fractionator. De#utani"er. $ild &acuum column.

$79+ .074T9C+7TC0 The feed to $ain .ractionator 4-,505 comes from the reactor

section low-pressure separator. The feed is preheated in reactor section #y heat exchange with reactor effluent. 7 #ypass of cold li!uid from low-pressure separator pro&ides temperature control. The feed enters main fractionator on Tray +o. 5% as a li!uid and &apor mixture. $ain .ractionator 0e#oiler =ump =-,505 circulates the column #ottoms through $ain .ractionator 0e#oiler .urnace .-,505. .uel gas to the #urners is flow-controlled #y ,5-.04)-0> which is reset #y $ain .ractionator .eed .low ,5-.T-A and compensated #y the density as measured #y ,5-:T-0>. 7 calculated amount of $= steam can also #e in'ected at .-,505 passes $ain out-let headers (two points* =ump &ia ,5-.04-555 as stripping media in 4-,505 for the purpose of maximum kero-gain (if re!uired*. and .ractionator <ottoms .low =-,502 pumps the net #ottoms product to the mild &acuum column &ia the Fero-stripperKs fractionator. to the main of de#utani"erKs re#oilers. 4ontroller ,5-.04-B5 is reset #y <ottoms 1e&el 4ontroller ,5-1047-5 in the main 7 slipstream of cooled #ottoms product is returned fractionator the under .low 4ontroller ,5-.94-,0. with This main

ensures that the heat input from the furnace is sufficient to allow re#oiling Fero-stripper and de#utani"er fractionator #ottoms product.

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3/17

April 1997

Ferosene is withdrawn from Tray +o. ,2 and is fed to the top tray of Ferosene )tripper 4-,502. The flow is controlled #y ,5-.042A and is reset #y the temperature on Tray +o. 2; (,5-T04-,*. Ferosene )tripper 0e#oiler 6-,50@ is re#oiled #y the fractionator column #ottoms. The stripper &apor is returned to the main fractionator <ottoms =ump #elow the kerosene drawoff tray. Ferosene )tripper

=-,50,Ldemolished pumpsM the kerosene to product rather than using pumps. The

#lending under 1e&el 4ontroller ,5-194-55. Total #y-pass of pumps ha&e #een pro&ided for normal use now hot kerosene is first used to preheat the de#utani"er feed in 6,50A. .inal cooling is achie&ed in Ferosene =roduct 7ircooler 6,50;. The main fractionator o&erhead &apor is partially condensed in $ain .ractionator C&erhead 4ondenser 6-,505. The fan pitch of 6-,505 is controlled #y Cutlet Temperature 4ontroller ,5-T04-50 which is reset #y 1e&el 4ontroller ,5-104-B of V-,505. =hase separation occurs in $ain .ractionator 0eflux Vessel V-,505. 7ll of the hydrocar#on li!uid is returned to the main fractionator as reflux &ia $ain .ractionator 0eflux =ump =-,50@. .low 4ontroller ,5-.04-2; is reset #y ,5-T04-2 the temperature controller on Tray +o. @B. 7 #oot on the reflux &essel is pro&ided to collect the small amount of condensate that forms. The condensate is drained manually as re!uired and sent to )our 2ater )tripper Unit >@00. no water is collected in V-,505. During normal plant operation

Vapor from the reflux &essel is further cooled and condensed in $ain .ractionator Top =roduct 7ircooler 6-,502 and Trim 4ooler 6-,50,. =hase separation occurs in $ain .ractionator Top =roduct Vessel V-,502. The li!uid hydrocar#on is fed to the de#utani"er. 1e&el is maintained in V-,502 #y 1e&el 4ontroller ,5-1047-5@ resets .low 4ontroller ,5-.04-,>. 4ondensate and 2ater )tripper Unit >@00 under 9nterface which water from V-,50@ ,5-

collects in the #oot of the top product &essel and is sent to )our 1e&el 4ontroller 194-5%.

OM/3000/3100/3200 Rev.1

3/18

April 1997

Vapor from the top product &essel is compressed and sent to the de#utani"er. To protect De#utani"er .eed 4ompressors F-,5057-< against H2) corrosion the &apor is first fed to 7D9= Treating U,200. 7 slipstream of compressed &apor is recycled to the reflux &essel to control the pressure in the main fractionator as measured #y ,5-=04-5.

De#utani"er consisting system &al&e of

.eed

4ompressors filter allow

F-,5057-< and at

are

motor-dri&en water of

reciprocating compressors. They are e!uipped with lu#e oil systems pumps that cooler operation closed-cooling 0 >0 and which has a tank unloaders pumps and cooler. The machines ha&e 500I

capacity. ,.2.2 D6<UT7+9N60 1i!uid hydrocar#on from Top =roduct Vessel V-,502 is pumped through the de#utani"er feed preheat train &ia De#utani"er .eed =ump =-,50>7-<. 7 start-up circulation line around =-,50> was added in 5AA, which ena#les the continuous operation of the De#utani"er .eed =ump in start-up. The preheat train consists of +aphtha and =roduct 6xchanger 6-,50B Ferosene =roduct 6xchanger 6-,50A

$V4 4irculating 0eflux 6xchanger 6-,550. The feed rate is under flow control reset #y the le&el in the top product &essel. The flow control &al&e is located so that &apori"ation occurs only in the last exchanger of the preheat train. The preheated feed enters De#utani"er measured #y 4-,50@ on Tray is +o. 2>. The #y feed temperature the as $V4 ,5-T04-2, controlled #ypassing

circulating reflux around 6-,550. The net flow of &apor from De#utani"er .eed 4ompressor F,505 is fed to the de#utani"er #elow Tray +o. 2;. The de#utani"er splits the feed streams into 1=3 and a full range naphtha. De#utani"er 0e#oiler 6-,555 is re#oiled #y #ottoms product from the main fractionator. +aphtha from the #ottom of the de#utani"er preheats the de#utani"er li!uid feed in 6-,50B. .urther cooling is achie&ed in +aphtha =roduct 7ircooler 6-,50% and Trim

OM/3000/3100/3200 Rev.1

3/19

April 1997

4ooler 6-,50>. The naphtha is run down to intermediate storage under the pressure of the column. .low is controlled #y De#utani"er <ottoms 1e&el 4ontroller ,5-1947-5A. The de#utani"er o&erhead &apor is partially condensed in

De#utani"er C&erhead 4ondenser 6-,552 and Trim 4ooler 6-,55,. =hase separation occurs in De#utani"er 0eflux Vessel V-,50@. 0eflux is pumped to the de#utani"er &ia De#utani"er 0eflux =ump =-,50%. .low 4ontroller ,5-.04-@> is reset #y a com#ination of pentane content of the o&erhead &apor as measured #y ,5-:04-52 and le&el in the reflux &essel as measured #y ,5-1047-22. 7lternati&ely the temperature on Tray +o. @2 can #e used as the reflux control point rather than pentane in the o&erhead &apor. The net li!uid o&erhead product is pumped to 7D9= Treating Unit ,200 &ia De#utani"er C&erhead 1i!uid =ump =-,50B. The flow of li!uid pentane product content is controlled of the #y ,5-.04-@% and is reset o&erhead &apor. #y the is de#utani"er =-,50B

e!uipped with minimum flow protection ,5 .94 A5. 4ondensate that separates out in the reflux &essel collects in a #oot. The water is drained to V-,502 on 9nterface le&el control. The light H4Ks a#sor#ed in this water steam are flashed off #efore sent to )our 2ater )tripper Unit >@00. The de#utani"er offgas is sent to 7D9= Treating Unit ,200 for treatment #efore discharge to the 1=3 U-5>00. .low is under #ack pressure control from the de#utani"er &ia ,5-=04-5;. ,.2., $91D V74UU$ 4C1U$+ The main fractionator #ottoms is fed to $ild Vacuum 4olumn 4-,50, after re#oiling the OFero stripper and de#utani"erP. The flow is reset #y the #ottoms le&el in the main fractionator. The feed enters the mild &acuum column on Tray +o. ;. $V4 0e#oiler =ump =-,50A circulates the column #ottoms

through $V4 0e#oiler .urnace .-,502. .uel gas to the #urners is

OM/3000/3100/3200 Rev.1 3/20 April 1997

flow-controlled #y ,5-.04)-;% the net #ottoms product

which is reset #y the feed flow rate the cooling circuit on 1e&el

to 4-,50, as measured #y ,5-.T-B5. $V4 <ottoms =ump =-,550 pumps through 4ontroller ,5-1047-2B. 7 slip stream of product returns to the #ottom of through the pumps is recycled to =roduct 7ircooler 4-,50, to ensure that there is sufficient flow works as minimum flow protection. The $V4 #ottom Hydrocracker 0eactor unit ,000 &ia $V4 <ottoms 6-,55B and 6-,55; &ia H-@A. 0est is #led to

fuel oil #lend &ia H->0.

.or operational control in the e&ent of hydrocracker reactor upsets a maximum of >0I of the normal recycle flow may #e di&erted to the flushing oil return system. The product directed to storage is then cooled #y heat exchange with gas oil in 6-,55A to pre&ent plugging due to its high pour point. $V4 <ottoms =roduct 4oolers 6-,55B-5; has #een modified in such a way that #oth can #e lined up in parallel fashion. <oth 6-,55B-5; can also #e operated in series depending on the amount of #ottoms product and the re!uirement of li!uid recycle temperature. <oth aircoolers 6-,55B and 6-,55; ha&e #een e!uipped with lou&ers and steam coils to a&oid pour point pro#lems with the $V4 #ottoms product. 7 #y-pass #etween 6-,55B and 5; has #een pro&ided to control final out-let temperature of 6-,55;. The mild &acuum column has a circulating reflux stream to pro&ide column temperature control. 1i!uid is withdrawn from Tray +o. 5B and pumped &ia $V4 4irculating 0eflux =ump =-,50; through De#utani"er 0eflux achie&ed Trim in =reheat 6-,55@ Train #y 6xchanger 6-,550 and the $V4 fan 4irculating control pitch. is The 7ircooler 6-,55@. 4olumn temperature

,5-T047-,A

ad'usting

reflux is returned to the column on Tray +o. 25. 3as oil product is withdrawn from Tray +o. 22. The tray is a total drawoff tray and the product is collected in $V4 3as Cil

OM/3000/3100/3200 Rev.1

3/21

April 1997

=roduct Vessel V-,50,. 7ll gas oil withdrawn is pumped #y $V4 Top 0eflux =ump =-,555. 7pproximately two-thirds of the gas oil is cooled in $V4 Top 0eflux 7ircooler 6-,55> and is returned to Tray +o. 2, as reflux under ,5-.04-;5 flow control. The temperature is controlled #y ,5-T04-%2 #y means of a #ypass around 6-,55>. The other one-third of the gas oil is cooled in $V4 3as 0i5 =roduct 4ooler 6-,55% and run down to product #lending on 1e&el 4ontrol ,5194-,5 of V-,50,. 7 slipstream after the product cooler is returned under .low 4ontroller ,5-.94-;2 to the top of the column as cold front reflux. 2hen necessary to use gas oil to cool the $V4 #ottoms in 6-,55A the gas oil flow is recycled to the $V4 gas oil product &essel. The gas oil flow is controlled #y the #ottoms product temperature. =art of 3as-oil product can also #e used as OpumpsP seal-flush mediaP except =-,50A 50. 4olumn &acuum conditions are maintained #y a two-stage e'ector set (G-,505 E G-,502*. +on-condensa#les are drawn through C&erhead 3as 4ondenser 6-,520 7-< and 9nter- and after-condensers 6,525 ,50>. The separated oil phase is intermittently pumped to wet and 6-,522. 4ondensed e'ector steam and any li!uid hydrocar#ons are collected in $V4 6'ector 4ondensate Vessel V-

slops &ia $V4 )lop Cil =ump =-,55,. 4ondensate is pumped under le&el control to )our 2ater )tripper Unit >@00 #y $V4 )our 2ater =ump V-,50% =-,552. The offgas is incinerated in flowing &ia 4ondensate Fnockout special #urners in $ain Vessel .ractionator

0e#oiler .urnace .-,505.

=-,552< has #een modified to work as

common spare pump for #oth =-,552 and =-,55,. (selector-switch ,5H9->> is to operate =-,552< with le&el-control logic of =-,55, selector-switch ,5-H9->> is to operate =-,552< with le&el control logic of =-,55,*. ,.2.@ )T67$ 36+607T9C+ Due to the high process temperature in the furnaces the

flue gases contain a large amount of useful heat. The flue gases

OM/3000/3100/3200 Rev.1

3/22

April 1997

are com#ined in 2aste Heat <oiler .-,50, and used to generate high pressure superheated steam which is discharged to the refinery high pressure steam system. High-pressure #oiler feedwater to .-,50, economi"er is flowcontrolled #y ,5-.04)7-500 with setpoint ad'ustment #y computer relay ,5-?-5>5 which recei&es inputs from )team .low Transmitter

,5-.T-AA and 1e&el 4ontroller ,5-104-@2 of )team Drum V-,555. The #oiler feedwater is heated in the economi"er tu#es and flows to the steam drum. 2aste Heat <oiler 2ater 4irculating =umps =-,55@7-< take suction from the steam drum and pump the water through the #oiler shock tu#es and e&aporator section #ack to the steam drum where steam is separated from the water phase. .rom the steam drum the steam flows through the superheater. The final steam temperature is controlled #y High-=ressure )team 7ttemperator G,50, #y ,5-T047-B5 and exits to the high-pressure steam system.

,.2.>

C=607T9+3 V7097<16) Varia#les that alter product specifications are pressure

temperature &aria#le. 5.

reflux

heat input

and product draw off rates. )ystem

pressure normally remains constant and should not #e considered a

$ain .ractionator The o&erhead naphtha product cutpoint is controlled #y ad'usting T04-2 7n 7)T$ which resets .04-2; and maintains the A>I point analy"er :0-; is desired temperature to produce a specification product. distillation pro&ided as a guide. The kerosene the product flow 7 of flashpoint hot oil is controlled the #y

ad'usting re#oiling

through analy"er

kerosene is

stripper re#oiler &ia ,5-?94-2%0 rate. flashpoint

there#y changing the :0-50

OM/3000/3100/3200 Rev.1

3/23

April 1997

pro&ided as a guide. The kerosene cutpoint is controlled #y ad'usting T04-, the desired product. guide. 7 gas-fired furnace pro&ides the primary heat input to the fractionator. The firing rate is ad'usted #y 0atio 4ontroller ,5-H?-2> reset #y ,0-.T-A feed to the fractionators. which resets .04-2A and maintains to produce :0-A a specification is pro&ided as a temperature

7 A>I point analy"er

OM/3000/3100/3200 Rev.1

3/24

April 1997

2.

De#utani"er 7 choice of two methods is pro&ided to control the

pentane content in the o&erhead li!uid. The first uses 4hromatograph 7naly"er :04-555 to master the spilt of o&erhead li!uid product and reflux. The second option utili"es Temperature 4ontroller T04-,0 to master the same spilt. The chromatograph should #e considered the primary mode of control. <utane content of the de#utani"er #ottoms product is

contingent on the proper heat input with the re#oiler while the column has the proper reflux. The heat input is controlled #y a flow of hot oil through the re#oiler with ?94-55>. 7 true &apor pressure analy"er pro&ided as a guide. ,. $ild Vacuum 4olumn The gas oil cutpoint is controlled #y controlling the temperature of Tray +o. 5> which in turn resets the temperature controller on the circulating reflux stream that will regulate the rate of production. 7n 7)T$ A>I point analy"er :0-5B is pro&ided as a guide. :0-B is

7 gas-fired furnace pro&ides the primary heat input to the mild &acuum column. The firing rate is ad'usted #y 0atio 4ontroller ,5-?-%> reset #y ,5-.T-B5 feed to the &acuum column. 3.3 ,.,.5 HYDROCRACKER ADIP - UNIT 3200 =0C46)) D6)409=T9C+ Hydrocracker 7D9= Treating Unit ,200 consists of three gas a#sor#er systems and one li!uid extraction system. 7D9= 0egenerator 4->0>5 in Unit >000 normally supplies lean 7D9= to this unit extractor are and regenerates fat 7D9= from up similarly as shown Hydrocracker 7D9= 7lternati&ely Treating Unit ,200. The three gas a#sor#er systems and the 1=3 lined #elow.

OM/3000/3100/3200 Rev.1

3/25

April 1997

inter connections ha&e #een pro&ided to line up U-,200 with 4->005 #ut with lower cracker-feed-rate.

OM/3000/3100/3200 Rev.1

3/26

April 1997

5.

Hydrocracker )cheme )our

Cffgas

Treating

(0efer

to

=rocess

.low

T-5.@;A.@2A.* gas from Hydrocracker 1ow-=ressure )eparator

V-,00@ is the only feed to 7D9= 7#sor#er 4-,205. The sour gas passes through .eed Fnockout Vessel V-,205 to remo&e any entrained li!uid prior to entering the #ottom section of 7D9= 7#sor#er 4-,205. 7fter counter-current washing >0>5* with in lean 7D9= from 7D9= 0egenerator Unit 99 (4the 7D9= 0egeneration )ection >000

treated gas is discharged into the refinery gas system under <ackpressure 4ontroller ,2-=04-2 &ia Treated 3as Fnockout Vessel V-,202. The fat 7D9= flows to 7D9= 0egenerator-99 under 1e&el 4ontroller ,2-1947-2. 2. .ractionator Cffgas Treating (0efer to =rocess .low

)cheme T-5.@;A.@2A.* The sour gas from $ain .ractionator Top =roduct Vessel V-,502 in Hydrocracker .ractionation Unit ,500 is com#ined with a small sour gas stream from )our 2ater .lash Vessel V-,00% in Hydrocracker 0eactor Unit ,000 and passes through .eed 3as Fnockout Vessel V-,20,. 7fter #y remo&al of li!uid present with The the lean gas 7D9= fat enters from the 7D9= is under is

#ottom section of 7#sor#er 4-,202 counter-current 99 washing 0egenerator (4->0>5*.

where H 2) is a#sor#ed 7D9=

resulting

pumped #y =-,205 to 7D9= 0egenerator 99 (4->0>5* connection to and from 7D9= 0egenerator 9 pro&ided for 7#sor#er 4-,202. The treated gas after remo&al of entrained

1e&el 4ontroller ,2-1947-B. 7n alternati&e lean-fat 7D9= 4->005

7D9=

in

V-,20@

is fed to de#utani"er column under tray +o 2; #y

compressors F-,5057-<.

OM/3000/3100/3200 Rev.1

3/27

April 1997

,.

De#utani"er )cheme

Cffgas

Treating

(0efer

to

=rocess

.low

T-5.@;A.@,0.*

The feed for this system consists of sour gas from the de#utani"ers fed in 4rude Distiller Units 5000-5500 and Hydrocracker .ractionation li!uid present into the Unit ,500. The streams are #ottom section of 3as 7D9=

&ia .eed 3as Fnockout Vessel V-,20% to separate any

7#sor#er 4-,20,. The H2) is a#sor#ed #y lean 7D9= from 7D9= 0egenerator 99 (4->0>5* and the resulting fat 7D9= is returned to 7D9= 0egenerator 99 (4->0>5*. Treated gas passes through Treated 3as Fnockout Vessel V-,20B prior to routing to 1=3 Unit 5>00. 7n alternati&e connection for routing a#sor#er o&erhead to refinery gas system is pro&ided for 7#sor#er 4-,20,. @. )our 1=3 Treating (0efer to =rocess .low )cheme

T-5.@;A.@,0.* This system treats sour 1=3 from 4rude Distiller Train 2 Unit 5500 and Hydrocracker .ractionation Unit ,500. The sour 1=3 flows into the #ottom section of 1=3 7D9= 6xtractor 4-,20@ which is packed with ,;-mm )).pall rings. 1ean 7D9= from 7D9= 0egenerator 99 (4->0>5* is #oosted up to re!uired pressure #y =-,202 and enters the top of the extraction column. )weet 1=3 lea&ing the top of the column passes through a small filter of polypropylene wool )-,205 to remo&e any solids prior to #eing washed with process in'ection water. 4omplete mixing of 1=3 and water is achie&ed with the mixing &al&e. The mixture is separated in 4oalescer V-,20;. )weet 1=3 flows under =ressure 4ontroller ,2-=04-; to 1=3 Unit 5>00. 7n alternati&e route for sweet 1=3 to fuel gas system in Unit A2B0 &ia &apori"er is pro&ided for 7D9= 6xtractor 4-,20@.

OM/3000/3100/3200 Rev.1

3/28

April 1997

.at 7D9= lea&ing the #ottom of the extractor under 9nterface 1e&el 4ontroller ,2-1047-5> com#ines with spent wash water from 4oalescer V-,20; and discharges into the #ottom section of 4-,205. 9n this column any entrained hydrocar#ons and some dissol&ed H 2) flash off. The com#ined fat 7D9= streams flow to 7D9= 0egenerator 99 (4->0>5* in Unit >000. ,.,.2 C=607T9+3 V7097<16) - H8D0C4074F60 7D9= U+9T ,200 The $a'or process &aria#les affecting the 7D9= treating unit are/ 5. 1ean 7D9= flow rate. 0esidual H2) content in lean 7D9=. Temperature of lean 7D9=. 1ean 7D9= .low 0ate The feed rates except is of as lean 7D9= will to not #e ad'usted purity which

normally control

necessary #y a

meet

product

re!uirements for the &arious 7D9= treating units. .low accomplished flow controller controls the lean 7D9= feed &al&e. 9ncreasing the lean 7D9= flow rate will decrease the H 2) content in the product #ut the amount that you can increase the flow rate is limited #y the column li!uid flow capacity. 2. 0esidual H2) 4ontent in 1ean 7D9= The residual H2) content in the lean 7D9= is affected #y the 7D9= regeneration residual H 2) operation le&el in in the Unit lean >000. 7D9= 2ith the increased

purity of treated product will #e ad&ersely affected.

OM/3000/3100/3200 Rev.1

3/29

April 1997

This increase in the lean 7D9= H 2) is normally corrected #y increasing the re#oiling rate in the regenerator. ,. Temperature of 1ean 7D9= The most important &aria#le used in maintaining the is H 2) H 2)

product purity in the 7D9= treating unit is the lean 7D9= temperature. This temperature lower partial solution temperature This will normally at >BD4 the solution the affected #y the regeneration operation in Unit >000. 7 lowers in turn pressure. increase

dri&ing force from &apor to solution exothermic a lower lean 7D9=

and will promote will also

the H2) 7D9= reaction. )ince the H 2) 7D9= reaction is temperature contri#ute to the efficient H 2) remo&al operation. The lean 7D9= temperature must the sour gas of condensation therefore ,20, 3.4 howe&er in #e maintained a#o&e to pre&ent and 49ndicator the a#sor#er 4-,202 and hydrocar#on hydrocar#ons Temperature dewpoint

foaming.

differential

alarms are pro&ided at the gas a#sor#ers

to detect such low temperature differentials.

QUALITY CONTROL 4ontinuous analytical recorders and-or alarms are pro&ided

on crucial streams where immediate process control or action is re!uired. These analy"ers are listed in Ta#le ,-5. Various sample stations are pro&ided where off-line analysis is sufficient for ade!uate process control. They are also re!uired where multiple measurements are re!uired. The sample stations are listed in Ta#le ,-2. 0efer to the 3eneral )afety $anual and the 1a#oratory $anual for a discussion of sampling procedures.

OM/3000/3100/3200 Rev.1

3/30

April 1997

Table 3-1. Anal !e"# Tag +um#er ,0-:07-2 ,0-:07-, ,0-:07-@ ,0-:0-55 ,0-:0-52 ,0-:0-25 ,0-:0-22 1ocation V-,005 inlet V-,05, li!uid F-,002 inlet .-,0057 flue gas .-,0027 flue gas .-,005< flue gas .-,002< flue gas )er&ice 4olor 4onducti&ity )pecific gra&ity C2-flue gas C2-flue gas C2-flue gas C2-flue gas

,5-:0-2 ,5-:0-> ,5-:0-B ,5-:0-; ,5-:0-A ,5-:0-50 ,5-:04-555 ,5-:0-5@ ,5-:0-5% ,5-:0-5B ,5-:0-25 ,5-:0-22

.-,505 flue gas V-,50A outlet 6-,50> outlet 6-,50> outlet 6-,50A outlet 6-,50A outlet 4-,50@ top .-,502 flue gas 6-,55% outlet 6-,55% outlet U-,500 outlet U-,500 inlet

C2-flue gas Density FV= A>I reco&ery A>I reco&ery .lashpoint =34 C2-flue gas .lashpoint A>I reco&ery H2) in refinery gas H2) in fuel gas

OM/3000/3100/3200 Rev.1

3/31

April 1997

,5-:07-2,

V-,555 li!uid

conducti&ity

7part from these analy"ers

there are H4-H 2) detectors in units to

warn people of gas leaks in the area.

OPC SA$PLIN% SCHEDULE

UNIT SAMPLE REQUIRED ANALYSIS
SAT 1500 Sour Water ex V-1502 #a$ to V-1501 Wax% D&$t&''ate (V-)001* L!"H!ADIP!H2S L N&tro+e, R R! L!V Rea-tor e..'ue,t )001A* )000 Rea-tor e..'ue,t )001/* (R(RN&tro+e, N&tro+e, "H!1!1e (2&$$o'3e2* L 1re$4 Water ()005* /'o6 Do6, ()01)* L&8u&2 Re-%-'e L S&O2!PO7 T/P P A Sour Water ()102* 1ue' #a$ ()109* )100 /'o6 Do6, (V-)111* #a$ O&' "H!1!1e (2&$$o'3e2* o:"o$&t&o, S&O2!PO7 u Str&"; 'ou2 Po&,t Rt 05:00AM D&$t&''at&o, <ero 1'a$4 Po&,t;S&'3er D&$t&''at&o, -)101 =otto: ADIP I ( -5001* a,2 5000 ADIP II ( -5051* H2 S R1/! So'&2$ 1e (2&$$o'3e2* AT/!T/ R1/!So'&2$!Water 0000 Lea, Su'.&,o' ( -0002* Oxa>o'&2o,e 1e (2&$$o'3e2*!AT/ /'o6 Do6, (V-0011* S&O2! o,2u-t&3&t%!"H A A A A A A A A A Rt Rt Rt 05:00AM 05:00AM A A 05:00AM 05:00AM 05:00AM A 05:00 AM A A A 05:00AM A A A A A A A A A A SUN A A A A

DAY
MON TUE WED

MONTHLY

Sour Water ()000**

OM/3000/3100/3200 Rev.1

3/32

April 1997

A ? A,a'%t&-a' La= Rt ? Rout&,e La=

Table 3-2. Sa&'le S(a()*n#

+"e,-en. N*. ,00.2 ,00.> ,02.5 T 'e L*.a()*n 6 D Q V-,05, outlet steam V-,00> outlet fractionator feed 6-,00B7 outlet effluent D 0 0 0 D 0 0 0 0 0 0 0 0 0 D D D D D D 0 0 0 : 0 0 0 : 0 0 0 0 0 0 0 0 : 0 0 0 4omposition H2) True #oiling point C2 4omposition H2) True #oiling point C2 4omposition H2) $olecular weight 4omposition H2) $olecular weight 4omposition H2) Density 4omposition H2) Density S(a"(-' ) ) N*"& 0 0 Anal !e/ P"*'e"()e# 4onducti&ity )iC2

,02.2-, D? ,0,.5 Q

.-,0057-.-,0027 flue gas 6-,00B< outlet effluent

,0,.2-, D? ,0@.5 D

.-,005<-.-,002< flue gas V-,00@ outlet sour gas

,0@.2

V-,00% outlet off gas F-,002 9nlet recycle gas V-,00A 9nlet H2 makeup

,0>.5

,0>.2

------------------------------------------------------------------------

OM/3000/3100/3200 Rev.1

3/33

April 1997

QD : 0 ) 2 TypeQ

Daily 4ontinuous #y :uality $easuring 9nstrument Cn re!uest =er shift 2eekly type. Table 3-2. Sa&'le S(a()*n# (contKd*
F"e,-en. S(a"(-' N*"& D D D ) ) 0 ) 0 D 0 D ) 0 0 0 0 0 0 : ) 0 0 : 0 0 0

- )ee Drawing +o.T-5.B%,.2%@ for special sample station

N*. ,0>.,

T 'e 6

L*.a()*n V-,055 outlet Hydrogen V-,555 outlet steam .-,505 flue gas 6-,55B outlet li!uid recycle .-,502 flue gas =-,552 discharge sour water =-,55, discharge slops

Anal !e/ P"*'e"()e# 4omposition H2) Density 4onducti&ity )iC2 C2 )pecific gra&ity True #oiling point H4 ratio C2 oil content pH 2ater content

,50.2

,55.5 ,5,.5

D? 4

,5,.2 ,5,., ,5,.@

D? 7? 7?

--------------------------------------------------------------------------------

D : 0 ) 2

- Daily - 4ontinuous #y :uality $easuring 9nstrument - Cn re!uest - =er shift - 2eekly - )ee Drawing +o. T-5.B%,.2%@ for special sample station type.

Type Q

OM/3000/3100/3200 Rev.1

3/34

April 1997

Table 3-2. Sa&'le S(a()*n# (contKd*

F"e,-en. N*. ,20.5 T 'e 6 L*.a()*n V-,20> outlet &ent gas V-,20> drain 7D9= 4-,205 outlet inlet 0 0 0 0 0 0 0 0 0 0 0 0 D D 0 0 0 0 0 0 D D 0 0 D D 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 S(a"(-' N*"& Anal !e/ P"*'e"()e# 4omposition H2) 0.< 0.< H2) 4C2 4omposition Dewpoint 4omposition $olecular weight H2) 0.< H2) 4C2 H2) 4omposition 4omposition $olecular weight H2) 0.< H2) 4C2 4omposition H2) 4omposition H2) 4omposition H2)

,20.2

<

,25.5-2 <

,25., ,25.@

D D

V-,202 outlet fuel gas V-,20, inlet sour gas

,25.>

<

4-,202 outlet fat 7D9=

,25.% ,22.5

D D

V-,20@ outlet treated gas V-,20% inlet sour gas

,22.2

<

4-,20, outlet fat 7D9=

,22.,

V-,20B outlet sweet 1=3 4-,20@ inlet sour 1=3 V-,20; outlet treated 1=3

,22.@

,22.>

------------------------------------------------------------------------

Q D : 0 ) 2

Daily 4ontinuous #y :uality $easuring 9nstrument Cn re!uest =er shift 2eekly

3/35 April 1997

OM/3000/3100/3200 Rev.1

Type Q

)ee Drawing +o. T-5.B%,.2%@ for special sample station type.

OM/3000/3100/3200 Rev.1

3/36

April 1997