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01 Aug 2002 Unit 14 Light Oil Hydrotreater Section 1.0 Rev. 12

Process System Description

TABLE OF CONTENTS

1.0 PROCESS SYSTEM DESCRIPTION.............................................2

1.1 Process Design asis...........................................................................................................2

1.2 Descri!tion o" #lo$...........................................................................................................2%

1.3 Descri!tion o" Process &ontrols.........................................................................................'4

1.4 Descri!tion o" ()ergency Syste)s...................................................................................*%

1.5 &he)icals and +aterials....................................................................................................,-

1.6 (nviron)ental Protection..................................................................................................-%

1.7 Utilities............................................................................................................................... -,

1.8 Design &odes and Standards..............................................................................................-

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1.0 PROCESS SYSTEM DESCRIPTION

1.1 Process Design Basis

1.1.1 Introdction

he Light Oil Hydrotreater Unit 14 is located in Hydrocrac3er Area '0. heunit is designed to !rocess a )iture o" the "ollo$ing5 straight run co)6ined

distillates "ro) the &rude Unit Unit 107 light co3er gas oil L&8O/ co3er

na!htha/ and co3er light ends "ro) the 8as Plant Unit 17 and cold distillate"ro) inter)ediate tan3age. he design ca!acity o" the Light Oil Hydrotreater

is *0/000 PSD.

Products leaving the Light Oil Hydrotreater are "urther !rocessed in the

do$nstrea) Hydro!rocessing Su!!ort Unit Unit 1'.

he o69ective o" the Light Oil Hydrotreater is to )ai)i:e &';*0

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• #eed &ase % is 6ased u!on 1-0/000 PSD o" Ha)aca &rude

"eed to the &rude Unit and 1000>

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Table 1.1.2-1 Feed Properties - Case 11!"#000 $PSD %a&a'a Cr(de Feed ) 1000*+F Co,er Feed

Combined

Distillate

Coker

Naphtha

Light Coker

Gas il#lash Point/

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Table 1.1.2-2 Co,er Napta /it Eds-Case 1

1!"#000 $PSD %a&a'a Cr(de Feed ) 1000*+FCo,er Feed

Co&poet Rate# lbr

&% 2/11'

&% %12

i&4 1/',,

@&4 */0-1

&4 4/*

1/% utadiene -'

otal/ l6hr 1'/0'

otal/ PSD 1/00

Table 1.1.2-3 Feed Properties - Case 2

1!"#000 $PSD %a&a'a Cr(de Feed ) "0*+F Co,er Feed

CombinedDistillate

CokerNaphtha

Light CokerGas il

#eed rate/ PSD 2-/%10 /-201 1/000

olu)e Percent o" #eed '0.1' 1-.0'2 %0.0

Beight Percent o" #eed '2.-* 1'.,%2 %1.%1

APC 8ravity 2*.2 *1.'4 %2.2

S!eci"ic 8ravity *0*0 0.-,' 0.,%%0 0.*40

Sul"ur/ $t? 2.% 1.0 2.*-

@itrogen/ $!!) %00 0 11,0

Bater/ vol. ? Saturated Saturated Saturated

&etane Cnde/ AS+ D;-,* %2 ; 41

&hloride/ $!!) 2.* 2.* 2.*

#lash Point/ / $!!) ; ; ;

&onradson car6on/ $t? F 0.1 ; 0.00

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Table 1.1.2-3 Feed Properties - Case 21!"#000 $PSD %a&a'a Cr(de Feed ) "0*+F Co,er Feed

Combined

Distillate

Coker

Naphtha

Light Coker

Gas il&, Cnsolu6les/ $!!) F 100 ; 4

&o)!osition/ vol. ?

Para""ins ; %.4 2*.

Ole"ins ; %%., 20.%

@a!hthenes ; 1%.' 21.*

Aro)atics ; 14.4 %1.%

Diene alue '.4,

&on9. Dienes/ $t? 2.%-

P &ut/

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!able 1.1.2"4 − Coker Naphtha Light #nds " Case 2

1!"#000 $PSD %a&a'a Cr(de Feed ) "0*+FCo,er Feed

Co&poet Rate# lbr

&% %/1,2

&% '*1

i&4 1/,1

@&4 */-'2

&4 '/-%1

1/% utadiene -'

otal/ l6hr 1/'2

otal/ PSD 2/220

Table 1.1.2-" Feed Properties - Case 310#000 $PSD %a&a'a Cr(de Feed ) 1000*+F Co,er Feed

Co&biedDistillate

Co,erNapta

/it Co,er4as Oil

#eed rate/ PSD %1/10 /,-1 1,/4%1

olu)e Percent o" #eed '%.0 1,.-2 2-.1

Beight Percent o" #eed ''., 14.,2 2-.*

APC 8ravity 2*. *%.1 %1.'S!eci"ic 8ravity *0*0 0.-4 0.,2, 0.,

Sul"ur/ $t? 2.1 1.0 2.,*

@itrogen/ $!!) 2,1 0 11-0

Bater/ vol. ? Saturated Saturated Saturated

&etane Cnde/ AS+ D;-,* %2 ; 41

&hloride/ $!!) 2.* 2.* 2.*

#lash Point/

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Table 1.1.2-" Feed Properties - Case 310#000 $PSD %a&a'a Cr(de Feed ) 1000*+F Co,er Feed

Co&bied

Distillate

Co,er

Napta

/it Co,er

4as Oil&o)!osition/ vol. ?

Para""ins ; %.4 2*

Ole"ins ; %%., 20

@a!hthenes ; 1%.' 22

Aro)atics ; 14.4 %2

Diene alue '.4%

&on9. Dienes/ $t? 2.%,

P &ut/

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Table 1.1.2-! Co,er Napta /it Eds -Case 3

10#000 $PSD %a&a'a Cr(de Feed )1000*+F Co,er Feed

Co&poet Rate# lbr

&% 1/-00

&% %%1

i&4 1/,-2

@&4 */'%

&4 '/',

1/% utadiene -'

otal/ l6hr 1*/'4-

otal/ PSD 1/-,0

1.1.2.5 Ma!ep $ydrogen

+a3eu! hydrogen "or the Light Oil Hydrotreater is su!!lied "ro)

the Hydro!rocessing Su!!ort Unit Unit 1'.

1.1.2." Lean Amine Spp%y

Lean a)ine "or the Light Oil Hydrotreater is su!!lied "ro) the

Hydro!rocessing Su!!ort Unit Unit 1'.

1.1.2.! &as" &ater Spp%y

Bash $ater "or the Light Oil Hydrotreater is su!!lied "ro) theHydro!rocessing Su!!ort Unit Unit 1'.

1.1.3 Design Processing Parameters

1.1.3.1 Cata%yst Description

Product yields/ !ro!erties/ and reactor conditions sho$n in this

o!erating )anual "or the Light Oil Hydrotreater are 6ased u!on thecatalysts s!eci"ied in a6le 1.1.%;1.

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Table 1.1.3-1 Rea'tor Catal6st

Rea'tor$ed

N(&ber Catal6st T6pe

@o. 1 ed 1 E;10/ E;''1/ @;204

@o. 1 ed 2 @;204/ H&;E

@o. 1 ed % H&;E

@o. 2 ed 4 H&;E

@o. 2 ed ' H&;E

1.1.3.2 Reactor Conditions

he Light Oil Hydrotreater Unit 14 is designed 6ased on the

reactor conditions listed in a6le 1.1.%;2.

Table 1.1.3-2 Rea'tor Coditios

Case 11!"#000 $PSD%a&a'a Cr(de

Feed ) 1000*+FCo,er Feed


Feed) "0*+F Co,er

Feed

Case 310#000 $PSD%a&a'a Cr(de

Feed) 1000*+F Co,er

Feed

SOR EOR SOR EOR SOR EOR

LHS/ &atalyst 1/ hr ;1 2*.% 2*.% 2'.* 2'.* 2*.% 2*.%

LHS/ &atalyst 2/ hr ;1 %.'1 %.'1 %.42 %.42 %.'1 %.'1

LHS/ &atalyst %/ hr ;1 0.,- 0.,- 0.,, 0.,, 0.,- 0.,-

Reactor Outlet Pressure/ !sig 1*00 1*00 1*00 1*00 1*00 1*00

Design Reactor Pressure Dro!/

!si

; 122 ; ; ; ;

Reactor Cnlet e)!/

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1.1.3.3 Co%d Feed

At startu!/ the Light Oil Hydrotreater Unit 14 is designed to !rocess cold "eed at a rate e=uivalent to '0? o" the design hot "eed

rate.

1.1.3.5 #nit Trndo'n

he Light Oil Hydrotreater is designed "or a through!ut o" '0? o"the design "eed rate $hile )a3ing on;s!eci"ication !roduct =uality.

Unit turndo$n is e!ected to last "or only a short ti)e !eriod on

the order o" one to three $ee3s.

1.1.3." A%ternate Feed

he Light Oil Hydrotreater )ay have to !rocess a !ortion o" the

8as Oil Hydrocrac3er Unit 1* "eed $hen the 8as OilHydrocrac3er is shut do$n.

Although the Light Oil Hydrotreater is not s!eci"ically designed "or

this condition/ the e!ected ca!a6ilities o" the catalyst loaded inthis unit to !rocess the alternate "eed is as "ollo$s5

a. he o!eration is "easi6le i" the )ai)u) "eed rate used

is '0? o" the design total "eed rates "or Units 14 and 1*5

a!!roi)ately ',/000 PSD.

6. he li)iting !roduct s!eci"ication is e!ected to 6e the3erosene s)o3e !oint. he o!erating te)!erature o" Unit14 should not 6e increased )ore than 10

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#lash Dru) 14;;004 li=uid routed to Unit 1' )ust 6e reduced to

%'

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ece!t "or e=ui!)ent !rovided in the Hydro!rocessing Su!!ort

Unit Unit 1' that is !rovided as co))on "or 6oth the Light Oil

Hydrotreater and the 8as Oil Hydrocrac3er Unit 1*.

Straight run distillate diesel range )aterial is to 6e used as start;u! oil "or the initial startu! o" the Light Oil Hydrotreater.&o)6ined distillate "ro) the &rude Unit is to 6e used as start;u!

oil "or su6se=uent startu!s o" the Light Oil Hydrotreater. #lushing

oil is to 6e used during shutdo$n o" the Light Oil Hydrotreater.

1.1.3.1" Feed Contro%

During nor)al o!eration/ cold "eed at a rate e=uivalent to 10? o"

the design "eed rate su!!le)ents hot "eed. his cold "eed strea) isused as the !ri)ary )eans o" level control in the "eed surge dru).

Su!!le)entary level control is !rovided to shut o"" the "lo$ o" "eed

on high level in the Light Oil Hydrotreater "eed surge dru).

1.1.3.1! Feed Srge Re.irements

he "eed surge dru) is designed "or a surge ti)e o" ten 10)inutes "ro) high to lo$ li=uid level.

1.1.3.17 Ric" Amine

Rich a)ine "ro) the Light Oil Hydrotreater is "lashed in the #uel8as Scru66er !rovided in the Hydro!rocessing Su!!ort Unit Unit

1' to !rotect a)ine regeneration e=ui!)ent "ro) high !ressureva!or.

1.1.3.18 Amine Smp

An a)ine su)! servicing the Light Oil Hydrotreater is !rovided inthe Hydro!rocessing Su!!ort Unit Unit 1'.

1.1.3.1 Feed (rom Tan!age

During nor)al o!eration/ 10? o" the unit charge rate is colddistillate "eed "ro) tan3age. &o3er na!htha and L&8O are not

nor)ally to 6e diverted to tan3age.

1.1.3.20 Feed Coa%escer

A coalescer is re=uired "or the cold "eed "ro) tan3age. he

coalescer is si:ed "or '0? o" the unit design "eed rate.

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1.1.3.21 C"arge Pmp Sparing P"i%osop"y

he 8as Oil Hydrocrac3er s!are charge !u)! is used as a co))ons!are charge !u)! "or 6oth the Light Oil Hydrotreater and the 8as

Oil Hydrocrac3er.

1.1.5 Prodct Rates and /a%ities

1.1.5.1 Prodct Speci(ications

he Light Oil Hydrotreater Unit 14 is designed to )eet theoverall Hydro!rocessing Area !roduct s!eci"ications indicated in

a6le 1.1.4;1. he s!eci"ications !rovided are )et 6y the 6lended

!roduct "ro) the Light Oil Hydrotreater Unit 14 and the 8as Oil

Hydrocrac3er Unit 1* a"ter !rocessing in the Hydro!rocessing

Su!!ort Unit Unit 1'.



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Table 1.1.5-1 O9erall %6dropro'essi :rea Prod('t Spe'i;'atios

Prod('t Spe'i;'atio

Case 1 ad Case

2 Case 3

Mii&(&

Ma

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% 1-0/000 PSD Ha)aca &rude #eed and 1000> ?ol@ FresFeed or SCF$$/

=its> At@Fres Feed

SOR EOR SOR EOR

&he)ical Hydrogen &onsu)!tion 1100 1100 1.-% 1.-%

H2S 1. 1. 2.4% 2.4%

@H% 4. 4. 0.0, 0.0,

H2O 4.2 4.2 0.0, 0.0,

&1 10.1 1*.2 0.14 0.2%

&2 *.1 10.1 0.1* 0.2,

&% 1'.2 1-.% 0.' 0.,4

C&4 0., 0. 0.4* 0.'%

@&4 2.% 2.4 1.' 1.*'

Light @a!htha &' ; 10 ?ol@ FresFeed or SCF$$/

=its> At@Fres Feed

SOR EOR SOR EOR

&he)ical Hydrogen &onsu)!tion 1110 1110 1.- 1.-

H2S ,,.1 ,,.1 2.%% 2.%%

@H% 4.% 4.% 0.0* 0.0*

H2O %. %. 0.0* 0.0*

&1 -. 1'. 0.14 0.22

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Table 1.1.5-3 Esti&ated Prod('t Yields - Case 21!"#000 $PSD %a&a'a Cr(de Feed ) "0*+F Co,er Feed

=its> ?ol@ Fres

Feed or SCF$$/

=its> At@

Fres Feed

&2 '.- -. 0.1* 0.2*

&% 1-., 2%.* 0.,, 0.-2

C&4 0. 0.- 0.'' 0.*1

@&4 2., 2. 1.% 1.-0

Light @a!htha &' ; 10 ?ol@ FresFeed or SCF$$/

=its> At@Fres Feed

SOR EOR SOR EOR

&he)ical Hydrogen &onsu)!tion 1110 1110 1.-* 1.-*

H2S ,4.4 ,4.4 2.24 2.24

@H% 4.1 4.1 0.0* 0.0*

H2O %. %. 0.0* 0.0*

&1 -. 1*.0 0.14 0.2%

&2 '.- 10.0 0.1* 0.2,

&% 14.0 1.0 0.'' 0.,0

C&4 0. 0.- 0.'% 0.'-

@&4 2., 2. 1.' 1.-2

Light @a!htha &' ; 10

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Table 1.1.5-5 Esti&ated Prod('t Yields - Case 310#000 $PSD %a&a'a Cr(de Feed ) 1000*+F Co,er Feed

=its> ?ol@ Fres

Feed or SCF$$/

=its> At@

Fres Feed

SOR EOR SOR EOR

Diesel '2'

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Table 1.1.5-" Esti&ated /it ) %ea96 Napta Properties

Case 1$165%&&& '()D

*ama+a Cr,de-eed 1&&&/0- Coker

-eed

Case 2$165%&&& '()D

*ama+a Cr,de-eed 5&/0- Coker

-eed

Case 3$1&%&&& '()D


-eed

) # ) # ) #

C8,2345F Lig"t Nap"t"a

APC 8ravity 0.* 0.* 0.* 0.* 0.% 0.'

Sul"ur/ $!!) 10 10 10 10 10 10

@itrogen/ $!!) F1 F1 F1 F1 F1 F1

Hydrocar6on y!es/ ol?

Para""ins ,, ,, ,, ,, -0 -0 @a!hthenes 22 22 22 22

Aro)atics 1 1 1 1 2 2

+erca!tan Sul"ur/ $!!) F' F' F' F' F' F'

RP/ !sia ; ; ; ; ; ;

RO@ &lear *' *' *' *' *' *'

Distillation/ P/

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Table 1.1.5-" Esti&ated /it ) %ea96 Napta Properties

Case 1$165%&&& '()D


-eed

Case 2$165%&&& '()D

*ama+a Cr,de-eed 5&/0- Coker

-eed

Case 3$1&%&&& '()D


-eed

) # ) # ) #

Distillation/ P/

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Table 1.1.5-! Esti&ated Berosee Properties


Feed) 1000*+F Co,er

Feed


Feed) "0*+F Co,er

Feed

Case 310#000 $PSD

%a&a'a Cr(de Feed) 1000*+F Co,er

Feed


@a!hthalenes/ vol? F % F % F % F % F % F %

#ree:e Point/

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Table 1.1.5-7 Esti&ated Diesel ) 4as Oil Properties


Feed) 1000*+F Co,er

Feed


Feed) "0*+F Co,er

Feed

Case 310#000 $PSD%a&a'a Cr(de

Feed) 1000*+F Co,er

Feed


Pour Point/

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1.2 Description o( F%o'

he Light Oil Hydrotreater is designed to hydrotreat a )iture o" straight;run distillates"ro) the &rude Unit Unit 10/ and crac3ed na!htha and light co3er gas oil "ro) the

Delayed &o3ing Unit Unit 12. he Light Oil Hydrotreater is a "ied;6ed catalytic !rocess designed to re)ove nitrogen and sul"ur "ro) the "eedstoc3 and to i)!rove !roduct !ro!erties such as cetane inde and s)o3e !oint.

Unit "eed and hydrogen;rich gas are )ied/ heated to reaction te)!erature/ andcontacted $ith hydrotreating catalyst in t$o "ied;6ed reactors arranged in series.

Reactor e""luent !asses through heat echangers and a cooler to a se!arator/ $here

hydrogen;rich recycle gas/ sour $ater/ and li=uid !roduct are se!arated. he recycle gasis contacted $ith a)ine to re)ove hydrogen sul"ide/ co)6ined $ith )a3eu! gas/ and

returned to the reactor. Li=uid "ro) the se!arator !asses through a "lash dru) to the

Hydro!rocessing Su!!ort Unit Unit 1' "or "urther !rocessing.

he Light Oil Hydrotreater Unit 14 consists o" the "ollo$ing )a9or sections5

• Unit #eed and #eed Surge Dru)

• &harge Pu)! and #eed Heating

• Reactors

• Reactor (""luent &ooling

• Se!arator

• #lash Dru)

• Recycle 8as Scru66er

• Recycle 8as &o)!ressor

• Recycle 8as Heater

he Light Oil Hydrotreater Unit Process #lo$ Diagra)s P#Ds and selected overall

re"inery &ontrol Cnter"ace Diagra)s &CDs/ $hich are located in Section 4.% o" the

O!erating +anual/ can 6e used as a su!!le)ental re"erence to the !rocess descri!tions.



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1.2.1 Sectiona% Descriptions

1.2.1.1 #nit Feed and Feed Srge Drm

he Light Oil Hydrotreater Unit 14 receives straight run

co)6ined distillate "eed "ro) the &rude Unit Unit 10/ light co3er

gas oil L&8O/ co3er na!htha/ and co3er light ends "ro) the 8asPlant Unit 1/ and cold distillate "ro) inter)ediate tan3age.

y!ically/ )ost o" the unit "eed is routed hot directly "ro) the

&rude Unit and 8as Plant. During nor)al o!eration/

a!!roi)ately 10? o" the &rude Unit co)6ined distillate is cooled

and routed to the gas 6lan3eted Light Oil Hydrotreater #eed an3.his cold distillate is then !u)!ed to the Light Oil Hydrotreater

under "lo$ control reset 6y level control at the #eed Surge Dru)/

14;;001.

he cold distillate is routed through the #eed &oalescer/ 14;;00'/$hich re)oves "ro) the distillate any $ater that )ay have 6een

!ic3ed u! in storage. he #eed &oalescer !revents $ater "ro)

)iing $ith the hot contents in the #eed Surge Dru)/ 14;;00'.

Bater re)oved in the #eed &oalescer is routed to the !henolic sour $ater collection header under inter"ace level control.

he individual unit "eeds are co)6ined and routed through the

#eed #ilters/ 14;#;001A. (ach o" the t$o "ilters is si:ed "or

100? o" design ca!acity. hese cartridge ty!e "ilters re)ove

!articulate )atter "ro) the "eed that $ould other$ise "oul thereactor catalyst 6eds. &o)6ined "eed eiting the #eed #ilters

enters the #eed Surge Dru)/ 14;;001. he #eed Surge Dru) is a

vertical vessel 6lan3eted $ith natural gas to )aintain a constantsuction !ressure "or the &harge Pu)!/ 14;P;001.

1.2.1.2 C"arge Pmp and Feed $eating

he &harge Pu)!/ 14;P;001/ is a )ulti;stage/ high;head/ )otordriven !u)! that increases the !ressure o" the unit charge to

reactor "eed !ressures. A co))on s!are &harge Pu)!/ 1*;P;001/

is !rovided to serve as a 100? s!are "or 6oth the Light OilHydrotreater &harge Pu)! and the 8as Oil Hydrocrac3er &harge

Pu)!.

#eed eiting the &harge Pu)! is trans"erred under "lo$ control to

the tu6eside o" the Reactor (""luent G #eed (changers 14;(;

002A&/ $here the "eed is heated against reactor e""luent. A"raction o" the "resh "eed is 6y!assed around the echangers



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through an auto)atic valve that controls the te)!erature o" the

)ied "eed at the outlet o" the echangers. A !ortion o" the unit

recycle gas is in9ected into the "resh "eed entering the tu6eside o"the echangers. he Reactor (""luent G #eed (changers consist

o" three shells o!erating in series.

1.2.1.3 Reactors

#eed eiting the Reactor (""luent G #eed (changers "lo$s to thereactors. e"ore entering the reactors/ the "eed is )ied $ith

recycle gas eiting the Recycle 8as Heater/ 14;H;001. he )ied

"eed then enters the to! o" Reactor @o. 1/ 14;R;001. Reactor @o. 1contains three 6eds. he "irst 6ed contains a guard 6ed/ de;

nitrogenation catalyst/ and a silica tra!. he second 6ed contains

)ore silica tra! catalyst and hydrotreating catalyst. he third 6edcontains hydrotreating catalyst. &old recycle gas is added on "lo$

control reset 6y te)!erature 6et$een the "irst and second 6eds

and the second and third 6eds to reduce and control =uench the

te)!erature o" the )aterial "lo$ing through the reactor. A =uenchdistri6utor/ )iing cha)6er and li=uid re;distri6ution trays are

!rovided 6et$een each 6ed.

(""luent "ro) Reactor @o. 1 is cooled $ith a "lo$ controlled

recycle gas =uench and then enters the to! o" Reactor @o. 2/ 14;R;002. Reactor @o. 2 contains t$o 6eds7 6oth 6eds contain

hydrotreating catalyst. &old recycle gas is added on "lo$ control

reset 6y te)!erature 6et$een the 6eds to reduce and control

=uench the te)!erature o" the )aterial "lo$ing through thereactor. A =uench distri6utor/ )iing cha)6er and li=uid re;

distri6ution trays are !rovided 6et$een the 6eds.

1.2.1.5 Reactor E((%ent Coo%ing

(""luent "ro) Reactor @o. 2 enters the shellside o" Reactor(""luent G Hot Recycle 8as (changer/ 14;(;001/ $here it is

cooled against hot recycle gas. he e""luent then enters the

shellside o" Reactor (""luent G #eed (changer/ 14;(;002A&/$here the e""luent is cooled against "resh "eed. his echanger

consists o" three shells in series.

Reactor e""luent eiting 14;(;002A& enters the shellside o" the

Reactor (""luent G &old Recycle 8as (changer/ 14;(;00%/ $here

it is cooled against cold recycle gas. he e""luent then enters theshellside o" Reactor (""luent G #lash Dru) Li=uid (changer/ 14;

(;004A&/ $here the e""luent is cooled against li=uid eiting the

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#lash Dru)/ 14;;004. his echanger consists o" three shells in

series.

he reactor e""luent then "lo$s to the air;cooled Product

&ondenser/ 14;(A;001A;P. e"ore entering the Product&ondenser/ $ash $ater is in9ected under "lo$ control into thereactor e""luent to !revent the de!osition o" salts that can corrode

and "oul the condenser. Bash Bater Pu)!s 1';P;00-A in the

Hydro!rocessing Su!!ort Unit Unit 1' !rovide the $ash $ater toUnit 14. he Product &ondenser consists o" 1* 6ays7 each 6ay is

!rovided $ith t$o "ans.

1.2.1." Separator

Reactor e""luent eiting the Product &ondenser/ 14;(A;001A;P/

enters the Se!arator/ 14;;002. he Se!arator is a high !ressure

vessel that !rovides the re=uisite residence ti)e "or se!aratingrecycle gas and sour $ater "ro) hydrotreated light oil !roduct. A 6oot section at the 6otto) o" the vessel collects the se!arated sour

$ater/ $hile the lighter hydrocar6on !roduct accu)ulates in the

)ain vessel.

a!or eiting the Se!arator is routed to the Recycle 8as Scru66er/14;&;001. he !ressure in the Se!arator is )aintained 6y

controlling the "lo$ o" )a3e;u! hydrogen into the recycle loo!/ or

alternatively 6y venting ecess va!or "ro) the recycle loo! to the

"lare header. he vent to "lare is not utili:ed under nor)al

o!erating conditions.

@O(5 he va!or outlet "ro) the Se!arator has a high

concentration o" $et hydrogen sul"ide H2S/ $hich )a3es this line

!rone to corrosion and lea3s. (nsure that detailed Re"inery !rocedures are "ollo$ed "or thoroughly ins!ecting the va!or outlet

line "ro) 14;;002 "or !otential corrosion at s!eci"ied intervals/

including during every turnaround.

Li=uid hydrocar6on and sour $ater strea)s leaving the Se!arator

are sent to the #lash Dru)/ 14;;004/ under level control/ via

)ulti;stage control valves.

1.2.1.! F%as" Drm

he #lash Dru)/ 14;;004/ receives "lashing hydrocar6on li=uid

and "lashing sour $ater "ro) the Se!arator/ 14;;002. he #lashDru) !rovides the re=uisite residence ti)e "or se!arating "lash gas

and sour $ater "ro) hydrotreated light oil !roduct. A 6oot section



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at the 6otto) o" the vessel collects the se!arated sour $ater/ $hile

the lighter hydrocar6on !roduct accu)ulates in the )ain vessel.

a!or eiting the #lash Dru) is routed to the #lash 8as Scru66er/

1';&;00'/ in the Hydro!rocessing Su!!ort Unit Unit 1'. he !ressure in the #lash Dru) is )aintained 6y controlling this "lo$o" "lash gas to the #lash 8as Scru66er/ or alternatively 6y venting

ecess va!or "ro) the #lash Dru) to the "lare header. he vent to

"lare is not utili:ed under nor)al o!erating conditions.

@O(5 he va!or outlet "ro) the #lash Dru) has a highconcentration o" $et hydrogen sul"ide H2S/ $hich

)a3es this line !rone to corrosion and lea3s. (nsure

that detailed Re"inery !rocedures are "ollo$ed "or

thoroughly ins!ecting the va!or outlet line "ro) 14;;004 "or !otential corrosion at s!eci"ied intervals/

including during every turnaround.

Li=uid hydrocar6on eits the #lash Dru) under level control and is

sent to the tu6eside o" the Reactor (""luent G #lash Dru) Li=uid(changer/ 14;(;004A&/ $here the li=uid is heated against

reactor e""luent 6e"ore "lo$ing to the Stri!!er/ 1';&;001/ in the

Hydro!rocessing Su!!ort Unit Unit 1'. A 6y!ass is !rovided

around the tu6eside o" 14;(;004A& to control the te)!eratureo" "lash dru) li=uid "lo$ing to Unit 1'.

Sour $ater eits the #lash Dru) under level control and is sent to

the non;!henolic sour $ater collection header.

1.2.1.7 Recyc%e =as Scr??er

Recycle gas "ro) the Se!arator/ 14;;002/ "lo$s to the Recycle

8as Scru66er/ 14;&;001/ $hich is a high !ressure colu)n $here

recycle gas is contacted $ith lean a)ine to re)ove H2S and

i)!rove the hydrogen !artial !ressure. Lean a)ine is !u)!ed"ro) the High Pressure Lean A)ine Pu)!s/ 1';P;00*A/ in the

Hydro!rocessing Su!!ort Unit Unit 1' under "lo$ control to the

Recycle 8as Scru66er.

he recycle gas is contacted $ith the lean a)ine in the scru66er/and the rich a)ine/ $hich is no$ saturated $ith H2S/ collects in the

6otto) section o" the colu)n. he rich a)ine is !ressured out

under level control to the #uel 8as Scru66er/ 1';&;00,/ in the

Hydro!rocessing Su!!ort Unit Unit 1' via a )ultistage controlvalve.

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Recycle gas "lo$s into the to! section o" the Recycle 8as Scru66er

$here the gas is contacted $ith a circulating $ater strea) to $ash

residual a)ine "ro) the gas. Bater &irculating Pu)!s 14;P;002A circulate the $ash $ater through the u!!er section o" the

Recycle 8as Scru66er. Bater &irculating Pu)! 14;P;002 is a100? s!are. he $ater circulating syste) can 6e re!lenished !eriodically 6y o!ening the )anual valve o"" the $ash $ater

header "ed 6y the Bash Bater Pu)!s/ 1';P;00-A/ in the

Hydro!rocessing Su!!ort Unit Unit 1'. he syste) can also 6e

6led !eriodically 6y o!ening the )anual valve connected to therich a)ine outlet "ro) the Recycle 8as Scru66er.

1.2.1.8 Recyc%e =as Compressor

Recycle gas eiting the Recycle 8as Scru66er/ 14;&;001/ "lo$s tothe Recycle 8as &o)!ressor Enoc3out Dru)/ 14;;00%/ $hich

3noc3s out any li=uid carryover "ro) the scru66er. Li=uid

accu)ulated in this dru) is )anually drained to the relie" header.

Recycle gas "ro) the Recycle 8as &o)!ressor Enoc3out Dru)

)ies $ith )a3eu! hydrogen gas "ro) the +a3eu! 8as&o)!ressor/ 1';E;001. +a3eu! gas enters the syste) under

Se!arator !ressure control. he )ied recycle gas and )a3eu! gas

"lo$s to the Recycle 8as &o)!ressor/ 14;E;001.

he Recycle 8as &o)!ressor is a stea) tur6ine driven centri"ugal

co)!ressor. Ct circulates recycle gas 6ac3 to the Recycle 8as

Heater/ 14;H;0017 to an in9ection !oint in the "resh "eed lineu!strea) o" the Reactor (""luent G #eed (changers/ 14;(;

002A&7 and to =uench in9ection !oints at Reactor @o. 1/ 14;R;001/ and Reactor @o. 2/ 14;R;002. e"ore entering the Recycle

8as Heater/ 14;H;001/ the recycle gas is heated on the tu6eside o"

the Reactor (""luent G &old Recycle 8as (changer/ 14;(;00%/ andthe Reactor (""luent G Hot Recycle 8as (changer/ 14;(;001.

1.2.1. Recyc%e =as $eater

he Recycle 8as Heater/ 14;H;001/ is a t$in;cell dou6le;"ired

vertical 6o;ty!e $ith a total o" eight !asses. (ach !ass isindividually "lo$ controlled to )aintain a 6alanced "lo$ throughthe heater. #uel gas is su!!lied to the heater under te)!erature

control that is )onitored 6oth at the "ired heater outlet and at the

Reactor @o. 1/ 14;R;001/ inlet. Recycle gas eiting the Recycle8as Heater )ies $ith "eed "ro) the Reactor (""luent G #eed

(changer/ 14;(;002A&.



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1.2.2 Process @aria?%es and C"emica% Reactions

his section includes a descri!tion o" the !rocess varia6les and che)icalreactions associated $ith the Light Oil Hydrotreater Unit Unit 14/ $hich

utili:es the UOP;licensed Union"ining !rocess technology. he "igures andgra!hs !resented in this section $ere !rovided 6y UOP "or the Union"ining !rocess and can 6e used as guidelines. S!eci"ic gra!hs can 6e develo!ed as

re=uired 6ased on actual unit o!erating data/ !ossi6ly in consultation $ith the

licensor.

Detailed descri!tions o" the unit !rocess control syste)s are !resented in

Section 1.%. Process control and alar) set !oints are !rovided in Section *.,.

1.2.2.1 S%(r Remo+a%

y!ical "eedstoc3s to a distillate hydrotreater contain si)!le

)erca!tans/ sul"ides/ and disul"ides. hese co)!ounds are easilyconverted to H2S. Ho$ever/ "eedstoc3s containing heteroato)icaro)atic )olecules are )ore di""icult to !rocess. Desul"uri:ation

o" these co)!ounds !roceeds 6y initial ring o!ening and sul"ur

re)oval "ollo$ed 6y saturation o" the resulting ole"in. hio!hene

is considered 1' ti)es )ore di""icult to !rocess co)!ared todiethylsul"ide.

a. +erca!tan

&;&;&;&;SH > H2 &;&;&;& > H2S

6. Sul"ide

&;&;S;&;& > 2H2 2 &;& > H2S

c. Disul"ide

&;&;S;S;&;& > %H2 2 &;& > 2H2S

d. &yclic Sul"ide

e. hio!henic

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1.2.2.2 Nitrogen Remo+a%

Denitrogenation is generally )ore di""icult than desul"uri:ation.

Side reactions )ay yield nitrogen co)!ounds )ore di""icult tohydrogenate than the original reactant. Saturation o" heterocyclic

nitrogen;containing rings are also hindered 6y large attached

grou!s/ as indicated in #igure 1.2.2;1.

he reaction )echanis) ste!s are di""erent co)!ared to

desul"uri:ation. he denitrogenation o" !yridine !roceeds 6y

aro)atic ring saturation/ ring hydrogenolysis/ and "inallydenitrogenation.

a. Pyridine

6. Juinoline

c. Pyrrole

1.2.2.3 Oygen Remo+a%

Organically co)6ined oygen is re)oved 6y hydrogenation o" the

car6on;hydroyl 6ond "or)ing $ater and the corres!ondinghydrocar6on.

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Fi(re 1.2.2-1 Deitroeatio



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a. Phenols

1.2.2.5 O%e(in Satration

Ole"in saturation reactions !roceed very ra!idly and have a high

heat o" reaction.

a. Linear Ole"in

&;&&;&;&;& > H2 &;&;&;&;&;& and iso)ers

6. &yclic Ole"ins

1.2.2." Aromatic Satration

Aro)atic saturation reactions are the )ost di""icult. he reactions

are in"luenced 6y !rocess conditions and are o"ten e=uili6riu)

li)ited. Unit design !ara)eters consider the desired degree o"saturation "or each s!eci"ic unit. he saturation reaction is very

eother)ic.

1.2.2.! Meta%s Remo+a%

he )echanis) o" the deco)!osition o" organo;)etallicco)!ounds is not $ell understood. Ho$ever/ it is 3no$n that)etals are retained on the catalyst 6y a co)6ination o" adsor!tion

and che)ical reaction. he catalyst has a certain )ai)u)

tolerance "or retaining )etals. Re)oval o" )etals nor)ally occurs

in !lug "lo$ "ashion $ith res!ect to the catalyst 6ed. y!icalorganic )etals native to )ost crude oils are nic3el and vanadiu)

@or)al "eed to the Light Oil Hydrotreater contains negligi6le



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nic3el and vanadiu). Cron can 6e "ound concentrated at the to! o"

catalyst 6eds as iron sul"ides/ $hich are corrosion !roducts.

Sodiu)/ calciu) and )agnesiu) are due to contact o" the "eed$ith salt $ater or additives. C)!ro!er use o" additives to !rotect

"ractionator overhead syste)s "ro) corrosion or to control "oa)ingaccount "or the !resence o" !hos!horus and silicon.

he use"ul li"e o" the catalyst )ay 6e deter)ined 6y the a)ount o"

)etals that are accu)ulated on it during the course o" o!eration.+ost Union"ining units are a6le to go through several o!erating

cycles $ithout eceeding the a6ility o" the catalyst "or re)oving

)etals. Cn a ty!ical Union"ining unit/ )etal re)oval is essentiallyco)!lete a6ove te)!eratures o" *00

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Fi(re 1.2.2-2 %6dropro'essi Rea'tio

Di'(lt6 /e9els



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he a!!roi)ate relative heats o" reaction !er unit o" hydrogenconsu)!tion "or these reactions are5

• Desul"uri:ation 1

• Ole"in Saturation 2

• Denitrogenation 1

• Aro)atic Saturation 1

All o" the reactions discussed a6ove are eother)ic and result in a

te)!erature rise across the reactor. Ole"in saturation and so)edesul"uri:ation reactions have si)ilarly ra!id reaction rates/ 6ut it

is the saturation o" ole"ins that generates the greatest a)ount o"

heat. he te)!erature rise e!ected "or a given charge stoc3 along$ith the desired !roduct =uality !lays a very i)!ortant role in

deter)ining the nu)6er/ si:e/ and arrange)ent o" the reactors/ heat

echange/ and hydrogen circulation rate.

1.2.2. $ydrocrac!ing Reactions

he !roducts o" the Union"ining reactions are o" a lo$er density

than the "eedstoc3. here"ore/ the total li=uid yield $ill 6e greater

than the "eed. So)e hydrocrac3ing )ay ta3e !lace in theUnion"ining !rocess. his is es!ecially evident to$ard the end o"

an o!erating cycle $hen reactor te)!eratures are raised to

co)!ensate "or lo$er catalyst activity. otal li=uid yield andhydrogen consu)!tion $ill increase as hydrocrac3ing reactions

!roceed. Cn general/ )ost o" the increase in li=uid volu)e yield$ill co)e "ro) )ore net stri!!er overheads at the e!ense o"

lo$er stri!!er 6otto)s !roduct. he ty!ical Union"ining unit isdesigned "or )ai)u) 6otto)s !roduction. (cono)ic

considerations deter)ine the a)ount o" 6otto)s !roduct that can

6e lost 6e"ore the unit is shutdo$n "or regeneration or catalystchange.

1.2.2.10 $ydrogen Consmption

he hydrogen consu)ed 6y Union"ining reactions is su!!lied

eternally and )ust 6e 6oosted to reaction syste) !ressure. hea)ount o" hydrogen re=uired to co)!lete the a6ove reactions

varies de!ending u!on "eed and desired !roduct =uality.

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1.2.2.11 Cata%yst Deacti+ation

&atalyst activity is reduced $henever )olecules cannot reachactive sites. &atalyst deactivation )ay 6e caused 6y one or )ore

o" the "ollo$ing )echanis)s5

a. &o3e De!osition

(ach catalyst syste) is designed to !ro)ote selective

hydrogenation reactions $hile su!!ressing undesira6le side

reactions. he )ost undesira6le side reaction is thecondensation o" !olynuclear and ole"inic co)!ounds into

high )olecular $eight/ lo$ hydrogen content co)!ounds

co))only re"erred to as co3e. &o3e "or)ation 6egins $ithadsor!tion o" high )olecular $eight )olecules and !roceeds

$ith "urther loss o" hydrogen. &o3e laydo$n is a ti)e;

te)!erature !heno)enon.

Deactivation increases $ith ti)e and )agnitude o" the

te)!erature catalyst is e!osed to. &o3e de!osition occurs ata relatively slo$ rate and the catalyst is a6le to o!erate

e""ectively "or !eriods o" one year or )ore 6e"ore

regeneration 6eco)es necessary he Light Oil Hydrotreateris designed "or a 2 year e!ected catalyst cycle length. he

co3e can cover active sites andor !revent access to these

sites 6y !hysical 6loc3age o" the entrance to the !ores leading

to the sites. Reactor te)!eratures )ust 6e increased to

co)!ensate "or the slo$ decline in activity caused 6y theaccu)ulation o" co3e and )etals on the catalyst. During

u!sets or $hen the catalyst is su69ected to o!eratingconditions 6eyond the design li)its o" the unit/ co3e

"or)ation accelerates and catalyst li"e is reduced. +ost o"

the catalyst activity can usually 6e recovered 6y regeneration.Ho$ever/ $hen deactivation is caused 6y etre)e conditions/

such as reactor te)!eratures over 00

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o" the catalyst. his de!osition creates a layer a""ecting the

accessi6ility to the catalyst interior and active sites.

c. &atalyst Sintering

&atalyst su!!ort and active )etal sites can 6e sintered u!on

e!osure to high te)!eratures. High $ater !artial !ressures

contri6ute to this e""ect as $ell. he active )etals can 6eco)e )o6ile and agglo)erate under these conditions. he

resulting loss in active sur"ace reduces catalyst activity. he

catalyst su!!ort $ill also lose sur"ace area "ro) the colla!seo" !ores or "ro) an increase in !ore dia)eter $ith !ore

volu)e re)aining constant.

d. Reactor e)!erature

Reactor te)!erature should 6e )ini)i:ed $hile )aintainingdesired !roduct =uality. Cncreasing reactor te)!erature $ill

greatly accelerate the rate o" co3e "or)ation and reduce thelength o" the o!erating cycle. he re=uired te)!erature is

de!endent u!on "eed rate and =uality. A general !ractice is to

reduce reactor te)!erature !rior to reducing "eed rate and

conversely/ to increase "eed rate !rior to increasingte)!erature.

e. #eed oiling Range

Sul"ur/ @itrogen/ and )etal content o" ty!ical "eedstoc3sincrease $ith relative volatility and end!oint re=uiring higher

reactor te)!eratures. Heavier "eeds contain )ore co3e

!recursors/ solids/ and )etals contri6uting to catalystdeactivation and increased reactor !ressure dro!. Ulti)ate

catalyst li"e and cycle length $ill decrease $ith heavier "eeds.

". &harge Rate

Unit o!eration )ay 6eco)e di""icult at reduced charge rates

due to )echanical and hydraulic considerations. Li=uid

distri6ution in the reactor )ay 6eco)e une=ual resulting in !re"erential "lo$ and !oor catalyst utili:ation. #or these

reasons/ the unit should not 6e o!erated at "eed rates 6elo$

the design turndo$n rate "or etended !eriods he Light OilHydrotreater is designed "or a turndo$n to '0? o" the design

"eed rate.

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g. Hydrogen Partial Pressure

Hydrogen !artial !ressure is the value o" the syste) !ressure

ti)es the hydrogen !urity. At a given syste) !ressure/ the

recycle gas !urity $ill deter)ine the !artial !ressure o"hydrogen in the reactor. At reduced hydrogen !urities/ theUnion"ining reactions do not !roceed at the sa)e rate. A

hydrogen de"icient at)os!here also creates a greater

tendency to "or) co3e. hese conditions cause the catalyst tolose a!!arent activity. o co)!ensate/ the !rocess technician

)ay increase reactor te)!erature to )aintain the sa)e

!roduct =uality/ $hich $ould "urther aggravate the !ro6le).C" recycle gas !urity cannot 6e increased/ action should 6e

ta3en to reduce hydrogen consu)!tion. his $ould re=uire

reducing reactor te)!eratures andor "eed rate. Cncreasing)a3e;u! hydrogen !urity andor rate $ill increase the recycle

hydrogen !urity and )ini)i:e catalyst deactivation.

h. Recycle 8as Rate

he large =uantity o" gas recycled "ro) the high !ressure

se!arator to the reactor serves the "ollo$ing !ur!oses5

• Provides the ecess hydrogen needed to assure that the

reactions are carried to co)!letion.

• A6sor6s so)e o" the heat o" reaction/ there6y )ini)i:ing

the catalyst 6ed te)!eratures.

• Hel!s hold do$n recycle gas heater and "eed and e""luent

echanger tu6e $all te)!eratures 6y increasing the "lo$

through the e=ui!)ent. he ecess hydrogen !reventsthe "or)ation o" co3e as the charge is heated to reaction

te)!erature.

he recycle gas heater/ "eed and e""luent echangers/

co)!ressors/ etc. have 6een designed to allo$ "or thecirculation o" a )ini)u) ratio o" recycle gas to hydrocar6on

charge. his ratio/ e!ressed as standard cu6ic "eet o" recyclegas !er 6arrel o" "eed S is co))only re"erred to as the

gas;to;oil ratio. he gas;to;oil ratio is an econo)ic o!ti)u)/ 6alancing initial invest)ent against catalyst li"e.

C" the unit is o!erated at less than the design gas;to;oil ratio/

higher catalyst 6ed te)!eratures $ill 6e re=uired to achieve

the sa)e !roduct =uality. his accelerates co3e "or)ation

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and e=ui!)ent $ear. A co)!lete loss o" recycle gas can

result in very serious da)age to the catalyst and e=ui!)ent.

A sa"ety device is incor!orated in the unit to shut do$n therecycle gas heater and unit charge $henever the recycle gas

"lo$ dro!s to a !redeter)ined )ini)u). Other ste!s to 6eta3en during such an e)ergency are e!lained in theDescri!tion o" ()ergency Syste)s section Section 1.4 o"

this O!erating +anual.

i. &atalyst Regeneration

Union"ining catalysts )ay 6e regenerated to re)ove co3e and

sul"ur co)!ounds "ro) the catalyst to recover activity. he

catalyst )ay 6e regenerated several ti)es 6e"ore re!lace)ent

6eco)es necessary i" the catalyst is not su69ected to etre)eo!erating conditions or e!osed to !er)anent !oisons such as

al3aline )etals. he regeneration !rocedure consists o"

6urning the car6on and sul"ur accu)ulated on the catalystunder controlled conditions. his !rocedure )ay 6e done e;

situ 6y a )erchant catalyst regenerator. he Light Oil

Hydrotreater is not designed "or in;situ catalyst regeneration.

9. Reactor e)!eratures

he reactor inlet te)!erature is )ost easily and co))only

controlled 6y the !rocess technician to ad9ust the sul"ur ornitrogen re)oved "ro) the "eed. he reactor outlet

te)!erature is a "unction o" the "eed =uality and cannot 6eeasily varied ece!t 6y changing the reactor inlette)!erature. he inlet te)!erature )ust al$ays 6e

controlled at the )ini)u) re=uired to achieve the desired

!roduct !ro!erties see #igure 1.2.2;%. e)!eratures a6ove

this )ini)u) $ill only lead to higher rates o" co3e "or)ationand reduced !rocessing !eriods.

he $eight average 6ed te)!erature BA is ty!ically

used to co)!are the relative catalyst activity. he BA can

6e calculated as indicated in #igure 1.2.2;4.

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-ig,re 1.2.2"3 − Des,l,riation and Denitri+ation s. Catalst !emperat,re



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-ig,re 1.2.2"4 − 9eight :erage 'ed !emperat,re Cal+,lation



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he rate o" increase in this te)!erature is re"erred to as the

deactivation rate e!ressed as

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-ig,re1.2.2"5 − 9:'! s. Catalst Lie



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he ty!e o" "eed 6eing !rocessed is 6est indicated 6y its

distillation range and APC gravity. An increase in the end

!oint o" the "eed $ill )a3e sul"ur and nitrogen re)oval )oredi""icult/ thus re=uiring higher reactor te)!eratures $hich/ in

turn/ accelerate co3e "or)ation and catalyst deactivation/ asindicated in #igure 1.2.2;*. &o3e de!osition is alsoaccelerated 6y the "act that heavier "eed contains )ore o" the

!recursors that "avor co3e "or)ation.

Cn addition to the a6ove/ high 6oiling "ractions also contain

increased =uantities o" )etals $hich lead not only to higher

reactor !ressure dro!/ 6ut to ra!id catalyst deactivation as$ell. Ct )ust 6e re)e)6ered that regeneration $ill not

restore the activity o" a catalyst that has 6een !oisoned 6y

ecessive =uantities o" )etals.

hus/ it is seen that !rocessing higher than design end !oint

"eeds $ill/ at 6est/ reduce the length o" the o!erating cycle/and under etre)e conditions/ )ay lead to an irrecovera6le

loss o" catalyst activity. here"ore/ every e""ort )ust 6e )ade

to )aintain the end !oint o" the "eed $ithin the design li)its 6y o!erating the crude and other units such that an acce!ta6le

"eed stoc3 is o6tained. Storage tan3s used "or the

accu)ulation o" "eed to the unit )ust 6e gas 6lan3eted $ithnitrogen or "loating roo" tan3s $ith torroidal seals in order to

)ini)i:e the "or)ation o" co3e !roducing and !oly)er

"or)ing )aterials that $ill "oul the catalyst 6ed and increase

!ressure dro!.

A reduction in the APC gravity o" the "eed "or the sa)e 6oiling range is an indication o" higher unsaturates content.

his ty!e o" "eed $ill result in increased hydrogen

consu)!tion and higher te)!erature rise across the catalyst 6ed. Ct also contains )ore o" the )aterials that easily

condense to "or) co3e in the reactor and associated

e=ui!)ent.



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-ig,re 1.2.2"6 − #;e+t o -eedsto+k

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l. Pressure

he reactor section o!erating !ressure is controlled 6y the

!ressure )aintained at the Se!arator. his !ressure/

)ulti!lied 6y the H2 !urity o" the recycle gas/ deter)ines the !artial !ressure o" H2 in the reactor. he hydrogen !artial !ressure re=uired "or the o!eration o" the unit is chosen 6ased

on the degree o" sul"ur or nitrogen re)oval that )ust 6e

achieved and is an econo)ic o!ti)u) that 6alances initialinvest)ent and o!erating costs against catalyst li"e see

#igure 1.2.2;,.

Hydrogen !artial !ressure is also a critical design !ara)eter

"or achieving the desired degree o" "eed saturation/ as

indicated in #igures 1.2.2; and 1.2.2;-.

he o!erating !ressure i.e./ the Se!arator !ressure )ust 6eheld constant at the design value "or the "ollo$ing reasons5

• Bhile higher than design o!erating !ressure directionally

"avors catalyst li"e and )ay result in so)e$hat 6etter

catalyst activity/ such o!eration $ould 6e detri)ental

since the e=ui!)ent heaters/ reactors/ co)!ressors/echangers/ sa"ety valves/ etc. has 6een designed 6ased

on a "ied Se!arator !ressure. An increase in the

Se!arator !ressure $ill lead to accelerated $ear on thee=ui!)ent/ and in etre)e cases could result in costly

and dangerous e=ui!)ent "ailures.

• A reduction o" the o!erating !ressure 6elo$ the design

level $ill have a negative e""ect on the activity o" the

catalyst and $ill accelerate catalyst deactivation due to

co3e "or)ation/ as indicated in #igure 1.2.2;10.

). 8as;to;Oil Ratio

he i)!ortance o" this varia6le to the satis"actory !er"or)ance o" the unit has already 6een descri6ed in this

)anual. Ct is once again e)!hasi:ed that the unit should not 6e o!erated at less than design gas;to;oil ratio since ra!id

catalyst deactivation $ill result. he design ratio is set to !rovide su""icient hydrogen "or the reactions assu)ing

recycle gas !urity is )aintained and to !rovide enough heat

sin3 to continuously re)ove the heat o" reaction.



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-ig,re 1.2.2"7 − Des,l,riation s. *drogen (artial(ress,re

-ig,re 1.2.2"8 − *drogen (artial (ress,re s. Distillate

Cetane N,mber

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Fi(re 1.2.2- #;e+t o *drogen (artial (ress,re on

)at,ration o :romati+s

-ig,re 1.2.2"1&−

Catalst Dea+tiation s. *drogen (artial(ress,re



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he gas;to;oil is calculated as "ollo$s5

8as;to;Oil Ratio

otal gas at standard conditions

!er unit ti)e to reactors

Ra$ oil charge !er unit ti)e

he =uantity o" gas circulated "ro) the Se!arator to the

reactor is relatively large. he gas "lo$ is re=uired "or the

"ollo$ing !ur!oses5

• Provides the ecess H2 needed to assure that the reactions

are carried to co)!letion.

• A6sor6s so)e o" the heat o" reaction )ini)i:ing the

catalyst 6ed te)!eratures.

• +ini)i:es recycle gas heater and "eed and e""luent

echanger tu6e $all te)!eratures 6y increasing the "lo$

through the e=ui!)ent. he ecess H2 also !revents

"or)ation o" co3e as the charge is heated to reaction

te)!erature.

A gradual reduction in recycle gas rate )ay 6e o6servedduring the course o" an o!erating !eriod as a result o" higher

reactor syste) !ressure dro!. his e""ect is es!ecially

!ronounced on units that use a centri"ugal recycle gas

co)!ressor. Such a reduction in the recycle gas rate isacce!ta6le as long as the calculated gas;to;oil ratio does not

"all 6elo$ the design value. Bhen it is no longer !ossi6le to

)aintain the )ini)u) gas;to;oil ratio/ the catalyst )ust 6eregenerated and screened in order to reduce the reactor

!ressure dro!. Cn all cases that result in less than design gas;

to;oil ratio due to !ressure dro! or )echanical di""iculties/ thera$ oil charge rate )ust 6e lo$ered in order to o6tain the

re=uired gas;to;oil ratio. Cn the event o" a co)!lete loss o"

recycle gas/ i))ediate re)edial action )ust 6e ta3en to !rotect the catalyst and e=ui!)ent/ as indicated in the

Descri!tion o" ()ergency Syste)s section o" this )anual.

n. S!ace elocity

he design =uantity o" catalyst !er unit o" "eed de!ends u!on

"eedstoc3 !ro!erties/ o!erating conditions/ and !roduct

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=uality re=uired. he li=uid hourly s!ace velocity LHS is

de"ined as "ollo$s5

catalysto" volu)e

hour !er chargeo" volu)eLHSA =

A si)!li"ied 3inetic e!ression 6ased on sul"ur andor

nitrogen re)oval deter)ines the initial li=uid hourly s!acevelocity "or )ost "eedstoc3s and !rocessing o69ectives. his

initial value )ay 6e )odi"ied due to other considerations

such as unit si:e/ etended catalyst cycle li"e/ a6nor)al levels

o" "eed )etals/ and re=uire)ents o" other !rocessing units inthe re"inery "lo$ sche)e.

A unit design is 6ased on o!eration to achieve o!ti)u)

!er"or)ance. One criterion is li=uid )ass "lu across the

catalyst 6ed. At reduced through!ut/ unit o!eration )ay 6eco)e di""icult due to hydraulic considerations i.e./ control

valves o!erating closed/ etc.. Also/ reactant distri6ution in

the reactor )ay 6eco)e une=ual as !re"erential "lo$ !aths

are esta6lished. #or these reasons/ the unit should not 6eo!erated 6elo$ the )ini)u) turndo$n ca!acity "or etended

!eriods. he Light Oil Hydrotreater is designed "or a unit

turndo$n o" '0? o" design ca!acity.

o. Recycle 8as Hydrogen Purity

he e""ective co)!letion o" the hydrogenation reactionsoccurring over the catalyst re=uires that a certain =uantity o"hydrogen 6e !resent at a )ini)u) !artial !ressure. As noted

!reviously/ 6oth the =uantity gas;to;oil ratio and !artial

!ressure are de!endent u!on the hydrogen content/ i.e./ !urity/ o" the recycle gas. Practical considerations/ such as

the cost o" co)!ression/ catalyst li"e/ etc./ li)it the !urity o"

the recycle gas to a )ini)u) value. Lo$ hydrogen !uritiesare detri)ental to the !er"or)ance o" the unit since higher

te)!eratures )ust 6e used to achieve the desired !roduct

=uality. he !urity o" the recycle gas is deter)ined 6y the

"ollo$ing "actors5

• he !urity o" the )a3eu! gas.

• he a)ounts o" light hydrocar6ons and H2S that are

allo$ed to accu)ulate in the recycle gas.

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Cn )ost instances/ the )a3eu! gas H2 !urity cannot 6e easily

)ani!ulated since it is "ied 6y the o!eration o" the H2

)anu"acturing !lant. Light hydrocar6ons !resent in therecycle gas enter the syste) $ith the )a3eu! gas in addition

to those 6eing "or)ed in the reactor. hese are either vented"ro) the Se!arator or accu)ulate to an e=uili6riu) value$ith ecess dissolved in the li=uid hydrocar6on leaving the

Se!arator the Light Oil Hydrotreater does not nor)ally

re=uire venting o" !urge gas. he a)ount o" hydrogen

re=uired is deter)ined 6y5

• &he)ical Hydrogen &onsu)!tion G he hydrogen

consu)ed during the hydrotreating reactions.

• Solution Losses G he hydrogen that is re)oved "ro) the

reactor circuit dissolved in the li=uid hydrocar6on leavingthe Se!arator.

• +echanical Losses G he hydrogen lost through the

)a3eu! and recycle gas co)!ressorsK !ac3ing vents and

seals. his value )ay 6e roughly esti)ated at %;'? o"the co)6ined che)ical consu)!tion !lus solution losses.

• enting Losses G he hydrogen lost in the !urge strea)

"ro) the Se!arator to )aintain recycle gas !urity the

Light Oil Hydrotreater does not nor)ally re=uire venting

o" !urge gas.

he H2S "or)ed in the reactors can accu)ulate to an

e=uili6riu) value in the recycle gas. his concentration o"H2S has a de!ressing e""ect on the activity o" the catalyst.

here"ore/ in )any cases it is desira6le to re)ove the H2S

"ro) the recycle gas. he re)oval o" H2S is !er"or)ed in aRecycle 8as Scru66er $here the recycle gas in contacted

$ith +D(A solution. Cn this )anner/ the H2S content o" the

recycle gas is reduced to a !art !er )illion range.

!. &atalyst &onta)inants

1. e)!orary &onta)inants

Process varia6les in"luence catalyst li"e 6y e""ecting the

rate o" car6on de!osition on the catalyst. here is a

)oderate accu)ulation o" car6on on the catalyst duringthe initial days o" o!eration. he rate o" increase $ill



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6e reduced to very lo$ levels under nor)al !rocessing

conditions. Cn a ty!ical Union"ining unit/ a car6on

level o" ' $t? )ay 6e tolerated $ithout a signi"icantdecrease in desul"uri:ation. Ho$ever/ denitrogenation

activity $ould 6e reduced.

he sul"ur and nitrogen "ound in the "eed can 6e

considered conta)inants to the etent that they !roduce

hydrogen sul"ide and a))onia/ $hich can react to"or) a))oniu) 6isul"ide. he $ater in9ected into the

reactor e""luent dissolves the a))oniu) 6isul"ide and

!revents echanger "ouling. Organic nitrogen in the"eed/ i" !resent in a)ounts higher than e!ected/ $ill

re=uire higher reactor te)!eratures "or !rocessing/ and

$ill lead to a reduction in catalyst li"e.

C" the $ater in9ection should 6e sto!!ed "or any !eriod

o" ti)e/ the H2S and @H% )ay accu)ulate in therecycle gas and result in a sudden loss in catalyst

activity. he activity $ill return to nor)al once $ash

$ater is reesta6lished. &atalyst 6ed te)!eraturesshould not 6e increased to co)!ensate "or the

te)!orary activity loss.

S)all a)ounts o" )olecular nitrogen/ &O/ and &O2

that enter the syste) $ith the )a3eu! gas are not

har)"ul to the catalyst/ 6ut )ust 6e vented to !revent

accu)ulation in the recycle gas venting is notnor)ally re=uired in the Light Oil Hydrotreater.

(cessive a)ounts o" &O and &O2 )ay have anadverse e""ect on catalyst !er"or)ance/ as they )ay 6e

)ethanated 6y the catalyst ta3ing u! active sites and

li6erating heat. his $ill raise the outlet te)!eratureand reduce the a!!arent catalyst activity. he unit

should never 6e !ressured u! $ith high &O > &O2

containing )a3eu! gas as a te)!erature runa$ay )ay

result. he !resence o" O2 could increase e=ui!)ent"ouling es!ecially the "eede""luent echangers.

2. Per)anent &onta)inants

Per)anent loss o" catalyst activity is usually caused 6ythe gradual accu)ulation o" inorganic s!ecies !ic3ed

u! "ro) the "eed/ )a3eu! hydrogen/ or e""luent $ash

$ater. (a)!les include arsenic/ lead/ calciu)/sodiu)/ silicon and !hos!horus. Lo$ concentrations



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o" these ele)ents and other al3aline )etals can cause

deactivation over ti)e as they are de!osited on the

catalyst and the integrated e""ect o" ti)e andte)!erature.

Organic )setal co)!ounds are deco)!osed andty!ically de!osit in the u!!er section o" the catalyst 6ed

as a )etal sul"ide. he graded catalyst 6ed/ i" used/

)ay contain de)etalli:ation catalysts/ $hich have ahigh )etals retention ca!acity. So)e o" these catalysts

)ay retain as )uch as 100 $t? o" the "resh catalyst

$eight as )etals "ro) the "eed. hese de)etalli:ationcatalysts ty!ically have a lo$er activity "or

desul"uri:ation and denitrogenation.

Union"ining catalysts ehi6it a )oderate tolerance "or

)etals such as arsenic and lead. otal )etal content o"

2;% $t? o" the Union"ining catalyst have 6eeno6served. Ho$ever/ !roduct analysis "re=uency should

6e increased to )onitor 6rea3through $hen

calculations sho$ the )etals level on the Union"iningcatalyst eceeds a6out 0.' $t?. +etals cannot 6e

re)oved during regeneration. Cn a ty!ical Union"ining

unit/ catalyst re!lace)ent should 6e considered $hen)etal loadings o" 1;2 $t? are eceeded on the

Union"ining catalyst.

A!!arent catalyst deactivation )ay 6e caused 6y theaccu)ulation o" de!osits on to! o" the catalyst 6ed.

Solid )aterial/ such as corrosion !roducts and co3e/$ill lead to ra!id "ouling o" the catalyst 6ed i" allo$ed

to enter the reactor. his !ro6le) can 6e re)edied 6y

s3i))ing a !ortion o" the catalyst/ screening/ andreloading. #eed "iltering is =uite e""ective in re)oving

solid )aterial/ and as such results in longer o!erating

cycles due to the lo$er rate o" reactor !ressure dro!

6uild;u!.

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1.3 Description o( Process Contro%s

his section descri6es the 3ey "eatures o" co)!le control loo!s designated 6y &@;nu)6er. #or a )ore detailed descri!tion and loo! diagra)s/ see Section *.1 o" this

O!erating +anual.

Re"er to the @or)al O!erating Procedures and Sa"e U!!er and Lo$er O!erating Li)its

sections o" this O!erating +anual Sections 2.2 and 2.'.1/ res!ectively "or discussions

o" the e""ect o" changes in controlled varia6les u!on the dyna)ics o" a !rocess syste).

he Light Oil Hydrotreater Unit Process #lo$ Diagra)s P#Ds and selected overallre"inery &ontrol Cnter"ace Diagra)s &CDs/ $hich are located in Section 4.% o" the

O!erating +anual/ can 6e used as a su!!le)ental re"erence to the !rocess control

descri!tions.

Lig"t Oi% $ydrotreater Feed System 027,CN,4429

Re"er to PCD @o5 421%00;14;A1;0100/ 0101/ and 010,.

During nor)al o!eration the "lo$ rates o" the L&8O/ co3er na!htha and co3er

light ends strea)s are )aintained in the 8as Plant using "lo$ control reset 6y

level control re"er to "ollo$ing &o)!le Loo! @arratives5 L&8O G 421%00;12;&@;00*7 co3er na!htha G 421%00;1;&@;00,7 co3er light ends G 421%00;

1;&@;010.

he "lo$ rate o" co)6ined distillate "ro) the &rude Unit to the Light Oil

Hydrotreater is )aintained on "lo$ control 6y 14;#C&;001.

Bithin the &rude Unit/ the !ressure controller 10;PC&;'1 on the co)6ined

distillate header diverts re)aining co)6ined distillate in ecess o" thede)and "or hot distillate "ro) 14;#C&;001 to inter)ediate tan3age *1;E;

00-01%. he "lo$ rate o" cold distillate/ $hich is !u)!ed "ro) tan3age to

the LOH/ is )aintained on "lo$ control/ 14;#C&;00'/ reset 6y the #eed SurgeDru) level control/ 14;LC&;004.

he overall Unit 14 "resh "eed rate is )aintained on "lo$ control 6y 14;#C&;

02'. his "lo$ controller should nor)ally 6e set at a rate a!!roi)ately e=ual

to the co)6ined rate that the Unit 14 "eed strea)s are !roduced in the

res!ective source units. he inter)ediate distillate tan3age !rovides a 6u""erto handle variations 6et$een the source rates and the Unit 14 "resh "eed rate.

he "lo$ rates o" L&8O/ co3er na!htha/ and co3er light ends to the LOH are

)easured 14;#C&;00%/ 14;#C&;002 and 14;#C&;004/ res!ectively and

su))ed 14;#M;0''.



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he distillate strea)s "ro) the &rude Unit and inter)ediate tan3age are

)easured 14;#C&;001 and 14;#C&;00'/ res!ectively and su))ed 14;#M;

0'%.

he Unit 14 "eed ratio controller/ 14;##C&;0'4/ receives su))ed "lo$ rates"ro) 14;#M;0'' and 14;#M;0'%. Bhenever the ratio o" the co)6ined 8asPlant strea) "eed rate to the total Unit 14 "eed rate eceeds 0.*0/ 14;##C&;0'4

sends a set !oint signal to the res!ective 8as Plant strea) "lo$ controllers 14;

#C&;00200%004. hese controllers then send a signal to the res!ective 8asPlant control valves via a lo$ selector to reduce the "lo$ rates o" L&8O/

co3er na!htha and co3er light ends re"er to "ollo$ing &o)!le Loo!

@arratives5 L&8O G 421%00;12;&@;00*7 co3er na!htha G 421%00;1;&@;00,7 co3er light ends G 421%00;1;&@;010. A D&S alar) $ill sound $hen

the ratio eceeds 0.*0.

he #eed Surge Dru) level control/ 14;LC&;004/ $hich !rovides the set !oint

"or "lo$ controller 14;#C&;00'/ $ill shut o"" the "lo$ o" cold distillate "ro)

tan3age on high surge dru) level 6y closing 14;#;00'. Cn addition/ ashutdo$n syste) 14;M&;002 is !rovided to shut o"" the "lo$s o" the hot Unit

14 "eeds on high high level in the #eed Surge Dru) re"er to Logic De"inition

Docu)ent 421%00;14;M&;002.

Feed Srge Drm Pressre Contro% System 027,CN,44;9

Re"er to PCD @o5 421%00;14;A1;0101.

he #eed Surge Dru) !ressure control syste)s )aintains the !ressure in #eed

Surge Dru) 14;;001 at an average value o" ,' !sig. C" the !ressure 6eginsto "alls 6elo$ ,% !sig/ !ressure controller 14;PC&;00'A allo$s natural gas to

"lo$ into the dru) 6y regulating !ressure control valve 14;P;00'A.

Si)ilarly/ i" the !ressure 6egins to rise a6ove ,, !sig/ !ressure controller 14;

PC&;00' releases natural gas "ro) the dru) to the lo$ !ressure relie" header 6y regulating !ressure control valve 14;P;00'. oth control valves should

6e in the closed !osition 0? i" the !ressure is 6et$een ,% and ,, !sig. Only

one o" the t$o control valves should 6e o!en at any given ti)e.

Recyc%e =as $eater Pass F%o' Ba%ance Contro% System 027,CN,44)9

Re"er to PCD @o5 421%00;14;A1;010%.

he Recycle 8as Heater 14;H;001 has eight !asses/ each $ith its o$n "lo$

controller and control valve. &ontroller 14;#C&;0*0 regulates control valve14;#;0*0 to )odulate the "lo$ o" recycle gas through Pass N1. Si)ilarly/

controllers 14;#C&;0*1/ ;0*2/ ;0*%/ ;0*4/ ;0*'/ ;0**/ and ;0*, regulate their

corres!onding control valves to )aintain the sa)e "lo$ rate in each !ass.

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(ach "lo$ controller generates a 0? to 100? signal/ $hich corres!onds to the

reverse valve !osition. he control valve is "ully o!en $hen the controller

out!ut is 0?/ and co)!letely closed $hen the out!ut is 100?. Lo$ signalselector 14;M;001 )onitors the out!ut signals "ro) each o" the eight "lo$

controllers/ and trans)its only the lo$est signal to the )aster controller/ 14;C&;001. he )aster controller resets this signal to 10? and sends it to thecorres!onding controller to hold the associated control valve in this !ass at

a!!roi)ately -0? o!en. he )aster controller also cascades the "lo$

)easured "ro) this !ass as a set!oint to the "lo$ controllers in the other seven

!asses.

y!ically/ the "lo$ controller out!uts "ro) the other seven !asses $ill all 6ea6ove 10?/ $ith the corres!onding control valve !ositions all less than -0?

o!en. Ho$ever/ hydraulic resistances in each !ass )ay change over a !eriod

o" ti)e. C" the "lo$ controller out!ut in any o" these !asses dro!s 6elo$ 10?/signal selector 14;M;001 $ill auto)atically select that out!ut and identi"y it

as the !ass $ith the highest hydraulic resistance. &ontroller 14;C&;001 $ill

then reset this signal to 10? to hold the corres!onding control valve in the

-0? o!en !osition/ and cascade the )easured "lo$ as the ne$ set!oint to theother seven "lo$ controllers.

Recyc%e =as $eater Firing Contro% System 027,CN,4479

Re"er to PCD @o5 421%00;14;A1;010%/ 0104/ and 010'.

he "unction o" the Recycle 8as Heater #iring &ontrol Syste) is to ad9ust the"iring o" #uel 8as so that the resultant te)!erature $hen the heated Recycle

8as is )ied $ith the #eed strea) is $ithin the s!eci"ied li)its "or thehydrotreating reactions. A te)!erature controller 14;C&;020 located in the"eed strea) at the inlet to Reactor @o. 1 cascades a set!oint to te)!erature

controller 14;C&;01, located in the Recycle 8as strea) at the outlet o" the

heater. #uel 8as "lo$ controller 14;#C&;0' regulates "uel control valve 14;

#;0' 6ased on the set!oint it receives "ro) te)!erature controller 14;C&;01,.

&o)6ustion air is su!!lied 6y )eans o" a natural dra"t. o "ine;tune the

a)ount o" co)6ustion air/ the !rocess technician can )anually ad9ust the

!osition o" 6lade da)!er 14;H;00* using D&S hand controller 14;HC&;00*.

Pressure controllers 14;PC&;0** and 14;PC&;01 )onitor the "uel gas !ressure

at the inlet to the 6urners. hese controllers are !rogra))ed $ith set!oints tooverride the out!ut o" "uel "lo$ controller 14;#C&;0' i" the "lo$ controllerKs

out!ut results in "iring a6ove or 6elo$ sa"e o!erating li)its. he u!!er

o!erating li)it is ty!ically set at the "uel gas !ressure corres!onding to the"iring rate li)ited 6y the co)6ustion air su!!ly. he lo$er o!erating li)it is

set at the )ini)u) !ressure re=uired "or "la)e sta6ility.

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#irst/ the D&S co)!ares the out!ut "ro) the "lo$ controller $ith that "ro) 14;

PC&;01/ $hich is set at the u!!er o!erating li)it. Lo$ signal selector 14;#M;

0' !revents over "iring 6y 6loc3ing the "lo$ controllerKs out!ut only $henit is higher than the out!ut "ro) 14;PC&;01. he D&S net co)!ares the

resultant signal "ro) 14;#M;0' $ith that "ro) 14;PC&;0**/ $hich is set atthe lo$er o!erating li)it. High signal selector 14;#M;0'& !revents o!erationat "uel gas !ressures 6elo$ )ini)u) "iring conditions 6y selecting the higher

o" the t$o signals to regulate the !osition o" control valve 1*;#;0'.

Reactor Temperatre Measrement

Re"er to PCD @o5 421%00;14;A1;010'/ 010*.

+ulti!le ther)ocou!les are !rovided "or Reactor @o. 1 14;R;001 andReactor @o. 2 14;R;002 to )easure catalyst 6ed and reactor $all s3in

te)!eratures. hese te)!erature !oints/ $hich are dis!layed in the D&S as

te)!erature indicators/ are used to )onitor reactor o!eration. Cn addition/each te)!erature indicator has a high te)!erature alar) to alert the !rocess

technician to ta3e corrective action. One o" the te)!erature !oints at the to!

o" the second and successive catalyst 6eds in each reactor is used to control the 6ed inlet te)!erature 6y ad9usting the "lo$ o" cold =uench gas to the =uench

:one u!strea) o" the 6ed.

he Unit 14 Reactor te)!erature instru)ents are su))ari:ed in a6le 1.%.';1.

Table 1.3."-1 - =it 15 Rea'tor Te&perat(reMeas(re&et

Ta N(&ber Rea'tor /o'atio

14;C;0*- thru 0,1 14;R;001 &atalyst ed N1 G o!

14;C;0,2 thru 0,4 14;R;001 &atalyst ed N1 G otto)

14;C&;0,' 14;R;001 &atalyst ed N2 G o!

14;C;0,* thru 0,, 14;R;001 &atalyst ed N2 G o!

14;C;0, thru 00 14;R;001 &atalyst ed N2 G +iddle

14;C;01 thru 0% 14;R;001 &atalyst ed N2 G otto)

14;C&;04 14;R;001 &atalyst ed N% G o!

14;C;0' thru 0* 14;R;001 &atalyst ed N% G o!

14;C;0, thru 0- 14;R;001 &atalyst ed N% G +iddle

14;C;0-0 thru 0-2 14;R;001 &atalyst ed N% G otto)

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Table 1.3."-1 - =it 15 Rea'tor Te&perat(reMeas(re&et

Ta N(&ber Rea'tor /o'atio

14;C;022 thru 0%4 14;R;001 S3in at ed N1 G otto)

14;C;0%' thru 04, 14;R;001 S3in at ed N2 G otto)

14;C;04 thru 0*0 14;R;001 S3in at ed N% G otto)

14;C;0*1 thru 0* 14;R;001 S3in at Reactor otto) Head

14;C;1%* thru 1% 14;R;002 &atalyst ed N1 G o!

14;C;1%- thru 141 14;R;002 &atalyst ed N1 G otto)

14;C&;142 14;R;002 &atalyst ed N2 G o!

14;C;14% thru 144 14;R;002 &atalyst ed N2 G o!

14;C;14' thru 14, 14;R;002 &atalyst ed N2 G +iddle

14;C;14 thru 1'0 14;R;002 &atalyst ed N2 G otto)

14;C;102 thru 114 14;R;002 S3in at ed N1 G otto)

14;C;11' thru 12, 14;R;002 S3in at ed N2 G otto)

14;C;12 thru 1%' 14;R;002 S3in at Reactor otto) Head

Prodct Condenser Fin,Fan Contro% System 027,CN,4489

Re"er to PCD @o5 421%00;14;A1;010-.

#in #an &ooler 14;(A;001 cools the Reactor (""luent "ro) the Reactor

(""luent #lash Dru) Li=uid (changers 14;(;004A&. he &ooler has

siteen 6ays A through P/ each $ith t$o "ans.

he &entral &ontrol uilding !rocess technician is !rovided $ith D&S screen

hands$itches 14;HS;02%A through 14;HS;024P to re)otely startsto! eachindividual cooler "an to ad9ust cooler duty and )aintain the te)!erature o" the

!roduct "lo$ing into Se!arator 14;;002.

he &entral &ontrol uilding !rocess technician is also !rovided $ith an

()ergency 8rou! StartQ D&S screen hand s$itch to re)otely re;start all %2"ans si)ultaneously in the event o" an electrical !o$er di!.

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Separator Le+e% Contro% System 027,CN,44

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and 14;LC&;01%/ res!ectively. he !rocess technician can select only one o"

the t$o controller out!uts using s$itch 14;LM;01%A to control 14;L;01%.

14;LC;01' and 14;L;014 )easure the hydrocar6on level in the )ain vessel

and !rovide in!uts to controllers 14;LC&;01' and 14;LC&;014/ res!ectively.he !rocess technician can select only one o" the t$o controller out!uts usings$itch 14;LM;01' to control 14;L;014.

Recyc%e =as Scr??er Ric" Amine Le+e% Contro% System 027,CN,4249

Re"er to PCD @o5 421%00;14;A1;0112 and 011%.

he Recycle 8as Scru66er 14;&;001 is a high;!ressure colu)n in $hichRecycle 8as is contacted $ith Lean A)ine to re)ove H2S and i)!rove the

hydrogen !artial !ressure. he Rich A)ine/ $hich is no$ saturated $ith H2S/

collects in the 6otto) section o" the colu)n "ro) $here it !ressured out under

level control to a su6stantially lo$er !ressure syste) via a )ulti;stage controlvalve. Due to this large di""erence in !ressure/ the !ro!er o!eration o" the

level controller and control valve is considered to 6e critical "or sa"e o!eration/and signi"icant redundancy has 6een 6uilt into the syste).

14;L;01- and 14;L;0%% )easure the rich a)ine level in the 6otto) o" theRecycle 8as Scru66er 14;&;001 and !rovide in!uts to controllers 14;LC&;01-

and 14;LC&;0%%/ res!ectively. he !rocess technician can select only one o"

the t$o controller out!uts using s$itch 14;LM;0%%. Another s$itch/ 14;LM;01-&/ allo$s the !rocess technician to direct the controller out!ut to either 14;

L;01-A or 14;L;01-. #or sa"ety reasons/ only one o" the t$o control

valves can 6e selected.

F%as" Drm Pressre Contro% System 027,CN,42;9

Re"er to PCD @o5 421%00;14;A1;0111.

he #lash Dru) Pressure &ontrol Syste) )aintains the !ressure in #lash

Dru) 14;;004 at %*0 !sig 6y !re"erentially sending the "lashed va!ors to

Unit 1'. he #lash Dru) has t$o D&S !ressure controllers that o6tain their !rocess varia6le "ro) !ressure trans)itter 14;P;044. Pressure controller 14;

PC&;044A is o!erated at lo$ range 0 to '0? to regulate the nor)al "lo$ o"

"lash gas to Unit 1' 6y )odulating control valve 14;P;044A. Pressurecontroller 14;PC&;044 is o!erated at higher range '0 to 100? to regulate

ecess "lo$ to the high !ressure "lare 6y )odulating 14;P;044 in case the

!ressure in the #lash Dru) continues to rise even though 14;P;044A haso!ened all the $ay.

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Condensate Pmp Ato,Start Logic 027,CN,42)9

Re"er to PCD @o5 421%00;14;A1;011,.

&ondensate Pu)!s 14;P;00%A !u)! condensate "ro) Sur"ace &ondenser14;(;00' to the cold clean condensate header via the Sur"ace &ondenser

vacuu) !ac3age. During nor)al o!eration/ only one !u)! is running either

Pu)!;A or Pu)!; and is designated as the )ain !u)!.

he re)aining !u)! "unctions as a hot;stand6y s!are set in AUO )ode/ready to 6e started auto)atically i" the !ressure in the co))on discharge

header "alls 6elo$ )ini)u) acce!ta6le syste) conditions. Pressure

trans)itter 14;P;20 and lo$ !ressure s$itch 14;PSL;20 initiate the

auto)atic start o" the stand6y !u)!. he !ur!ose o" this interloc3 is toauto)atically restore the nor)al circulation o" condensate in the event o" a

!artial or total "ailure o" the )ain !u)!.

C"arge Pmp L?e Oi% Ai%iary Pmp Ato,Start Logic 027,CN,4239

Re"er to PCD @o5 421%00;14;A1;0%00.

Lu6e oil is su!!lied to &harge Pu)! 14;P;001 6y +ain Lu6e Oil Pu)! 14;P;

001;P1/ or 6y Auiliary Lu6e Oil Pu)! 14;P;001;P2. he )ain lu6e oil !u)!

is a sha"t driven !u)! that runs continuously $hen the &harge Pu)! is ino!eration. he Auiliary Lu6e Oil Pu)! is used to su!!ly lu6e oil "or startu!

o" the &harge Pu)! and to act as a stand6y lu6e oil !u)! "or auto)atic

o!eration i" the lu6e oil !ressure "alls 6elo$ a !reset value.

Lo$ !ressure s$itch 14;PSL;2% initiates the auto)atic start o" the stand6y

!u)!.

Compressor L?e Oi% Ai%iary Pmp Ato,Start Logic 027,CN,429

Re"er to PCD @o5 421%00;14;A1;0%10 and 0%11.

Lu6e oil is su!!lied to the Recycle 8as &o)!ressor 14;E;001 6y +ain Lu6e

Oil Pu)! 14;E;001;P1A and the Auiliary Lu6e Oil Pu)! 14;E;001;P1.he )ain lu6e oil !u)! is stea) tur6ine driven and is nor)ally in service.

he auiliary lu6e oil !u)! acts as a stand6y lu6e oil !u)! "or auto)atic

o!eration i" the lu6e oil !ressure "alls 6elo$ a !reset value.

(ither the lo$ lu6e oil header !ressure s$itch/ 14;PSL;104/ or the lo$ lu6e oil

su!!ly !ressure s$itch/ 14;PSL;112/ $ill initiate the auto)atic start o" thestand6y !u)!.

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1.3.1 Typica% DCS Inpt Bypass Fnctiona%ity 044,CN,429

Unless noted other$ise on a s!eci"ic co)!le loo! narrative/ all in!uts to theDistri6uted &ontrol Syste) D&S that e""ect auto)atic e=ui!)ent !rotective

shutdo$ns

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