ProSimulator

ProSimulator
AMINE TREATING UNIT
AMI01

Version 3.1
Mar 2015

Sim

Infosystems

Private Limited, Chennai

Amine Treating Unit
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ProSimulator

Table of Contents
1.
OBJECTIVE ................................................................................................................... 3
2.
PROCESS DESCRIPTION ............................................................................................ 3
2.1 Absorber Section ....................................................................................................... 3
2.2 Turbines and Pumps Section ..................................................................................... 5
2.3 Stripper Section ......................................................................................................... 7
3. PROCESS CONTROL SYSTEM .................................................................................. 9
3.1 Flow Controllers ....................................................................................................... 9
3.2 Level Controllers .................................................................................................... 10
3.3 Pressure Controllers ................................................................................................ 10
3.4 Temperature Controller ........................................................................................... 11
4.
INTERLOCKS .............................................................................................................. 13
5.
PROCESS CONDITION SUMMARY ........................................................................ 14
6.
MALFUNCTIONS ....................................................................................................... 16
7.
STARTUP PROCEDURE ............................................................................................ 19
8.
SHUTDOWN PROCEDURE ....................................................................................... 23
9.
AMINE
TREATING UNIT-P&ID ............................................................................... 25

Amine Treating Unit

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AMINE TREATING UNIT

1. OBJECTIVE
The primary objective of Amine Plant model is to teach trainees the operating
fundamentals of a Amine plant using dynamic simulation.
ProSimulator provides opportunities to identify the main equipments associated with
Amine Plant, to describe the operation of the plant, how to startup and shutdown the
process using documented procedures, how to respond safely and efficiently to
disturbances and malfunctions in the process.
Mc tiu chnh ca m hnh Amine thc vt l dy cho hc vin cc nguyn tc c bn
iu hnh mt nh my Amine s dng m phng ng.
ProSimulator cung cp c hi xc nh cc thit b chnh kt hp vi Amine thc vt,
m t cc hot ng ca nh my, lm th no khi ng v tt my qu trnh s
dng th tc ti liu, lm th no p ng mt cch an ton v hiu qu trc nhng
xo trn v trc trc trong qu trnh ny.
2. PROCESS DESCRIPTION
In Amine plant, CO

2 present in the feed synthesis gas is reduced from 54.0% to

0.06% by selective absorption using MEA (Mono Ethanol Amine). Gas handling capacity
of the simulated amine plant is 114 TPH of synthesis gas.
Amine plant consists of the following three sections :

Absorber Section
Turbine and Pumps Section

Stripper Section

MIU T QU TRNH

Trong Amine nh my, CO 2 c trong kh tng hp thc n gim t 54,0% xung

0.06% bi chn lc hp th dng MEA (Mono Ethanol Amine). Nng lc x l kh ca nh my
amin m phng l 114 TPH kh tng hp.

nh my Amin bao gm ba phn sau:

Absorber Mc
tua-bin v my bm Mc
Mc Stripper
2.1 Absorber Section
Absorber section contains the following equipments namely,

Absorber Column (T-01)

K.O Drum (D-03)

Lean Solvent Cooler (E-03)

Lean Solvent Heat Exchanger (E-02)

Amine Guard Inhibitor system (A-01)

Feed Synthesis gas with 54% CO
Amine Treating Unit

2 enters the bottom tray (Tray 38) of the

2.1 Mc Absorber
phn Absorber cha cc thit b sau y c th l,
Absorber Ct (T-01)
K.O Drum (D-03)
nc Solvent Cooler (E-03)
nc Solvent trao i nhit (E-02)
H thng Amin Guard cht c ch (A-01)

Thc n tng hp kh c 54% CO 2 vo khay di cng (Khay 38) ca

Amine n v iu tr
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Absorber Column

(T-01).

Absorber column is maintained at a pressure of 26 Kg/cm2 (g). Feed gas is contacted with
Lean MEA solvent cascading from Tray 3. MEA solvent
after absorbing CO

2 present in the Feed gas gets collected at the bottom drum in the

Absorber Column as Rich MEA Solvent. Heat of absorption raises the temperature of the
MEA solvent from 37.4 Deg C to 86.5 Deg C.
The top two trays of the Absorber column is Wash Section in which continuous flow of
steam condensate of 1.3 m3 /hr is maintained by using Absorber Wash Water Pump (P-01).
Steam condensate collected in the trough of Tray 2 is fed to Reflux Drum (D-02)
maintaining steam condensate level within wash section. Wash water (steam condensate)
circulation removes any solvent entrained in the product gas.
Ct Absorber (T-01). ct hp th c duy tr p sut 26 kg / cm2 (g). kh Feed c
lin lc vi nc MEA tng dung mi t Tray 3. MEA dung mi
sau khi hp th CO 2 c trong cc kh ngun cp d liu c thu thp ti trng pha di
trong
Ct Absorber nh Rich MEA dung mi. Nhit hp thu lm tng nhit ca dung mi
MEA t 37,4 C n 86,5 Deg C.
Hai khay trn cng ca ct Absorber l Ra Mc trong dng chy lin tc ngng t hi
nc l 1,3 m3 / hr c duy tr bng cch s dng Absorber Ra My bm nc (P-01).
Hi nc ngng t thu c trong mng ca Khay 2 c a n tro ngc Drum (D02) duy tr mc ngng t hi nc bn trong phn ra. Ra nc (ngng hi) lu
thng loi b dung mi bt k cun trong kh sn phm.

Synthesis gas with low concentration of CO

into

2 exits the top of Absorber

Knock-out Drum where traces of wash water are removed from the product
gas and temperature of Product gas is reduced if it is above design limit.
Quench water circulation is maintained in K.O Drum using Quench Water
Circulation pump (P-02).
Lean Solvent from Turbine and Pumps section transfers its sensible heat
content to the Rich Solvent leaving the bottom of the absorber in the Lean

Solvent Exchanger 2 (E-02).

Lean Solvent leaving E-02 is cooled down further to 37.4 Deg C in Lean
Solvent cooler (E-03) using Cooling water as cooling medium. Bypass flow
across Lean Solvent cooler is maintained manually to control Lean
Solvent
temperature.
Continuous recirculation of Lean Solvent is
maintained through Amine Guard Inhibitor system (A1. ) where corrosion inhibitors and antifoam additives are mixed with Lean

Solvent not shown in Graphic.

kh tng hp vi nng thp ca CO 2 thot ra khi u ca Absorber vo
Knock-out Drum ni du vt ca nc ra c ly ra t kh sn phm v
nhit ca kh Sn phm c gim bt nu n l trn gii hn thit k.
Dp tt tun hon nc c duy tr trong K.O Drum s dng my bm lu
hnh dp tt bng nc (P-02).
Da dung mi t tua-bin v bm phn chuyn ni dung nhit hp l ca n
Rich Solvent b ri di cng ca cht hp th trong dung mi nc trao
i 2 (E-02).
Nc Solvent b li E-02 c lm lnh xung thm 37,4 C trong mt dung
mi nc (E-03) s dng lm mt nc nh l phng tin lm mt. dng
chy Bypass trn mt dung mi Lean Manufacturing c duy tr bng tay
kim sot nhit dung mi nc. tun hon lin tc ca Lean dung mi c
duy tr thng qua h thng Amin Guard cht c ch (A1.), ni cc cht c ch n mn v ph gia chng to bt c trn vi nc
dung mi - khng hin th trong ha.

ProSimulator

2.2 Turbines and Pumps Section

This section consists of the following process equipment,

Lean Solvent Pump A (P-03A) - Motor Driven

Lean Solvent Pump S (P-03S) - Motor Driven

Lean Solvent Pump B (P-03B) - Hydraulic Turbine Driven

Hydraulic Turbine (X-02)

Rich solvent from the bottom of the Absorber Column after passing through Lean Solvent
Exchanger 2 (E-02) exchanger enters Flash Drum through Hydraulic Turbine and
Hydraulic Turbine Bypass Valves.
High pressure Rich solvent from Absorber column drives the Hydraulic Turbine (X2. ) as it passes through it, which in turn drives the Lean Solvent Pump (P-03B) thereby
utilizable energy of Rich Solvent is recovered. Rich solvent at the downstream of
Amine Treating Unit
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Hydraulic Turbine recombines with the Rich Solvent passing through the Hydraulic
Turbine Bypass Valves (LV101B & C) and enters into Flash Drum (D-01).
Lean Solvent from the bottom of the Stripper Column (T-02) is pumped to Absorber
Column by Lean Solvent Pumps A or S & B (P-03 A or S & B). Lean Solvent Pump A (P03A) and Lean Solvent Pump S (P-03S) are motor Driven Pumps and Lean Solvent Pump
B (P-03B) is Turbine Driven Pump (Hydraulic Turbine).
Lean Solvent Pump S (P-03S) is a standby pump which can be taken on line when P03A fails to maintain required Circulation flow.
2.2 Tuabin v Bm Mc
Phn ny bao gm cc thit b x l nh sau,
nc dung mi bm A (P-03A) - motor
nc dung mi bm S (P-03s) - motor
nc dung mi bm B (P-03B) - tuc bin thy lc Driven
thy lc Turbine (X-02)
Giu dung mi t di cng ca ct Absorber sau khi i qua nc Solvent trao i 2 (E-02)
trao i vo flash Drum qua tua bin thy lc v thy lc Turbine Van Bypass.
p lc cao Giu dung mi t ct Absorber a Turbine thy lc (X2.) khi n i qua n, m ln lt cc a vi dung mi bm nc (P-03B) nng lng do
utilizable ca Rich dung mi thu hi. dung mi giu h lu
Turbine thy lc ti kt hp vi Rich dung mi i qua tua bin thy lc Bypass Van
(LV101B & C) v i vo Flash Drum (D-01).
Da dung mi t di cng ca ct Stripper (T-02) c bm vo Absorber Ct do Lean
Solvent Bm A hoc S & B (P-03 A hoc S & B). Da dung mi bm A (P-03A) v da
dung mi bm S (P-03s) c bm ng c Driven v da dung mi bm B (P-03B) l
Turbine Driven bm (Turbine thy lc).
Da dung mi bm S (P-03s) l mt my bm d phng c th c thc hin trn
ng khi P- 03A khng duy tr dng chy lu thng cn thit.

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2.3 Stripper Section
Stripper Section consists of the following equipments,
Flash Drum (D-01)
Stripper Column (T-02)
Reflux Drum (D-02)
Lean Solvent Exchanger 1 (E-01)
Stripper Overhead Condenser (E-04)
Steam Reboiler (E-05)
Hot Oil Reboiler (E-06)

Rich Solvent from Absorber flashes into the Flash Drum (D-01) partly stripping off CO
2 present. Flash Drum is maintained at a pressure of 0.72 Kg/cm2 (g).
Rich Solvent from the bottom of the Flash Drum after getting preheated by Lean Solvent
from the Stripper Bottom in Lean Solvent Exchanger (E-01) enters Stripper Column above
Tray 3. Stripper is maintained at a pressure of 0.63 Kg/cm2 (g).
Similar to Absorber column, top two trays are wash section of Stripper Column. Wash
section is fed with Reflux Drum (D-02) Bottom Liquid.
Rich Solvent as it cascades down within the Stripper Column countercurrent to a
flow of rising steam and carbon dioxide, strips off the CO 2 from the solvent. The solvent
gets progressively hotter, releasing CO 2, as it continues flowing down the column. The
liquid accumulates in a chimney tray sump and circulates through the stripper reboilers (E05 & E-06).
The stripper reboilers E-05 & E-06 provide the heat required for generating steam. In
steam Reboiler (E-05), steam is used as the heating medium and in Hot Oil Reboiler (E06), Hot Oil is the heating source. In stripper reboilers, steam is generated and CO
liberated along with it. CO 2 and steam vapors return back to the stripper, providing vapor
stripping action required to regenerate the MEA solution.

2 is

The liquid in the reboiler overflows to the bottom of the stripper. Temperature of the bottom liquid in
Stripper is maintained at 121.0 Deg C at which the concentration of lean amine is maintained. By
controlling the boiling point of the solution, the concentration of the lean solvent is controlled.
Lean solvent from the bottom of the Stripper is pumped to Absorber by Lean Solvent
Pumps.
Vapors along with CO 2 exits the top of Stripper Column and combines with exit
vapors from Flash Drum. These vapors are then condensed in Stripper Overhead
Condenser (E-04), which are then separated from CO

2 gas in Reflux Drum. Reflux

Drum is maintained at 0.5 Kg/cm2 (g). Reflux Drum bottom liquid is circulated back to
Wash Section of Stripper by Reflux Pumps (P-04 A/B).
2.3 Mc Stripper
Stripper mc bao gm cc thit b sau y,
Flash Drum (D-01)
Stripper Ct (T-02)
Tro ngc Drum (D-02)
Nghing Solvent trao i 1 (E-01)
Stripper ngng Overhead (E-04)
Hi Reboiler (E-05)
Hot Du Reboiler (E-06)

Giu dung mi t Absorber nhy vo trong Flash Drum (D-01) mt phn l tc CO

2 mt. Flash Drum c duy tr p sut 0,72 Kg / cm2 (g).
Giu dung mi t y ca Flash Drum sau khi b lm nng trc do Lean dung mi t y Stripper
Lean Solvent trao i (E-01) vo Stripper Ct trn Tray 3. Stripper c duy tr p sut 0,63 Kg /
cm2 (g).
Tng t nh ct Absorber, u hai khay l phn ra ca Stripper Column. phn Wash c cho n
vi tro ngc Drum (D-02) di dng lng.
Giu Solvent nh thc xung trong ct Dng ngc Stripper n mt
dng chy ca hi nc tng cao v carbon dioxide, di ra CO 2 t cc dung mi. cc dung mi
cng ngy cng nng hn, gii phng CO 2 khi n tip tc chy xung ct. Cc
cht lng tch t trong mt thng ng nc thi khay ng khi v lu thng qua reboilers v n
thot y (E-05 & E-06).
Nhng v n thot y reboilers E-05 & E-06 cung cp nhit cn thit to ra hi nc. Trong
Reboiler hi (E-05), hi nc c s dng nh l phng tin si m v trong Hot Oil Reboiler
(E06), Hot Oil l ngun si m. Trong reboilers v n thot y, hi nc c to ra v CO 2 l

gii phng cng vi n. CO 2 v hi nc bc hi tr li vi v n thot y, cung cp hi

tc hnh ng cn thit ti to cc gii php MEA.

Amine Treating Unit

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3. PROCESS CONTROL SYSTEM

3.1 Flow Controllers
FIC101
Flow of Feed Synthesis gas to Absorber Column is controlled at 113.7 TPH by a Flow
Controller FIC101 linked with control valve FV101.
FIC102
Wash Water flow to Absorber Wash section is controlled at 1.3m3 /hr by Flow Controller
FIC102 linked with FV102.
FIC103
Lean Solvent Flow to Absorber Column is controlled at 529.6 m3 /hr by Flow Controller
FIC103 linked FV103 A/B. This is a Split range controller.
H THNG KIM SOT 3. QUY TRNH

3.1 B iu khin dng chy

FIC101
Dng chy ca kh Thc n tng hp hp th Ct c kim sot mc 113.7 TPH bi mt dng iu
khin FIC101 lin kt vi van iu khin FV101.
FIC102
dng chy ra nc phn Absorber Ra c kim sot mc 1.3m3 / hr bi lung iu khin FIC102
lin kt vi FV102.
FIC103
Da dung mi Flow Absorber Ct c kim sot mc 529,6 m3 / hr bi lung iu khin FIC103 lin
FV103 A / B. y l mt b iu khin tm Chia

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When the controller output is

from 0% to 50%, control valve FV103A opens from 0% to 100%. At 50% controller
output, valve FV103A is 100% open. When the controller output is from 50% to 100%,
the control valve FV103B opens from 0% to 100%. At 100% controller output, both the
control valves FV103 A & B are 100% open.
Khi u ra iu khin l
t 0% n 50%, van iu khin FV103A m t 0% n 100%. 50% sn lng iu khin, van FV103A l 100% open. Khi
u ra iu khin l t 50% n 100%, cc FV103B van iu khin m ca t 0% n 100%. Ti 100 u ra% iu khin, c
hai van iu khin FV103 A & B l 100% open.

3.2 Level Controllers

LIC101
Absorber Column Bottom Drum level is maintained at 51.1% by split range controller
LIC101 linked with three control valves LV101A/B/C. When the output signal of
controller LIC101 is from 0% to 42%, control valve LV101A opens from 0% to 100%
(provided output of Manual Loading Station (HIC106) is higher than the signal from
LIC101). When the output signal of LIC101 is from 42% to 75%, control valve LV101B
opens from 0% to 100%. If the output signal of LIC101 is from 67% to 100%, control
valve LV101C opens from 0% to 100% (provided LIC101 signal is in selected
condition).
3.2 B iu khin mc
LIC101
Absorber Ct mc Drum di c duy tr mc 51,1% vo chia LIC101 iu khin
phm vi lin kt vi ba van iu khin LV101A / B / C. Khi tn hiu u ra ca b iu
khin LIC101 l t 0% n 42%, van iu khin LV101A m t 0% n 100% (sn lng
cung cp ca i ti Manual (HIC106) cao hn so vi cc tn hiu t LIC101). Khi tn
hiu u ra ca LIC101 l t 42% n 75%, van iu khin LV101B m t 0% n 100%.
Nu tn hiu u ra ca LIC101 l t 67% n 100%, van iu khin LV101C m t 0%
n 100% (cung cp tn hiu LIC101 l la chn iu kin).
LIC102
Absorber Wash section level is controlled at 52.6% by LIC102 which is linked with
control valve LV102.

LIC103
Flash Drum Level is maintained at 48.4% by LIC103, which is linked with the control
valve LV103.
LIC104
Reflux Drum Level is maintained at 51.4% by LIC104 linked with control valve LV104.
LIC102
Absorber Ra phn Cp c kim sot mc 52,6% ca LIC102 c lin kt vi van iu
khin LV102.
LIC103
Flash Drum cp c duy tr mc 48,4% ca LIC103, c lin kt vi cc LV103 van iu khin.
LIC104
Tro ngc Drum cp c duy tr mc 51,4% ca LIC104 lin kt vi van iu khin LV104.

Amine Treating Unit

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3.3 Pressure Controllers
PIC101
Knock Out Drum Pressure is maintained at 25.7 Kg/cm2 (g) by the pressure controller
PIC101 linked with control valve PV101.
PIC102
Reflux Drum Pressure is maintained at 0.5 Kg/cm2 (g) by the pressure controller PIC102
linked with control valve PV102.
PIC103
Flash Drum Pressure is maintained at 0.72 Kg/cm2 (g) by the pressure controller PIC103
linked with control valve PV103.
3.3 B iu khin p sut
PIC101

Knock Out Drum p sut c duy tr mc 25,7 kg / cm2 (g) ca PIC101 iu khin p
lc lin kt vi van iu khin PV101.
PIC102
Tro ngc Drum p sut c duy tr mc 0,5 Kg / cm2 (g) ca PIC102 iu khin p
lc lin kt vi van iu khin PV102.
PIC103
Flash Drum p sut c duy tr mc 0,72 kg / cm2 (g) ca PIC103 iu khin p lc
lin kt vi van iu khin PV103.

Manual Loading Station

3.4 Temperature Controller

TIC101
Stripper Bottom Temperature is maintained at 121.0 Deg C by the Temperature
Controller TIC101, which is linked with TV101.
HIC101
Flow of Product gas from K.O Drum to Battery limit is manually controlled using
HIC101.
HIC102
Nitrogen supply for pressurizing the Absorber and K.O Drum during startup is manually
controlled using HIC102.

HIC103
Quench Water circulation flow is manually controlled using HIC103.

Amine Treating Unit

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B iu khin nhit 3.4
TIC101
Stripper Nhit di c duy tr 121,0 C ca iu khin nhit TIC101, c lin kt vi TV101.
HIC101
Dng chy ca kh Sn phm t K.O Drum n gii hn ca pin iu khin bng tay s dng
HIC101.

HIC102
cung cp nit cho p lc cho cc Absorber v K.O Drum qu trnh khi ng c iu khin bng tay dng HIC102.

HIC103
dng chy lu thng tt la nc c iu khin bng tay dng HIC103

HIC104
Quench water flow from K.O Drum to Reflux Drum is manually controlled using
HIC104.

HIC105
Bypass flow of Lean Solvent Cooler is manually controlled using HIC105.

HIC106
Lean Solvent Flow through Hydraulic Turbine is manually controlled using HIC106.

HIC107
Lean Solvent Flow through Bypass Valve LV-101C is manually controlled using
HIC107.
HIC109
CO2 to Battery Limit Flow is manually controlled using HIC109.
HIC110
Hot Oil Flow into Reboiler is manually controlled using HIC110.
HIC111
Makeup Solvent Flow is manually controlled using HIC111.

HIC104
Dp tt lu lng nc t K.O Drum n tro ngc Drum c iu khin bng tay dng HIC104.

HIC105
dng chy Bypass ca Lean Solvent Cooler c iu khin bng tay dng HIC105.

HIC106
Nghing dng dung mi qua tua bin thy lc c iu khin bng tay dng HIC106.

HIC107
Nghing dng dung mi qua Bypass Van LV-101C c iu khin bng tay dng HIC107.
HIC109
CO2 Battery Gii hn lu lng c iu khin bng tay dng HIC109.

HIC110
Hot du chy vo Reboiler c iu khin bng tay dng HIC110.
HIC111
Trang im dng dung mi c iu khin bng tay dng HIC111.

Amine Treating Unit

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4. INTERLOCKS

Amine Treating Unit

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5. PROCESS CONDITION SUMMARY

TAG

TAG DESCRIPTION
ENGINEERING

NAME

TYPE DESIGN
VALUE UNIT

LIC101 Absorber Column Level Controller

CTL 51.1

LIC102 Absorber Wash Section Level Controller

CTL 52.6

LIC103 Flash Drum Level Controller

CTL 48.4

LIC104 Reflux Drum Level Controller

CTL 51.4

FIC101 Feed gas Flow Controller

CTL 113.7 TPH

FIC102 Steam Condensate Flow Controller

CTL 1.3

FIC103 Lean Solvent to Absorber Flow Controller

CTL 529.6 m3/hr

PIC101 K.O. Drum Pressure Controller

CTL 25.7

Kg/cm2 (g)

PIC102 Reflux Drum Pressure Controller

CTL 0.5

Kg/cm2 (g)

PIC103 Flash Drum Pressure Controller

CTL 0.72

Kg/cm2 (g)

TIC101 Stripper Bottom Temperature Controller

CTL 121.0 Deg C

HIC101 K.O. Drum Top to Battery Limit

MLD 17.9

HIC102 Nitrogen Supply

MLD 0.0

HIC103 Quench Water Circulation

MLD 70.3

HIC104 Quench Water to Reflux Drum

MLD 0.0

HIC105 Bypass Flow of Lean Solvent Cooler

MLD 11.3

HIC106 Lean Solvent Flow through Hydraulic Turbine

MLD 100.0 %

HIC107 Lean Solvent Flow through Bypass Valve LV-101C MLD 0.0

m3/hr

HIC109 CO2 to Battery Limit

MLD 100.0 %

HIC110 Hot Oil Flow into Reboiler

MLD 50.0

HIC111 Makeup Solvent

MLD 0.0

LI101 Stripper Level

IND 53.7

LI102 K.O Drum Level

IND 49.3

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FI101 Boiler Feed Water Flow

IND 0.00

m3/hr

FI102 Absorber Wash Water Flow to Reflux Drum

IND 1.57

m3/hr

FI103 Quench Water Circulation Flow

IND 10.3

m3/hr

FI104 Quench Water Flow to Reflux Drum

IND 0.00

m3/hr

FI105 Nitrogen Flow

IND 0.0

TPH

FI106 Product Gas Flow from K.O Drum to Battery Limit IND 52.9

TPH

FI107 Product Gas Flow from K.O Drum to Flare

IND 0.00

TPH

FI108 Bypass Flow of Lean Solvent Cooler

IND 56.6

m3/hr

FI109 Lean Solvent flow through Lean Solvent Pump A IND 395.5 m3/hr FI110
Lean Solvent flow through Lean Solvent Pump B IND 162.0 m3/hr
FI111 Rich Solvent Flow through Hydraulic Turbine

IND 635.1 m3/hr

FI112 Lean Solvent Flow through Lean Solvent Pump S IND 0.0

m3/hr

FI113 Rich Solvent Flow into Flash Drum

IND 666.7 m3/hr

FI114 Flash Drum Bottom Flow to Stripper

IND 636.1 m3/hr

FI115 Hot Oil Flow through Reboiler

IND 10.74 TPH

FI116 Steam Flow into Reboiler

IND 8.28

TPH

FI117 Makeup Solvent Flow

IND 0.0

m3/hr

FI118 CO2 Flow from Reflux Drum to Flare

IND 18.6

TPH

FI119 CO2 Flow from Reflux Drum to B/L

IND 45.8

TPH

FI120 Reflux Drum Bottom Flow To Stripper

IND 14.6

m3/hr

PI101 Feed gas Battery Limit Pressure

IND 30.0

Kg/cm2 (g)

PI102 Absorber Top Pressure

IND 26.0

Kg/cm2 (g)

PI103 Suction Pressure of Lean Solvent Pumps

IND 0.63

Kg/cm2 (g)

PI105 Stripper Top Pressure

IND 0.63

Kg/cm2 (g)

DPI101 Absorber Differential Pressure

IND 0.28

Kg/cm2

DPI102 Stripper Differential Pressure

IND 0.21

Kg/cm2

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TI101 Feed Gas Temperature

IND 48.4

Deg C

TI102 Absorber Bottom Temperature

IND 86.5

Deg C

TI103 Lean Solvent Temperature (at the inlet to Absorber) IND 37.4

Deg C

TI104 Rich Solvent Temp (at the inlet of Flash Drum) IND 93.7

Deg C

AI101 CO2 Concentration in K.O Drum Outlet

IND 0.06

AI102 CO2 Concentration in Absorber Inlet

IND 54.14 %

ZI101 FV103 A Position

IND 36.4

ZI102 FV103B Position

IND 0.0

ZI103 LV101A Position

IND 100.0 %

ZI104 LV101B Position

IND 4.9

ZI105 LV101C Position

IND 0.0

6. MALFUNCTIONS

S. NO DISTURBANCES CHANGE EFFECTS

Lean Solvent into Absorber Temperature (TI103)
Increases.
1

CWS Temperature Increased Absorber Bottom Temperature (TI102) Increases. CO2

Content (AI101) in K.O Drum Outlet
Increases.
Absorber Bottom Temperature (TI102) Decreases.
CO2 Content (AI101) in K.O Drum outlet

Absorber Efficiency Decreased Increases.

Absorber Pressure (PI102) increases. K.O Drum
Pressure (PIC101) increases.

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Feed Gas Absorber Bottom Temperature (TI102) Increases.

Temperature
Increased CO2 Content (AI101) in K.O Drum Increases.
Flow into Stripper from Flash Drum (FI114) Drops..
Concentration of CO2 in Lean Solvent into
4

E-01 Tube Leakage Increased Absorber increases thereby increasing concentration of

CO2 (AI101) in Product gas leaving K.O Drum
because of reduced absorption rate.
5

E-01 Flow Fouling Increased Tube side flow through E-01 Decreases. FIC103
Decreases.Stripper Level increases (LI101).
K.O Drum Pressure (PIC102) Decreases.

Stripper Efficiency Decreased CO2 flow (FI118 & FI119) Decreases.

SLNO FAILURES

CHANGE EFFECTS
Steam Condensate flow (FIC102) drops to zero.

P-01 Pump Fail On

Absorber Wash Water Level (LIC102) Decreases.

Wash Water Flow to D-02 (FI102) Decreases.

2

Absorber Relief Valve Absorber Pressure (PI102) Drops.

Blow
On
K.O Drum Pressure (PIC101) Drops.
Concentration of CO2 (AI101) in K.O Drum

High CO2 in Feed gas On Outlet Increases. Absorber Bottom Temperature (TI102)

Increases.
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Lean Solvent flow into Absorber (FIC103) Drops.
4

P-03A Pump Fail On

Absorber Level (LIC101) Drops. Rich Solvent

Flow (FI111) through X-02 Turbine
Drops because of corrective action by LIC101.
Lean Solvent flow into Absorber (FIC103) Drops.

P-03S Pump Fail On

Absorber Level (LIC101) Drops. Rich Solvent

Flow (FI111) through X-02 Turbine
Drops because of corrective action by LIC101.
Hydraulic Turbine Fails.

P-03B Pump Fail On

Lean Solvent Flow (FIC103) Drops and the

controller takes action accordingly.
Absorber Level (LIC101) Increases and the
controller takes action accordingly.

P-04A/B Fail On

Reflux flow into Stripper (FI120) Drops to zero.

Reflux Drum Level (LIC104) increases.
Stripper Level (LI101) Drops.

Flash Drum Relief

Flash Drum pressure (PIC103) drops.

Valve Blow On

Level of Flash Drum (LIC103) increases due to

reduced flow to stripper.

Concentration of CO2 (AI101) in Product gas at
Design flow rate of Feed gas and Lean Solvent
9

High Water in Makeup Circulation is more than the required specification

Solvent
On
tak. Applicable only when make up solvent is en
while invoking the fault

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7. STARTUP PROCEDURE
SL NO DESCRIPTION
Pressurization of Absorber with Nitrogen
Take K.O Drum Pressure Controller (PIC101) (GR02) in Auto mode and set 25.7
Kg/cm2 (g) as its set point.
Open Absorber Top to K.O Drum On-Off valve HV114 (GR06) .
Pressurize K.O Drum and Absorber by opening HIC102 (GR06) till 7.0 Kg/cm2 (g).
Close Nitrogen Supply HIC102 after pressurizing till 7.0 Kg/cm2 (g)
Establishment of Solvent Circulation
Open Solvent Makeup valve HV111 using Manual Loading Station HIC111 and charge
the solvent into Stripper Bottom.
Allow level to buildup in Stripper till 60% (LI101) (GR04) .
Open P-03A suction valve HV118 (GR08) .
Start P-03A (GR08)by clicking on the pump.
Open P-03A Discharge valve HV119(GR08).
Open FV103A manually using FIC103 (GR02)and charge Solvent into Absorber.
Allow level to buildup in Absorber till 60% (LIC101)(GR02).
Reset XV101 ESD using BYP101 & RST105(GR05).
Ensuring HIC106 at 0%, Open LV101B manually using LIC101(GR02) setting its
output above 50% and charge Flash Drum with Solvent.
Allow the level of Flash Drum to buildup till 50% (LIC103)(GR04).
Open LV103 manually using LIC103(GR04) and then charge Solvent into stripper trays.
(After filling of trays, Reboiler gets filledup. After filling of Reboilers solvent
overflows into Stripper Bottom.)
Establish circulation of 250m3/hr with Absorber at 7.0 Kg/cm2(g).
Open Cooling water to Stripper Condenser (E-04) using On-Off valve HV127(GR07).

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Raise the temperature of circulating Solvent till 120 Deg C slowly by manually
charging steam into Reboiler (E-05) using TIC101 (GR04)or manually charging Hot Oil
into Hot Oil Reboiler (E-06) using HIC110 (GR07).
Take Lean Solvent flow controller (FIC103) (GR02) in Auto mode with its set point as
250m3/hr.
Open Amine Guard System Block valve HV160 (GR06) to establish continuous flow
through Amine Guard Inhibitor System.
Take Absorber Level Controller (LIC101)(GR02) in Auto with its set point of 50%.
Take Flash Drum Level Controller (LIC103) (GR04) in Auto with its set point of 50%.
Take Flash Drum Pressure Controller PIC103 (GR04) into Auto and set 0.72 Kg/cm2
(g) as its set point.
Take Reflux Drum Pressure Controller PIC102 (GR04) into Auto and set 0.5 Kg/cm2
(g) as its set point.
Allowing temperature of Lean Solvent to raise, simultaneously start filling Condensate
in K.O Drum (D-03) and Reflux Drum (D-02) (GR04) adopting the following
procedure.
Commissioning of K.O Drum and Reflux Drum
Start Steam Condensate Pump (P-01)(GR02) .
Open Block valve HV116 (GR06) and then open HV103 to 5% using HIC103 (GR04)
and charge condensate into K.O Drum (D-03).
Allow K.O Drum Level (LI102) (GR02) to buildup till 30%.
Once K.O Drum Level reaches 30%, keeping HIC103 (GR04) at 70% open, start Quench water
circulation pump (P-02) (GR02) and establish Quench water circulation
of around 10m3/hr.
Allow K.O Drum Level (LI102) (GR02) to buildup till 50%.
Open HV104 using HIC104 (GR06) and allow condensate to buildup level (LIC104)
(GR04) in Reflux Drum (D-02) till 25%.

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Once Reflux Drum Level (LIC104) (GR04) reaches 30%, open Reflux pump Suction
valve (HV123/HV125)(GR07)and start Reflux Pump (P-04A/B) and then open
32

(HV124/HV126) (GR07).
Open LV104 using LIC104 manually and establish Reflux flow (FI120)(GR04)

33

maintaining the level of Reflux Drum (D-02).

34

Take Reflux Drum Level Controller (LIC104) (GR04)in Auto with its setpoint as 50%.
Pressurization of Absorber with Feed Gas
Open Feed Gas Block Valve HV113 (GR06) and slowly pressurize Absorber with Feed
gas using FIC101(GR02) in Manual mode till 26.0Kg/cm2 (g) (PI102). (Pressurization
must be performed very slowly such that levels of Absorber, Stripper and Flash Drum

35

are maintained.)
Increase Lean Solvent flow to 60-70% of Design Flow (FIC103) (GR02)around

36

350m3/hr.
Charge cooling water into Lean Solvent Cooler (E-03) using HV117(GR06) and
maintain the temperature of Lean Solvent into Absorber temperature TI103 at 37.8 Deg

37

C using Bypass valve HV105(GR06).

Adjust levels in Absorber (T-01)(GR02), (GR04)Stripper (T-02) and Flash Drum (D-

38

01).
Commissioning of Wash Section

39

Open FV102 using FIC102 (GR02)and charge Wash Water into Absorber Wash Section.

40

Allow level to buildup in Absorber Wash Section (LIC102) (GR02)till 50%.

41

Take FIC102(GR02) into Auto mode with its set point as 1.3 m3/hr.
Open LV102 using LIC102 (GR02)and establish wash water circulation to Reflux Drum

42

maintaining the level in Wash Section.

43

Take LIC102 into Auto mode with its set point as 50%.
Establishment of Feed Gas flow

44

Slowly Establish Feed gas flow through Absorber till less than 50% of design flow.

45

Accordingly adjust Lean Solvent flow into Absorber (FIC103)(GR02).

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When the Product gas meets the specification of 0.06% (mass) of CO2 (AI101)(GR02),
slowly open Product Gas to Downstream unit valve HV101 using HIC101
46

(GR02)maintaining the pressure of the Absorber and K.O Drum at Operating Value.
Maintain the stripper Bottom temperature TIC101 (GR04)at Design value of 121 Deg C

47

manually.
(If required take Hot oil Reboiler (E-06) into line by opening Hot Oil into Reboiler using
HIC110.)
Stabilization of Plant
Slowly increase the Feed gas flow through Absorber (FIC101)(GR02) keeping the Feed
gas flow controller in Auto mode by slowly incrementing the set point of it till Design

48

value, maintaining the pressure of Absorber.

Accordingly increase Lean Solvent Circulation rate (FIC103) (GR02) till Design value

49

maintaining CO2 concentration in the Product gas meeting the Specification

Maintain the temperature of the Lean Solvent into Absorber (TI103) (GR02)at its

50

Design value.

51

Take Stripper Bottom Temperature Controller (TIC101) (GR04)in Auto with its set
point as 121.0 Deg C
Commissioning of Hydraulic Turbine (X-02)
Open Lean Solvent Pump (P-03B)(GR03) Suction valve HV120 (GR08) and Discharge

52

valve HV121(GR08).

53

Slowly charge Rich Solvent into Hydraulic Turbine by increasing the output of
HIC106(GR03).
(Initially till 50% of the Design rate of flow through Turbine, the Hydraulic Turbine will
not produce any net power. Above 50% of the Design flow rate, Turbine will produce net
power and speed of P-03B increases consequently Lean Solvent flow rate through

54

P-03B increases.
Slowly raise the flow across Turbine using HIC106 (GR03)till 100% such that Lean

55

Solvent Flow is not disturbed much and levels of Absorber, Stripper and Flash Drum are
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maintained.

8. SHUTDOWN PROCEDURE
S.NO

DESCRIPTION

Stop Feed gas flow rate into Absorber using FIC101 (GR02)and block valve
HV113(GR06) in the Feed gas line.

Line out Hydraulic Turbine by reducing HIC106 (GR03)output to zero slowly. Slowly

close Product gas to Downstream unit valve using HIC101(GR02) and maintain the Absorber
pressure at 7.0 Kg/cm2 (g) using PIC101(GR02). This will take considerable
3

time to get depressurized.

Reduce the temperature of Circulating Lean solvent by cutting Hot Oil supply to Hot Oil
Reboiler

(E-06) using HIC110(GR07) and reducing steam flow rate into Steam Reboiler

(E-05) manually using TIC101 (GR04) and maintain the temperature at 80 to 90 Deg C.

Stop Condensate flow to Absorber Wash section using FIC102 (GR02)and put OFF
5

Condensate pump (P-01).

Continue Lean Solvent Circulation till 30 min using Lean Solvent Pump A/S. Maintain

Absorber (T-01) pressure at around 7.0Kg/cm2 (g) for maintaining the circulation. Reduce

the Level of Absorber Wash Section (LIC102) (GR02) to 0.0% by draining it to

7

Reflux Drum (D-02) using LV102 valve.

Stop Quench Water Circulation Pump (P-02) and drain K.O Drum (D-03) to Reflux Drum
(D-02) using HIC104(GR06).

Stop Lean Solvent Pump (P-04A/S)(GR07).

10

Cut Steam supply to Steam Reboiler (E-05) using TIC101(GR04).

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11

Start draining Stripper (T-02) using HIC129(GR07).

12

Stop Reflux Pump (P-04A/B) and start draining condensate using HIC130(GR07).

13

Depressurize Flash Drum (D-01) and drain it to Stripper (T-02) using LIC103(GR04).
Depressurize Absorber (T-01) to 0.2 Kg/cm2(g) using PIC101 for further shutdown

14

process to continue.

15

Start draining Absorber (T-01) using HIC128(GR06).

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9.

AMINE TREATING UNIT-P&ID

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Amine Treating Unit

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