Recovery Plus Operating Manual

RELIANCE PETROLEUM LIMITED

OPERATING MANUAL RECOVERY PLUS

JAMNAGAR

UNIT 233

RECOVERY PLUS OPERATING MANUAL Table of Contents

1.0

General 1.1

1.2

Introduction

Glossary 1.3

2.0

3.0

4.0

Abbreviation

Unit Description 2.1

Design Basis

2.2

Process Flow Description and Controls

2.3

DCS Description

2.4

Design Flow Plan

2.5

Refinery Site, Underground Piping and Unit Layout Plan

2.6

Material Balance

2.7

Feed and Product Specifications

2.8

Catalyst and Chemicals Details

2.9

Utility conditions and requirement

Interconnectivity 3.1

Inter Unit Relationship

3.2

Inter Plant Relationship

3.3

Utility / Offsite Relationship

Preparing the Unit for Initial Start-up 4.1

Introduction

CHECKED BY SR APPROVED BY MG

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RELIANCE PETROLEUM LIMITED JAMNAGAR

4.2

Utility System Readiness

4.2.1

Piping Network

4.2.2

Commissioning of Utilities

4.3

Inspection of Equipments

4.3.1

Piping and Supports 4.3.1.1

Visual Inspection

4.3.1.2

Hydrostatic Test

4.3.1.3

Flushing

4.3.1.4

Air Blowing and Drawing

4.3.1.5

Tightness Test

4.3.2

Vessels

4.3.3

Exchangers

4.3.4

Pumps

4.3.5

Compressors

4.3.6

Instrumentation System

4.3.7

Electrical System

4.4

Chemical Cleaning and N2 Blaketing

4.5

Run-in Pumps

4.6

Run-in Compressors

4.7

Tightness Test and Inertisation

5.0

4.7.1

Tightness Test

4.7.2

Vacuum Test and Inertisation

4.8

Safety Checks Before Start-up

OPERATING MANUAL RECOVERY PLUS UNIT 233

Commissioning / Initial Start up 5.1

notification to other departments


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6.0

7.0

UNIT 233

5.2

Utilities Start-up

5.3

Outline of Initial Start-up

5.4

Evacuation of Air, Nitrogen and Water Removal

5.5

Charging of Lube Oil

5.6

Oil Circulation

5.7

Inventory Refrigeration Circuit with Refrigerant

5.8

Initial Compressor Start-up

Start up 6.1

General

6.2

Notification to Other Departments

6.3

Utilities Start-up

6.4

Outline of Initial Start-up

6.5

Compressor Start-up

Normal Shutdown 7.1

General

7.2

Notification to Other Departments

7.3

Preshutdown Preparation

7.4

General Outline of Normal Shutdown

7.5

Refrigeration Circuit Shut Down

7.6

Process Circuit Shut Down

7.7

Refrigerant Retained in Receiver

7.8

Post Shutdown Checks

7.9

Equipment Handing/Taking Over to/from Maintenance


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8.0

9.0

10.0


Normal Operation 8.1

Process Principles

8.2

Process Variables

8.3

Control Philosophy & Key Analyses

Unit Safeguarding System 9.1

Relief Device Summary

9.2

Instrument Alarm

9.3

Instrument Trip

Emergency Shutdown 10.1

General

10.2

Interconnectivity During Emergencies

10.3

Process and Utility Failure

10.3.1 Power Failure 10.3.2 Loss of Cooling Water 10.3.3 Loss of Refrigerant 10.3.4 Loss of Instrument Air

11.0 Special Procedures 11.1 Initial Refrigerant Loading

12.0

Fire & safety 12.1

Introduction

12.2

Repair Work, Permit to Work System, Housekeeping and Maintenance on


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UNIT 233

12.3

Safety During Sample Withdrawal

12.3

Fire Fighting and Safety Equipment

12.5

Precautions for Entering any Contaminated or Inert Atmosphere

12.6

General RECOVERY PLUS Unit Safety Notes

12.7

Material Safety Data Sheet (MSDS)

13.0

Laboratory Requirements and Schedule

14.0

Major Equipment and Instruments’ Summary 14.1.1 Vessels 14.1.2 Shell and Tube Exchangers 14.1.3 Pumps 14.2

15.0

Instruments Summary

List of Reference Drawings PFD, P & ID, MFD, Plot Plan, PSFS, MSD, Area Protection Layout, Safety Equipment Layout, Safety Signs Layout, PIB#4 Gaseous Fire Extinguishing System


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1.O

GENERAL

1.1

Introduction The Aromatics plant at Jamnagar is designed to produce 1,200,000 tons of Paraxylene per annum and 150,000 tons of Orthoxylene from naphtha feed stock (2641 KTPA) available from Jamnagar Refinery Complex and Mixed Xylenes (80 KTPA) from Hazira. Feed Naphtha from the refinery consists of: 

Straight run naphtha



Delayed Coker naphtha



FCC heart cut Naphtha Paraxylene Plant basic technology has been provided by UOP. It will process special cut Naphtha (105 oC – 165 oC) to produce Paraxylene as the major product and other side cut products. These are as follows.



LPG

= 305

TPD



Light Reformate

= 752

TPD



Benzene

= 326

TPD



Toluene

= 300

TPD



Paraxylene

= 3600 TPD



Orthoxylene

= 450

TPD



Heavy aromatics to blend = 407

TPD



Heavy aromatics to fuel

=

48

TPD



Hydrogen

= 171

TPD

In addition some gases will go to fuel gas system.



Paraxylene plant in Jamnagar consists of the following units: 1.

Heavy Naphtha Unionfining Unit

Unit No.221

2.

Platformer Unit

Unit No.231

3.

Cyclemax Continuous Regeneration Unit

Unit No.232

4.

Recovery-Plus

Unit No.233

5.

PSA

Unit No.234

6.

Xylene fractionation unit (3 trains)

Unit No.241/242/243

7. Orthoxylene fractionation unit

Unit No. 251

8. Parex Unit (3 trains)

Unit No. 261/262/263

9. Isomar Unit (3 trains)

Unit No. 271/272/273

10. Tatoray Unit

Unit No.281

11. Aromatics Tankage

Unit No.201

12. Aromatic Blowdown

Unit No.202

Key Features As a part of the Jamnagar Refinery complex, aromatic plant is being established. A great emphasis has been placed on maximizing the ratio of Paraxylene to Benzene product. This serves to minimize the quantity of naphtha feed stock required per ton of Paraxylene product and avoids excess production of Benzene. A key element of UOP’s strategy is to maximize Paraxylene to Benzene ratio by controlling the Naphtha initial points and end points upstream in the refinery. Heavy Naphtha feed stock for Platforming unit is obtained from three sources as follows.


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Boiling range a. Saturate Gas Concentration Unit Naphtha 105 to 165 oC b. Sydec Delayed coker Unit Naphtha

105 to 165 oC

c. FCC heart cut naphtha

105 to 180 oC

For naphtha streams initial boiling point of 105 oC has been selected and a wide gap specified. This cut point, combined with a sharp fractionation, will serve to drive most of the C7 paraffin’s up into the light naphtha storage, but retain most of Toluene in the heavy naphtha to be used for aromatics production via Platforming units. The 105 oC cut point also eliminates Benzene precursors from the Platforming unit feed stock. The end point of 165 oC will ensure that almost all C8 molecules and many C9 molecules will go into the heavy naphtha feed stock for aromatics production. To maximize Paraxylene production, it is important to retain all the C8 precursors and obtain just the right amount of C9 to generate enough C9 aromatics to fully load the Tatoray unit.


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1.2

OPERATING MANUAL UNIT 233

Glossary

Terms Absorption

-

Description The process by which one substance draws into itself another substances i.e. CO2 absorbed in K2CO3 solution, HC absorbed in lean oil from net gas stream, etc.

Accumulator

-

A vessel for the temporary storage of a gas or liquid usually used for collecting sufficient material for a continuous charge to some refining process.

Adsorption

-

The physical separation of multiple components by solid adsorbent. i.e. removal of moisture, CO2 from air by air dryer using silica / alumina as adsorbent.

API

-

An arbitrary scale expressing the gravity or density of liquid petroleum products. The measuring scale is calibrated in terms of degrees API. It may be calculated in terms of the following formula : Deg. API = (141.5/sp.gr. @60 °F) - 131.5

Aromatic

-

Derived from, or characterized by the presence of the benzene ring and having sweet odor. The name usually

applied

to

the

benzene

series

of

hydrocarbons; derived from the characteristic odor of the series; Paraxylene, Ethyl Benzene(EB), Tri-


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Terms

UNIT 233

Description methyl benzene(TMB), Para di-ethyl benzene(PDEB).

Aromatic

-

A naphtha rich in aromatics precursors

Naphtha Atom

-

The smallest complete particle of an element which can be obtained which retains all physical and chemical properties of the element.

Atomize

-

To divide a liquid into extremely minute particles, either by impact with a jet of steam or compressed air, or by passage through some mechanical device.

Back pressure

-

1. The pressure on the outlet or downstream side of a flowing system. 2. In an engine, the pressure which acts adversely against the piston, causing loss of power.

Barrel

-

A common unit of measurement of liquids in the petroleum industry; it equals 42 U.S. standard gallons.

Baume

-

Specific gravity of liquids expressed as degrees on the Baume scale. For liquids lighter than water, the formula is : Sp. gr. 60 F/600 F = 140 /(130+deg. Be) For liquids heavier than water, the formula is : Sp. gr. 60 F/600 F = 145 / (145 - deg. Be)


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Terms

UNIT 233

Description

Bleeding Blend

-

Diverting a small portion of the material contained in

-

a line or vessel, usually by opening a valve slightly. Any mixture prepared for a special purpose; e.g. the products of a refinery are blended to suit market

Boiling Point

-

requirements. The temperature at which a substance boils or is converted into vapor by bubbles forming within the

Boiling Range

-

liquid; it varies with pressure. The range of temperature, usually determined at atmospheric

pressure

in

standard

laboratory

apparatus over which the boiling or distillation of an oil commences, proceeds, and finishes. Bottoms

-

The liquid which collects in the bottom of a vessel / column / tank during processing/storage. i.e. column bottom

Byproduct

-

A secondary or additional product produce during production

of

Major

product,

not

of

primary

importance. i.e. Benzene byproduct in production of Paraxylene. Calibration

-

Determination of the accuracy of an instrument by finding its variation from true measurement.

Carryover

-

1. Relatively nonvolatile contaminating material which is carried over by the overhead effluent from a


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Terms


Description fractionating column, absorber, or reaction vessel. It may be carried as liquid droplets or finely divided solids suspended in a gas/vapor/discrete liquid. 2. That portion of a finely divided catalyst

which

escapes the cyclones of cracking units. Catalyst

-

A substance which affects, provokes, or accelerates reactions without itself being altered.

Caustic Soda

-

Sodium hydroxide, a very strong alkali.

Centrifugal

-

Consists of one or more impellers mounted on a

Pump

(Volute

rapidly rotating shaft. The liquid enters the impellers

Type)

at the center, or ‘eye’, and is thrown outward at a high velocity into the volute of the pump casing. The function of the volute is to catch the impeller discharge and convert velocity head into pressure head while conducting the liquid to the discharge nozzle of the pump casing.

Compressor

-

A machine which draws in air or other gas, compress it and discharges it at a higher pressure.

Condensation

-

The act or process of changing a vapor to a liquid, or a lighter liquid to another and denser form by depression of temperature or increase of pressure.

Condenser CHECKED BY SR APPROVED BY MG

-

Ordinarily a water-cooled heat exchanger used for PAGE : 12 REVISIO : 00 OPERATING MANUAL N : 01 ISSUE RECOVERY PLUS UNIT

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Terms


Description cooling and liquefying oil vapors. Where the cooling medium used is air, the condenser is called an air condenser.

Conduction

-

The flow of heat by contact.

Convection

-

The flow of heat through liquid or gas by actual

-

mixing of the fluids A heat exchanger whose primary purpose is to

Cooler

reduce the temperature of one of the passing fluids. Cracking

-

A phenomenon by which large oil molecules are decomposed into smaller, lower boiling molecules; at the same time, certain of these molecules, which are reactive, combine with one another to give even larger molecules than those in the original stock. The more stable molecules leave the system as cracked gasoline, but the reactive ones polymerize, forming tar and even coke. Note: Cracking may be in either the liquid or vapor phase. When a catalyst is used to bring about the desired chemical reaction, this is called catalytic cracking; otherwise, it is assumed to be thermal

Crude Oil

-

cracking. A synonym for petroleum. A naturally occurring mixture consisting predominantly of hydrocarbons and/ or sulfur, nitrogen, and oxygen derivatives of


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Terms


Description hydrocarbons which is removed from the earth in a liquid state or is capable of being, so removed.

Discharge Line

-

Product line usually under pressure due to a pumping force being applied.

Distillate

-

That portion of a liquid which is removed as a vapor and condensed during a distillation process.

Distillation

-

Vaporization

of

a

liquid

and

its

subsequent

condensation in a different chamber. The separation of one group of petroleum constituents from another by means of volatilization in some form of closed apparatus, such as a still, by the aid of heat. Drawoff

-

A connection which allows liquid to flow from the side or bottom of a vessel.

Effluent

-

Outflow from vessel/equipment/tank

Extraction

-

The process of separating a material, by means of a solvent, into a fraction soluble in the solvent (extract) and an insoluble residue.

Flammable

-

Capable of being easily set on fire; combustible.

Flash

-

1. A sudden release in pressure resulting in partial or complete vaporization. 2. A sudden burst of light; a


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Terms


Description momentary blaze.

Flash Point

-

The lowest temperature at which vapors arising from the oil will ignite momentarily (i.e. flash) on application of a flame under specified conditions.

Flooding Flue Gas

-

In a fractionating column, the filling up of a liquid due

-

to high pressure drop across trays or packing. Gas from the combustion of fuel, the heating value of which has been substantially spent and which is therefore, discarded to the flue or stack.

Fuel Oil

-

Any liquid or liquefiable petroleum product burned for the generation of heat in a furnace or firebox, or for the generation of power in a engine (exclusive of oils

Header

-

with a flash point below 100 °F ) A common manifold in which a number of pipelines are united.

Heat

-

Exchanger

Apparatus for transferring heat from one fluid to another. Specifically, a piece of equipment having a tubular piping arrangement which effects the transfer of heat from a hot to a relatively cool material by conduction through the tube walls.

Heater

-

The furnace -and- tube arrangement which is the principal heating element in a processing unit.


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Terms Hydrocarbon

-


Description A compound containing only hydrogen and carbon. The simplest hydrocarbons are gases at ordinary temperatures, but with increasing molecular weight, they change to the liquid form and finally to the solid state. They form the principal constituents of petroleum.

Impingement

-

The contact of flame on skin of radiant tubes in the furnace.

Induced Draft

-

Air drawn rather than forced into a furnace.

Inert gas

-

A noncombustible gas such as nitrogen or carbon dioxide.

Inhibitor

-

A substance the presence of which, in small amounts, in a petroleum product prevents or retards undesirable chemical changes from taking place in the product, or in the condition of the equipment in which the product is used. In general, the essential function of inhibitors is to prevent or retard oxidation or corrosion.

Knockout Drum

-

A drum or vessel constructed normally with baffles, through which a mixture of gas and liquid is passed to disengage one from the other. As the mixture comes in contact with the baffles, the impact frees


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Terms

UNIT 233

Description the gases and allows them to pass overhead; the heavier substance falls to the bottom of the drum.

Liquefied

-

Petroleum Gas

Light hydrocarbon material, gaseous at atmospheric temperature and pressure, held in the liquid state by pressure

to

facilitate

storage,

transport,

and

handling. Commercial LPG consists essentially of propane, butane, or mixtures thereof. Manifold

-

A piping arrangement which allows one stream of liquid or gas to be divided into two or more streams, or which allows several streams to be collected into one.

Molecule

-

Unit of matter; the smallest portion of an element or a compound which retains chemical identity with the same particular substance enmasse.

Multi-Stage

-

Centrifugal Pump Naphthene

Centrifugal pump which has two or more impellers mounted on the same shaft.

-

A saturated hydrocarbon having the general formula CnH2n and a cyclic molecular structure; i.e. cyclopropane, cyclo-butane, cyclo-pentane, cyclohexane.

Natural Gas

-

Naturally occurring mixtures of hydrocarbon gases and vapors, the more important of which are methane, ethane, propane, butane, pentane, and hexane.


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Terms

UNIT 233

Description

Olefin

-

An open chain, unsaturated hydrocarbon having one double bond. i.e. Ethylene C2H4

Orifice

-

A device for restricting the flow through a pipe. The difference in pressure on the two sides of an orifice plate can be used to measure flow through the pipe.

Packed Tower

-

A fractionating or absorber tower which is filled with small objects (packing material, i.e. rasching ring,) to effect an intimate contact between rising vapor and falling liquid.

Paraffin

-

That series of noncyclic hydrocarbons having the general formula CnH2n

, and having no double &

+ 2

triple bonds. i.e. Butane C4H10 , Hexane C6H14 , etc. .

Petrochemical

-

A naphtha lean in aromatics precursors

Naphtha Petroleum

-

A

material

occurring

naturally

in

the

earth,

predominantly composed of mixtures of chemical compounds of carbon and hydrogen with or without other nonmetallic elements such as sulfur, oxygen, nitrogen,

etc.

Petroleum

may

contain,

or

be

composed of, such compounds in the gaseous, liquid,


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Terms


Description and / or solid state, depending on the nature of these compounds

and

the

existent

conditions

of

temperature and pressure. Petroleum

-

Naphtha

A generic term applied to refined, partly refined, or unrefined petroleum products and liquid products of natural gas, not more than 10 per cent of which distill below 175 °C, and not less than 95 percent of which distill below 240 °C, when subjected to distillation in accordance with ASTM Method D-86.

pH Value

-

The logarithm of the reciprocal of the hydrogen ion concentration. This indicates the acid or alkaline condition of a substance, pure water and neutral solutions having a pH of 7. Acid solutions have a pH less than 7 ; alkaline solutions, a pH greater than 7.

Polymer

-

Product of polymerization of normally gaseous olefin hydrocarbons.

Power pump

-

A reciprocating pump in which the liquid pistons are driven by other means than direct acting steam pistons and rods.

Preheater

-

Any form of equipment in which heat is applied to a material prior to its introduction into the main heating equipment. The application of heat is usually


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Terms


Description accomplished by means of hot fluid which have to be cooled and whose heat would otherwise be wasted.

Pressure Drop

-

The decrease in pressure due to friction/plugging, which occurs when a liquid or gas passes through a pipe/filter/vessel, etc.

Pressure

-

Vessel

An enclosed container in which greater than atmospheric pressure is maintained.

Pump Priming

-

The filling of the liquid end of a pump with liquid to remove vapors present and eliminate the tendency to become vapor lock.

Purging

-

The displacement of one material with another in process equipment; frequently, displacement of hydrocarbon vapor with steam or inert gas.

Quench

-

To suddenly cool hot material discharging from a cracking coil, usually by injecting cool oil into the discharge line; its purpose is to check the cracking reaction quickly.

Radiation

-

The act of emitting energy, particularly rays of light or heat.

Reactor

-

The vessel in which the major part of a reaction or conversion takes place. In catalytic cracking it is the


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Terms


Description enlarged space in which hot oil is converted to simpler compounds.

Reciprocating

-

Pump

A Positive displacement type of pump consisting of a plunger or a piston moving back and forth within a cylinder. With each stroke of the plunger or piston, a definite volume of liquid is pushed out through the discharge valves.

Reflux

-

In fractional distillation, that part of the distillate which may be returned to the column to assist in making a better separation into desired fractions is called Reflux. Reflux may be either circulating or induced. Circulating reflux is liquid/vapor which is withdrawn hot, normally cooled, and pumped back to the tower. Induced reflux is liquid formed within a fractionation tower by condensation of vapors by means of an internal cooling coil.

Residue

-

Heavy oil or bottoms left in the still after gasoline and other relatively low-boiling constituents have been removed.

Rich Oil

-

The oil drawn off the bottom of an absorber tower containing fractions absorbed from a gas.

Riser

-


That portion of the bubble plate assembly which

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Terms


Description channels the vapor and causes it to flow downward to escape through the liquid.

Rotary pump

-

A positive displacement pump used mainly to pump liquids which are either too viscous or too difficult to pick up suctions with a centrifugal pump. There are many types of rotary pump designs, one of the most common being the gear type - in which two gears mesh and rotate toward each other within a very close fitting casing. The liquid is trapped between the gear teeth and the casing and carried around to the discharge side of the pump. The meshing gear teeth prevent the liquid from returning to the suction side.

Rundown Tank

-

One of the tanks in which product is received from the plant and from which the product is pumped to larger tanks known as storage tanks. Rundown tank is also known as Receiving tank or Day tank, designed to store only one day’s production(with enough cushion) . If the product was received directly into the large storage tanks, the offspec. product due to plant upset would contaminate unnecessarily larger size product storage tank.

Scrubbing

-

Purifying a gas by washing with water or chemical; less frequently, the removal of entrainment. The


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Terms


Description material to be purified is called a scrubber.

Separator

-

A holding vessel used to aid in the separation of light and heavy gravity material. i.e. Separator in reactor section separate liquid and recycle gas.

Simplex pump

-

A reciprocating pump that has one liquid cylinder on a single drive.

Sour Crude

-

Crude oil containing an abnormally large amount of sulfur compounds which, upon refining, liberate corrosive sulfur compounds.

Specific Gravity

-

The ratio of the weight of a volume of a body to the weight of an equal volume of some standard substance. In the case of the liquids and solids, the standard is water. In the case of gases, the standard is hydrogen or air.

Stabilizer

-

A fractionating tower for removing light hydrocarbons from an oil to reduce vapor pressure; particularly applied to gasoline.

Steam

-

Water in the vapor state.

Straight Run

-

Product of distillation of crude petroleum without subjected to cracking.


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Terms Stripping

-

UNIT 233

Description Removal of the lightest fractions from a mixture. The process is usually carried out by passing the hot liquid from a flash drum or tower into a stripping vessel or section (stripper), through which open steam or inert gas is passed to remove the more volatile components of the cut.

Suction Line

-

Intake

line

leading

from

vessel/storage

to

pump/compressor suction. Superheated

-

Water vapor above the saturation temperature at a given pressure.

Surge Drum

-

A vessel or accumulator which serves as a reservoir for liquid being pumped through a line, thereby overcoming fluctuations in the rate of flow caused by the pump.

Sweet

-

Having a good odor; pleasant to the sense of smell; negative to the doctor test. i.e. sweet naphtha lean in sulphur content.

Temperature

-

An

arbitrary

measurement

of

the

amount

of

molecular energy of a body, or the degree of heat possessed by it. It should be distinguished from heat itself. Heat is a form of energy; temperature is a measurement of its intensity.


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Terms

UNIT 233

Description

Thermocouple

-

The junction of two wires of dissimilar metals, which develops an electrical potential that is a function of the temperature; an instrument for measuring temperature by means of the electrical potential produced at a heated junction of two dissimilar metals.

Thermowell

-

A tube having one end closed, inserted into a vessel pipe, or furnace as protection for a thermocouple or thermometer bulb.

Throttling

-

To control a flow by operating a valve by hand ,making moves in small increments; such as closing a valve in the steam line of a boiler for controlling the flow of steam to any apparatus.

Treating

-

The contacting of petroleum products with chemicals to improve the quality.

Turnaround

-

Time necessary to clean and make repairs on refinery equipment after a normal run. It is the elapsed time between drawing the fires (shutting the unit down) and putting the unit on stream again.

Vapor Pressure

-

The pressure exerted by the vapors released from any material, at a given temperature, when enclosed in a vapor tight container.


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Terms


Description

Vessel

-

A closed container to hold gas and/or liquid under pressure or vacuum. It may be used solely for storage, in which case it is often called a drum, e.g., butane drum, reflux drum, etc. Process vessels will permit volume fluctuations, settling of mixed stocks, demisting of vapors, or reactions (such as treaters or reactors).

Viscosity

-

The measure of the internal friction or the resistively to flow of a liquid. In measuring viscosity of petroleum products, the values of the viscosity are usually expressed as the number of seconds required for a certain volume of the oil to pass through a standard orifice under specified conditions.

Volatility

-

The extent to which liquids vaporize; the relative tendency to vaporize.

Water Hammer

-

The energy or impact developed by the sudden collapse of vapor bubbles.

Weathering

-

The exposure of crude oils or light oils to the weather, with subsequent evaporation of volatile constituents, resulting in loss; in some cases, oxidation and polymerizing effects are noted also, particularly with cracked and asphalt oils.


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Terms


Description

Wet steam

-

Steam containing entrained water droplets.

Wet Gas

-

A gas containing a relatively high proportion of hydrocarbons which are recoverable as liquids.


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1.3


Abbreviation Item 0 C 0 F Amps API ASME

Details Degree Centigrade Degrees Fahrenheit Amperes American Petroleum Institute American Society of Mechanical

ASTM BD BFW BPD Btu. Cat. Col. Cond. CS Dept. Div. EB Eng. EOR EP GC HC HP Kg/cm2.g Lab LPG Maint. MP MW MX OX PARAXYLENE

Engineers American Standard Testing Method Blow Down Boiler Feed water Barrels per day British thermal unit Catalyst Column Condensate Carbon steel Department Division Ethylbenzene Engineer End of run End boiling point (of a distillation) Gas chromotagraph Hydrocarbon High pressure Pressure Unit Laboratory Liquefied Petroleum Gas Maintenance Medium pressure Molecular weight Metaxylene Orthoxylene Paraxylene


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Item ,PX SAE SOR Supt. Xyl. Frac. PCC PIB


OPERATING MANUAL RECOVERY PLUS UNIT 233 Details

Society of Automotive Engineers Start of Run Superintendent Xylene Fractionation Plant Control Center, control room Plant Interface Building

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2.0

UNIT DESCRIPTION

2.1

Design Basis The UOP RECOVERY PLUS system has been designed to improve the recovery of LPG and Reformate from Platforming Process Unit net gas streams. Increased hydrocarbon liquid recovery translates into improved liquid product yields and, therefore, higher production of more valuable products. Added benefits are improved LPG recovery. Under the design conditions, the RECOVERY PLUS system improves C5 + yields by 4 LV% and LPG yields by 0.5 LV% based on fresh feed H2 purity of the net gas is increased by 8 mol%.

2.2

Process Flow Description and Controls RECOVERY PLUS system is composed of a process circuit and a closed loop refrigeration circuit. The process circuit consists of a net gas stream and a slipstream of liquid from the platforming Unit Debutanizer column feed. The refrigeration circuit provides cooling to promote the absorption of LPG and reformate hydrocarbons that would normally exit the Platforming Process Unit in the net gas stream. The net gas & liquid streams are individually cooled & then enter the Absorber, MV-AY233-V01. Vapor & liquid separation occurs through counter current flow. The recovered liquid is sent to the Platforming process Unit’s Debutanizer column for stabilization prior to being sent to storage. The gas stream exits the RECOVERY PLUS system to chloride Treaters (MVAY231-V04 A/B). The RECOVERY PLUS system contains four circuits. a. Closed loop Refrigeration circuit b. Oil Reclaimer / oil separator circulation



c. Net Gas Circuit d. Liquid Circuit a) Closed loop Refrigeration circuit Starting at the Refrigerant Subcooler 233-S06, the propylene refrigerant (liquid) is pressured through LV014 and enters into the receiver / Economiser (233V03). From the Receiver / Economiser (233-V03), the vapor portion of the refrigerant is sent to a side port of the compressor (233 C01) through a back pressure control valve (PV 038). This ensured there is enough driving force between the 233-V03 and 233-C01 Suction during low load conditions. 233-V03 improves the efficiency of the Refrigeration compressor. The refrigerant remaining in 233-V03 is pressured to the Combined VaporLiquid Chiller (233-S03) via control valve LV002. The chilled liquid refrigerant is maintained 2” below the top of the tubes of the chiller. Frothing of the refrigerant in the chillers covers the rest of the tubes. Process fluids (H2 / HCBN) pass through the tubes of Combined Vapor-Liquid Chiller (233-S03) where they are cooled by evaporation of the refrigerant. The Disengaging drum on Top of the chiller shell allows any entrained liquid to be removed from the vaporized refrigerant. The vaporized refrigerant leaving the Chiller (233-S03) passes through PV012. PV012 controls the compressor 233-C01 suction pressure during startup only. During normal conditions PV012 is 100% open.


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JAMNAGAR

UNIT 233

Within the compressor, refrigerant vapor comes in contact with circulating synthetic oil and the compressed gas/oil mixtures discharges from the compressor to the oil separator # 1, 233 V02. In the oil separator #1 (233-V02), the refrigerant disengaged from the oil and passes overhead though a series of coalescing elements where entrained oil is removed. The oil is recycled to the Compressor. Refrigerant is then sent through oil separator #2 233-V04, where oil is removed to below 10 ppm level. Oil build up in the 233-V04 is sent back into the 233-C01 suction via FO-004. Any entrained oil will settle in the chiller and is recovered in the Oil Reclaimer Circuit. The refrigerant leaves oil separator #2 & enters the shell side of the condenser 233-S05, where it exchanges heat with cooling water (tube side) & condenses. Condensed refrigerant drains from the condenser (233-S05) in to the tube side of the subcooler, 233-S06. In 233-S06, the condensed refrigerant is cooled further by the Rich oil leaving the liquid Exchangers, 233-S02 A/B. This subcooling allows the compressor capacity to increase without affecting the energy requirements. The subcooled refrigerant is collected in 233-V03 Receiver / Economiser. 233-V03 is designed to hold the total circuit charge at 90% level.

b) OIL RECLAIMER / OIL SEPARATOR CIRCULATION


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Entrained oil in the refrigerant stream settles in the Combined Vapor-Liquid Chiller (233-S03), where refrigerant boiling occurs. With liquid refrigerant boiling off at - 29 0C the heavier oil settles to bottom of the chiller. The drained oil / refrigerant mixture from 233-S03 goes to Oil Reclaimer (233-Vv07). The oil is reclaimed through a batch process of draining, boiling off the refrigerant and pumping the oil back to the suction of compressor 233-C01. The batch operation is controlled by a logic system. After compression, a refrigerant / oil mixture is discharged into the oil separator #1 (233 V02). The separation between the oil / gas mixture is achieved in the body

of the separator and further separation takes place in coalescing

elements positioned inside the separator close to the separator outlet. The bottom of the separator serves as an oil reservoir and is equipped with a level gauge (LG-012) for positive oil level indication. A temperature controlled oil heater (233-Y01) is inserted in the separator to maintain the oil temperature for proper oil viscosity and to minimize oil dilution by the refrigerant during compressor shutdown. Lube Oil is pumped from the 233-V02 by oil pump 233P02 A/B. The oil then flows through the shell side of the Lube oil coolers (233S04 A/B) oil passes through a 25 micron element filter 233-F01 A/B before the oil is fed to the bearings, balance piston, shaft seal, compression chamber and compressor slide valve actuator. c) NET GAS CIRCUIT The Net gas in (Rich Gas) passes through the tube side of the vapor exchanger (233-S01), where it is cooled by exchanging heat with NET OFF GAS (Lean


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Gas shell side). The RICH NET GAS IN then enters the tube side of the 233S03, where it is further cooled by exchanging heat with refrigerant (shell side). The temperature of the vapor out of the chiller is controlled by TIC-009. As the vapor outlet temp begins to decrease, TV 009 begins to open causing a position of the warm Lean oil to bypass the Liquid Exchangers (233-S02 A/B), and mix with the vapor entering the tube side of the Chiller, causing a change in the heat capacity of the fluid. If the temperature of the Vapor leaving the chiller is too warm, TV 009 will close. The partially condensed Net Gas, leaving the 233-S03 enters the lower section of Absorber 233-V01. The rich liquid is removed from the bottoms of 233-V01 on LIC-004. The Absorber off gas (NET OFF GAS) is then heated through the shell side of the vapor exchangers 233-S01 & is sent to chloride treaters 231V04 A/B. d) LIQUID CIRCUIT The liquid into the RECOVERY PLUS system is a slipstream from the Debutanizer column feed, and is controlled by FIC-002. This stream is pumped by 233-P01 A/B to the tube side of Liquid Exchanger 233-S02 A /B, where it is cooled by exchanging heat with the Absorber rich liquid (shell side). The lean liquid enters the second tube bundle of the Combined Vapor-Liquid Chiller, 233S03 and flows to the top of the Absorber. The temperature of the lean liquid entering the absorber is controlled by TIC-011.


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JAMNAGAR

UNIT 233

As the temperature of the lean oil exiting the chiller, fluctuates, TIC-011 adjusts the compressor capacity control by varying the slide valve position. The rich oil is removed from the bottom of the Absorber, 233-V01 on level control LV-004. The net liquid is heated through the shell side of the subcooler 233-S06, and then flows to the Debutaniser feed Bottoms Exchanger 231-S05 A / B on pressure. 2.3

DCS Description Distributed Control System for Jamnagar Refinery Complex is of Foxboro I/A series 50 and is capable of plant wide automation. The architecture of the system will accommodate both functional and geographical distribution of the hardware, software, and database over the plant while allowing system wide access to the distributed data. The DCS hardware will be state of the art, microprocessor based design, that will be fully tested and reliable. It will permit control and data acquisition functions to be distributed to remote Plant Interface Buildings (PIBs) with operator-consoles located in Plant Control Centre (PCCs). As stated above all DCS hardware will be in the PIBs, all field inputs will be terminated in the PIBs, all controllers will be in the PIBs and field outputs will be from PIBs only. Monitoring and Control will be by Operator Console located in the PCC, which in turn is connected to all the PIBs through Fibre Optic Plantwide Control Network.


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JAMNAGAR

UNIT 233

Foxboro I/A series 50: Following are the main hardware of the system. 

WP51B – Operator console with two 19” CRT, Keyboard, trackball and touchscreen.



CP30 & CP40 – Control processor for control and data acquisition.



AW51C – Engineering Station for configuration of the system.



FBM & FBC – Field I/O card.

The entire operator console will be mounted in two tier consoles in the PCCs. The hardware distribution and configuration of the Platforming Unit is as under: 

For HNUU (221), Platformer (231), CCR (232), Recovery Plus (233) and PSA (234), CP40.

FBMs/FBCs will be in PIB 4 and will be linked to

Aromatics PCC with Fibre optic cable. PIB 4 is a SCS having two operators console (two CRTs) for start-up and shutdown. 2.3.1

DCS Graphics Process graphics show process equipment, piping and the instrumentation and control.

They closely follow the project PFD’s and P&ID’s.

They will be

arranged in four hierarchy levels:  Plantwide (Level 1)


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 Complex (Level 2)  Unit (Level 3)  Detailed (Level 4) At each of these levels, the graphics provide the means to move up and down the graphic hierarchy, and also sideways. The Plantwide Level graphic shows an overview of the whole Reliance Jamnagar Refinery Plant. It displays the main plant areas, their statuses and primary plant data. There shall be no control or process information at this level. The main purpose of this display is for navigation to other displays. The Complex Level graphics show overview of the Aromatic complex of Reliance Jamnagar Refinery. Only the major flows and other important data specific to each area will be shown. There shall be no process control from this level. Additionally, the Complex Level graphics should indicate when a fault occurs at any point within the process, which will allow the operator to navigate to detailed graphic. The Platforming Unit Level graphics show most process equipment and major piping and instrumentation. All controllers, important process variables and general monitoring parameters are indicated at this level. ESD trips are also indicated. Facilities are provided for operator actions such as alarm acknowledgement, manipulation of control loops, operation of valves, pumps, etc. Each plant unit is represented by several unit level graphics. The graphics


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at this level follow the project PFD’s. Unit Level graphics are intended to be used most of the time for plant operations. The Detailed Level graphics show all instrument functions implemented in the I/A Series – indicating loops, monitoring functions, equipment statuses, trips, ESD’s, etc. Facilities are provided for alarm acknowledgement; access to all control loops, faceplates, groups and trends. The graphics at this level closely follow the project P&ID’s and indicate almost all P&ID level information. This level of graphics is used to pursue detailed information on the process and the instrumentation. 2.3.2

Graphic Displays The console subsystem has facility of viewing multiple windows on one screen enabling the operator to conveniently access and control all the necessary factors at the same time. The graphics shall consist of the following types and overall content:  Overview.  Plant graphics.  Group loop displays.  Loop display.  Trend display


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 Alarm and event summary At a minimum, the operator will be able to operate, via touch screen or “track ball” the control strategies i.e., change set points, control modes, Page linking to more detailed process graphics, as well as alarm summaries will be made from these overviews. The operator can call up directly, any group display covered by the overview screen.

In addition, linking will also be possible to:

2.3.3



Group loop display



Loop display



Alarm and event summaries

Group Displays Important analog measurements grouped according to the process will be implemented as vertical bar graphs. Measurements, such as pressure, temperature etc profiles will give a meaningful operator-overview of the normal/upset status of the plant. Bar graphs will include operator adjustable ‘set points’ and high/low alarms when measurement deviates from the desired ‘set point’. In this case, ‘Set point’ may include both controller set points and normal operating parameters for indication-only measurements.


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UNIT 233

The group displays will consist of measurements and statuses presented in vertical bar graph formats. These are often referred to as “face plate” displays, since the vertical bar graphs are arranged in the manner of single-loop controller or indicator faceplates. The grouping is defined on logical grouping of related controllers and indicators within the process unit. The displays will indicate the following information per group:  Loop tag number and description.  Process variable (measurement, set point and output).  Status indication (on, off, run, stop, open, close, etc.).  Alarm status  Mode (auto/manual, remote/local (set point), tracking, etc.).  Units of measurement. The operator will be able to quickly address any point and make appropriate changes to mode, set point and output and so forth. This display will give the operator direct access to all status and parameters related to one loop, including the ability to change set points, modes of operation and give on/off output commands.


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Several of the operator actions will be password (preferred) or key-lock protected, such as:

2.3.4



Changing controller-tuning constants.



Controller configuration data.



Enable/disable of alarms, control actions, changing of alarm settings.

Trend displays In addition to trending shown on the loop displays, the DCS shall provide the capability of displaying both real time (short-term) and historical trending of process variables with a facility to change the trended variable on the trends display.

The trend displays are operator assignable to group in graphical

presentation with : 

Vertical axis – variable, including measured range/units.



Horizontal axis – time base.

All points shall be available on real-time trend with a minimum sample interval of one (1) second. 2.3.5

Alarm and Event Summary Either as a standard or a custom display, the DCS will provide a separate tabular listing of alarms and events, which can be called up by the operator with


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JAMNAGAR

UNIT 233

a single keystroke. Each alarm or event will be listed in order of occurrence and will include a buffer memory so that no alarms are lost. The alarm and event summary will include: 

Date and time.



Tag and service.



Alarm type and priority.



Alarm limit.



Current process variable with Engineering units.

Alarms acknowledge will be possible, using this display or the loop display.


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2.4


Design Flow Plan


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2.5


Refinery Site, Underground Piping and Unit Layout Plan


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RECOVERY PLUS

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2.6


Material Balance INPUT Kg/Hr 169953 44578

Lean Oil Net Gas OUTPUT

Kg/Hr Hydrogen rich gas to refinery hydrogen 25309 header Rich oil to debutaniser Feed/Bottom 189222 exchanger at platforming NOTE: 2.7

Liquid recovered

19269 Kg/Hr

Feed and product Specification Component

Gas In

Gas Out

Liquid

Kg-mol/h H2O H2 C1 C2 C3 IC4 NC4 IC5 NC5

0.19 4836.2 201.03 417.11 299.61 34.86 36.50 4.89 5.11

0.114 4814.30 186.77 263.53 79.92 8.12 8.23 0.92 0.84

Recovered 0.07 21.90 14.26 153.58 219.67 26.74 28.27 3.98 4.27


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RECOVERY PLUS

JAMNAGAR

Component

Gas In

Kg-mol/h C5OLEFIN CP C6+ Total, Kg/hr Temperature, 0C Pressure, Kpag Molecular Weight 2.8

0.34 0.15 9.94 44578.07 37 3.601 7.63


Gas Out

Liquid

0.07 0.02 0.77 25309.19 28.7 3.474 4.72

Recovered 0.27 0.13 9.17 19268.88 --------43.1

Chemicals - Details Chemical Propylene

Service Refrigerant

Required Quantity 250ft3 ( 7 m3 )

Specification for propylene product PROPERTY VALUE Propylene, vol.% Methane plus Ethane, vol. ppm Ethylene, vol. ppm C4 & Heavier, vol. ppm Acetylene, vol. ppm Butadiene, vol. ppm Methyl Acetylene + Propadiene, vol. ppm Hydrogen, vol. ppm Carbon Monoxide, vol. ppm Carbon Dioxide, vol. ppm Oxygen, vol. ppm Ammonia, vol. ppm Ammonia, wt. ppm Nitrogen (molecular), vol. ppm Sulfur, vol. ppm


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MAX / MIN 99.50min. 500max. 50 max. 20 max. 10 max. 10 max. 20 max. 20 max. 5 max. 5 max. 10 max. 12.1 max. 5.0 max. 30 max. 3 max. PAGE REVISIO N ISSUE

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PROPERTY VALUE Water, vol. ppm Green Oil, vol. ppm Carbonyl Sulfur (COS), vol. ppm Arsine, vol. ppm Phosphine, vol. ppm Propane 2.9

Utility conditions and requirement

2.9.1

Utility Conditions UTILITY

MAX / MIN 10 max. 1 max. 1 max. 0.03 max. 0.03 max. Balance

UTILITY BATTERY LIMIT CONDITIONS PRESSURE TEMPERATURE (KG/CM2G) Normal Design 4.5 2.5 3.0 7.0 3.0 7.0 3.0 7.0 7.0 10 7.7 10 7.7 10

Fresh CW Supply Fresh CW Return Desal, Water Potable Water Utility Water Plant Air Instrument Air Breathing Air Nitrogen Fuel Gas Import Fuel Gas Export LPG 2.9.2

OPERATING MANUAL

7 3.5 3.9 3.5

( 0C ) Normal Design 32 150 45 150 44 44 65 44 65 40 65 40 65 40 65

10.5 6.5

25 38

65 122

6.5

38

122

Utilities Requirements Reliance Estimated Utility Consumption


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Electric Power, KW (High Voltage >415V) Electric Power, KW (Low Voltage =<415V) Cooling Water, m3/hour Instrument Air, Nm3 /hour Nitrogen, Nm3/hour Refrigerant (Propylene) Lube Oil, Kg/Annum


RECOVERY PLUS 3000 30 520 m3 580 m3 To be determined2 None3 7 m3 To be determined2

Reliance Estimated Waste Discharges RECOVERY PLUS None4 None3

Vents, Nm3/hour Drains, Kg/hour The above numbers are estimates.

1. The 520 m3 is the estimated cooling water during normal operation with the straight run feed case. The 580 m 3 is the estimated cooling water usage during turn-down with the straight run feed. 2. Instrument air and lube oil usage not known at this time. 3. Nitrogen is not required for regular operations. However, nitrogen is required for start-up and shut down. Once the compressor section is finalized, a specification will be provided to determine the amount of nitrogen needed in these instances. 4. During normal operations, there will be no regular discharges to vents or drains. CHECKED BY SR APPROVED BY MG

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3.0


INTER CONNECTIVITY General This section examines the interfaces of the Recovery Plus system with the other processing units of Aromatic Complex.

3.1

Inter Unit Relationship  The Unit obtains its feed from the Platforming unit  Lean oil from Recontact Drum No.1 (MV-231-V02) through pumps MP231-P02 A/B at 21.17KSC & 300 C at Platforming unit to the Recovery Plus Unit.  Net Gas from Recontact drum no.2 MV-231-V03 at Platforming unit to Recovery Plus Unit at 37.13 KSC & 370C  Reach oil goes to Debutaniser Feed-bottoms Exchanger ME231-S05 A/B at 18.6 KSC & 300 C to the Debutaniser MV231-C05 at Platforming unit.



Net Gas (Hydrogen Rich Gas) to chloride Treaters MV-231-V04 A/B at 35.86 KSC & 28.70 C at platforming Unit to Hydrogen Purification system (PSA) Start up  The Platforming Unit will be started up prior to the Start up of Recovery Plus system.


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 Once the Platforming unit is on stream, Net Gas can be supplied to Recovery Plus from Recontact drum no.2 231-V03, and Lean oil can be supplied from MV-231-V02 (Recontact drum No.1) through pumps MP231-P02 A/B. Shutdown If the Platforming unit shutdowns, then Recovery Plus unit and hence subsequent downstream units i.e. Net Gas chloride treater 231-V04 A/B & Hydrogen Purification system (PSA) will also shutdown respectively. Normal operations During normal operations, the Recovery Plus Unit must be operated so that the main objective to recover. LPG and Reformate from Platforming net gas stream is achieved. 3.2

Inter Plant Relationship General This section explores the interfaces of the Recovery Plus system with other processing Units in Refinery complex. Inter Relationship Propylene, which is used as a liquid refrigerant, will be available from propylene Recovery plant of Fluidized Catalytic cracking complex, once refinery will be started.


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JAMNAGAR

UNIT 233

Start up Before attempting to allow any of the above feeds/ products between the Plants, all necessary details with regard to the operating unit must be complete. Additionally, the foreman and the operating units concerned should be notified of the impending startup. Shutdown For normal planned shutdowns, each plant will be responsible for notifying the foreman and operating units concerned, of all shutdown operations. Emergencies between the plants must be recognized and acted upon immediately. Plant operators must aware of steps to be taken in such situations. While some of the emergencies may not result in shutdown, it could cause serious trouble on the units if not properly handled. 3.3

Utility /Off site Relationship General This section describes the interfaces of the Recovery Plus Unit with the utility and offsites Areas. Inter Relationship The Recovery Plus Unit inter relationship with the following Utilities.  Cooling Water Supply  Cooling Water Return


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 Potable Water  Fire Water  Plant Air  Instrument Air  Breathing Air  Nitrogen  Fuel Gas Start-Up Before attempting to allow any of the above feeds/ products between the Plants, all necessary details with regard to the operating unit must be complete. Additionally, the foreman and the operating units concerned should be notified of the impending startup. Shutdown For normal planned shutdowns, each area will be responsible for notifying the foreman and operating areas/ units concerned, of all shutdown operations. Emergencies between the plants must be recognized and acted upon immediately. Plant operators must aware of steps to be taken in such situations. While some of the emergencies may not result in shutdown, it could cause serious trouble on the units if not properly handled.


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4.0

PREPARING THE UNIT FOR INITIAL START-UP

4.1

Introduction This phase of the work covers the requirements and activities to be performed prior to commissioning the Platforming Unit. The objective of the pre-commissioning phase is to: 

Verify that the unit and all parts thereof comply with the project specifications, data sheets and design drawings



Ensure that all items and equipment forming part of the unit have been installed correctly and in accordance with the manufacturer’s instructions.



Check the integrity of the unit and all parts thereof.



To prepare the equipment for operation by washing, running in, etc.



To acquaint the operators with the unit The pre-commissioning works will encompass general activities as follows:

a) Check that all vendor’s documents for all equipment such as test certificates, inspection certificates and performance test certificates, etc., are available and acceptable. b) Check that all necessary documentation of the tests carried out during the construction phase including hydrostatic tests, radiographic inspection and any other relevant electrical, mechanical and civil works tests is available and satisfactory.


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c) Carry out site checking of all items of the unit and equipment and piping systems as indicated in Inspection Section herein. d) Prepare a punch list of outstanding items, and assign action parties. e) Complete and sign all checklists, test reports and log sheets as applicable to the pre-commissioning works. Use applicable standard checklist for monitoring progress and recording of the Contractor’s pre-commissioning works. f) Ensure that the Reliance/Bechtel/UOP representative witness all check lists, test reports and log sheets as required. g) Procedures for storing pre-commissioning documentation shall be provided by the Contractor and approved by RPL in order to establish a clear audit trail for all pre-commissioning activities. h) Complete all punch list items which affect the safety and operability of the unit. 4.2

Utility system readiness:

4.2.1 Piping Network Please refer interconnectivity P and I. D. of Platformer Unit for Utility distribution and network 4.2.2

Commissioning of Utilities For ease of operation, the utility systems such as water, air, N2, firewater, etc. should be put in operation as soon as construction schedule allows. Fuel Gas, Flare, etc. should be prepared but not to be commissioned until process units are ready for hydrocarbon entry.


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UNIT 233



Fresh Cooling water supply/return



Desalinated/Potable/Utility/Fire water



Plant /Instrument/Breathing Air



Nitrogen



Fuel Gas Import/Fuel Gas Export/LPG



Flare/Blowdown system, aromatic closed drain



Other system i.e. Feed, Product, Chemical, etc.



Communication System



Fire detection/protection and gas detection system

Cooling Water system: After mechanical completion of CW Supply/Return system, ensure flushing / testing of each system. Ensure that all-utility valves at equipment / service stations are closed. Charge the header up to battery limit and then charge header/ sub header in Plot. Water system (Desalination Water / Potable Water / Utility water / Fire Water) After mech. Completion of various water system, ensure through flushing /testing of each system. Ensure that all utility valves at equipment / service stations are closed. Change the header up to battery limit and then charge header / sub-header in Plot.


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Air system (Plant Air/ Instrument Air/ Breathing Air) After pneumatic test, system should be blown with air. These systems should be as dry as possible. Instrument air system to be dried with instrument air and after checking dew point (-40 0C) at various points, system can be charged. Ensure that all utility valves at equipment/service stations are closed. Carry out tightness test /leak test at service pressure, check and rectify leaks. Nitrogen system Carryout the blowing and flushing operation of the Nitrogen system with air. Carryout the tightness / leak test with air. Once system became leak free, air free the system with N2 purging. Ensure that the nitrogen system oxygen content is within limit prior to charging of header/ sub-header with N2. Ensure that all utility valves at service stations are closed and connections to all equipment are blinded. Caution: Nitrogen is an asphxyant gas and is both odourless and colourless. Installation causes rapid unconsciousness by blocking of the oxygen supply followed by death within a short time. Fuel Gas Import / Fuel Gas Export / LPG Carryout the blowing and flushing operation of the above system with air. Carryout the tightness / leak test with air. Ensure that all utility valves at equipment are closed. Once system became leak free, air free the system with


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N2 purging. Ensure that the system oxygen content is within limit (< 0.2%) prior to charging of header / sub-header wit FG/LPG. Flare / blow down system, Aromatic closed drain Carryout the thorough blowing and flushing operation of the above system with air. Carryout the tightness / leak test with air. Ensure that all utility valves at equipment are closed. Once system became leak free, air free the system with N2 purging. Keep the system under positive pressure of N2 and monitor. Ensure that the system oxygen content is within limit prior to charging of header/ sub header with Hydrocarbon. Keep flare header under positive flow of N2 still purge FG is available (the jobs are pertaining to the offsites). Other system All feed, product, chemical, etc. piping to / from battery limit and storage facility thoroughly flushed, blown, leak tested, dried and air free prior to charging hydrocarbon. Communication system Ensure that Public address system/ Walkie talkie/ Pagers / Telephone system etc. as per project specification and drawings are installed in plant. System must be functional checked and performing as required. A clear, loud and uninterrupted

communication

link between

field

and

Control

room

Maintenance / Utility block / Laboratory / offsite, etc. must be established.


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/



Fire Detection/ Protection system and Gas Detection System Fire and gas detection system as per project specification and drawings are installed in plant. System must be functionally checked and performing as required. Energise the system and make it functional prior to commissioning of unit. Ensure that fire protection system and potable fire extinguishers are installed at specified place, prior to entry of Hydrocarbon in process/ utility system. 4.3

Inspection of Equipment General Checks For most of above items, general checks are required and can be carried out as follows: Refer UOP/ Bechtel data sheet and compare against vendors’ data sheet and actual equipment at site. A. Specifications check for a. Pressure, Temperature and vacuum, flow ratings, Capacity, surface area, etc., b. Material of construction, thickness and corrosion allowance c. Head, capacity, speed, NPSH requirement, type, seals, bearings, number of stages, lubrication and cooling systems, etc. d. Type of driver, its power ratings, etc. e. Nozzle sizes and orientation, flange rating, type and finish f. Type of lining, thickness and material g. Stress relieving and / or heat treatment h. Foundation design for full water weight


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B. Confirm that the equipment is hydrotested and date / time/ witness by, etc. are recorded (wherever it is applicable and agreed upon). In case of rotary equipment ensure the test run carried out at shop and results are available. C. Verify that all code plate information are correct D. Material test certificates are available 4.3.1 Piping and Supports The unit must be constructed in accordance with the Bechtel P & ID and Isometrics. The note, elevations, dimensions, etc. must be correct. One should be able to start and shutdown the unit as per suggested procedure. Piping for special procedure like dryout special material preparation as well as alternate flow schemes must be incorporated into the system. If the unit is connected to other process facilities adequate means must be provided to receive feed and send products to various facilities without contaminating any stream with another streams. To check and ensure that adequate means for measuring flow temperature pressure and sampling as well as is available. 4.3.1.1 Visual Inspection Line by line visual inspection of the complete piping system and associated parts there of to ascertain completeness against P and I D drawings and accepted practice for installed piping systems. a.

Verify that all quality control inspection requirements (X-rays, stress relieving, etc.) have been fulfilled.


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b. Check that piping system has been pressure tested in accordance with the code governing their design and approved by Reliance. c. Check that piping system have been properly flushed / blown as required. d. Check that piping system has been properly supported. Pipe hangers/ supports are allowed expansion in proper direction. e. Check that drains in the process / utility lines are at the lowest points. f. Check that spectacles are in their correct position as identified on the P & ID drawings. g. Check that insulating joints are proper at interface & electrical continuity / bonding is proper. h. Check that lines are connected to the correct nozzles of the equipment. i. Check for desired flange ratings, bolts & gaskets specifications. j. Check and inspect that all flanges are properly aligned and tightened. k. Check that all temporary strainers are presently fitted in the required positions l. Check that all inline instruments are correctly mounted m. Check that all instruments connections are proper n. Check insulation and colour code as specified o. Check that piping routing is proper and all valves are accessible without any hindrance for movement 4.3.1.2 Hydrostatic Test The piping system will be pressure tested to prove the pressure integrity of the main components (pipe, valves, flanges, gaskets) of the system. The test shall be performed in accordance with Standard Construction specification, supplemented by the Contractor’s standard hydrostatic test procedure


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approved by RPL. For test purposes, the piping system has been divided into a series in Document “Line Designation Table”. All the piping systems will be hydrostatically tested except specific system where hydraulic fluids are not allowed due to operation reasons. Those systems will be subject to pneumatic testing. A pressure test report will be completed for each test loop for record purposes using Reliance Standard Form. All untested joints shall be clearly shown on the hydrotest diagrams. SAFETY NOTE: Hydrostatic testing is carried out to prove the pressure integrity of the piping system under test. Accidents, sometimes fatal, have been recorded during such testing. Manning levels in areas where hydrostatic testing is to be performed should be kept to a minimum. All personnel engaged in the test should be fully briefed and all precautions taken in respect of personnel safety. Danger signs and notices should be erected at all strategic locations. Piping routed outside of the main plant boundary should be cordoned off and manned to prevent accidental access by unauthorised or third party personnel. All safety equipment shall be on site for the duration of testing. All personnel directly or indirectly engaged during the test shall be equipped with personnel protective and safety equipment. Important Checks and Guidelines a. On line instruments and instrument impulse lines will be temporarily removed and / or disconnected before testing.


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b. Check that hydrotest pump, valve, fittings, pressure gauge are in good working order. Filling line/ test equipment shall be connected at lowest possible point to avoid entrapment of air in the system while filling. c. Check that all test gauges are available with relevant latest test certificates, with direct reading gauge and suitable range so that test pressure readable in 40-60% range. The test gauge shall be mounted at lowest point to account liquid head of system. d. Check that all in-line valves are in fully open position. e. Check that all safety equipment like cordoning rope, sign board, etc. are available at testing site and placed at strategic location. f. Check that check valves are removed from the line or its internal removed, if required. g. All welds shall be free of slag, grease, oil, paint and any other foreign materials, which prevent proper examination. h. Vents to be provided on test fittings if it is not provided on the line i. Blinds used shall be in accordance with Pipe Line Class j. There are sufficient numbers of vents/ drains located in suitable position. While filling the piping, ensure that all air is vented at highest point and system is full of test fluid. k. Vessel and water temperature should be always above 15 0C to eliminate the possibility of cold fracturing of the metal. l. Hydrotest pressure should be as per LDT (line designation table) or as per piping class & should not be higher than lowest rated component of system. ANSI B 31.3 must be followed while testing piping system. m. The weld joints, flange connections and the sections of greatest strain (the areas close to opening and those where two different types of materials are


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connected) must be checked visually. The test is acceptable if no loses, sweating or fall of pressure are detected for the time of test. n. Test pressure will be held for sufficient time to visually determine if there are any leaks, but not less than 2 hours. o. Drain out the water from the section after the hydrotest is completed. Note: Ensure that under no circumstances the pressure applied does not exceed the allowable test pressure of the lowest rated component in the loop. Keep the vents open to prevent from pulling a vacuum and possibly collapsing equipment, while draining the system after hydrotest. Ensure that, chloride content of the treated water used for hydrotest of the section that contains austenitic steel is below 50-ppm wt%. If this is not possible then the test water should have a max. of 0.5 wt% sodium nitrate / specific chemical added to it. Such system should be drained and dried after hydrotest as soon as possible. 4.3.1.3

Flushing The piping system will be flushed in order to remove construction debris, accumulated corrosion products and scale to prevent blockages and damage to equipment during actual start-up Prior to commencing the flushing operation, the contractor will divide the piping system into a series of flushing loops. Configuration of flushing loop mostly remains as hydrotest loop. The loops will be presented in diagrammatic form, as a markup to the plant P & Ids using local site knowledge and the guidelines


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presented below, as the basis for determining the extent and the number of flushing loops needed. Use this opportunities to break in and run in as many pumps as possible (High head pumps should not be run on water). Water flushing helps in spotting the problems and correcting the problems before the start-up. The progress of the flushing operation will be recorded by marking up the flushing loop diagrams. Important Checks and Guidelines a. Install blinds the flanges of the equipment, which will not be operated on water. b. Install fine mesh screens on the pump suction lines. c. Bypass the filters and traps in line, as per requirement. d. Identify and ensure suitable water hose connection points and draining points for injection and draining of water. e. In case of exchangers, flush the inlet line upto the exchanger inlet flanges and then connect the inlet flanges, and flush the exchangers. f. Restriction orifices must be removed prior to flushing. g. Control Valves and in line instrumentation must be removed prior to flushing h. Instrument impulse lines and sampling systems will be disconnected prior to flushing. During flushing, each process valve on instrument process connections should be opened to flush the connection and be checked for tightness after closure. i. Check valves should be removed, or installed in reverse (subject to selected direction of flow for flushing) and all other valves fully opened. j. Flow rates should be maintained in the range 3 to 4 m/s for water flushing, 30 to 40 m/s for air blowing.


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k. The flushing water is fully drained (properly) and system dried with air immediately after completion of flushing, water containing upto 20 mg/kg chlorides may be used for flushing of austenitic stainless steel piping systems or sub-systems. In cases where proper drainage is not possible, and the metal temperature in operation exceeds 50 0C, general recommended practice is to use water containing less than 1 mg/kg chloride; i.e. condensate or demineralised water for austenitic SS piping. l. Isolate vessels and equipment from the flushing loop to prevent damage/ accumulation of debris within these items. m. Flush through open end lines. Do not restrict flow in principle. n. Flush through all drains and vents. o. Where possible, flush downward or horizontally p. Flush the main header from source-to-end, each lateral header from the mainto-end, and each branch line from the lateral header to end. q. Always flush through bypasses, where provided, to an open end before flushing through equipment. r. On completion of flushing, reinstate all removed equipment items (control valves and in-line instrumentation), install orifice plates and reconnect instrument lines to process valve connections. s. On completion of flushing, standard RPL form, duly signed by the RPL / Bechtel/ UOP / Contractor representative will be prepared and placed on file for record purposes 4.3.1.4 Air Blowing and Drying


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The piping system will be blown using compressed air to remove entrained water in the pipes after draining of test and / or flushing water. The system will be blown utilising the same piping configuration as that used for the hydrotest test. A blowing record will be completed for each loop as defined in Hydrotest diagram using RPL Standard Form. A temporary air compressor will be used for the work. Temporary connections will be installed between the compressor and piping loops to be blown. All drain lines will be fully opened. The test will be completed when only dry air is seen to exit the system. On completion, the blown system will be fully reinstated with all items previously removed and / or disconnected in preparation for hydrostatic testing replaced in accordance with the reference drawings and removal records. 4.3.1.5 Tightness Test On completion of hydrotest and blowing, and after reinstating the piping system in accordance with the design drawings and removal records, the entire process system will be subject to a pneumatic soap bubble test maximum pressure of 5 bar. This action required just prior to inerting of process unit. All flanged joints and the bonnets and glands of any item which were not subjected to hydrostatic test will be tested with soap solution. Any leaks detected by the formation of bubbles will be retightened or attended to arrest the leak. After the system has been leak tested, the air of the system will be displaced with N2 for inerting of unit and hydrocarbon entry.


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A tightness test and purge record will be completed using RPL Standard Form. 4.3.2

Vessels 1. Absorber

MV-AY233-V01

2. Oil Separator # 1

MV-AY231-V02

3. Refrigerant/Receiver Economiser

MV-AY231-V03

4. Oil Separator # 2

MV-AY231-V04

Specifications 1. Pressure, temperature and vacuum ratings 2. Shell metallurgy, thickness and corrosion allowance 3. Nozzle size and orientation, flange rating, type and finish 4. Type of lining, thickness and material 5. Stress relieving and/or heat treatment 6. Foundation design for full water weight 7. Confirm that the vessels are hydrotested and that the date / time / witnessed by etc. are recorded. 8. Verify that all code plate information are correct 9. Material test certificates are available Internal Inspection 1. Mesh blankets and outlet screens


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

size,

location,


levelness, tight fit up (no bypassing allowable) blanket

metallurgy, blanket support tie-wires and grids 2. Vortex breakers 

Type ,size and orientation

3. Baffles 

Type, orientation and levelness

4. Instrument nozzles 

Location, orientation, cleanliness, thermowell length and metallurgy

5. Inlet distributors 

Type, size, orientation, levelness and freedom to expand

External Inspection a. Manways and nozzles 

Location, size and flange rating / finish metallurgy, proper gasket, proper nuts and bolts

b. Ladder and platforms 

Correct positioning, secure and free to expand

c. Insulation  

Properly provided

Correct grounding of vessels


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

Correct vessel elevation



Valves and instrumentation 

4.3.3

UNIT 233

Easily accessible from platform and grade.

EXCHANGERS 1.

Vapor Exchanger

ME-AY231-S01

2.

Liquid Exchanger

ME-AY231-S02 A/B

3.

Combined Vapor Liquid ChillerME-AY231-S03

4.

Lube Oil Coolers

ME-AY231-S04 A/B

5.

Refrigerant Condenser

ME-AY231-S05

6.

Refrigerant Subcooler

ME-AY231-S06



Refractory lining, metallurgy, tubes, grounding wires, expansion provisions



Manufacturer’s rating for temperature, pressure & pressure drop



Nozzle size, flange type, rating, facing and metallurgy



Vent and drain connections



Design differential pressure between shell and tube sides of the exchanger



Piping symmetry for parallel exchangers



Slot length of sliding plates adequate for expansion. 

Ensure that sliding ends of multi-shell exchangers make sense with

regard to expansion of exchangers and connecting pipe. 4.3.4

PUMPS


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1. Lean Oil Pump

MP-AY231-P01A/B

2. Lube Oil Pump

MP-AY231-P02A/B

3. Oil Reclaimer Pump

MP-AY231-P03A/B

Centrifugal pumps: Centrifugal pumps should be reviewed against the curves and data provided by vendor to confirm agreement on the following: 

Head and capacity



Pressure and temperature rating



Speed



NPSH requirement



Pump type, MOC, flange ratings, seals, bearings, number of stages, lubrication and cooling systems etc.



Type of driver



Balancing lines for multistage pumps must have flange joints



Proper direction of rotation



cooling water to pedestals for pumps operating above 250 oC



Cooling water to pumps operating above 120 oC

Proportioning pumps Proportioning pumps should be reviewed to confirm agreement on the following:


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

Head and capacity



MOC



Cooling and lubrication systems



Pressure and temperature ratings



Testing of relief valve setting on the bench



Pump speed and stroke



Pulsation damper devices


General check for pumps 

Lubrication and cooling systems are operational



Pumps and drivers are aligned correctly



Check valves are installed in the correct direction



All drains from pumps and associated piping are routed to safe location



Adequate means for venting and draining the pump casing are available



Restriction orifice in the minimum flow line as required



Warm up lines are provided across discharge check valve, when pumping hot liquid

4.3.5

COMPRESSOR 1. Refrigerant Compressor


MC-AY231-C01A/B

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Start-up of compressors should be carried out according to manufacturer’s instructions. Pre-start-up checks a. The lube oil system must be cleaned. Ensure that 20 mesh wire screen is installed at the lube oil supply to each bearing remove the 20 mesh wire screen when the lube oil system is ready for service. b. Check the driver for correct direction before coupling to the compressor. c. Remove paint and slushing compounds from all moving parts before starting the compressor. d. Check that the lube oil level is sufficient and there is no leakage from the system. e. Ensure that all trips and alarms are simulated and are operational. In addition the lube oil pump auto start is functional. f. Ensure that the compressor suction lines and suction drums are acidified as per the procedure for the removal of dirt and fine scales that would otherwise land up in the compressor, damaging the compressor valves. g. Commission cooling water to the lube oil cooler. 4.3.6

Instrumentation System Carry out the following inspection and tests in preparation of the unit instrumentation for start-up and operations: a.

Visual inspection of instruments to verify compliance with specifications


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b.


Visual inspection of instrument installation to verify compliance with installation specifications in the instrument instruction manual

c.

Pressure testing of instrument piping

d.

Testing and calibration of instruments

e.

Testing of instrument air signal lines

f.

Testing of thermocouple wiring

g.

Loop checking

h.

Testing of safety relief valves

i.

Final preparation While inspecting the instruments for compliance to specification, give attention to the following Instrument range, pressure rating, connections, MOC, size, electrical features, and special features Inspection of orifice plates for size, MOC, location of weep hole (if any), counter bore, overall condition, measurement of orifice bore, verification of information stamped on tab While inspection of the installation attention should be given to the following:

-

Location of transmitters with respect to the connection point

-

Control valves and transmitters are not installed backwards

-

Orifice installation for the straight run requirement


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-

Insulation/steam tracing provision

-

Point by point verification of the multi point temperature indicator Testing and calibration of instrument should include the following:

a. Calibration of Transmitters b. Control Board equipment c. Local Controllers d. Stroke checking of the control valves and adjustment of positioners Special attention to the instruments used in critical services such as, Heater firing control, automatic shutdowns, etc. Loop checking: Carry out loop checking of the loop to ensure that the piping and wiring are properly installed. Give special attention to the critical loops such as Reactor loop. All transmitters should be checked by simulating signal from field and observe correct response in control board. Similarly signal from controller on control board should get response from control elements. ESD should be simulated for each trip signal and observe responses on all tripping elements. Final Preparation: Final preparation check should include the following: -

Valves are in the proper position

-

Preliminary control mode adjustments

-

Filling seal pots and seal legs


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-


Making sure that instrument air and electrical power are supplied to all the instruments

-

Commissioning of steam tracing

-

Commission the instruments as the unit comes on stream.

-

Commission the analysers in accordance with the instructions in the instruction manual.

4.3.7

Electrical system Carry out the following inspection and tests in preparation of the unit electrical system for start-up and operation: Electrical equipment and system precommissioning has to be performed to ensure that:  All electrical equipment performs as per the required specifications. The installation of the electrical equipment is complete and in accordance with design drawing and good engineering practice.  The systems are not damaged during transportation and storage phases and function satisfactorily during start-up and operations. The precommissioning plan described below has been defined taking into consideration the functional performance of the electrical equipment in the plant. The Precommissioning plan has been subdivided in the following phases: a) Checks before installation


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b) Checks after installation All tests and operations shall be recorded and maintained in typical RPL check list. The presence of Vendor representative will be required wherever necessary. Check Before Installation Visual Checks:  Verify the equipment and for correct storage in the warehouse.  Check for physical damages.  Check for correct application of conservation.  Check for proper environmental condition limit during the storage as specified by the manufacturer.  Check for correct tag.  The technical compliance of equipment with the individual specification.  Check for availability of testing equipment.  Check for equipment and accessories as per part list. Checks after Installation After installation, the following checks shall be performed to ensure correct mechanical completion of electrical installation. a.

Preliminary checks common to all electrical installation:


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 After erection and before testing, all the equipment, including their accessories, will be checked to verify:  Compliance with the general procedures for installation of electrical equipment.  That the paint, grease, oil , etc. necessary for good material and equipment conservation have been applied.  That all the supports are complete and rigid and the equipments are correctly installed.  Equipment and their connections have not been damaged during the installation stage.  Check for manufacturer’s test certificates.  Equipment must be free of dust, moisture and oily chemicals. b.

Electric Installation and cable connections check: The following checks shall be carried out:  Cable trays, conduits, junction boxes, equipment housing and supports are correctly installed as per design requirement and protected from heat source.  Conduit radius bends are as per design specification  Conduit termination shall not damage the cable and threaded joints are properly tightened.  Flexible pipes, and terminal boxes are located as per design requirements.  All cables should have their proper identification tag in switch gear room panels, junction boxes, at MCC cabinet and racks, and along the cable route.  Cables are properly fastened on cable trays.


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 Buried cables are completely covered.  All cables are properly connected at the terminals of the equipment. c.

Testing and functional checks of electrical installations:  All the electrical installation are subjected to applicable test and functional checks as soon as their installation are completed.  These test are normally insulation test, applied voltage test, continuity test, resistance measurements, setting of protective relays, polarity test, no load motor run, operational test of MCC, switch gear and local/remote switches, specific test for transformers and specific equipment. All the test must be recorded. After satisfaction of competent authority, electrical system can be charged (energised). In order to fully execute the instrumentation pre-commissioning and functional tests, LV switchboard will be energised as soon as practical after precommissioning completion. The power supply will also be utilised to commission the switchboard, plant & building lighting, motors, compressors, pumps, package units, etc.

4.4

Chemical Cleaning and N2 Blanketing


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The purpose of the chemical cleaning is to remove the mild scale, dirt, heavy greases, and other foreign materials that would enter the compressor, there by resulting in operating and maintenance problems. Carry out chemical cleaning of the following items as per the cleaning procedure supplied by the cleaning contractor, who must ensure that the chemicals and chemical solutions used in carrying out the operation will not be injurious to the items cleaned. The acid cleaning step includes the following:

4.5



Flushing



Degreasing



Chemical cleaning



Neutralizing



Passivating

Run-in Pumps While starting all the moving equipment watch for,  excessive vibration  overheating of bearings  excessive heating of the driving motor  unusual noises Before any attempt is made to run the pumps and drivers ensure that the pumps and drivers are properly aligned by qualified personal and the cooling


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water systems and lubrications are placed in service. It is always advisable to run the drivers in the decoupled condition and then coupled to the pumps. Before putting the pumps into operation check the following 

Proper lubricants are provided and lubricators filled.



Cooling water circulation established through bearing housings, stuffing box jackets and pedestals.



Fine mesh strainers are installed in the pump suction line.



Pumps are not field hydrostatically tested.



All pumps are in good mechanical condition and are ready to break them in. The length of time for break in may vary for different pumps but a period of four hours are usually considered satisfactory.



Check the push buttons of all the motor driven pump to ensure that they are in proper working order.



The pumps and drivers are free by rotating them by hand

(at least one

revolution) 

NO WATER CIRCULATION SHOULD BE CARRIED OUT THROUGH THE GAS COMPRESSORS.

 4.6

Ensure that the compressor is not exposed to excessive moisture. Run-in Compressor


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Start up of compressor should be carried out according to manufacturer’s instructions. Pre-start-up checks 

The lube oil system must be cleaned. Ensure that 20 mesh wire screen is installed at the lube oil supply to each bearing remove the 20 mesh wire screen when the lube oil system is ready for service.



Check the driver for correct direction before coupling to the compressor.



Remove paint and slushing compounds from all moving parts before starting the compressor.



Check that the lube oil level is sufficient and there is no leakage from the system.



Ensure that all trips and alarms are simulated and are operational. In addition the lube oil pump auto start is functional.



Ensure that the compressor suction lines and suction drums are acidified as per the procedure for the removal of dirt and fine scales, that would otherwise land up in the compressor, damaging the compressor valves.



Commission cooling water to the lube oil cooler.

4.7

Tightness Test and Inertisation

4.7.1

Tightness Test After water flushing/drying steps and before admitting hydrocarbon, the plant must be subjected to tightness test/pneumatic soap bubble test. On completion of hydrotest and blowing, and after reinstating the piping system in accordance


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with the P and I. D., the entire system along with equipment will be subject to a pneumatic soap bubble test at maximum pressure of 15 kg/cm²g. Always follow design pressure limitation of the system. Check all flanged joints and the bonnets and glands of all items, which were not subject to hydrostatic test with, soap solution. Check the manways of equipment, its connecting flanges, etc. for leakage. Any leaks detected by the formation of bubbles will be retighten / repaired. Hold the air pressure in the system for specific time and estimate drop in pressure to determine leakage rate. Once such system passes the tightness test, it is to be subjected to vacuum hold test. 4.7.2

Vacuum Test and Inertisation Pull vacuum in the system with the help of a vacuum pump. Required vacuum is 1 mmHg A. If the desired vacuum is not achieved, it is the indication of leaks or moisture in the system. Break the vacuum with N 2. Pressure test the system and fix the leaks. For removing moisture from the system, purge the system with dry N2 several times. Check water in all low point drains. Pull the vacuum and hold it for 4Hrs. Once the vacuum test is over, break the vacuum with N 2 and keep the system under slight positive pressue. Nitrogen is an asphxyant gas and is both odourless and colourless. Inhalation causes rapid unconsciousness by blocking of the oxygen supply followed by death within a short time. Strict safety precautions must therefore be applied when using nitrogen gas for purging operations and especially when a high concentration of nitrogen may be present.


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If any doubt exists personal breathing apparatus must be worn. Fatal accidents have occurred during purge operations. Before purging operations commences, the area shall be chained off and adequate warning notice displayed. These shall remain inplace until purge operations are complete. 4.8

Safety Checks Before Startup The following safety related checks are to carry out before startup.

1. All fire extinguishers should be available at site in their respective positions. 2. Fire detectors and Hydrocarbon detectors should be functional. 3. Firewater network is charged and hose boxes are having hoses, branches or nozzles, etc. 4. Safety shower / eye washer and other Personal Protective equipments are in position. 5. Plant area declared operational with no unauthorised entry to plant and work permit system implemented. 6. Necessary safety and warning sign boards are placed as required. 7. Communication systems i.e. Public Address, Telephone, Walkie Talkie,etc. are functional.


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5.0

COMMISSIONING / INITIAL START-UP

5.1

Notification to Other Departments a.


Inform concerned intraplant department i.e. Mech. / Electrical / Instrument / Laboratory / etc. prior to startup so that they will be ready for action.

b.

Inform concerned inter plant department i.e. off site, utility, CES, Central Lab., safety and fire prevention, refinery units, etc. prior to startup so that they will be ready for action.

c.

Notify the operators of the other process units in the aromatic complex of the intended Recovery Plus startup.

d.

Plant supervisor and other operating units in the complex which are related with the unit should be informed well in advance about the exact time of start up by proper communication media, preferably in writing.

5.2

Utilities Startup Inform Utility department about the Startup and also the approximate quantity that will be required. Cooling Water Supply / Return headers and Nitrogen headers are to be charged and made ready for consumption by different users. Electrical power should be available and charged up.

5.3

Outline Of Initial Startup


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The initial startup of the Recovery Plus section can be divided into the following steps: 1. Evacuation of Air, Nitrogen and Water Removal 2. Charging of Lube Oil 3. Oil Circulation 4. Inventory Refrigerant Circuit with Refrigerant 5. Initial Compressor Start-up 5.4

Evacuation for Air, Nitrogen and Water Removal

All air must be removed and purged before safe system operation is assured. The system should be purged with nitrogen until the vent gas has an Oxygen content of < 0.5%. The refrigerant circuit must be evacuated to remove Air Nitrogen and Moisture. Consequently a vacuum pump is required. A vacuum pump capable of creating a vacuum of less than 1 mm Hg absolute pressure is required. To accurately measure the vacuum an absolute pressure gauge is required. This should be a Meriam closed end U-tube type gauge or equal. To ensure that the refrigeration circuit is properly dehydrated with the least amount of time, it is recommended that a vacuum point be provided on each of the modules. This will ensure that the entire circuit is being pulled down and help in isolating sections if necessary. Pipe all the vacuum points to the suction of the vacuum pump. Provide an isolation valve on the suction the vacuum


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pump to allow for isolation of the circuit when the vacuum pump has been stopped to change oil or after a low vacuum has been reached. When the vacuum pump is started, the vacuum should pull down rapidly to approximately 25 mm Hg. At approximately 10 mm Hg evaporation of free water in the circuit will be rapidly accelerated and the vacuum tend to remain constant as the evaporation rate approaches the vacuum pump capacity. Depending upon the total amount of water, ambient temperature and vacuum pump capacity, it may take several hrs or days to make any noticeable decrease in vacuum below 10 mm Hg. After pulling down the circuit to below an absolute pressure of 1 mm Hg or below, check to see that the vacuum reading is stable and does not rise above 1 mm Hg Abs. If the vacuum reading is stable at a value below 1 mm Hg than the test is considered acceptable. 5.5

Charging of Lube Oil Inventory Oil Separator # 1 (MV-AY233-V02) through a 2” oil flushing nozzle. Initial inventory of Oil Separator # 1 should be 152-229 mm below the top of the level glass, LG-012, when the oil circuit is full. The recommended level when the compressor is 100% loaded is 400 mm below the top of the level glass, LG012. Fill Oil Separator # 1 for initial circulation so as to not cavitate the oil pump when it is first started. While the oil circuit is being inventoried, add sufficient oil to the Oil Reclaimer to cover the heater.


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5.6


Oil Circulation The following steps are recommended to commission the lube oil circuit:



A temporary jumper line will be required to connect 233-LO-124-3”-ES32EH-NI at valve 630 to Oil Separator # 1, MV-AY233-V02, AT VALVE 931. Valves 614, 615 and 618 at the Refrigerant Compressor, AY233-C01 must be closed.



Commission cooling water to the lube oil coolers, ME-AY233-S04 A/B.



The lube oil should be circulated a minimum of 4hrs bypassing the compressor, prior to start-up and until the oil is free of debris.



After removal of debris replace filters if required. Bleed of gas from oil filters until oil is present. Set the safety valves at 25 Kg/Cm 2.



Inventory oil if required. The level in Oil Separator # 1 should be 152-229 mm below the top of the level glass.



Remove temporary piping when circulation is complete.



Replace the oil with new, clean oil for operations.

5.7 

Inventory Refrigeration Circuit with Refrigerant After the dehydration, charge the circuit with vapor refrigerant to create a positive pressure of 1 Kg/Cm2.



Close the inlet valves (valves 1004 and 1019 around LV-014) to the Refrigerant Receiver/Economiser, MV-AY233-V03.



Close the filter inlet valve (valve 1013) of Refrigerant Receiver/Economiser, MVAY233-V03.


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


Open the Refrigerant Filter/Dryer, F02, outlet valve (valve 1017) and Refrigerant Receiver/Economiser, MV-AY233-V03, outlet valve (valve 1018).



Connect refrigerant charging and equalising lines from tank, truck or refrigerant source to the 2” flanged connection provided on the refrigeration circuit.



Gradually pressurise the Refrigerant Receiver/Economiser, MV-AY233-V03, by slowly opening the equalising stop valve (valve 1006). Note that the entire refrigerant circuit vacuum will have to be broken before a positive pressure will be indicated at PG-039.



As soon as the pressure is equalised, gradually open the charging valve (valve 1015) and start the charging pump. The charging pump should not be started with the pressure below 1.03 Kg/Cm2 g.



Use the Refrigerant Receiver/Economiser, MV-AY233-V03, level gauge LG-016 to verify the desired level. The normal operating level is 120 mm from the bottom of the vessel. The receiver should be filled to 1080 mm if there is no refrigerant in the remainder of the system. Stop the pump when the charging is completed.



Close charging valve (valve 1015), equalizing valve (valve 1006) and fitter/dryer outlet valve. Venting of Non Condensibles The presence of non-condensibles affects the heat transfer area in the Refrigerant Condenser, which leads to a higher Refrigerant Compressor discharge pressure and an increased power consumption. Non-condensibles and air should be purged from high point vents in the Refrigerant Compressor discharge circuit.

5.8

Initial Compressor Start-up


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Refrigerant circuit is inventoried with refrigerant. The Oil Reclaimer has been inventoried with oil and oil has been circulated through the Oil Separator to remove dirt and debris. The Net Gas In has been pressured and is flowing through the circuit. The Refrigerant Compressor is controlled by the Distributed Control System DCS and a PLC. The PLC control circuit is designed to ensure the compressor is unloaded prior to start-up. 1. Check level in Oil Separator # 1. Initial inventory of the Oil Separator # 1 should be 152-229 mm below the top of the level glass. 2. Check oil level in Oil Reclaimer. The oil level should be such that the electrical heater element is immersed in oil and oil level should be above level switch setting. 3. Ensure the Oil Heaters Y-01/02 are energised. The heaters are designed to turn on only when the oil temperature is less than the designed setpoint and when the compressor is not running. 4. Line out cooling water to lube oil coolers S04 A/B and refrigerant condenser S05. 5. Line out refrigerant circuit and check that all block valves are open or in normal operating position. 6. Check that PDV-018 is set to obtain a 3.5 Kg/Cm 2 differential between the lube oil pump discharge pressure and the Oil Separator # 1 operating pressure. This will ensure a 4.5 Kg/Cm2 differential between the oil header pressure and Refrigerant Compressor discharge pressure. 7. Set the Refrigerant Receiver/Economiser pressure PV-038 to design pressure. This will ensure that there is sufficient driving force between the Refrigerant


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Receiver/Economiser and the Combined Vapor-Liquid Chiller, during low load conditions when the suction port and Economiser port are at the same pressure. 8. Ensure that the compressor is unloaded prior to start-up. If the Compressor is started in loaded condition then the motor will draw a higher starting torque and can get damaged. 9. Start Net Gas In circulation. Ensure the 12” bypass valve is open. DO NOT CUT IN NET GAS FLOW UNLESS H2O IS < 35 MOL PPM. Gradually open the valves located at battery limits Tie points # 1 and 2 for the net gas in and pressure up the circuit. Lean Oil: Establish a liquid level in the Absorber V01. Temporarily start the lean oil pump, P01 A/B, in order to establish a liquid level in the Absorber. 10. Ensure that the refrigerant for the Combined Vapor-Liquid Chiller is on level control, LIC-002. Initially keep a low setting of LIC-002. Gradually increase the level setpoint to the desired operating level. A high level can lead to entrained liquid carry over to the Compressor. 11. Set capacity switch to auto. 12. Ensure the Compressor is 10% loaded. This is the minimum loading of the compressor. 13. The starting of the Compressor consists of a sequence of events when the start button is pushed. The first task is to clear all the trips and permissive. Next the sequence will start with the starting of the lube oil motor. As soon as the lube oil pressure is build up the compressor motor should start. Once the Compressor motor starts, valves open or close automatically. 14. Check the temperature of the Rich Gas stream (TIC-009) and Lean oil Stream (TIC011). Set TIC-009 and TIC 011 in automatic at approximately 5 oC higher than the refrigerant in the Combined Vapor-Liquid Chiller. The signal resulting from TIC-011


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being set at 5 oC higher than the refrigerant temperature, will start closing the slide valve, thereby increasing the mass flow rate of refrigerant pushed through the Compressor. This will increase the current drawn to the motor. An override activated by the motor current draw is provided to regulate the time it takes the slide valve to close to avoid drawing too much current. This ensures the capacity of the compressor is gradually increased and subsequently the process temperature is decreased. 15. If the suction pressure decreases below 0.35 Kg/Cm 2 and the refrigerant compressor shuts down, decrease the temperature of TIC-011 approximately 2-4 oC, thereby increasing the load and suction pressure of the refrigerant compressor. 16. Gradually decrease the temperature of TIC-009 to approximately 5 oC. hold the lean oil temperature TIC-011 constant and start the lean oil pump. Set the lean oil rate at 50% of design flow. Gradually increase the lean oil rate to design. 17. Hold the net gas into the Absorber temperature constant, 5 oC, and gradually increase the Rich Gas In flow to design by closing the bypass. 18. Before the Rich Gas In and Lean Oil In temperature can be decreased to design, ensure that the circuit is dried out. 19. Gradually decrease the Combined Vapor-Liquid Chiller temperature to design.


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6.0 6.1


START UP General For subsequent start-ups, the procedure as described in the initial start up procedure is to be followed except the following: a) Evacuation of Air, Nitrogen and Water removal will not be required. b) No need to inventory the refrigerant since it is already available in the system. The following procedure is to be followed for subsequent startups:

6.2

Notification to Other Departments a) Inform concerned intra plant department i.e. Mech. / Electrical / Instrument / Laboratory / etc. prior to startup so that they will be ready for action. b) Inform concerned inter plant department i.e. off site, utility, CES, Central Lab., safety and fire prevention, refinery units, etc. prior to startup so that they will be ready for action. c) Notify the operators of the other process units in the aromatic complex of the intended Recovery Plus startup. d) Plant supervisor and other operating units in the complex which are related with the unit should be informed well in advance about the exact time of start up by proper communication media, preferably in writing.


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e) Tank farm/Refinery Control Room should be informed as startup of Recovery Plus will require Tank farm/Refinery to supply the necessary raw materials. 6.3

Utilities Startup Inform Utility department about the Startup and also the approximate quantity that will be required. Cooling Water Supply / Return headers and Nitrogen headers are to be charged and made ready for consumption by different users. Electrical power should be available and charged up.

6.4

Outline Of Initial Startup The initial startup of the HNUU section can be divided into the following steps:



Compressor start-up

6.5

Compressor Start-up The Refrigerant Compressor is controlled by the Distributed Control System DCS and a PLC. The PLC control circuit is designed to ensure the compressor is unloaded prior to start-up.

1

Check level in Oil Separator # 1. Initial inventory of the Oil Separator # 1 should be 152-229 mm below the top of the level glass.

2

Check oil level in Oil Reclaimer. The oil level should be such that the electrical heater element is immersed in oil and oil level should be above level switch setting.


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3


Ensure the Oil Heaters Y-01/02 are energised. The heaters are designed to turn on only when the oil temperature is less than the designed setpoint and when the compressor is not running.

4

Line out cooling water to lube oil coolers S04 A/B and refrigerant condenser S05.

5

Line out refrigerant circuit and check that all block valves are open or in normal operating position.

6

Check that PDV-018 is set to obtain a 3.5 Kg/Cm 2 differential between the lube oil pump discharge pressure and the Oil Separator # 1 operating pressure. This will ensure a 4.5 Kg/Cm2 differential between the oil header pressure and Refrigerant Compressor discharge pressure.

7

Set the Refrigerant Receiver/Economiser pressure PV-038 to design pressure. This will ensure that there is sufficient driving force between the Refrigerant Receiver/Economiser and the Combined Vapor-Liquid Chiller, during low load conditions when the suction port and Economiser port are at the same pressure.

8

Ensure that the compressor is unloaded prior to start-up. If the Compressor is started in loaded condition then the motor will draw a higher starting torque and can get damaged.

9

Start Net Gas In circulation. Ensure the 12” bypass valve is open. DO NOT CUT IN NET GAS FLOW UNLESS H2O IS < 35 MOL PPM. Gradually open the valves located at battery limits Tie points # 1 and 2 for the net gas in and pressure up the circuit. Lean Oil: Establish a liquid level in the Absorber V01. Temporarily start the lean oil pump, P01 A/B, in order to establish a liquid level in the Absorber.

10

Ensure that the refrigerant for the Combined Vapor-Liquid Chiller is on level control, LIC-002. Initially keep a low setting of LIC-002. Gradually increase the


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level setpoint to the desired operating level. A high level can lead to entrained liquid carry over to the Compressor. 11

Set capacity switch to auto.

12

Ensure the Compressor is 10% loaded. This is the minimum loading of the compressor.

13

The starting of the Compressor consists of a sequence of events when the start button is pushed. The first task is to clear all the trips and permissive. Next the sequence will start with the starting of the lube oil motor. As soon as the lube oil pressure is build up the compressor motor should start. Once the Compressor motor starts, valves open or close automatically.

14

Check the temperature of the Rich Gas stream (TIC-009) and Lean oil Stream (TIC-011). Set TIC-009 and TIC 011 in automatic at approximately 5 oC higher than the refrigerant in the Combined Vapor-Liquid Chiller. The signal resulting from TIC-011 being set at 5 oC higher than the refrigerant temperature, will start closing the slide valve, thereby increasing the mass flow rate of refrigerant pushed through the Compressor. This will increase the current drawn to the motor. An override activated by the motor current draw is provided to regulate the time it takes the slide valve to close to avoid drawing too much current. This ensures the capacity of the compressor is gradually increased and subsequently the process temperature is decreased.

15

If the suction pressure decreases below 0.35 Kg/Cm 2 and the refrigerant compressor shuts down, decrease the temperature of TIC-011 approximately 2-4 o

C, thereby increasing the load and suction pressure of the refrigerant

compressor.


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16


Gradually decrease the temperature of TIC-009 to approximately 5 oC. hold the lean oil temperature TIC-011 constant and start the lean oil pump. Set the lean oil rate at 50% of design flow. Gradually increase the lean oil rate to design.

17

Hold the net gas into the Absorber temperature constant, 5 oC, and gradually increase the Rich Gas In flow to design by closing the bypass.

18

Before the Rich Gas In and Lean Oil In temperature can be decreased to design, ensure that the circuit is dried out.

19

Gradually decrease the Combined Vapor-Liquid Chiller temperature to design.


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7.0

Normal Shutdown

7.1

General


The following shutdown procedure covers a normal planned shutdown such as would be required for periodic cleaning and inspection of vessels. The shutdown instructions, which follow, are divided into sections for convenience. 7.2

Notification to Other Departments Notify Shift superintendent and other units, which are likely to be affected. Inform the Shift superintendent and other affected/concerned operating units about the exact date and time of the impending shutdown. This will facilitate various planning activities at their end.

7.3

Preshutdown Preparation Planning of unit shut down along with other unit of the aromatic plant / other plants of complex require thorough understanding and review of pre and post effect of shutdown. All the concerned intra departments and inter department like, Off Site, Utility, CES, Central Lab., Safety supporting services, Fire Prevention, Refinery Units, Production Planning, etc. must be informed in advance and action plan for all of them must be prepared.


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Prior to shut down of unit, list out the activities to be carried out in the unit, other units and other plants. Prepare detailed action plan for each activity and schedule those activities in a shutdown period with action party assigned to each activity. Plan the availability of resources, spare parts, special materials, special tools and tackles, safety equipment, etc. Ensure that above items are available or will be available at the time of need. Prepare the action plan of preparation / shutdown / post shut down preparation of the unit for operation group and list out all the activities required to be performed prior to shutdown, during shutdown, after shutdown and prior to startup of the unit. 7.4

General Outline of Normal Shutdown Normal Shutdown of the Recovery Plus can be broadly divided into two steps:

1. Refrigerant Circuit 2. Process Circuit 3. Refrigerant Retained in Receiver 7.5

Refrigerant Circuit Shutdown The Refrigerant Compressor should always be shutdown first to avoid any possibility of freeze up at the Combined Vapor-Liquid Chiller. Manually unload the compressor. Press the system stop push button. The following will be observed at once:



Compressor will stop.


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

Lube oil pump continues to run.



Slide valve will return to 10% load if the compressor was not already 10% loaded.

7.6 

Process Circuit Shutdown Stop the lean oil pump and block in the Platforming process unit liquid to the Recovery Plus System. The Platforming process unit liquid will continue to flow to the fractionation section via the separator level control.



Open the 12” block valve on the Net Gas bypass line and then close both double block valves on the Net Gas inlet and outlet lines.

7.7

Refrigerant Retained in Receiver This procedure assumes the system is to be taken out of service and the inventory of propane refrigerant is to be retained in the receiver.



Reduce the rich gas and lean oil flow.



Adjust Combined Vapor-Liquid Chiller level control, LIC-002, and Refrigerant Condenser level Control, LIC-014, to their minimum set point.



Close the outlet valve on the Refrigerant Receiver/Economizer (valve 1018) and block in LV-002. The above action will unload the refrigeration circuit returning as much of the refrigerant as possible to the Refrigerant Receiver/Economizer. Continue vaporising refrigerant from the Combined Vapor-Liquid Chiller, condensing the compressor discharge and collecting liquid in the Refrigerant


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Receiver/Economizer, until the compressor suction pressure is reduced to the low pressure shutdown. The logic system will then shutdown the compressor. When the refrigerant level in the Combined Vapor-Liquid Chiller is as low as possible close the Rich Gas and Lean Oil into the Recovery Plus system and open the 12" bypass line for the Rich Gas. 7.8

Post Shutdown Checks Post shut down checklist should be prepared for each unit and should consist of critical parameters of critical sections/equipment of unit. This is required to assure that unit was placed in best possible safe condition during shut down and for any corrective action if required. The checklist must cover level of tanks, HC ingress to equipment open for inspection, specific cooling requirement, barring of compressor, etc. The checklist must be monitored by each shift and ensure that plant is safe even under shutdown and will not endanger / detriment to the unit/equipment.

7.9

Equipment Handing / Taking Over to/from Maintenance. The general procedure must be prepared for overall complex to safely hand over the equipment / piping system to Maintenance department for the shut down activity. Similarly general procedure must be prepared for overall complex to safely hand over the equipment / piping system to Operation department after completing jobs on equipment/ piping. These procedures must be in line


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with RPL safety policy and should aid RPL work permit system and good housekeeping.


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8.0

NORMAL OPERATION

8.1

Process principles


The purpose of the Recovery Plus unit is to improve the recovery of LPG and Reformate from Platforming Process Unit Net Gas streams. Increased HCBN recovery translates into improved liquid product yields and therefore higher production of more valuable product. Added benefits are increased Hydrogen purity of net gas stream and improved LPG recovery and Reformate recovery. The RECOVERY PLUS system is composed of a process circuit and a closed loop refrigeration circuit. The process circuit consists of a net gas stream and a slipstream of liquid from the Platforming Unit Debutanizer (MV-AY231-V05) feed. The refrigeration circuit provides cooling to promote the absorption of LPG and Reformate hydrocarbons that would normally exit the Platforming Unit in the net gas stream. The net gas and liquid streams are individually cooled and then enter the Absorber, MV-AY233-V01. Vapor and liquid separation occurs through counter-current flow. The recovered liquid is sent to the Platforming Process Unit’s Debutanizer column for stabilization prior to being sent to storage. The gas stream exits the RECOVERY PLUS system to Chloride Treaters (MV-AY231-V04A/B). Under the design conditions, the RECOVERY PLUS system improves C5 + yields by 4 LV% and LPG yields by 0.5 LV% based on fresh feed. Hydrogen purity of the Net Gas is increased by 8 mol%.


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8.2


Process Variables The two major variables that effect the RECOVERY PLUS efficiency are temperature (TIC-009 and TIC-011) and lean oil rate (FIC-002). The set points of these parameters were considered to optimize recovery operation.

A.

Adsorber Inlet Temperatures The temperature at which RECOVERY PLUS system operates is the variable, which has the greatest effect on the Reformate and the LPG recovery. Generally the colder the system operates the greater the recovery. Lower operating temperatures are considered after analyzing metallurgical constraints and icing. The temperature TIC-009/011 of the vapor and liquid entering the Absorber are used as the temperature control points. Temperature of the liquid stream is controlled by regulating the loading and unloading of the compressor, which determines its capacity. Temperature of the vapor stream is controlled by regulating the amount of liquid, which mixes with the vapor prior to entering the Combined Vapor-Liquid Chiller.

B.

Lean Oil Rate The second process variable which has an effect on recovery is the Lean Oil Rate, FIC-002. This rate has also been established based on process economics and hydrocarbon recovery. The lean oil flow rate should be maintained at a constant liquid to vapor ratio (L/V) depending upon desired recovery. A lower liquid rate results in a decrease


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in Reformate and LPG recovery, while a higher rate may produce no marked increase in Reformate and LPG recovery but will result in higher utility cost. 8.3

Control Philosophy and Key Analysis

A.

Compressor Control Logic The starting of refrigerant compressor consists of a sequence of events when the start button is pushed. The first task is to clear all the trips and permissive. Next the sequence will start with the starting of the lube oil pump motor. As soon as the lube oil pressure is developed the compressor motor should start. Once the compressor motor starts valves open or close automatically. Control logic is as follows: The following permissive have to be satisfied before starting the compressor:



Refrigerant Receiver/Economizer high level switch LAH-015B indicates level is not high.



Refrigerant Compressor discharge high pressure switch PAHH-016A indicates pressure is not high.



Refrigerant Compressor suction low pressure switch PALL-014A indicates pressure is not low.



Combined Vapor-Liquid Chiller high level switch LAHH-003A indicates level is not high.



Lube oil high temperature switch TE-025 indicates temperature is not high.



System stop switch is not in the stop position.



Refrigerant compressor motor has not been started within the past 60 minutes. CHECKED BY SR APPROVED BY MG

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JAMNAGAR




Refrigerant compressor slide valve position switch ZSL-39 indicates slide valve is in the 10% loaded position.



Low temperature switch TE-029 indicates temperature in the oil separator # 1 is not low.



Remote stop if used does not indicate the stop position. Once the above permissive are met the remaining shutdown must be bypassed by pressing the local panel system reset push-button. The following will occur.



The lube oil low differential switch PDAL-015A will be bypassed and remain bypassed for 5 seconds.



Compressor suction high pressure switch PAHH-014A will be bypassed and remain bypassed for 3 minutes. It is expected that within three minutes of compressor starting the suction pressure will drop down below the alarm value. Once the shutdowns are clear the compressor start button at the local panel can be pressed. The following will occur:



The lube oil motor will start.



Lube oil low differential pressure switch PDAL-0015A indicates the differential pressure has exceeded the switch setting, clearing switch.



Compressor start contact is closed.



Oil separator heater Y01 is locked out.



The following solenoid valves will get energised

1. LY-002B 2. LY-014B 3. PY-038B


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4. PY-012  B.

Compressor motor will start. Refrigerant Compressor Load Control Logic The loading of the compressor is accomplished by adjustment of slide valve. The slide valve is positioned by actuating one of two solenoids conducting lube oil to either extend or retract the slide valve on the compressor casing. One solenoid causes the slide valve to retract, increasing the load on the compressor and one solenoid causes the slide valve to extend unloading the compressor. The load solenoid XY-011A is energised if the following requirements are satisfied:



The compressor motor running indication is on.



The compressor motor amperage is not high.



The logic determines additional loading is required based on the DCS temperature output signal TT-011.



The local panel compressor Capacity Control switch is in auto position. The unload solenoid XY-011B is energised if any of the following groups are satisfied. All items in the group must be satisfied.

1. Unload on high current 

The compressor motor amp switch IT-004 indicates amperage is high.

2. Unload on compressor shutdown. 

The compressor motor stopped.


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UNIT 233



One of the lube oil motor is running.



Compressor slide valve position switch ZIL-002b indicates slide valve is not in the 10% loaded position.

3. Unload on Combined Vapor-Liquid Chiller outlet temperature. 




TIC-011 output is indicating a reduction in load is required via a low output signal.



The local panel compressor switch is in auto posiyion.

4. Manual unload 




The local panel compressor capacity control switch is in manual position.



The local panel compressor unload push button is pressed.


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9.0

UNIT SAFEGUARDING SYSTEM

9.1

Relief Devices Summary


Set Tag

Service

P&ID No.

Pressure

Discharge

G41-

(kg/cm2g)

Disposition

RA221-

PSV-007

Liquid Exchanger Shell Side

103

41.85

HP Flare

PSV-008A/B

Outlet Combined Vapor-Liquid Chiller

104

21.09

HP Flare

PSV-010A/B PSV-019 PSV-023 PSV-025A/B PSV-027A/B PSV-030A/B

Disengaging Drum Absorber Lean Oil Pump Discharge Oil Reclaimer Lube Oil Filter Lube Oil Cooler Shell Side Lube Oil Pump P02a/B

105 107 107 108 108 109

41.85 21.09 21.09 25.0 25.0 21.09

HP Flare Oil Reclaimer HP Flare HP Flare HP Flare Oil Separator

PSV-031A/B PSV-033 PSV-036A/B PSV-037A/B

Discharge Oil Separator # 1 Oil Separator # 2 Condenser Shell Side Refrigerant

21.09 21.09 21.09 21.09

#2 HP Flare HP Flare HP Flare HP Flare

109 109 110 110

Receiver/Economiser


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9.2


Instrument Alarm

Tag No. FI-001 FIC-002 TAH-010 TIC-011 TIC-011 LIC-002 LIC-002 LIC-004 LIC-004 PIC-002 PIC-002 PAH-016B TAH-020B PDAL-015B TXI-022 LI-009 LI-009 TI-021 TI-021 PDAH-026B TAH-025B TXI-030 PDAH-034B LAH-011B LI-015 LAH-018B ZIL-002B ZIH-002B LSH-

Description Rich Gas Flow Low Lean Oil Low Flow Chiller Low Vapor Temperature Chiller Low Liquid Temperature Chiller High Liquid Temperature Chiller Low Level Chiller High Level Absorber Low Level Absorber High Level Compressor Low Suction Pressure Compressor High Suction Pressure Compressor High Discharge Pressure Compressor High Discharge Temperature Low Lube Oil Differential Pressure Oil Reclaimer Heater High Temperature Oil Reclaimer Low Level Oil Reclaimer High Level Oil Reclaimer Low Temperature Oil Reclaimer High Temperature Lube Oil Filter High Differential Pressure Lube Oil High Temperature Oil Separator Heater High Temperature Oil Separator # 2 High Differential Pressure Relief Knockout Drum # 1 High Level Receiver/Economiser High Level Relief Knockout Drum # 2 High Level Compressor Side Valve Minimum Position Compressor Side Valve Maximum Position Lean Oil Pump Seal Pot High Level

019A/020A LSL-

Lean Oil Pump Seal Pot Low Level

Set Point 98,000Nm3/Hr 160 M3/Hr -2.2 OC -23 OC -15 OC 380 mm 990 mm 860 mm 3300 mm 1.0 Kg/Cm2 g 3.8 Kg/Cm2 g 18.0 Kg/Cm2 g 100 OC 2.5 Kg/Cm2 140 OC 100 mm 275 mm 40 OC 50 OC 0.5 Kg/Cm2 55 OC 140 OC 0.4 Kg/Cm2 250 mm 800 mm 300 mm 10% 100% -

021A/022A


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9.3

UNIT 233

Instrument Trips

Tag No. PALL-014B PAHH-014B PDALL-015B PAHH-016B TAHH-020B TAHH-025B TALL-029B LAHH-015B LAHH-003B TALL-010B TALL-012B TXAHH-030B TXAHH-022B LI-005 LI-006

Description Compressor Low Suction Pressure Compressor High Suction Pressure Low Lube Oil Differential Pressure Compressor High Discharge Pressure Compressor High Discharge Temperature Lube Oil High Temperature Lube Oil Low Temperature Refrigerant Receiver/Economiser High Level Chiller High Level Chiller Low Vapor Temperature Chiller Low Liquid Temperature Oil Separator Heater High Temperature Oil Reclaimer Heater High Temperature Absorber High Level Absorber Low Level


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Set Point 0.8 Kg/Cm2 g 4.0 Kg/Cm2 g 2.0 Kg/Cm2 19.0 Kg/Cm2 g 110 OC 60 OC 40 OC 890 mm 1100 mm -28.8 OC -28.8 OC 150 OC 150 OC 3680 mm 250 mm


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JAMNAGAR

10.0

EMERGENCY SHUTDOWN

10.1

General


Emergencies must be recognised and acted upon immediately. The Operators must be able to take the necessary steps in such situations. While some of the emergencies may not result in a unit shutdown, they could cause serious trouble on the unit if not handled properly. In addition damage to the catalyst might occur. The following outlines some situations, which might arise and suggested means of handling the situation. 10.2

Interconnectivity During Emergencies

10.2.1 Loss of Net Gas Compressor in Platforming Unit Loss of Net Gas Compressor in Platforming unit will result in stoppage of gas feed to RECOVERY PLUS unit. Refrigeration Compressor will go to minimum load. If the suction pressure goes low because of lack of evaporation in VaporLiquid Chiller then Compressor will trip on low suction pressure. Actions to be taken: 

Shut down the refrigeration compressor.



Block in the lean oil and shut down lean oil pump.

10.2.2 Loss of Lean Oil from Platforming Unit


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

LPG and C5+ recovery will fall drastically because of lean oil failure.



RECOVERY PLUS operation can be continued for some time but if the fault is for longer duration bypass recovery plus.

10.2.3 PSA failure In case of PSA failure divert Net Gas Chloride treater outlet to unsaturated sweet gas collection header. 10.3

Process and Utility Failure

10.3.1 Power Failure When the compressor logic system detects a power failure, it will immediately initiate a compressor shutdown. Do following: 

Isolate lean oil and net gas in to the system



Isolate lean oil going to debutaniser feed bottom exchanger

10.3.2 Loss of Cooling Water Hook up 

Refrigerant condenser S-05



Lube oil cooler S-04 A/B


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A loss of cooling water will cause the lube oil temperature to increase and increase in the discharge pressure of the compressor. Eventually one or both of these will cause a compressor shutdown. Action required: Stop the compressor at once and isolate the net gas and lean oil circuit. 10.3.3 Loss of Refrigerant Loss of refrigerant is a dangerous situation. The system should be shut down immediately. Leak in the refrigerant system will cause the loss of refrigerant. Bypass the rich gas and lean oil circuit. Identify the leak and fix the leak. If it is not possible to fix the leak depressurise the refrigerant system. 10.3.4 Loss of Instrument Air A loss of instrument air will result in control valves moving to their fail safe position. Stop the compressor immediately.


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11.0

SPECIAL PROCEDURE

11.1

Initial Refrigerant Loading


Evacuation for Air, Nitrogen and Water Removal

All air must be removed and purged before safe system operation is assured. The system should be purged with nitrogen until the vent gas has an Oxygen content of < 0.5%. The refrigerant circuit must be evacuated to remove Air Nitrogen and Moisture. Consequently a vacuum pump is required. A vacuum pump capable of creating a vacuum of less than 1 mm Hg absolute pressure is required. To accurately measure the vacuum an absolute pressure gauge is required. This should be a Meriam closed end U-tube type gauge or equal. To ensure that the refrigeration circuit is properly dehydrated with the least amount of time, it is recommended that a vacuum point be provided on each of the modules. This will ensure that the entire circuit is being pulled down and help in isolating sections if necessary. Pipe all the vacuum points to the suction of the vacuum pump. Provide an isolation valve on the suction the vacuum pump to allow for isolation of the circuit when the vacuum pump has been stopped to change oil or after a low vacuum has been reached. When the vacuum pump is started, the vacuum should pull down rapidly to approximately 25 mm Hg. At approximately 10 mm Hg evaporation of free


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water in the circuit will be rapidly accelerated and the vacuum tend to remain constant as the evaporation rate approaches the vacuum pump capacity. Depending upon the total amount of water, ambient temperature and vacuum pump capacity, it may take several hrs or days to make any noticeable decrease in vacuum below 10 mm Hg. After pulling down the circuit to below an absolute pressure of 1 mm Hg or below, check to see that the vacuum reading is stable and does not rise above 1 mm Hg Abs. If the vacuum reading is stable at a value below 1 mm Hg than the test is considered acceptable. Inventory Refrigeration Circuit with Refrigerant 

After the dehydration, charge the circuit with vapor refrigerant to create a positive pressure of 1 Kg/Cm2.



Close the inlet valves (valves 1004 and 1019 around LV-014) to the Refrigerant Receiver/Economiser, MV-AY233-V03.



Close the filter inlet valve (valve 1013) of Refrigerant Receiver/Economiser, MVAY233-V03.



Open the Refrigerant Filter/Dryer, F02, outlet valve (valve 1017) and Refrigerant Receiver/Economiser, MV-AY233-V03, outlet valve (valve 1018).



Connect refrigerant charging and equalising lines from tank, truck or refrigerant source to the 2” flanged connection provided on the refrigeration circuit.



Gradually pressurise the Refrigerant Receiver/Economiser, MV-AY233-V03, by slowly opening the equalising stop valve (valve 1006). Note that the entire refrigerant


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circuit vacuum will have to be broken before a positive pressure will be indicated at PG-039. 

As soon as the pressure is equalised, gradually open the charging valve (valve 1015) and start the charging pump. The charging pump should not be started with the pressure below 1.03 Kg/Cm2 g.



Use the Refrigerant Receiver/Economiser, MV-AY233-V03, level gauge LG-016 to verify the desired level. The normal operating level is 120 mm from the bottom of the vessel. The receiver should be filled to 1080 mm if there is no refrigerant in the remainder of the system. Stop the pump when the charging is completed.



Close charging valve (valve 1015), equalizing valve (valve 1006) and fitter/dryer outlet valve. Venting of Non Condensibles The presence of non-condensibles affects the heat transfer area in the Refrigerant Condenser, which leads to a higher Refrigerant Compressor discharge pressure and increased power consumption. Non-condensibles and air should be purged from high point vents in the Refrigerant Compressor discharge circuit.


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12.0 Fire & Safety 12.1

Introduction Safety of individual overrides all production targets. This is the safety policy of Reliance Group. Hence safety has to be ensured in all walks of life especially in plants and operating areas. Though plants are designed properly considering hazards involved in process, effective use of safe working procedures and practices cannot be underestimated. Regular checks of plant atmosphere for inflammable material and through investigation of accidents/near miss incidences is a must. The principal objective of fire and safety equipment is to minimize the risk and consequences of accidental event, minimize the potential for hazardous occurrences, ensure a safe working environment and minimize the potential for pollution of the environment. This section of manual briefly describes fire and safety equipment and procedures. This section should be read in conjunction with Safety manual of Aromatics Complex, which describe various safety procedures to be followed in Aromatics Complex.

12.2

Repair work, Permit to work system, housekeeping and maintenance of onstream equipment Maintenance on any equipment will be carried out as per Works Procedure adhering strictly to Permit To Work system. There are various types of work


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permits viz. fire permit, vessel entry permit and excavation permit which are issued depending on type of hazard involved in maintenance work. Issuer of permit ensures that equipment under maintenance is isolated from hazards. If it is not possible to nullify the hazard involved in maintenance work, issuer of permit clearly identifies the type of hazard and precautions to be taken during maintenance. Person in Plant area should always wear helmet. Safety goggles should be used as and when required. Safety belts should be used while working at heights. Fire permits or hot work permits are issued if there is likelihood of fire during maintenance. Hence Explosivity check is carried out in work area before issue of fire permit and issuer of permit ensures that work area is free from inflammable hydrocarbons. Issuer of permit ensures that adequate precautions are taken for fire fighting in case of fire during maintenance. Entry to confined space is governed by vessel entry permit. Issuer of permit ensures that atmosphere is free from hydrocarbons and toxic materials. Issuer of permit also ensures that atmosphere is safe for breathing with oxygen check. If it is not possible to make atmosphere safe, then use of breathing air should be considered. During normal operations housekeeping is primarily the responsibility of Production department. However clearing up of work area after maintenance before returning Permit is the responsibility of Maintenance department. All stairways, passageways and gangways must be kept free of materials, supplies and obstructions of every kind. Materials and supplies must be kept away from


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the edges of hoistways, ladder access and floor openings. Spillage of oil or other substances must be cleaned up immediately using the appropriate procedure. Tools not in use should be placed in a toolbox and not strewn about to cause tripping hazard. Remove scrap and rubbish regularly to the allocated containers or disposal units. Toilets wash up facilities and drinking water facilities should be kept clean. Special precautions are to be taken while performing maintenance on onstream equipment. All hazards involved in maintenance work should be clearly identified and precautions to be taken accordingly. 12.3

Safety during sample withdrawal Exposure of hydrocarbons during sampling should be minimized. Operation and Laboratory personnel involved in sampling should wear chemical safety goggles/shield, protective apron, laboratory coat, solvent resistance gloves, respiratory protective equipment, etc. These protective equipment are no substitute to safe working conditions, proper ventilation, good personal practices, proper maintenance of operating/safety equipment and proper procedure.

Please

refer

sampling

procedure

AYJ/PDN/GEN/051

AND

AYJ/PDN/GEN/052. Some of the hydrocarbons handled in Aromatics Complex are toxic in nature. Material safety data sheet (MSDS) on such hydrocarbons gives information on nature of toxicity, potential health effects and precautions to be taken during handling and storage. It also gives information on measures to be taken during accidental release of chemicals. MSDS of some of the hydrocarbons handled in Aromatics Complex are attached at the end of this section of Operating


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Manual. Precautions mentioned in MSDS on chemicals/hydrocarbons should be obeyed religiously. 12.4

Fire fighting and safety equipment Fire and safety is an integral part of Petroleum & Petrochemical Industry and it has always has been considered as of prime importance. The Petroleum and Petrochemicals being processed and handled in the Refinery Complex are highly inflammable & volatile in nature. Therefore Fire & Explosions are some of the potential hazards in such process industries resulting in property damage and loss of human lives. Fire is a rapid, self sustaining oxidation process accompanied by the evolution of heat and light of varying intensity. Fire results from the combination of fuel vapor, heat and oxygen in proper proportion. This combination of elements causing combination is referred to as FIRE TRIANGLE. The definition of these three elements is given below: 1. Fuel: combustible substance in the from of vapor, Liquid or incandescent solid. 2. Heat: a source of Ignition sufficient to initiate and propagate the Chemical Reaction of Combustion. 3.

Oxygen: Oxygen content in atmospheric Air in sufficient proportion to form a combustible Vapor-Air mixture. Fire Extinguishment principle involves removal or limiting of one or more of the factors depicted by the Fire Triangle. The Principle of Extinguishment of fire may be classified under the following heads:



Starvation


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This is accomplished by removing combustibles from the scene of fire e.g., transferring fuel from burning tanks, cutting of fuel supply by closing of valve etc. It is also achieved by subdividing the burning material to small isolated pockets of fire. 

Smothering This is accomplished by eliminating air supply of diluting the available air (Oxygen) to the fuel e.g., blanketing, inerting the atmospheric air by nitrogen/ steam etc.



Cooling If the rate at which the heat is generated by combustion is less than the rate at which is dissipated then the combustion does not persist. The application of water spray or jet results in Extinguishment of fire by this principle. The cooling principle is also adopted to protect neighbouring equipment/facilities from the radiation exposure hazards. RESPONSIBILITY OF PERSON NOTICING A FIRE

1. Activate the nearest manual call point. Inform plant control centre of respective area. 2. Alert nearby people for help. 3. Try to extinguish the fire with the help of nearby fire extinguisher. 4. Carry out the instructions of shift / operation incharge. 12.5

Precautions for Entering Any Contaminated or Inert Atmosphere


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Nitrogen is non-toxic. 79 mol-% of the air we breath is nitrogen, 21 mol % is oxygen. However, in vessels or areas where there is a high concentration of nitrogen, there is also a deficiency of oxygen for breathing. Breathing an atmosphere deficient in oxygen (i.e. an inert atmosphere) will rapidly result in dizziness, unconsciousness or death depending on the length of exposure. Do not enter or even place your head into a vessel, which has a high concentration of nitrogen. Do not stand close to a valve where nitrogen is being vented from equipment at a high rate, which might temporarily cause a deficiency in oxygen close to the valve. It is also important to emphasize that if a person has entered a vessel and becomes unconscious, no individual should go in to help him without first putting on a fresh air mask, confirming that the air supply is safe, wearing a safety harness, and enlisting the aid of a minimum of two other people to remain immediately outside of the vessel to assist him. This may seem an obvious warning, but people do forget this in the trauma of an emergency situation. Often the first thought is to save the person in distress and people enter the vessel without proper protection only to succumb to the same hazard without anyone else being present to save them. 12.6

General RECOVERY PLUS Safety Notes RECOVERY PLUS is part of Platforming plot. All the lists, which are attached at the end of this chapter includes RECOVERY PLUS. Fire extinguishers


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There are various types of fire extinguishers whose location depends on type of fire likely to occur at such location. List of fire extinguishers is given at the end of this section of manual. Location of fire extinguishers has been given in safety equipment layout drawing G56-AY231-007 for Platformer plot. Fire and gas detector Automatic Fire and Gas detectors are placed at strategic locations in Platforming plot at aromatics complex. List of Fire and Gas detectors is attached at the end of this chapter. Refer drawing J61-AY231-017 for details. Hydrants and monitors For fire fighting, hydrants and fire monitors are installed at strategic locations in Platformer plot at aromatics complex. List of hydrants and monitors in Platformer plot is enclosed as annexure. Refer drawing safety equipment layout G56-AY231-007 and safety signs layout G56-AY231-010 for details. Manual call points for fire Manual call points are installed in the plot. Observer on sight of fire can activate manual call point . Refer drawing safety signs layout G56-AY231-010 for details. Locations of manual call points are as follows. South of plot East of plot West of plot Substation 200-50


2 5 5 2

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South of PSA North/East of PSA North/East of net gas compressor East side Pillars of walkway West side Pillars of walkway South of CCR

12.7

1 1 1 5 1 1

Material Safety Data Sheets (MSDS) The MSDS requirement falls primarily on chemical manufacturers, importers and distributors. The OSHA standard requires them to develop and provide a MSDS for each hazardous chemical they produce or handle. Each MSDS can vary in format but should include the following information: 

Chemical and common name



Ingredient information



Physical & chemical characteristics



Physical hazards - potential for reactivity, fire and/or explosion



Health hazards



Symptoms of exposure



Primary route of likely entry into body upon exposure



OSHA permissible exposure level



Precaution for use



Waste disposal



Protective measures and equipment , including during spills & maintenance



Emergency & first aid procedures


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UNIT 233



Date of MSDS preparation and last revision



Emergency contact of manufacturer of distributor

MSDS for chemicals used in the Platforming process are included at the end of this section.


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13.0

UNIT 233

LABORATORY REQUIREMENTS AND SCHEDULE Laboratory Test Methods / Schedule Sample No.

PA-231-003

Name of the Stream &

Test Method

Frequency

Parameters

Number

Normal

Treater)

U114

2/M

Relative density

U539

2/M

Composition

Dragger

2/M

H2S

Dragger

2/M

Net Gas (After Chloride

HCl


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14.0


MAJOR EQUIPMENT AND INSTRUMENT SUMMARY


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JAMNAGAR

14.1

UNIT 233

Equipment Summary

14.1.1 Vessels

Item No.

MV-AY

Equipment Title

ID

T/T

(mm)

(mm)

Material Of

Pressure

Temperature

2

o

(kg/cm g)

( C)

Construction 233-V01 233-V03

Absorber

1575(T)

Refrigerant

2080(B) 1200

9600

(Head & Shell) Killed carbon

6000

steel Killed carbon

Receiver/

Operating

Design

Operating

Design

41.85

-11

-28

steel

Economiser


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Remarks



JAMNAGAR

UNIT 233

14.1.2 Shell and Tube Exchanger

Item No

Equipment

Heat

ME-AY

Title

Duty

Shellside Fluid

(MMKcal/hr) 233-S01

Vapor

1.577

Lean Gas

Tubeside

Flow

Op. Press

Op. Temp

(kg/hr)

(kg/cm2g)

In/Out

25309

37.96

(°C) -11.1/28.4

MOC

KCS

exchanger 233-

Liquid

S02A/B

exchanger

233-S03

Vapor

Fluid

Rich

Flow

Op. Press

Op. Temp

MOC

(kg/hr)

(kg/cm2g)

In/Out

44579

38.59

(°C) 37.2/6.1

KCS

169995

40.21

37.2/8.9

KCS

-11.8/

KCS

Gas 2.077

Rich oil

1.26

Propylene

189224

23.83

-3.9/21.1

KCS

Lean oil

-23.5

KCS

Gas

Chiller

-23.5

Exchanger


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Item No

Equipment

Heat

ME-AY 233-S03

Title Liquid

Duty 1.97

Chiller

(MMKcal/hr)

Exchanger Refrigerant

3.927

Propylene

47074

0.515

Rich oil

189588

233-S05

UNIT 233

Shellside Propylene

Tubeside -23.5

KCS

Liquid

19.56

69.4/42.8

KCS

Water

415000

23.48

23.3/29.4

KCS

Propyle

45208

9.2/-20.9

KCS

4.5

31.4/40.9

KCS

19.11

43.3/27.2

KCS

condenser 233-S06

Refrigerant subcooler

ne


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UNIT 233

14.1.3 Pumps

Item No

Equipment

MP-AY

Title

Type

Rated

Pumping

Suct.

Disch.

Diff.

Capacity

Temp

Press

Press

Head

Driver

2

2

(kW)

3

233P01A/B

Lean oil

Centrifugal

(m /hr)

(° C)

(kg/cm g)

(kg/cm g

(m)

239

37

20.9

40.5

251

RPM

Installed

2950

280

1 stage

Casing

Dia Centerline

Between

Radial

bearings

Double volute


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Impeller Rated Mount


14.2


Instruments Summary

Tag No.

Description

Normal Value

FI-001 FIC-002 TI-001 TI-002 TI-020 TI-021 TI-026 TIC-009 TIC-011 PI-001 PI-016B PIC-012 PIC-038 PDIC-018 PDI-026 PDI-034 LIC-004 LIC-002 LIC-014 LI-009 LI-015

Gas To Vapor Exchanger Lean Oil Flow Rate Net Gas Inlet Temperature Net Gas From Recovery Plus Temperature Compressor Discharge Temperature Oil Reclaimer Temperature Lube Oil Temperature From Cooler Lean Gas From Chiller Lean Oil From Chiller Temperature Net Gas Inlet Pressure Compressor Discharge Pressure Compressor Suction Pressure Refrigerant Receiver/Economiser Pressure Lube Oil Differential Pressure Lube Oil Filter Differential Pressure Oil Separator # 2 Pressure Differential Absorber Level Combined Vapor-Liquid Chiller Level Refrigerant Condenser Level Oil Reclaimer Level Refrigerant Receiver Economiser Level

131,039 Nm3/Hr 213 m3/Hr 37 oC 28.4 oC 70 oC 15 oC 50 oC -12.2 oC -21.2 oC 36.6 Kg/Cm2 g 17.0 Kg/Cm2 g 2.7 Kg/Cm2 g 3.59 Kg/Cm2 g 14.3 Kg/Cm2 < 0.35 Kg/Cm2 < 0.2 Kg/Cm2 1720 mm 890 mm 350 mm 30-275 mm 445 mm


OPERATING MANUAL

RECOVERY PLUS UNIT


: 134 : 00 : 01

DATE AUTHOR

: 06-04-16 : BKN/AG



15.0

P&IDS AND LIST OF REFERENCE DRAWINGS

15.1

PFD REFERENCE DRAWINGS MS0004-LAC-C01-001

15.2

P & ID REFERENCE DRAWINGS G41-AY231-017 G41-AY231-019 G41-AY231-020 G41-AY231-025 G41-AY231-041

15.3

MFD REFERENCE DRAWINGS MS0004-LAC-C02-003 MS0004-LAC-C02-004 MS0004-LAC-C02-005 MS0004-LAC-C02-006 MS0004-LAC-C02-007


OPERATING MANUAL

RECOVERY PLUS UNIT


: 135 : 00 : 01

DATE AUTHOR

: 06-04-16 : BKN/AG



MS0004-LAC-C02-008 MS0004-LAC-C02-009 MS0004-LAC-C02-010 MS0004-LAC-C02-011 MS0004-LAC-C02-012 MS0004-LAC-C02-013 MS0004-LAC-C02-014 15.4

PLOT PLAN REFERENCE DRAWINGS P50-AY231-002 (SHEET 1 OF 2) P50-AY231-002 (SHEET 2 OF2)

15.5

PSFS (Safe Guarding) REFERENCE DRAWINGS G55-AY231-001 G55-AY231-002 G55-AY231-003 G55-AY231-004

15.6

MSD


OPERATING MANUAL

RECOVERY PLUS UNIT


: 136 : 00 : 01

DATE AUTHOR

: 06-04-16 : BKN/AG



REFERENCE DRAWINGS G34-AY231-001 G34-AY231-002 G34-AY231-003 G34-AY231-004 15.7

Area Protection Layout G56-AY231-004

15.8

Safety Equipment Layout G56-AY231-007

15.9

Safety Signs Layout G56-AY231-010

15.10

PIB#4 Gaseous Fire Extinguishing System G56-AY221-203


OPERATING MANUAL

RECOVERY PLUS UNIT


: 137 : 00 : 01

DATE AUTHOR

: 06-04-16 : BKN/AG

Recovery Plus Operating Manual

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