Reformer Plant Normal Operations 1
Work Instructions 1.1
Splitter Section
1.2
Splitter section splits heavy naphtha and light straight run naph tha and produces solvent oil through side stream stripper. stripper.
1.3
Feed to splitter is taken from following three sources: 1.3.1
From tank # 17
1.3.2
Direct from Howe aker !nits
1.3.3
From tank # " During startup and shutdown$
1.4
Solvent oil is also produced from splitter through solvent side stripper as per demand of oil movement %y ad&usting the splitter operating conditions.
1.5
'ight straight run naphtha is stored in rundown tanks for %lending to produce premium gasoline.
1.6
Heavy naphtha is used as feed to hydrotreater section.
1.7
Field (perator takes the reading of the different pumps after every two hours and logs it in the )'og ) 'og Sheet of Splitter Section*. Section*.
1.
Shift +ngineers of morning, evening and night shifts signs the )'og )'og Sheet of Splitter Section*. Section*.
1.!
"#$rotreater Section
1.1%
Hydrotreater section produces sweet feed for reformer section %y removing mainly sulfur, nitrogen, o-ygen, heavy metals, etc.
1.11
Heavy naphtha feed from splitter %ottom is charged to hydrotreater section. inimum 1/ wt ppm sulfur is maintained in feed naphtha. 0f it is less in heavy naphtha feed, dimethyldisulfide is in&ected to maintain the a%ove value.
1.12
y product hydrogen from reformer section is fed to hydrotreater reactor for the removal of poisonous material from naphtha.
1.13
Field (perator takes different reading of the section after every two hours and logs it in the )'og ) 'og Sheet of Hydrotreater Section*. Section*.
1.14
Shift +ngineers of morning, evening and night shifts signs the )'og )'og Sheet of Hydrotreater Section*. Section*.
1.15
Reformer Section
1.16
eformer section produces "2 (34 reformate.
1.17
Sweet feed from hydrotreater section is charged to reformer section.
1.1
Following materials are in&ected and maintained in the feed to provide proper chemical %alance on the reformer section catalyst.
1.1.1 4hloride is in&ected to maintain 52./ wt ppm chloride in hydrogen
recycle gas. 1.1.2 6ater is in&ected to maintain 1/82 wt ppm water in hydrogen
recycle gas. 1.1!
Hydrogen is also recycled through reformer reactor to ensure proper reactions in the reformer reactors.
1.2%
Field (perator takes different readings of the reformer section after every two hours and logs it in the )'og Sheet of eformer Section*.
1.21
Shift +ngineers of morning, evening and night shifts signs the )'og Sheet of eformer Section*.
1.22
Ne& 'oolin( )o&er
1.23
3ew cooling tower supplies cooling water to reformer plant and heavy crude unit.
1.24
Do9ing rate of chemicals sulfuric acid, performa- 21;, chlorine$ is maintained for proper
1.25
Field (perator takes different readings of the cooling tower after every two hours and logs it in the )'og Sheet of 3ew 4ooling =ower *.
1.26
Shift +ngineers of morning, evening and night shifts signs the )'og Sheet of 3ew 4ooling =ower *.
1.27
Recor$s
1.2
!nder normal operation of the reformer plant following records are generated: 1.2.1 eformer Shift eport =hree shift in one day$ 1.2.2 eformer Daily eport 1.2.3 eformer onthly eport 1.2.4 3H=>?latformer Daily Summary prepared %y using the data from
'a%oratory eformer ;nalysis eport =21F28$ 1.2.5 eformer Daily ;verage eport 1.2!
S*ift +ut# "an$in( O,er 1.2!.1 Shift +ngineer logs all important parameters>activities %eing done
at plant and during overlap time 12 minutes$ ver%ally communicate the same to ne-t Shift +ngineer. 1.2!.2 oard (perator logs important parameters and conveys the same to
ne-t Shift %oard man during overlap time 12 minutes$. 1.2!.3 ?lant (perator logs all important conditions of plant and conveys
the same to ne-t Shift (perator during overlap time 12 minutes$.
2
Work -n,ironment at ''R 2.1
?reference %e given for location of the 44 in the safe ;rea
2.2
0nside temperature conditions to suit local occupational health regulations
2.3
=he 4entral 4ontrol oom 44$ is such that it is dust proof and the humidity should %e kept low.
2.4
=here %e no opening on the plant side from where vapors or dust can enter
2.5
;ll wiring inside 44 is @ero halogen
2.6
Flooring inside the 44 is of the raised floor type
2.7
+ntry to 44 is restricted only to concerned staff and to ensure dust free environment shoes are not allowed and if re
2.
Smoke detectors and fire alarm %uttons are installed
2.!
4ommunication system is such that the operator uses the same with out getting distracted from the process control
2.1%
'ights installed are such that there is no glare o n the screens or the panel
2.11
'ighting is at least A/"2 'u-
2.12 3
3oise level should %e less then A/d% ma-
Statistical nal#sis 3.1
;ll the data of different parameters of reformer plant is stored in the Digital 4ontrol System, which can %e viewed and printed whenever re
3.2
Digital 4ontrol System can generate 7 hours trend line of different parameters on each point during the process.
3.3
0n case more than 7 hours old data is re
Shift +ngineer daily takes the printout of the trend o%tained from the Digital 4ontrol System of different parameters and files it. 0n case of any pro%lem, esearch and Development work or continual improvement this statistical data are used 3.4
Reformer S*ut$o&n Proce$ure 3.5
4
;ll safety concerns given in )!(? ?latforming ?rocess Safety anual* are applica%le to this work instruction.
Work Instructions 4.1
educe the feed of 3H= and eformer to A mB>hr. maintain 0= of 3H= CB1/4 and reduce the reformer 0=S 8A24.
4.2
Switch over the eformer charge to sweet feed, 4hange feed from =ank # 17 to =ank 2"$. 0t takes )1 hr* to flush the system.
4.3
educe 3H= feed to /2E of the design 17mB>hr$ at the temperature of B1/4 compensate the reformer feed through F02".
4.4
educe 0= of 3H= B224. ;t this temperature stop feed to 3H=. ;lso stop the in&ection of !nicor 4.
4.5
Stop Dimethyldisulfide in&ection 0f in service$.
4.6
aintain the ma-imum H flow through 3H= rector to sweep the hydrocar%ons. educe the 0= of 3H= C 24 during sweeping DonGt go %ellow 24. the reducing rate is B24 to 824>hr. if catalyst is re
4.7
eep circulation of H through 3H= until li
4.
;fter circulation keep /2E level in H=I 22/ and %lock '4I2A/ H=H 22 automatically shut off when gas flow to 3H= stop$.
4.!
Divert the reformate >D to tank # 1.
4.1%
Decrease reformer 0=Gs to 8//4, also reduce the feed to reformer simultaneously to /2E of the design 17mB>hr$.
4.11
Stop feed to reformer C8/24, also stop the =4+ K condensate in&ections.
4.12
eep circulation of H to reformer for hours until there is no further accumulation of li
4.13
educe 0=Gs of reformer to 8224 during sweeping.
4.14
Shutdown the heater at 8224 and also stop the compressor after the 1/ min of shutdown of heaters.
4.15
Depressuri9e the system to recm in fuel gas or flare =he rate of depressuri9ing is 21 kg>cm in 21 min$.
4.16
For further details a%out the normal shutdown and emergency shutdown, refer to )eformer ?lant (perating anual*.
Reformer Startup 5
Work Instructions 5.1
Startup fter S*ort S*ut$o&n
5.2
Start compressor overhead fans, S+22B and all other overhead fans.
5.3
Start recycle gas compressor S4221 as per the procedure given in operating instruction manual.
5.4
4heck the compressor suction vessel level time to time. 6hen it increases, start the pump S?221 to maintain its level a%o ut B2/2E.
5.5
'ine up sweet naphtha from =ank # " to (S' eformer ?lant charge pump and start it.
5.6
Start the splitter charge pump H=?221.
5.7
6hen the level in the splitter is around 12E, start splitter re%oiler pump H=?22/ %efore starting, confirm the opening of control value H=FI21 around 12E$.
5.
Start one main %urner in each reformer heater as per reformer plant heaters operating procedure.
5.!
y pass hydrotreater unit %y closing H=F4211 and operating H=F02" direct to stripper H=I22$.
5.1%
Start hydrotreater feed pump H=?228 as per reformer plant highspeed centrifugal pump operating procedure.
5.11
'ine up stripper %ottom to =ank # 1 through F0"2 %ypassing reformer unit closing of SF4221$.
5.12
eep tank to tank circulation from tank # " to splitter H=I221$, stripper and %ack to =ank # 1 for one hour and ensure complete flushing of sour naphtha from the system.
5.13
0ncrease the reformer furnaces outlet temperature C 82/24 per hour, up to B724.
5.14
4ut the reformer feed to reformer unit %y opening SF4221 and stopping tank to circulation %y closing F02"2 glo%e value.
5.15
aintain reformer feed rate 17 mB>hr as early as possi%le.
5.16
Start all the main %urners of reformer heaters and increase the reformer heaters outlet temperatures up to 8724.
5.17
;fter 1/ minutes divert reformate to storage tank i.e., tank1/ or tank1".
5.1
eep close eye on compressor suction vessel SI221 and start the %ottom pump S?221 when level starts increasing.
5.1!
Start chloride in&ection pump S?22B to maintain chloride level in recycle gas %etween 2.1 to 2./ ppm.
5.2%
4ommission hydrogen gas to hydrotreater unit through H=F427B when e-cess hydrogen gas is availa%le from reformer unit.
5.21
Start hydrotreater furnace H=H22 %y putting one main %urner in operation as per operating procedure, when hydrogen from to hydrotreater reaches more than 1A22 mB>hr.
5.22
Start increasing hydrotreater reactor outlet temperature up to "24 temperature difference in hydrotreater reactor inlet and outlet should not %e more than /24 in any case$.
5.23
4ut the hydrotreater feed at "24 hydrotreater reactor outlet temperature C 17 mB>hr, %y opening H=F4211.
5.24
eep a close eye on hydrotreater heater and increase firing to maintain the re
5.25
Stop feed through F12" when level in H=I22/ is enough to maintain level in H=I22.
5.26
Start stripper reflu- when the level is availa%le in H=I227.
5.27
Start !nicore4 in&ection pump to maintain 2.2.8 ppm of !nicore4 in the overhead system.
5.2
4hange the reformer feed tank from tank # " to tank # 17, also change the reformat rundown tank to tank # 1/.
5.2!
4heck the H4l, HS and moisture in the recycle gas, and increase the reformer feed up to BB mBhr.
5.3%
;d&ust the hydrotreater reactor outlet temperature L B1/4 ma-imum design BB/ 4$.
5.31
0ncrease reformer reactor inlet temperatures to maintain "2 (34 ma-imum design /B24$.
5.32
Startup fter )urnaroun$ an$ 'atal#st Re(eneration
5.33
Startup after turnaround and catalyst regeneration is done as per the 3H=>?latformer Startup ?rocedure.
