NHT Unit

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Draft
OPERATING MANUAL FOR
NAPHTHA HYDROTREATER UNIT, Rev. A
VRCFP, HPCL VISAKH Page 1 of 197
OPERATING MANUAL
FOR
NAPHTHA HYDROTREATING UNIT

(UNIT NO. 72)
VISAKH REFINERY CLEAN FUEL PROJECT

HINDUSTAN PETROLEUM CORPORATION LIMITED
VISAKH
A Issued for comments

Rev No. Date Purpose Prepared by Checked by Approved by
Template No. 5-0000-0001-T2 Rev A Copyrights EIL- All rights reserved

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PREFACE
This operating manual for Naphtha Hydrotreater Unit of HPCL, Visakh has been prepared by M/s
Engineers India Limited for M/s Hindustan Petroleum Corporation Limited.
This manual contains process description and operating guidelines for the unit and is based on
documents supplied by the process licensor. This manual contains process description and
operating guidelines for the unit and is based on documents supplied by the Process
Licensor (UOP). Hence the manual must be reviewed /approved by the licensor before the
start-up /operation of the unit.
Operating procedures & conditions given in this manual are indicative. These should be treated as
general guide only for routine start-up and operation of the unit. The actual operating parameters and
procedures may require minor modifications/changes from those contained in this manual as more
experience is gained in operation of the Plant.
For detailed specifications and operating procedures of specific equipment, corresponding Vendor's
operating manuals/instructions need to be referred to.
.

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Table of Contents
SECTION-1 .................................................................................................................................... 8
INTRODUCTION .......................................................................................................................... 8
1.1 INTRODUCTION ............................................................................................................ 8
SECTION-2 .................................................................................................................................... 9
DESIGN BASIS.............................................................................................................................. 9
2.1 INTRODUCTION ............................................................................................................ 9
2.2 UNIT CAPACITY ........................................................................................................... 9
2.3 TURNDOWN CAPABILITY .......................................................................................... 9
2.4 FEED ................................................................................................................................ 9
2.5 PRODUCTS ................................................................................................................... 13
2.6 BATTERY LIMIT CONDITIONS FOR NHDT ........................................................... 14
2.7 UTILITY CONDITION ................................................................................................. 15
SECTION-3 .................................................................................................................................. 19
CHEMISTRY OF THE PROCESS .............................................................................................. 19
3.1 PROCESS CHEMISTRY .............................................................................................. 19
3.2 SULFUR REMOVAL .................................................................................................... 19
3.3 NITROGEN REMOVAL ............................................................................................... 20
3.4 OXYGEN REMOVAL .................................................................................................. 21
3.5 OLEFIN SATURATION ............................................................................................... 21
3.6 AROMATIC SATURATION ........................................................................................ 22
3.7 METALS REMOVAL ................................................................................................... 22
3.8 HALIDES REMOVAL .................................................................................................. 23
3.9 REACTION RATES ...................................................................................................... 23
3.10 HYDROCARACKING REACTIONS .......................................................................... 24
3.11 CATALYST DEACTIVATION .................................................................................... 24
SECTION-4 .................................................................................................................................. 29
PROCESS DESCRIPTION .......................................................................................................... 29
4.1 PROCESS VARIABLES ............................................................................................... 29

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4.2 PROCESS FLOW DESCRIPTION ............................................................................... 42

4.3 UTILITIES SPECIFICATION AND REQUIREMENT ............................................... 52
SECTION-5 .................................................................................................................................. 55
PRECOMMISSIONING............................................................................................................... 55
5.1 PRECOMMISSIONING ................................................................................................ 55
5.2 VESSELS INSPECTION ............................................................................................... 56
5.3 PIPING ........................................................................................................................... 59
5.4 FIRED HEATERS ......................................................................................................... 61
5.5 HEAT EXCHANGERS ................................................................................................. 64
5.6 PUMPS ........................................................................................................................... 65
5.7 COMPRESSORS ........................................................................................................... 68
5.8 INSTRUMENTATION .................................................................................................. 70
5.9 CATALYST/CHEMICAL INVENTORY ..................................................................... 70
5.10 PRELIMINARY OPERATIONS ................................................................................... 71
SECTION 6 ................................................................................................................................. 77
COMMISSIONING ...................................................................................................................... 77
6.1 STARTUP PROCEDURE WITH FRESH CATALYST............................................... 77
6.2 PRESTARTUP CHECKLIST ........................................................................................ 78
6.3 NOTIFICATION TO OTHER DEPARTMENTS ......................................................... 79
6.4 REACTOR LOOP .......................................................................................................... 79
6.5 STRIPPER, SPLITTER AND FEED PREHEATING SECTION ................................. 81
6.6 STARTUP NAPHTHA INTRODUCTION AND REACTOR PRESSURING ............ 83
6.7 CATALYST SULFIDING ............................................................................................. 84
6.8 ESTABLISH NORMAL FEED ..................................................................................... 86
6.9 STARTUP PROCEDURE FOR USED CATALYST ................................................... 87
SECTION 7 ................................................................................................................................. 89
NORMAL OPERATING PROCEDURES................................................................................... 89
7.1 INTRODUCTION .......................................................................................................... 89
7.2 CONTROL PHILOSOPHY ........................................................................................... 89

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7.3 NORMAL OPERATING PARAMETER...................................................................... 90

7.4 SET VALUES OF ALARM .......................................................................................... 94
7.5 LIST OF CONTROL VALVES ..................................................................................... 99
7.6 LIST OF PSV ............................................................................................................... 102
SECTION-8 ................................................................................................................................ 104
NORMAL SHUTDOWN ........................................................................................................... 104
8.1 FEED REMOVAL FOR CATALYST TURNAROUND ........................................... 104
8.2 TEMPORARY SHUTDOWN ..................................................................................... 106
SECTION-9 ................................................................................................................................ 108
TROUBLE SHOOTING............................................................................................................. 108
9.1 GENERAL ................................................................................................................... 108
9.2 REACTOR TEMPERATURE INCREASES .............................................................. 108
9.3 REACTOR PRESSURE DROP ................................................................................... 110
9.4 REACTOR BED MALDISTRIBUTION .................................................................... 111
9.5 REACTOR SECTION OPERATION .......................................................................... 112
9.6 REACTOR HYDROGEN PARTIAL PRESSURE ..................................................... 114
9.7 PRODUCT CONDENSERS ........................................................................................ 115
9.8 PRODUCT SEPARATOR LEVEL CONTROL ......................................................... 116
9.9 NAPHTHA SPLITTER BOTTOM PRODUCT .......................................................... 117
SECTION-10 .............................................................................................................................. 119
SPECIAL PROCEDURES ......................................................................................................... 119
10.1 PRESSURE TESTING AND LEAK CHECKING GUIDELINES ............................. 119
10.2 TESTING THE EMERGENCY DEPRESSURING SYSTEM ................................... 121
10.3 EMERGENCY DEPRESSURIZING TEST ................................................................ 122
10.4 CALCULATION OF DEPRESSURIZING RATES ................................................... 122
10.5 PREPARATION FOR REACTOR LOADING........................................................... 124
10.6 CATALYST LOADING .............................................................................................. 126
10.7 CATALYST UNLOADING ........................................................................................ 133
10.8 AUSTENITIC STAINLESS STEEL PROTECTION ................................................. 137

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SECTION-11 .............................................................................................................................. 149

SAMPLING PROCEDURE AND LABORATORY ANALYSIS REQUIREMENT ............... 149
11.1 GENERAL ................................................................................................................... 149
11.2 SAMPLING PROCEDURE ......................................................................................... 149
11.3 LABORATORY TEST METHOD AND SCHEDULE .............................................. 152
SECTION -12 ............................................................................................................................. 158
EMERGENCY PROCEDURES................................................................................................. 158
12.1 GENERAL ................................................................................................................... 158
12.2 CHARGE PUMP FAILURE ........................................................................................ 159
12.3 LOSS OF STRAIGHT RUN NAPHTHA FEEDSTOCK ........................................... 159
12.4 RECYCLE GAS COMPRESSOR FAILURE ............................................................. 160
12.5 LOSS OF MAKEUP GAS ........................................................................................... 161
12.6 LOSS OF WASH WATER .......................................................................................... 161
12.7 TEMPERATURE EXCURSION ................................................................................. 162
12.8 INSTRUMENT AIR FAILURE .................................................................................. 164
12.9 CHARGE HEATER TUBE RUPTURE ...................................................................... 164
12.10 EXTERNAL FIRE ....................................................................................................... 165
SECTION -13 ............................................................................................................................. 166
SAFETY PROCEDURE............................................................................................................. 166
13.1 INTRODUCTION ........................................................................................................ 166
13.2 SAFETY OF PERSONNEL......................................................................................... 166
13.3 WORK PERMIT PROCEDURE ................................................................................. 167
13.4 PREPARATION OF EQUIPMENT FOR MAINTENANCE ..................................... 169
13.5 PREPARATION FOR VESSEL ENTRY.................................................................... 171
13.6 HAZARDOUS CHEMICAL HANDLING ................................................................. 176
13.7 FIRE FIGHTING SYSTEM......................................................................................... 184
13.8 USE OF LIFE SAVING DEVICE ............................................................................... 186
SECTION -14 ............................................................................................................................. 187
GENERAL OPERATING INSTRUCTIONS FOR EQUIPMENT ........................................... 187

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14.1 GENERAL ................................................................................................................... 187

14.2 CENTRIFUGAL PUMPS ............................................................................................ 187
14.3 POSITIVE DISPLACEMENT PUMPS....................................................................... 190
14.4 CENTRIFUGAL COMPRESSOR............................................................................... 191
14.5 HEAT EXCHANGERS ............................................................................................... 194

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SECTION-1
INTRODUCTION
1.1 INTRODUCTION
The purpose of the "Naphtha Hydrotreater" is to produce clean hydrotreated feedstocks to feed
the isomerization unit and CCR unit. These feedstocks must be sufficiently low in contaminants
such as sulfur, nitrogen, water, halogens, diolefins, olefins, arsenic, mercury and other metals so
as not to affect the downstream unit performance in particular the isomerization unit.
Naphtha hydrotreater feed is a blend of full boiling range straight run naphthas (97.6 wt %) and
visbroken naphtha (2.4 wt% maximum, 166 deg). from CDU-1, CDU-2, CDU-3 and VBU
naphtha. Apart from this FCC heart cut naphtha and naphtha from storage can also be processed.
These feed all contain levels of contaminants which would be detrimental to the isomerization &
CCR catalysts and therefore pretreatment is necessary.
This process involves the treatment of the naphtha in an adiabatic reactor over a fixed bimetallic
catalyst bed within a hydrogen environment. A moderately high temperature in the range of 280-
310C is required to promote the chemical reactions. After the reaction process, the naphtha is
stripped to remove light ends, gaseous products including H2S and water. The naphtha from
stripper bottom is the feed to the naphtha splitter. The naphtha splitter top is fed to the
Isomerization unit and splitter bottom is fed to the Platformer unit.
When diolefins and olefins are present in the feed, then a separate treatment step is required at a
lower temperature with a special catalyst to hydrogenate the unsaturated components prior to the
higher temperature treatment.
The performances of the isomerization unit are very much dependent upon the efficiency of the
naphtha hydrotreater.

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SECTION-2
DESIGN BASIS
2.1 INTRODUCTION
The unit is designed for two different cases. Case-I, is the proposal feed case which was based on
feed supplied in HPCL (NIT case) and Case-II is Bombay High (BH Case). The purpose of the
NHDT unit is to produce clean desulfurized light naphtha cut to be processed in the Platformer
unit after removal of all impurities which are poisons for catalysts (sulfur, nitrogen, water,
halogens, diolefins, olefins, arsenic, mercury and other metals).
Important content of design basis is given below.
2.2 UNIT CAPACITY

NHDT Unit is designed for a capacity of 1,154,000 MT per annum.
2.3 TURNDOWN CAPABILITY

The facility is capable of operating at 40 percent of design feed capacity, while maintaining the
designated product specification.
2.4 FEED
Naphtha hydrotreater feed is a blend of full boiling range straight run naphthas (97.6 wt %) and
visbroken naphtha (2.4 wt% maximum, 166 deg). The straight run naphthas are from CDU-1,
CDU-2, and CDU-3; visbroken naphtha from VBU. Apart from this FCC heart cut naphtha and
naphtha from storage can also be processed. These feed all contain levels of contaminants which
would be detrimental to the CCR catalysts and therefore pretreatment is necessary.

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2.4.1. Feeds specification

NHDT unit
The three feeds are straight run naphtha and are described as follows:
NIT case BH case
Flowrate, kg/h 144270 144318
Molecular weight 99.73 94.72
Density (Std) 0.725 0.735
FEED, mass fraction FBR Naphtha % Case-I FBR Naphtha % Case-I
i-Pentane 2.83 7.45

n-Pentane 3.17 5.10
1-Pentane 0.11 0.00
Cyclopentane 0.39 0.04
22-Mbutane 0.15 0.16
23-Mbutane 0.47 0.55
2-Mpentane 3.08 3.75
3-Mpentane 2.66 3.37
n-Hexane 9.16 5.24
1-Hexene 0.26 0.00
Mcyclopentan 2.58 2.76
Cyclohexane 4.28 2.84
Benzene 1.45 2.91
3-Epentane 0.34 0.24
33-Mpentane 0.17 0.12
24-Mpentane 0.49 0.24
23-Mpentane 1.02 0.71
22-Mpentane 0.33 0.12
3-Mhexane 3.52 2.45
2-Mhexane 2.81 2.04

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223-Mbutane 0.00 0.06

n-Heptane 8.00 4.04
Ecyclopentan 1.79 2.62
11 Mcycpentan 0.36 0.26
1-tr2-MCC5 0.70 1.18
1-tr3-MCC5 0.70 1.18
Mcyclohexane 5.48 5.45
Toulene 3.30 11.46
1-Heptene 0.29 0.0
224-Mheptane 1.89 1.16
2-Mheptane 2.00 2.32
33-Mhexane 2.00 2.32
2233-Mbutane 0.00 0.0
n-Octane 4.33 3.96
113-MCC5 2.55 4.92
Ecyclohexane 3.72 5.10
E-Benzene 0.54 0.93
p-xylene 0.54 0.88
m-xylene 1.41 2.58
o-xylene 0.71 1.10
1-Octene 0.17 0.00
2244Mpentane 4.93 2.28
n-Nonane 4.92 1.56
1Mci2n-PCC5 2.14 1.05
n-Pcychexane 2.12 1.07
Cumene 0.06 0.11
n-PBenzene 0.10 0.11
Indane 0.00 0.04

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1M2-EBenzene 0.11 0.12

135-EBenzene 0.19 0.18
124-EBenzene 0.52 0.52
123-EBenzene 0.17 0.15
1-Nonene 0.20 0.0
4-Mnonane 0.57 0.14
n-Decane 0.57 0.0
n-Pen-CC5 0.37 0.24
sec-BCC6 0.37 0.24
mDiEBenzene 0.09 0.05
sec-BBenzene 0.08 0.03
o-Cymene 0.16 0.03
14-EBenzene 0.08 0.03
1245-M-BZ 0.17 0.05
i-C11 0.46 0.06
n-C11 0.46 0.00
n-Hex-CC5 0.32 0.04
n-pen-CH 0.32 0.0
n-Pentyl-BZ 0.36 0..0
Total 100 100
Impurities:
FBR Naphtha contaminants:
Value
Total sulfur wt ppm 670 max
Total Nitrogen wt ppm 2.2 max

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Total oxygen wt ppm 2.0 max

Bromine Number 2.34 max
Fluoride wt ppm 0.5 max
Chloride wt ppm 2.0 max
Silicon wt ppm 0.1 max
Arsenic wt ppb 10 max
Lead wt ppb 20 max
Copper wt ppb 20 max
Nickel wt ppb 20 max
Mercury wt ppb 2 max
Total metals (including heavy metals
100 max
other), wt ppb
2.4.2. Hydrogen
Hydrogen make-up to this unit is needed for naphtha hydro treatment. Hydrogen is supplied from
Net Gas Chloride Treater at Platforming unit through a 2 header to upstream of product
condenser 73-A-01.
2.5 PRODUCTS
The NHT unit shall produce hydrotreated and stripped light naphtha and heavy naphtha suitable
fro downstream processing. The light hydrotreated naphtha will be used as feed to isomerization
unit and heavy naphtha will act as feed to Platformer. The hydrotreated light naphtha from the
NHT unit shall have the following specs:-
Product Value
Sulfur wt ppm 0.5 max
Nitrogen wt ppm 0.1 max
Metals wt ppb Nil
Chlorides wt ppb Nil

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The hydrotreated heavy naphtha from the NHT unit shall be designed to meet the following
required product properties and conditions:
Product Value
Sulfur wt ppm 0.5 max
Nitrogen wt ppm 0.5 max
Stripper column off gases are routed to amine treating (by others) and then to the refinery fuel
gas system. Sour water from the separator and stripper column is sent to sour water stripping and
then to the refinery.
2.6 BATTERY LIMIT CONDITIONS FOR NHDT
Incoming Stream Source Temperature ( C) Pressure ( Kg/cm2 g)
SR Light Naphtha CDU 1,2,3 75 4.5

SR Heavy Naphtha CDU 1,2,3 75 4.5
VB Naphtha Visbreaker 75 4.5
Steam
NHT Wash Water 100 4.0
Condensate
Start-up H2 Platformer 45 20.0
Outgoing Stream Destination Temperature ( C) Pressure ( Kg/cm2 g)
SRU Integration
Stripper off gas 53 5.6
Project
Naphtha Splitter Bottom Platformer 93 9.6
Naphtha Splitter Overhead Isomerization 40 6.1
Sour Water
Sour Water 55 5.0
Stripper

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Outgoing Stream Destination Temperature ( C) Pressure ( Kg/cm2 g)
Closed Blow
Stripper Overhead ** 1.7
Down
2.7 UTILITY CONDITION

2.7.1. Steam System
Minimum (for Mech.

Sr. No. Parameter Normal Maximum
thermal design) Design
1 VVHP STEAM
Pressure, Kg/cm2g 43.5 43.5 43.5 50.5
Temperature, oC 264 264 264 395
2 VHP STEAM
Pressure, Kg/cm2g 33 35 38 40.0
Temperature, oC 340 360 380 400
3 MP STEAM
Pressure, Kg/cm2g 9 10 11 12.5
Temperature, oC Satd 250 280 300
4 LP STEAM
Pressure, Kg/cm2g 2.5 3.0 4.0 5.5
Temperature, oC Satd 150 170 190
2.7.2. Condensate Return System

Steam Source Designation Condensate Destination Grade Level Battery Limit
HP , MP HP. MP 5.5
LP LP 1.5

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2.7.3. Process Water and Boiler Feed water

Deareated Treated Boiler Feed water
Description
Very high Pressure Medium Pressure
Supply Header Maximum
Operating Pressure Normal 50 20.5
Kg/cm2 Minimum 47 17.5
Supply Header Maximum
Operating Normal 120 120
Temperature oC Minimum 110 110
Mechanical Design Pressure Kg/cm2 71 29
Conditions Temperature oC 155 155
2.7.4. Cooling Water

Description Circulating Sea Water
Source Cooling Tower
Supply pressure Kg/cm2 5.3
Return pressure Kg/cm2 3.5
Supply temperature 33
Return Temperature 44 max
2.7.5. Fuel Oil System

Maximum 11.0
Supply Header Operating
Normal 8.0
Pressure Kg/cm2
Minimum 7.0
Supply Header Operating Maximum **
Temperature oC Minimum 2.5
Mechanical Design Pressure Kg/cm2 17.0
Conditions Temperature oC 200

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2.7.6. Fuel gas System

Maximum 3.5
Normal 3.0
Pressure Kg/cm2
Minimum 2.5
Maximum 60
Normal 30-50
Temperature oC
Minimum 30
Conditions Temperature oC 100
2.7.7. Plant and Instrument Air

Plant Air Instrument Air
Dew Point, (at header condition) oC Saturated -40 oC
Minimum Operating Pressure Kg/cm2 3.0 4.0
Normal Operating Pressure Kg/cm2 4.0 5.0
Maximum Operating Pressure Kg/cm2 5.0 6.0
Mechanical Design Pressure Kg/cm2 9.0 9.0
2.7.8. Nitrogen
Minimum Operating Pressure Kg/cm2 5.0
Normal Operating Pressure Kg/cm2 6.0
Maximum Operating Pressure Kg/cm2 7.0
2.7.9. Caustic
Caustic Strength wt% 10
Supply Pressure Kg/cm2 3.0
Supply Temperature oC 40

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2.7.10. Spent Caustic

Destination To ETP
2
Destination Pressure Kg/cm 6.0

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SECTION-3
CHEMISTRY OF THE PROCESS
3.1 PROCESS CHEMISTRY

Naphtha, like other petroleum fractions, contains varying amounts of naturally occurring
contaminants including organic sulfur, nitrogen, and metal compounds. These contaminants are
removed by hydrotreating process which is a proprietary, fixed bed, catalytic hydrogenation
method developed by UOP to upgrade the quality of light kerosene with a negligible effect on
the boiling range of light kerosene product. Hydrotreating is designed primarily to remove sulfur
and nitrogen. In addition, the process does an excellent job of saturating olefinic and aromatic
compounds and removing other contaminants such as oxygenates halides and organometallic
compounds.
Hydrotreating of naphtha is carried out at elevated temperatures and pressures in a hydrogen
atmosphere to make it suitable for CCR. Catalysts of naphtha hydrotreater are formulated by
compositing varying amounts of nickel and cobalt with molybdenum oxides on an alumina base.
Design of the unit is based on feed quality, desired product properties, ease of operation, desired
cycle length, operating flexibility and operating costs. The following chemical steps and / or
reactions occur during hydrotreating of naphtha:
3.2 SULFUR REMOVAL

Naphtha feedstock to the unit contains simple mercaptans, sulfides and disulfides. These
compounds are easily converted to H2S. However, feed stocks containing heteroatomic aromatic
molecules are more difficult to process. Desulfurization of these compounds proceeds by initial
ring opening and sulfur removal followed by saturation of the resulting olefin. Benzothiophene is
considered 15 times more difficult to process compared to diethylsulfide. Desulfurization
reaction takes place with sulfur removal followed by olefin saturation. At high conversion level,
desulfurization reactions follow first order kinetics.

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The comparison of the relative difficulty of hydrotreating different classes of sulfur containing
compounds is shown in figure1.
3.3 NITROGEN REMOVAL

Denitrogenation is generally more difficult than desulfurization. Side reactions may yield
nitrogen compounds more difficult to hydrogenate than the original reactant. Nitrogen removal
follows closely first order kinetics. Both increasing temperature and increasing hydrogen
pressure enhance the removal of total nitrogen. The reaction mechanism steps are different
compared to desulfurization. The denitrogenation of pyridine proceeds by aromatic ring
saturation, ring hydrogenolysis, and finally denitrogenation.
Saturation of heterocyclic nitrogencontaining rings is also hindered by large attached groups as
shown in the figure-2.

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3.4 OXYGEN REMOVAL

Organically combined oxygen is removed by hydrogenation of the carbonhydroxyl bond
forming water and the corresponding hydrocarbon.
3.5 OLEFIN SATURATION

Olefin saturation reactions proceed very rapidly and have a high heat of reaction than other
hydrotreating reactions.
A. Linear Olefin
C-C=C-C-C-C + H2 C-C-C-C-C-C (and isomers)

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B. Cyclic Olefins
C C
C C C C
+ H2
C C C C
C C
3.6 AROMATIC SATURATION

Aromatic saturation reactions are the most difficult. The reactions are influenced by process
conditions and are often equilibrium limited. Unit design parameters would consider the desired
degree of saturation for each specific unit. The saturation reaction is very exothermic.
3.7 METALS REMOVAL

Typical organic metals native to most crude oils are nickel and vanadium. Iron can be found
concentrated at the top of catalyst beds as iron sulfides that are corrosion products. Sodium,
calcium and magnesium are due to contact of the feed with salt water or additives.
Lead may also deposit on the hydrotreating catalyst from reprocessing leaded gasoline through
the crude unit. Lead has a large effect on the catalyst activity. Arsenic occurs naturally in certain
crude oil and is observed in all crude oil fractions. It is even more severe poison than lead.
Improper use of additives, to protect fractionator overhead system from corrosion, and to control
foaming, account for the presence of phosphorus and silicon. Metal removal is essentially
complete above temperatures of 315 0C to a metals loading of 2-3 wt% of the total catalyst.
Above this level, the catalyst begins to approach equilibrium saturation and metals breakthrough
is likely.
The total metals retention of the catalyst system can be increased by using a guard reactor or a
guard bed of catalyst specifically designed for demetallization. Some demetallization catalysts

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may retain as much as 100 wt% metals based on fresh catalyst weight. Such catalysts typically
have a lower activity for desulfurization and denitrogenation.
3.8 HALIDES REMOVAL

Organic halides, such as chlorides and bromides, present in naphtha are decomposed in the
reactor. The inorganic ammonium halide salts that are produced when the reactants are cooled
are then dissolved by injecting water into the reactor effluent or leave with the stripper off-gas.
Decomposition of organic halides is considered difficult with a maximum removal of
approximately 90%.
C C
C C -C-C-C-Cl C C -C-C-C
+ H2 HCl +
C C C C
C C
HCl + NH3 NH4Cl
3.9 REACTION RATES

The relative reaction difficulty for several major hydrotreating reactions are indicated in figure 3.
The approximate relative heats of reaction per unit of hydrogen consumption for these reactions
are shown below
Hydroprocessing reaction Relative heat of reaction
Desulfurization 1
Olefin Saturation 2
Denitrogenation 1
Aromatics Saturation 1
All of the reactions discussed above are exothermic and result in a temperature rise across the
reactor. Olefin saturation and some desulfurization reactions have similarly rapid reaction rates,

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but it is the saturation of olefins, which generates the greatest amount of heat than any other
hydrotreating reactions.
3.10 HYDROCARACKING REACTIONS

The products of the hydrotreating reactions are of a lower density than that of the feedstock.
Therefore, the total liquid yield will be greater than the feed and may be as high as 102 LV%.
Some hydrocracking may take place in the hydrotreating process. This is especially evident
toward the end of an operating cycle when reactor temperatures are raised to compensate for
lower catalyst activity. Total liquid yield and hydrogen consumption will increase as
hydrocracking reactions precede. Most of the increase in liquid volume yield will come from
more net stripper overheads at the expense of lower stripper bottoms product. Economic
considerations will determine the amount of bottoms product that can be lost before the unit is
shutdown for regeneration or catalyst change. Under normal operation, the net stripper overhead
liquid produced in the unit should not exceed 2 LV% of the unit feed.
3.11 CATALYST DEACTIVATION

Catalyst activity can be lost by several mechanisms. Under normal circumstances, the catalyst
should deactivate continuously and gradually throughout the entire run period due to coke
formation. However, several mechanisms exist for deactivation which can cause unusually high
deactivation rates.
3.11.1. COKE DEPOSITION

The catalyst system is designed to promote selective hydrogenation reactions while suppressing
undesirable reactions. The most undesirable side reaction is the condensation of polynuclear and
olefinic compounds into high molecular weight, low hydrogen content compounds commonly
referred to as coke. Coke formation begins with adsorption of high molecular weight molecules
and proceeds with further loss of hydrogen. The coke can cover active sites and / or prevent
access to these sites by physical blockage of the entrance to the pores leading to the sites. Coke
deposition is a time-temperature phenomenon. Deactivation increases with time and temperature

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of the catalyst. Coke deposition occurs at a relatively slow rate and the catalyst is able to operate
for periods of one year or more before regeneration becomes necessary. Reactor temperatures
must be increased to compensate for the slow decline in activity caused by the accumulation of
coke on the catalyst. During upsets or when catalyst is subjected to operating conditions beyond
the operating limits of the unit, coke formation accelerates and catalyst life is reduced. Most of
the catalyst activity can usually be recovered by regeneration by oxidizing the coke to carbon
dioxide gas and hence coke deposition can be considered as temporary deactivation of catalyst.
However, when deactivation is caused by extreme conditions, such as very high reactor
temperatures or high end point feed, regeneration may not be successful.
3.11.2. METALS ACCUMULATION

Metals may come into the system via organometallic compounds (Ni,Va), feed stock
contaminants ( Pb,Fe,As,P,Na,Ca,Mg ) and additives such as anti-foaming agents. The
deposition of metals usually occurs at the pore entrances or near the outer surface of the catalyst.
This deposition creates a layer affecting the accessibility to the catalyst interior and active sites.
These metals are non-regenerable poisons to the catalyst and hence metals accumulation can lead
to permanent deactivation of catalyst.
3.11.3. CATALYST SINTERING

Catalyst supports and active metal sites can be sintered upon exposure to high temperatures.
High water partial pressures contribute to this effect as well. The active metals can become
mobile and agglomerate under these conditions. The resulting loss in active surface reduces
catalyst activity. The catalyst support will also lose surface area from the collapse of pores or
from an increase in pore diameter with pore volume remaining constant.

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RELATIVE DIFFICULTY OF DESULFURISATION REACTIONS
Approximate
factor of difficulty
FIGURE-1

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FIGURE-2

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FIGURE-3

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SECTION-4
PROCESS DESCRIPTION
4.1 PROCESS VARIABLES

The proper operation of the unit will depend on the careful selection and control of the
processing conditions. Process variables are of utmost importance to the performance of the unit
and hence care to be taken to maintain them within acceptable limits.
4.1.1. Catalyst Temperature

The reactor inlet temperature is the process variable most easily and commonly controlled by the
operator to adjust the amount of sulfur (or nitrogen) removed from the feed. The reactor outlet
temperature is a function of the feed quality and cannot be easily varied except by changing the
reactor inlet temperature. The inlet temperature must be controlled at the minimum required to
achieve the desired product properties.
Figure III-1
Desulfurization and Denitrification vs. Catalyst Temperature
Temperatures above this minimum will only lead to higher rates of coke formation and a reduced
cycle length. Guidelines for temperature adjustments are summarized below.

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Do not exceed an average temperature rise (average outlet temperature-average inlet

temperature) of 42C (75F) per bed of catalyst. When making changes in feed rate,
increase feed rate first, then increase catalyst temperature. Conversely, decrease catalyst
temperature first, then decrease feed rate.
Always make catalyst temperature increases gradually and smoothly. The rate at which
temperatures can be safely increased will depend on the age of the catalyst and the
severity of the operation. Fresh catalyst is very sensitive to temperature. Increases above
about 315C (600F) on fresh catalyst should not exceed 3C/hour (5F/hour).
If any upsets in flows are observed, immediately reduce reactor inlet temperatures. Loss
of any of the streams flowing through the reactors will result in less heat removal
capability and could lead to a temperature runaway.
All operating personnel should be thoroughly familiar with the Emergency.
The weight average bed temperature (WABT) is typically used to compare the relative
activity of the catalyst. The WABT can be calculated as indicated in Figure III-2.
Figure III-2
Weight Average Bed Temperature

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The rate of increase in WABT is referred to as the deactivation rate expressed as C per m3 of
feed per kilogram of catalyst (F per barrel of feed per pound of catalyst), or more simply as C
per day (F per day). During the course of an operating cycle, the temperature required to obtain
the desired product quality will increase as a result of catalyst deactivation (See Figure III-3).
The gradual loss in catalyst activity can be compensated for by increasing reactor temperatures.
In general, above a certain level, cracking and coke formation become very rapid and little
improvement in performance is obtained.
Catalyst bed thermocouples are extremely useful for judging the effective utilization of the
catalyst. However, it must be remembered that the bed couple is measuring the temperature at
one point in a large cross sectional area. If temperature maldistribution is occurring, then the bed
couple may not necessarily be representative of the average catalyst temperature. Causes of
temperature maldistribution include poor catalyst loading, mechanical problems with internals or
coke formation resulting from unit upsets or a temperature excursion.
Figure III-3
WABT Vs/ Cycle Life
420
410
400
390
380
370
0 1 2 3 4 5 6
Life, M3/kg

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A reactor temperature profile plot is a useful tool for evaluating catalyst performance,
effectiveness of quench, and reactor flow patterns. A temperature profile can be constructed by
plotting the catalyst temperature versus distance into the catalyst bed (or more accurately versus
weight percent of catalyst). In addition to monitoring the temperature profile, the radial
temperature spread needs to be monitored.
The reactor temperature profile should be adjusted to maintain equal peak temperatures across
each catalyst bed. This ensures equal utilization of the catalyst inventory. The design
temperatures of the reactor and charge heater will also determine the maximum allowable
operating values. The temperature rise across the reactors must be monitored continuously in
order to assure that the design limitation of the unit is not exceeded. This can be especially
important when increasing the ratio of cracked stock to straight run material in the feed since
olefin saturation results in considerably higher heats of reaction. Units are typically designed for
a maximum reactor bed temperature rise of <42C (75F).
4.1.2. Fresh Feed Quality

The amount of catalyst loaded into the reactors as well as other design parameters are based on
the quantity and quality of feedstock the unit is designed to process. While minor changes in feed
type and charge rate can be tolerated, wide variations should not be tolerated since they will tend
to reduce the useful life of the catalyst.
a) Distillation range
Increase in the end point of the feed will make sulfur and nitrogen removal more difficult, thus
requiring higher reactor temperature with more coke deposition. High boiling fractions also
contain increased quantities of metals, which lead to higher reactor bed pressure drop and rapid
catalyst deactivation.
b) API gravity
Reduction in API gravity of the feed for the same boiling range is an indication of higher
unsaturates present in the feed. This will result in increased hydrogen consumption and higher
temperature rise across the reactor bed. This will also enhance the condensation reaction which
leads to more coke formation.

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c) UOP K
Higher UOP K of the feed stock is an indication of higher paraffinicity of the feed stock. The
feed with lower UOP K will result in increased hydrogen consumption and higher temperature
rise across the reactor bed.
d) Bromine number
Higher bromine number of the feed stock is an indication of higher unsaturates content. The feed
with higher bromine number will result in increased hydrogen consumption and higher
temperature rise across the reactor bed. This will also enhance the condensation reaction to form
more coke in the reactor. This will reduce the cycle length.
e) Sulfur content
Higher sulfur content increases operating severity and increases hydrogen consumption. Also
reactor temperatures should be increased, which will lead to coke formation, to achieve the
required product sulfur.
f) Nitrogen content
Higher nitrogen content demands high reactor temperatures which will lead to coke formation.
Also hydrogen consumption increases if feed is having higher nitrogen content.
g) Conradson carbon
Conradson carbon is a measure of residue after destructive distillation. The feed with higher
Conradson carbon is an indication of higher coking tendency and this will reduce the cycle
length.
h) ASTM colour
ASTM colour is a measure of residue entrainment. Higher value will reduce the cycle length and
vice-versa.
i) Metal content
Organo-metallic compounds contained in the feed will decompose and the metals will be
retained on the catalyst, thus decreasing catalyst activity. Since metals are normally not
removable by oxidative regeneration, once a catalyst has been poisoned by metals, its activity
can not be restored.

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An increase in the charge rate will require higher reactor temperature to achieve a constant
desulfurization, as well as higher recycle gas rate to maintain a constant ratio of H2 to
hydrocarbon. The increased reactor temperatures will also lead to a faster rate of coke formation
which will reduce the period between regenerations. The reduced feed rate may lead to bad flow
distribution through the catalyst, such that higher temperatures will be required to obtain good
product quality. In order to minimize the effect of variations in charge rate, it should be made
common practice to reduce the reactor temperature before lowering the feed rate, and conversely,
to increase the feed rate before raising the reactor temperature. The type of feed being processed
is best indicated by its distillation range and API gravity. An increase in the end point of the feed
will make sulfur and nitrogen removal more difficult, thus requiring higher reactor temperatures
which then accelerates coke formation (See Figure III-4).
Figure III-4
Catalyst Deactivation
Good Bad
Feed Quality
Coke deposition is also accelerated by the fact that heavier feed contains more of the precursors
that favor coke formation. In addition to the above, high boiling fractions also contain increased
quantities of metals which lead not only to higher reactor pressure drop, but to rapid catalyst

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deactivation as well. It must be remembered that regeneration will not restore the activity of a
catalyst that has been poisoned by excessive quantities of metals.
Thus, it is seen that processing higher than design end point feeds will, at best, reduce the length
of the operating cycle, and under extreme conditions, may lead to an irrecoverable loss of
catalyst activity. Therefore, every effort must be made to maintain the end point of the feed
within the design limits by operating the crude and other units such that an acceptable feed stock
is obtained. A reduction in the API gravity of the feed for the same boiling range is an indication
of higher unsaturated content. This type of feed will result in increased hydrogen consumption
and higher temperature rise across the catalyst bed. It also contains more of the materials that
easily condense to form coke in the reactor and associated equipment.
Organo-metallic compounds contained in the feed will decompose and the metals will be
retained on the catalyst, thus decreasing its activity. Since metals are normally not removable by
oxidative regeneration, once a catalyst has been poisoned by metals, its activity cannot be
restored. Therefore, metals content of the feedstock is a variable that should be monitored.
Naphtha feedstock metals contamination is rare might be some metals which are introduced by
upstream processing or contamination such as lead, sodium, silicon and phosphorous. Iron
sulfide is usually present as a corrosion product and is normally not considered a poison to the
catalyst. Thus it is usually omitted when referring to total metals.
Hydrotreating catalysts exhibit a moderate tolerance for metals such as arsenic and lead. Total
metal content of 2-3 wt% of the Hydrotreating catalyst have been observed. However, product
analysis frequency should be increased to monitor breakthrough when calculations show the
metals level on the Hydrotreating catalyst exceeds 0.5 wt%. Catalyst replacement should be
considered when metal loadings of 1-2 wt% are exceeded on the Hydrotreating catalyst.
The graded catalyst bed, if used, may contain demetallization catalysts that have a high metals
retention capacity. Some of these catalysts may retain as much as 100 wt% of the fresh catalyst
weight as metals from the feed. These demetallization catalysts typically have a lower activity
for desulfurization and denitrogenation.
Apparent catalyst deactivation may be caused by the accumulation of deposits on top of the
catalyst bed. Solid material, such as corrosion products and coke, will lead to rapid fouling of the

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catalyst bed if allowed to enter the reactor. This problem is remedied by skimming a portion of
the catalyst, screening and reloading. Feed filtering is quite effective in removing solid material,
and as such results in longer operating cycles due to the lower rate of reactor pressure drop build-
up. The use of feed filtering will depend on the type of feed processed and its source.
4.1.3. Fresh Feed Rate (LHSV)

The amount of catalyst loaded into the reactors is based on feedstock properties, operating
conditions, and product quality required. The variable that is normally used to relate the amount
of catalyst to the amount of feed is termed liquid hourly space velocity (LHSV). LHSV is the
volume of charge per hour

LHSV =
volume of catalyst
ratio of volumetric feed rate per hour to the catalyst volume and is defined as:
A simplified kinetic expression based on sulfur and/or nitrogen removal determines the initial
liquid hourly space velocity for most feedstocks and processing objectives. This initial value may
be modified due to other considerations such as unit size, extended catalyst cycle life, abnormal
levels of feed metals and requirements of other processing units in the refinery flow scheme.
An increase in the LHSV will require higher reactor temperature to achieve a constant level of
desulfurization, as well as higher recycle gas rate to maintain a constant ratio of H2 to
hydrocarbon. The increased reactor temperatures will also lead to a faster rate of coke formation
that will reduce the period between regenerations. A reduction in LHSV may lead to bad flow
distribution through the catalyst, such that higher temperatures will be required to obtain good
product quality. In order to minimize the effect of variations in LHSV, it should be made
common practice to reduce the reactor temperature before lowering the feed rate, and conversely,
to increase the feed rate before raising the reactor temperature.
Unit designs are based on operational criteria to achieve optimal performance. One criterion for
hydrotreating is liquid mass flux across the catalyst bed. A mass flux of 2000 lb/hr/ft2 is
considered a reasonable minimum for adequate flow distribution. At reduced throughput, unit
operation may become difficult due to hydraulic considerations (i.e. control valves operating

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closed, etc.). Also, reactant distribution in the reactor may become unequal as preferential flow
paths are established. For these reasons, the unit should not be operated below the minimum
turndown capacity for extended periods. Unit turndown will vary for each design and is typically
50-70% of design capacity.
4.1.4. Hydrogen Partial Pressure

The reactor section operating pressure is controlled by the pressure that is maintained at the
product separator. This pressure, multiplied by the H2 purity of the recycle gas, determines the
partial pressure of H2 in the reactor. The hydrogen partial pressure required for the operation of
the unit is chosen based on the degree of sulfur (or nitrogen) removal that must be achieved and
is an economic optimum that balances initial investment and operating costs against catalyst life
(See Figure III-5). Hydrogen partial pressure is also a critical design parameter for achieving the
desired degree of feed saturation (See Figure III-5 and Figure III-6
Figure III-5
Desulfurization vs. H2 Partial Pressure
H2 Partial Pressure
H2 Circulation

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A reduction in operating pressure below its design will have a negative effect on the activity of
the catalyst and will accelerate catalyst deactivation due to increased coke formation. Figure III-6
shows the general trend in the effects of lower hydrogen partial pressure on catalyst deactivation.
Operating at higher than design pressure may not be possible. There will be a practical
equipment limitation on most units that will not allow significantly higher pressure than design,
such as the pressure rating of the heaters, exchangers, and vessels. Also, the recycle gas
compressor usually will not be able to put up the required head on a significantly lighter, higher
purity recycle gas. The major control variable for hydrogen partial pressure is the recycle gas
purity that should be monitored closely to assure it is always maintained above the minimum
value. The hydrogen purity can be improved by increasing the hydrogen purity of the makeup
hydrogen, venting gas off the product separator, or reducing the temperature at the product
separator.
Figure III-6
Catalyst Deactivation
Low High
H 2 Partial Pressure
4.1.5. Recycle Gas Rate

In addition to maintaining a prescribed partial pressure of hydrogen in the reactor section, it is
equally important to maintain the physical contact of the hydrogen with the catalyst and

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hydrocarbon so that the hydrogen is available at the sites where the reaction is taking place. This
is accomplished by circulating the recycle gas throughout the reactor circuit continuously with
the recycle gas compressor. The amount of gas that must be recycled is a design variable again
set by the design severity of the operation. The standard measure of the amount of gas required is
the ratio of the gas being recycled to the rate that fresh feed is being charged to the catalyst.
As with hydrogen partial pressure, the recycle gas to feed ratio should be maintained at the
design ratio. The definition for the gas-to-oil ratio is:
Gas to Oil Ratio = Total Circulating Gas to Reactor, Nm3 /hr

Total Fresh Feed to Reactor m3 /hr
As with hydrogen partial pressure, any reduction of the gas-to-oil ratio below the design
minimum will have adverse effects on the catalyst life Figure III-7 gives a general observation of
this effect. The gas-to-oil ratio can be affected by several ways in the Hydrotreating Unit.
Figure III-7
Effect of Reactor Recycle Gas Rate on Catalyst Stability
Gas Rate, SCFB

10,000
5,000
Catalyst Life
The quantity of gas circulated from the product separator to the reactor is relatively large. The
gas flow is required for the following purposes:

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Provides the excess hydrogen needed to assure that the reactions are carried to
completion.
Absorbs some of the heat of reaction minimizing the catalyst bed temperatures.
Minimizes charge heater and combined feed exchanger tube wall temperatures by
increasing the flow through the equipment. The excess hydrogen also prevents formation
of coke as the charge is heated to reaction temperature.
A gradual reduction in recycle gas rate may be observed during the course of an operating period
as a result of higher reactor system pressure drop. This effect is especially pronounced on units
that use a centrifugal recycle gas compressor. Such a reduction in the recycle gas rate is
acceptable as long as the calculated gas-to-oil ratio does not fall below the design value. When it
is no longer possible to maintain the minimum gas-to-oil ratio, the catalyst must be regenerated
and screened in order to reduce the reactor pressure drop. In all cases that result in less than
design gas-to-oil ratio due to pressure drop or mechanical difficulties, the raw oil charge rate
must be lowered in order to obtain the required gas-to-oil ratio. In the event of a complete loss of
recycle gas, immediate remedial action must be taken to protect the catalyst and equipment.
4.1.6. Recycle Gas Hydrogen Purity (Make-Up Hydrogen)

The effective completion of the hydrogenation reactions occurring over the catalyst requires that
a certain quantity of hydrogen be present at a minimum partial pressure. As noted previously,
both the quantity (gas-to-oil ratio) and partial pressure are dependent upon the hydrogen content,
i.e. purity, of the recycle gas. Practical considerations, such as the cost of compression, catalyst
life, etc., limit the purity of the recycle gas to a minimum value usually in the range of 70-80
mol%. Lower hydrogen purities are detrimental to the performance of the unit since higher
temperatures must be used to achieve the desired product quality. The purity of the recycle gas is
determined by the following factors:
The purity of the makeup gas.
The amounts of light hydrocarbons and H2S that are allowed to accumulate in the recycle
gas.

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In most instances, the makeup gas H2 purity cannot be easily manipulated since it is fixed by the
hydrogen source, typically naphtha reforming unit or a hydrogen manufacturing plant. The light
hydrocarbons present in the recycle gas enter the system with the makeup gas in addition to those
being formed in the reactor, and must be vented from the product separator to prevent their
accumulation in the recycle gas. The amount of hydrogen required is determined by:
Chemical Hydrogen Consumption The hydrogen consumed during the hydrotreating
reactions.
Solution Losses The hydrogen that is removed from the reactor circuit dissolved in the
liquid hydrocarbon leaving the product separator.
Mechanical Losses The hydrogen lost through the makeup and recycle gas
compressors' packing vents and seals. This value may be roughly estimated at 3-5% of
the combined chemical consumption plus solution losses.
Venting Losses The hydrogen lost in the purge stream from the product separator to
maintain recycle gas purity.
The H2S formed in the reactors can reach equilibrium values as high as 5 mol% in the recycle
gas. This concentration of H2S has a depressing effect on the activity of the catalyst. Therefore,
in many cases it is desirable to remove the H2S from the recycle gas by venting it from the
product separator.
The sulfur and nitrogen found in the feed can be considered contaminants to the extent that they
produce hydrogen sulfide and ammonia which can react to form ammonium bisulfide. The water
injected into the reactor effluent dissolves the ammonium bisulfide and prevents exchanger
fouling. Organic nitrogen in the feed, if present in amounts higher than expected, will require
higher reactor temperatures for processing, and will lead to a reduction in catalyst life.
If the water injection should be stopped for any period of time, the H2S and NH3 may accumulate
in the recycle gas and result in a sudden loss in catalyst activity. The activity will return to
normal once wash water is reestablished. Catalyst bed temperatures should not be increased to
compensate for the temporary activity loss.
Small amounts of molecular nitrogen, CO and CO2 that enter the system with the makeup gas are
not harmful to the catalyst, but must be vented to prevent accumulation in the recycle gas.

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Excessive amounts of CO and CO2 may have an adverse effect on catalyst performance as they
may be methanated by the catalyst taking up active sites and liberating heat. This will raise the
outlet temperature and reduce the apparent catalyst activity. The unit should never be pressured
up with high CO + CO2 containing makeup gas as a temperature runaway may result. The
presence of O2 could increase equipment fouling (especially the feed/effluent exchangers).
4.2 PROCESS FLOW DESCRIPTION

Naphtha hydrotreater unit consists of a feed section, a high pressure reactor section, medium
pressure stripper section and a low pressure splitter section.
Feed section: Cold/hot feed lines at battery limit feed surge drum (73-V-01) charge
pumps suction.
High pressure reactor section: Charge Pump (72-P-01 A/B) Feed Filter (73-X-01)
Combined Feed Exchanger (72-E-01) Charge Heater (72-F-01) Reactor (72-R-01)
Separator (72-V-04) recycle gas compressor knockout drum (72-V-05) recycle gas
compressors (72-K-01 A/B).
MP Stripper Section Stripper Feed Naphtha Splitter Bottom Exchanger (72-E-02)
Stripper Feed Bottom Exchange (72-E-03) Stripper (72-C-01) Stripper Reboiler (72-E-
04) Stripper condenser (72-A-02) Stripper Receiver (72-V-06) Stripper Reflux
Pumps (72-P-04 A/B).
Naphtha Splitter Bottom pumps (72-P-05 A/B) Stripper Feed Naphtha Splitter Bottom
Exchanger tube side (72-E-02) battery limit.
Naphtha Splitter Overhead pumps 72-P-06 A/B Naphtha Splitter Overhead Cooler (72-E-
05 A/B) battery limit.
Low pressure product fractionation section: Naphtha Splitter (72-C-02) Naphtha
Splitter Reboiler Heater (72-F-02) Naphtha Splitter Condenser (72-A-03) Naphtha
Splitter Receiver (72-V-07).

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A. FEED
The feed to the Naphtha Hydrotreater unit is a blend of full boiling range straight run naphthas
from CDU-1, CDU-2, CDU-3 and visbroken naphtha from visbreaking unit.
Hot feed
In order to maximize energy efficiency, Naphtha Hydrotreater unit will be normally processing
hot straight run naphtha at 75 oC and pressure of 4.5 Kg/cm2 exiting CDU-1, CDU-2 and CDU-3.
VB naphtha from visbreaking unit will also come along with SRN from CDU. Hot feed is taken
into the unit through an 8 header. FCC heart cut naphtha and Naphtha with contaminated DSO
from CFC can also be processed in the NHT when required.
Cold feed
Naphtha hydrotreater unit will be processing cold feed from storage during unit start up, and
during normal operation if necessary.
B. FEED SURGE DRUM

Feed is routed to feed surge drum (72-V-01) from battery limit. Feed surge drum pressure is
controlled by split range controller PIC0601, which operates via push and pull system with
makeup through PV0601 A from fuel gas header and venting through PV0601 B to flare header.
Feed surge drum level is controlled by LIC0602 which is cascaded with flow controllers in cold
feed line. Two nos. of pressure safety valves PSV 01A/B are provided on the feed surge drum.
These pressure safety valves safeguard the vessel during fuel gas makeup control valve
(PV0601A) failure and fire case. Charge pumps (72-P-01A/B) are multi-stage centrifugal pumps.
It takes suction from feed surge drum and charge the reactor with naphtha through feed filter (72-
X-01), combined feed exchanger (72-E-01) and charge heater (72-F-01). A common spillback
line to feed surge drum with flow control valve FV0701 is provided for both the pumps to
maintain minimum flow at reduced throughput. A 1 sulfide injection line is provided in the
suction of charge pumps, which will normally be blank-off when not in use.

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C. FEED FILTRATION
Straight run naphtha is clean products and doesnt contain much of contaminants viz., pipe scale,
dirt, and degradation products. However, small quantities of contaminants are always present.
These contaminants, if enter the reactor along with naphtha, accumulate in the reactor catalyst
beds. This accumulation of particulate matter in the catalyst beds builds up the pressure drop
across the reactor. Naphtha Hydrotreater unit has (72-X-01) continuous magnetic feed filters.
Charge pump discharge is filtered through this filter to a filtering degree of 50 micron before
going to reactor. Maximum clean pressure drop across these filters is 0.2 kg/cm2 (g) and
maximum dirty pressure drop across these filters is 1.8 kg/cm2 (g). The pressure drop across the
filters is indicated by PDT0703 in the field and by PDI0703 on DCS panel. A nitrogen supply
line connection is given to the inlet line of each filter for purging purpose, and also to drain the
filter in a short period of time under nitrogen pressure.
D. COMBINED FEED EXCHANGER

Combined feed exchanger (72-E-01 A-G) is train of 7 nos. of exchangers connected in series.
Recycle gas from recycle gas compressor discharge is mixed with naphtha going to the reactor.
The combined feed and gas is preheated on shell-side from 79 oC to 287 oC with hot reactor
effluent on tube-side cooling from 343 oC to 128 oC. A 2 wash water connection is provided
upstream and downstream of the combined feed exchanger to dissolve the ammonium salts
before they solidify on the exchanger tubes.
E. CHARGE HEATER
Charge Heater (72-F-01) is a vertical cylinder fuel oil / fuel gas fired heater with 2 pass entering
convection section. It is vertical cylindrical type having two pass vertical tubes in the radiant
section. Flue gas leaving the convection section of charge heater shall be ducted beneath the
common convection section of stripper reboiler heater (72-F-02). It has 6 nos. of low NOX
combination of oil and gas burners. Preheated combined feed is further heated from 278 oC to
332 oC. The combined feed enters the heater at a pressure of 30.0 kg/cm2 (g) and exits at a
pressure of 24.9 Kg/cm2 (g). A 3 multipurpose point is provided at inlet and outlet of both the

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passes for neutralization purposes. Charge heater outlet temperature i.e. reactor inlet temperature
is an important control parameter for the reactor performance and is controlled by TIC0809. This
temperature control is being achieved by controlling the fuel oil / fuel gas and combustion air
flow rates to the charge heater cascaded through fuel oil / fuel gas flow controller and
combustion air flow controller.
F. REACTOR
The two phase combined feed exiting heater enters the top of the reactor at a temperature of
332 oC and at a pressure of 24.9 Kg/cm2 (g). As the reaction mixture flows downward through
the catalyst beds, the hydrotreating reactions occur which are exothermic in nature. The heat
liberated is absorbed by the liquid and gas streams and hence the reactor effluent outlet
temperature increases to 343 oC. The reactor inlet temperature is controlled by TIC0809. The
pressure at reactor outlet is 24.4 Kg/cm2 (g) and it decreases towards EOR. The pressure drop
across the reactor is monitored by PDI0903 which gets the input from PI-0901 and PI-0902.
G. REACTOR EFFLUENT COOLING

Due to the exothermic nature of hydroprocessing reactions, the reactor effluent is at a high
temperature of 343 oC. In order to increase the energy efficiency, the cooling of reactor effluent
is carried out by routing through a series of exchangers as given below:
Combined feed exchanger (72-E-01 A-G): The reactor effluent is cooled on tube side from
343 oC to 128 oC by exchanging heat with fresh feed. Fresh feed is heated on shell side from
79 oC to 287 oC
Wash water injection: Wash water injection to reactor effluent brings down its temperature
from 128 oC to 114 oC.
Product condenser (72-A-01): The reactor effluent is further cooled down on tube side in
product condenser from 114 oC to 55 oC.
Reactor effluent from combined feed exchanger is routed to the product condenser (72-A-01)
before entering the separator (72-V-04). It is recognized that the inherent corrosivity of the

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reactor effluent stream is a function of the ammonia and hydrogen sulfide content. The primary
corrosive component in the system is aqueous ammonium bisulfide formed when the process
stream is condensed. Presence of oxygen in the system may aggravate the corrosion problem. It
is also noted that the corrosive medium acts in conjunction with high tube velocities, generally in
excess of 4-6 m/sec. This subjects the tube to corrosion-erosion type of attack. Areas of high
velocity and high turbulence, such as tube ends, return bends and downstream pipe bends are
most prone to attack with the corrosion occurring in a highly localized, random manner. Thus the
specific design of the air cooler restricts the velocities to 6 m/sec max and 3 m/sec min from
common junction at inlet to the common junction at the outlet. Uneven distribution of flow to the
condenser may result in tube velocities in excess of the recommended maximum limit of 4-6
m/sec. The importance of the good distribution has been recognized and symmetrical
manifolding at the condenser inlet and outlet is provided. A constant supply of wash water is
necessary to dissolve ammonium bisulfide and ammonium chloride salts from the reaction
products. Both ammonium bisulfide and ammonium chloride can solidify and precipitate on cold
surfaces in the combined feed exchangers if the ammonium concentration is allowed to build up
in the recycle gas. Low condenser temperatures may result in tube plugging due to the
precipitation of solid ammonium bisulfide, ammonium chloride that can corrode/foul the product
condenser tubes. If the temperature in any of the bundles drop below the salt deposition
temperature, tube plugging can occur which in turn increases the velocity through the tubes
exposing them to attack by corrosion-erosion. It is not sufficient to measure and control the
temperature of the combined stream leaving the condenser, since the outlet temperature from
some of the bundles may be considerably lower as a result of uneven flow distribution or
excessive air flow to some areas.
H. WASH WATER INJECTION

The sulfur and nitrogen contained in the naphtha feed are converted to hydrogen sulfide and
ammonia by desulfurization and denitrogenation reactions in the reactor. These two reaction
products combine to form ammonium salts viz. ammonium bisulfide and ammonium chloride,
which are insoluble in hydrocarbon, solidify and precipitate as the reactor effluent is cooled.

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Ammonium Chloride may be formed if there is any chloride in the system. The purpose of the
wash water injection is to dissolve these salts before they precipitate on tube surfaces in
exchangers and piping surfaces. To avoid the precipitation of these salts that can corrode and a
foul cooler tubes, wash water is injected into the reactor effluent stream before it enters product
condenser. There are two injection points. One injection point, usually in line, is at the inlet of
product condenser (72-A-01) and the other one is at the inlet of combined feed exchanger (72-E-
01 A-G). Wash water injection upstream of 72-E-01 is intermittent and is carried out if fouling is
suspected due to ammonia salts. Wash water is injected in a vertical run of pipe through an
injection quill that facilitates mixing. Following are the guidelines to determine wash water rate
and quality:
Sufficient water should be injected to ensure at least 20% of water remains liquid after
injection. This is to avoid flashing of the water and creating an acidic environment when the
first drop of water begins to condense or a localized high concentration of salts.
Sufficient water should be injected to maintain the concentration of ammonium bisulfide in
the sour water below 8 wt%. This will minimize the potential corrosivity of the sour water in
the air cooler tubes and outlet piping.
The minimum wash water injection rate is 5 vol% of the fresh feed.
Wash water should be clean condensate. Stripper sour water can be used up to maximum 50
% of the total rate depending on its quality. However, stripper sour water should come from a
sour water stripper that does not process sour from other units particularly FCCU.
The product condenser inlet and outlet piping should be symmetrical to ensure even
distribution of flow through each tube bundle. The velocity through the tubes should be in the
range of 3-6 m/sec.
Wash water used in the unit is clean cold condensate. Wash water break tank level is controlled
by LIC1101 with cold condensate make up. Cold condensate is received via 3 line. Wash water
pumps (72-P-02 A/B) take suction from wash water break tank and the pump discharge is going
to product condenser inlet line and combined feed exchangers tube side inlet line by separate 2
lines. Wash water injection rate to the inlet of the product condenser (72-A-01) is controlled by
FIC1101. Alternative wash water injection point has been provided in the upstream of 72-E-01

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via 2 pipe. If fouling due to ammonium salts is suspected in the combined feed exchangers,
washing of these exchangers can be performed by changing wash water injection point location
from the upstream of product condenser to the upstream of these exchangers. Tube side pressure
drop across 72-E-01 indicates fouling of tubes.
I. SEPARATOR
Reactor effluent finally enters the separator (72-V-04) via inlet distributor at a temperature of
55 oC. Separator is a horizontal KCS vessel having a water boot welded to the underside. The
purpose of the separator is to separate the recycle gas, water phase and hydrocarbon phase in the
reactor effluent. A mesh blanket is provided to coalesce water droplets from the hydrocarbon
phase. The bottom half of the separator is lined with a 3mm layer of SS for corrosion protection.
The reactor effluent enters the separator through a slotted inlet distributor at one end. The sour
water coming out from separator water boot is sent to the sour water treating unit on interphase
level control LIC1301. This sour water contains a large concentration of highly toxic H2S and
NH3. The hydrocarbon level in the separator is controlled by LIC1302, which actuates level
control valve LV1302 going to the stripper feed naphtha splitter bottom exchanger (72-E-02).
This stream then passes through stripper feed bottom exchanger 72-E-03 A/B for preheating
before entering stripper (72-C-01) on feed distributor tray between 20th and 21st trays. Separator
pressure i.e. system pressure is controlled by pressure controller PIC1301. Low pressure in the
separator will open PV1301 and introduce more make up hydrogen upstream of the product
condenser. High pressure in the separator will be lowered by opening HIC1301 and venting
hydrogen rich gas to flare.
J. RECYCLE GAS COMPRESSOR KNOCK OUT DRUM

The recycle gas from separator is routed to recycle gas compressor knock out drum (72-V-05).
The entrained liquid by recycle gas is removed in recycle gas compressor knock out drum before
recycle gas entering recycle gas compressors. Recycle gas compressor knock out drum is a
vertical vessel made of KCS. Internally the vessel has 240 mm thick Monel mesh blanket, which
will help in knocking out entrained liquid from the recycle gas. Entrained liquid is routed to

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separator hydrocarbon to stripper line via 1.5 line from the bottom of the drum periodically.
Level indicator LI1401 provides high/low level alarm in the DCS control room.
K. RECYCLE GAS COMPRESSORS

The recycle gas compressors (72K-01 A/B) are motor driven reciprocating compressors. It takes
suction from the recycle gas compressor suction drum. The recycle gas compressors have
lubricator system, lube oil console and cooling water system. Recycle gas from recycle gas
compressor discharge is at a pressure of 37.3 Kg/cm2 (g) and at a temperature of 107 oC. Make
up hydrogen is provided upstream of the product condenser.
L. STRIPPER FEED PREHEATING

Stripper feed i.e. hydrocarbon exiting the high pressure separator is first preheated on shell side
of stripper feed naphtha splitter bottom exchanger (72-E-02) from 55 oC to 93 oC. This heated
stream is further heated in stripper feed bottom exchanger (72-E-03 A/B) to a temperature of
166 oC before entering the stripper between tray 20th and 21st.
M. STRIPPER
Stripper (72-C-01) is a vertical vessel constructed of killed carbon steel. It has 25 nos. of valve
trays. Feed is introduced on the 20th tray via distributor. A reboiler is provided to strip off H2S
and lighter components from the hydrotreated naphtha by providing necessary heat of
vaporization. Reboiler vapor stream is admitted below the bottom tray i.e. 1st tray. Unstabilized
naphtha from stripper reflux pumps is introduced on the top tray i.e. 25th tray as cold reflux to
control stripper overhead temperature and to achieve product specifications. Two nos. of
pressure safety valves (PSV05A/B) are provided on the stripper to relieve the pressure build up
by loss of reflux due to partial power failure/cooling water failure. Preheated separator
hydrocarbon enters the stripper at 166 oC.
Stripper runs on total reflux. Stripper overhead vapors leaving the top of the stripper are cooled
in stripper overhead condenser (72-A-02) from 122 oC to 55 oC. Stripper overhead condenser
handles stream containing high H2S. Overhead product exiting overhead condenser is routed to

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Stripper overhead Receiver. Stripper overhead receiver (72-V-06) is a horizontal vessel

constructed of KCS. It has a water boot at the bottom. It has a slotted inlet distributor attached to
the inlet nozzle to facilitate water, hydrocarbon and sour gas separation. The hydrocarbon outlet
is at the opposite end of the vessel from the inlet distributor. Stripper receiver is provided with
1.5 nitrogen connection for pressurization during unit startup. Stripper receiver pressure is
controlled by PIC1801 which gets the signal from PT1801. Stripper receiver sour gases are
routed to SRU integration project.
A VHP steam reboiler (72-E-04) is provided to supply necessary reboiling heat to strip off H2S
and lighter hydrocarbons. The vapors generated in stripper reboiler are routed to stripper below
1st tray at a temperature of 210 0C. The stripper bottom are routed to naphtha splitter (72-C-02)
through stripper feed bottom exchanger (72-E-03 A/B)
N. CORROSION INHIBITOR PACKAGE

Low temperature corrosion problems in Hydrotreater fall in following two major categories:
Aqueous HCl or Ammonium chloride (NH4Cl) corrosion
Aqueous H2S or Ammonium Bisulfide (NH4HS) corrosion
In the stripper overhead these components combine and will condense as solid NH4Cl / NH4HS
on stripper condenser 72-A-02 tubes. However in presence of water vapor, NH4HS will cause
corrosion in condenser and the associated piping. This corrosion is highly localized in area of
high turbulence. Attack is often limited to the inlet ends of the tubes and localized attack on the
tube sheet. Chloride accelerates the corrosion rate tremendously. Filming amine type corrosion
inhibitors are excellent and have good light hydrocarbon solubility. UOP has recommended
dosing of UNICOR C at the rate of 7.87 L/hr on total overhead vapor. The very low nitrogen
content and high solubility in C4+ distillates permits easy application in hydrotreater stripper
overhead without fear of contamination to downstream products. It has minimal surfactant
properties, which eliminates foaming or potential emulsion. The low viscosity and pour point
permit easy application in low temperature climates.
Inhibitor injection package consists of two nos. of inhibitor injection pumps (72-P-12 A/B). They
are reciprocating pumps, which take suction from the inhibitor drum. Inhibitor is injected to the

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stripper overhead vapor line through a line which expands to 1 before connecting to stripper
overhead line.
O. NAPHTHA SPLITTER COLOUMN

Naphtha Splitter (72-C-02) is a vertical vessel having 50 nos. of valve trays. Feed is introduced
on the 24th tray via distributor. A reboiler is provided to split the naphtha to lighter and heavier
fraction by providing necessary heat of vaporization. Reboiler vapor stream is admitted below
the bottom tray i.e. 1st tray. Light naphtha from naphtha splitter overhead pumps is introduced on
the top tray i.e. 50th tray as cold reflux to control splitter overhead temperature. Splitter top
temperature is controlled by TIC1904 cascaded with FIC2101 sending light isomerate to
Isomerisation unit as feed. Three nos. of pressure safety valves (PSV06 A/B/C) are provided on
the splitter to relieve the pressure build up by loss of reflux due to partial power failure / cooling
water failure. The feed to splitter is fed at the temperature of 118 oC.
Splitter overhead vapors leaving the top of the naphtha splitter are cooled in naphtha splitter
overhead condenser (72-A-03) from 92 oC to 76 oC. Overhead product exiting overhead
condenser is routed to naphtha splitter receiver (72-V-07). It is a horizontal vessel constructed of
Carbon Steel. PDIC2202 is provided to maintain the pressure of naphtha splitter receiver. The
hydrocarbon outlet is at the opposite end of the vessel from the inlet distributor. Naphtha splitter
receiver is provided with 1.5 fuel gas connection for pressurization during unit startup.
A reboiler fired heater (72-F-02) is provided with heat duty of 17.16 MMkcal/hr to supply
necessary reboiling heat to split off lighter and heavier fraction. Naphtha splitter reboiler heater
has 10 burners with one radiation section and one convection section. Naphtha splitter bottom
pumps 72-P-07 A/B take suction from splitter bottoms. The discharge of 72-P-07 A/B is divided
into 6 passes which enter the reboiler heater through pass flow control valves FV2001
A/B/C/D/E/F first in convection section and then in radiation section. The vapors generated in
reboiler heater are routed to naphtha splitter below 1st tray. The vapor flow from stripper reboiler
heater outlet is controlled by PDIC2001.The differential pressure controller (PDIC2001) controls
the firing duty of the heater based on degree of vaporization at the outlet of heater. This is being
achieved by adjusting the fuel gas / fuel oil and combustion air flow rates to the reboiler

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cascaded through fuel gas flow controller. Stripper naphtha splitter bottom level is controlled
bottom level is controlled by LIC1901 cascaded with FIC1601 controlling flow to storage.
Naphtha splitter bottom is routed to CCR unit through stripper feed splitter bottom exchanger
tube side (72-E-02).
4.3 UTILITIES SPECIFICATION AND REQUIREMENT

Dedicated common utilities are provided which cater the needs of Unit 72and unit 74. Individual
branch lines, from the main header, lead to the corresponding equipment/utility stations of
Naphtha hydrotreater unit.
UTILITY SYSTEM
4.3.1. Sea cooling water system
Sea cooling water to Naphtha hydrotreater is supplied to NHT / CCR ISBL through 26 header.
A 24 cooling water supply header supplies cooling water in Unit 72 to exchangers (72-E-06
A/B/C/D), (72-E-05 A/B/C/D) and compressor (72-K-01 A/B).
4.3.2. Bearing cooling Water System

Bearing cooling water to Naphtha hydrotreater is supplied to NHT / CCR ISBL through 8
header. Bearing cooling water is supplied to all the pumps of NHT and compressor 72-K-01
A/B.
4.3.3. Service Water System

A 3 service water header in Naphtha hydrotreater supplies service water in Unit 72 to hose
stations. The header pressure and temperature are indicated by PI8305 and by PI8302 with low
pressure alarm on DCS at the battery limit. Temperature at battery limit is indicated by TI8303.

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4.3.4. Instrument Air System

A 6 header supplies instrument air to Naphtha hydrotreater. The pressure of the instrument air
header at the battery limit is indicated by PI8301 and by PI8302 with high & low pressure alarm
on DCS. A 1 instrument air line is going to recycle gas compressor.
4.3.5. Plant Air System

In naphtha hydrotreater, the plant air header is of 4 size. A 2 branch line supplies plant air to
all hose stations in naphtha hydrotreater. The pressure of Plant air header at the battery limit is
indicated by PI8303 and by PI8304 with high & low pressure alarm on DCS.
4.3.6. Fuel Gas System

A 4 header in naphtha hydrotreater supplies fuel gas in Unit 72. The pressure and temperature
of the header at the battery limit are indicated by PI8409 and TI8409 respectively. Fuel gas
consumption rate is indicated by FI8405. Line is steam traced in order to avoid condensation in
the line. Fuel gas is supplied to the following equipments:-
Feed Surge Drum (72-V-01)
Stripper Receiver (72-V-06)
Naphtha Splitter Receiver (72-V-07)
Charge heater via fuel gas knock out drum
Naphtha splitter reboiler heater through fuel gas knock out drum.
Flare header.
4.3.7. Fuel Oil System

A 4 header in naphtha hydrotreater supplies fuel oil in Unit 72 to charge heater 72-F-01 and
naphtha splitter reboiler heater 72-F-02. The pressure and temperature of the header at the
battery limit are indicated by PI8401 and TI8401 respectively. Fuel oil consumption rate is
indicated by FI8401. Line is steam traced in order to avoid condensation in the line.

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4.3.8. Nitrogen System

A 6 nitrogen header in naphtha hydrotreater supplies nitrogen in Unit 72 to:-
Feed Filter (72-X-01)
Recycle gas compressors (72-K-01 A/B)
Stripper Receiver (72-V-06)
To motors of recycle gas compressors as purge gas
The pressure of the header is indicated at battery limit by PI8602 with high & low pressure alarm
on DCS. The flow of nitrogen is indicated at battery limit by FI8601.
4.3.9. VHP Steam System

VHP steam desuperheated in platformer is supplied through 8 header to stripper reboiler. It is
used as reboiling media in the stripper reboiler 72-E-04 tube side. VHP condensate downstream
of the reboiler is routed to LP condensate flash vessel located in unit 74 to give LP steam and LP
condensate.
4.3.10. MP Steam System

MP steam to the Naphtha hydrotreating unit is supplied to charge heater 72-F-01 and naphtha
splitter reboiler heater 72-F-02 as atomization steam during firing with fuel oil. MP steam is also
provided to ejector 72-J-01 for making unit oxygen free at the time of start-up.
4.3.11. LP Steam System

A 14 LP steam header is provided in naphtha hydrotreater, which can either import or export LP
steam. LP steam header is supplying LP steam to Steam hose stations, snuffing steam rings and
also to vessels for steaming out. The pressure and temperature of the header at the battery limit
are indicated by PI8801 and TI8801 respectively. LP steam consumption rate or export rate and
quantity are indicated by FI8801.
4.3.12. DM Water System

DM water is supplied through 2 header to neutralization storage tank.

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SECTION-5
PRECOMMISSIONING
5.1 PRECOMMISSIONING
As the new unit nears completion, there is a large amount of preparatory work, which should be
performed by the operating crew. A planned check of the unit will not only set the foundation of
a smooth start-up, but will also provide a firm basis for acquainting operators with the
equipment. Start-up is a critical period and the operator must know exactly the operation of all
equipments.
Some of the pre-commissioning works can be carried out simultaneously along with
construction. But, care in the organization of this work is necessary so that it will not
interfere with construction work. It is most important to plan schedule and record with
checklists and test schedules all the preliminary operation and to co-ordinate the
construction program.
Once contractor completes work, sections of the unit should be checked out by both refinery and
UOP personnel in those areas. Immediately punch lists that indicate the deviations from the
design specifications, should be written following inspection of those areas, and distributed to
the contractor. In this manner mistakes in construction can be found and corrected early.
Inspection of the plant can be basically divided into the following areas:
Vessels
Piping
Heater
Exchanger
Pumps
Compressors
Instrumentation
Catalyst/Chemicals Inventory

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A discussion and lists of the major points that must be examined in the inspection of these areas
follows:
5.2 VESSELS INSPECTION

The actual installations must be compared against the drawings to assure that the vessels will
function as intended. The reactor internals must conform exactly to the design specifications if
good distribution is to be attained and catalyst migration is to be avoided. Particular attention
must be paid to the following details:
5.2.1. Specification Check

1. Review design specifications with the vendor drawings to verify agreement on:
Pressure, temperature, and vacuum ratings.
Shell metallurgy, thickness, and corrosion allowance.
Nozzle size and orientation; flange rating, type and finish.
Type of lining, thickness and material.
Stress relieving and/or heat treatment.
Foundation design for full water weight.
2. Confirm that the vessel has been hydrostatically tested.
3. Verify that all code plate information on the vessel is correct.
5.2.2. Internal Inspection

A. Reactors
Inlet distributors, quench distributors: metallurgy, type, size, opening sizes, freedom to
expand.
Vapor/liquid collection and distribution trays: tightness, vertical positioning, liquid
tightness of bubble caps and risers, metallurgy, dimensions, packing, supports, welding,
levelness, cleanliness.
Catalyst support grids: metallurgy, grid type and dimensions, screen type and size,
supports, welding.

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Catalyst unloading nozzles: metallurgy, orientation, length.

Thermowells: orientation, length, and metallurgy.
It must be verified that sufficient quantities of bolts, washers and hold downs of the
proper size and metallurgy are available to reassemble any disassembled portions of the
reactor internals.
B. Other Vessels
1. Vessel trays: spacing; levelness, orientation and dimensions of weirs, downcomers,
accumulators, drawoff and trap trays, seal pans, distributors, baffles, nozzles, tray contact
devices; metallurgy of trays, contact devices, clips, bolts, nuts and gaskets; freedom of
movement of valve caps or other contact devices; number, size, and distribution of tray
contact devices or perforated plate holes; proper fit of all internals and proper welding of
support rings or other support devices; liquid tightness of drawoff trays, seal pans and
accumulators, all bolting and clips tightened.
2. Mesh blankets and outlet screens: size, location, levelness, suitability of fit (no bypassing
allowed), metallurgy of blanket, support, tie wires, and grids.
3. Vortex breakers: type, size, and orientation.
4. Baffles: type, orientation, levelness.
5. Instrument nozzles: location, orientation, cleanliness, thermowell length and metallurgy,
baffle size and type.
6. Inlet distributors: type, size, orientation, levelness, freedom to expand.
7. Non-fired reboilers: location, orientation, proper supports.
8. Packing: type, size, support, installation.
9. Internal ladders and other devices: location, size, orientation, properly secured.
10. Lining and refractory:-
Hex-steel for concrete lining: clean and properly secured. Lumnite or other specified
cement applied according to the specifications, with no holes or gaps in the
applications.

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Metal linings in good condition. Weld overlays have no gaps or holes in the
application.
Lining is of the proper thickness and covers the required portion of the vessel.
Other refractory installed correctly with no gaps or holes in the application.
C. General
The vessel should be clean (free from trash) and should not have excessive mill scale.
5.2.3. External Inspection

1. Manways and nozzles: location, size, flange rating and finish, metallurgy, with proper
gaskets, nuts and bolts.
2. Ladders and platforms: correctly positioned, secure and free to expand.
3. Insulation and steam tracing: provided as specified and has expansion joints as required.
4. Vessel grounded correctly.
5. Correct vessel elevation.
6. Valves and instrumentation: easily accessible from grade or platform.
7. Piping:
Adequate supports and guides for all connecting lines.
Level and pressure instrument connections drain to a safe location.
Vents to atmosphere or blowdown provided as specified.
Relief valves have been bench tested.
Check valves exist on utility line connections where hydrocarbon backup could occur.
Connections available for steaming/purging of the vessel.
8. Fireproofing of structure and supports is complete.
9. Instrumentation:
Level glass floats center positioned correctly with respect to vessel tangent line, and
are readable from grade or platform.
Through-view level glasses have rear light for illumination.
Flange ratings, metallurgy, size, etc. are all correct.

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Reactor skin thermocouples are located properly and installed so that they have good
contact with the wall.
5.3 PIPING
The unit must be constructed in accordance with Piping and Instrumentation Diagrams (P&ID's),
including all details, elevations, dimensions, arrangements, and other notes on the P&ID's. One
must be able to startup, shutdown and conduct normal operations on the unit as envisioned in the
licensor design. Also, piping for special procedures such as dry-out, special materials
preparation, regeneration and/or alternative flow schemes may have been incorporated into the
unit's design, and the unit should be able to operate in all of these modes with piping as designed
and constructed.
If the unit is connected to other process facilities, adequate means must be provided to receive
feed from or send products to these facilities without contamination of these streams, and
minimize as much as possible the effects of upsets of other process units especially where
contamination of feed or product stream might occur. Check all tankage interconnections to
minimize the possibility of stream contamination outside of the battery limits.
Check that adequate means of measuring flows, pressures, and temperatures, and sampling of all
process streams has been provided.
The following items must be checked to ensure conformity to the design specifications:
1. Flanges: rating, facing, and metallurgy; type (typically, 2" and smaller are socket weld, 2"
and larger are weld neck flanges).
2. Gaskets: type; metallurgy (materials of retainer, jackets, winding, filler, etc.); thickness, ring
size, etc.
3. Fittings, connections and couplings: rating and metallurgy.
4. Valves: rating and metallurgy (body, trim, seats, etc.); packing; seat inserts; bonnet gaskets;
grease seals; socket-weld or flange type, rating and facing; installed in correct direction of
flow; lubricant provisions; gear operators; extended bonnets; stops; ease of operation.
5. Bolting: stud or machine bolts; bolt and nut metallurgy; bolt size.

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6. Pipe: metallurgy, thickness; seamed or seamless; lining.

7. Tubing: size and thickness; metallurgy; seamed or seamless.
8. Gauge glasses:
Through-view types should have rear-mounted lights.
Design pressure and temperature.
Special materials of construction.
Drains to safe location.
Visible from grade (or platform, if required).
9. Pressure relief valves:
Size and style.
Lever requirement.
Inlet/outlet flange material, facing and rating.
Set pressure - must be bench tested.
Metallurgy of nozzle, disc, spring, etc.
Type (pilot operated, balanced, etc.).
Inlet/outlet block valves car-sealed open; valve stems installed in horizontal or below.
10. General:
a. Utility systems within the battery limit should follow all relevant pipe class specifications in
the same detail required for process lines.
b. Package systems (modular units, etc.) shown on the P&ID should follow all relevant pipe
class specifications in the same detail required for other process lines.
c. Expansion: review the physical installation to ensure that no expansion problems will occur
when the unit gets hot and that:
Column overhead, reflux, feed and other lines are free to expand.
Rotating equipment will not be pulled out of alignment.
Sufficient expansion loops have been provided on long hot lines.
Pipe shoes are free to move in one direction, and are resting on supports of sufficient
size that the shoe will not fall off the support.
d. High point vents and low point drains should be installed where necessary.

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e. Spectacle blinds should be provided where required.

f. Car-sealed valves should be locked in proper position.
g. Spring hangers should have locking pins removed (after hydrotesting) and necessary
adjustments should be made for hot/cold position after startup.
5.4 FIRED HEATERS

The heaters must be inspected to ensure that they can be operated in a safe and efficient manner
and that the required heat duty needed for the process can be provided. After all, it is important
that the possibility of a tube rupture or other heater mishap be minimized. In particular the
following items must be checked:

All design specifications should be reviewed with vendor drawings to verify agreement on:
1. Conformity to process requirements.
2. Heater type.
3. Tube arrangement, metallurgy, size, and thickness (note that tube metallurgy may be
different for radiant, convection, and convection shield tubes).
4. Instrumentation connections.
5. Tube supports and support metallurgy.
6. Refractory.
7. Access doors, observations ports, steam smothering connections, and explosion doors.
8. Stack arrangement.
5.4.2. Internal Inspection

1. Radiant Section
a. Arrangement and symmetry of tube-coil with respect to heater wall, burner rings, and
tube spacing.
b. Vertical length of tube coil with respect to supports and guides.

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c. Fuel gas, fuel oil and pilot burner tips are clean and oriented properly. Burners are
properly mounted with clearance for firing and removal. Castable refractory has not
been used for burner blocks. Fuel oil tip sizing is adequate with respect to actual fuel
oil viscosity.
d. Tubeskin thermocouples, if required, are located properly and installed so that they
have good contact with the tubeskin.
e. Refractory is in good condition before and after refractory dry-out. No refractory is
resting on tubes.
f. Heater shell expansion joints are packed with designed insulation material and clean.
g. Adequate space for tube expansion.
h. Heater shell is sealed to prevent escape of hot gases and entrance of atmospheric
moisture during shutdown.
i. Smothering steam and instrumentation connections are not covered by refractory.
j. Heater is clean and free from debris.
k. Heater instrument connections are open - not filled or covered with refractory.
2. Convection Section and Stack

a. If extended surface elements are allowed, the bottom three or more rows of
convection tubes must be bare.
b. No refractory is on the tubes.
c. Expansion provisions are adequate.
d. Damper is free to move fully open and closed; its position indicator is correct both at
the stack and at the damper control; damper is weighted to fail open; the damper,
support pipe and bolting are all of the correct metallurgy.
e. Soot blowers, if specified, are provided with provision for inspecting the sootblowing
operation.
f. Other checks should be conducted as in the Radiant Section inspection.

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5.4.3. External Inspection

1. Location with respect to process equipment.
2. Platforms for access to all observation ports, instrumentation, sample connections,
sootblowers, and damper connections.
3. Adequate number and arrangement of observation ports to permit visual inspection of the
entire length of all wall, hip and shock/shield tubes, and the burner blocks.
4. Hand firing equipment located adjacent to an observation port from which that burner can be
viewed.
5. Explosion doors located such that heater gases will not flow towards process equipment and
platforms.
6. Explosion doors located such that doors can open completely.
7. Symmetry of external piping and crossovers.
8. Instrumentation and sampling connections.
9. Damper position indicator visible from damper control; damper control functioning properly.
10. Pocketed crossover connections have flanged drains.
11. Decoking connections as specified.
12. Sufficient smothering steam connections into heater firebox. Box valves on smothering steam
are located remote from the heater, with drain valves and/or steam traps upstream of final
block valve for condensate removal. Weep holes provided in smothering steam lines at low
points.
5.4.4. Fuel Systems

1. Fuel lines have battery limit block valves that are remote from the heater and easily
accessible. Fuel oil piping and its steam tracing are arranged such that no dead legs or
pockets are formed. Fuel lines to burners can be easily disconnected from burners for burner
removal. All fuel lines have been leak tested.
2. Fuel oil lines at burner valves are correctly piped with steam crossovers. All steam lines have
adequate traps and condensate drains.
3. Shutdown solenoids for fuel shutoff valves have been set properly.
4. Fuel oil circulating lines are provided.

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5.4.5. Heater Instrumentation

1. All draft gauge, pyrometer and analyzer connections are as specified.
2. All heater TRC's fail upscale during power failure or open circuit.
5.5 HEAT EXCHANGERS

The design specifications should be reviewed with the vendor drawings to check:
1. Metallurgy of shell, tubes, tubesheet, channel cover, baffle, header box, etc.
2. Tube size and thickness: number of shell and tube passes and direction of flowing streams;
max/min allowable velocities.
3. Design temperature, pressure and pressure-drop ratings.
4. Nozzle size, flange type, rating, facing and metallurgy; vent and drain connections.
5. Design differential pressure between shell and tube sides of the exchanger.
5.5.2. Field Inspection

In the field the following items should be checked:-
1. Name plate verifies specifications.
2. Flange size, rating, facing and gaskets.
3. Insulation for heat retention and personnel protection.
4. Exchanger properly grounded.
5. Tubular exchangers:
a. Elevation
b. Slot length of sliding plates adequate for expansion. Exchanger should not be tied
down at both ends. Check that sliding ends of multi-shell exchangers make sense with
regard to expansion of exchangers and connecting pipe.
c. Piping symmetry for parallel exchangers.
d. Non-condensable vents in steam service or in totally condensing systems.

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e. Water coolers; inlet at bottom of exchangers; inlet/outlet block valves with a thermal
relief valve inside the outlet block valve; vent and drain connections inside the block
valves.
f. Witness a shell/tube differential pressure test, if possible (especially important in
feed/effluent exchangers). When leak testing piping and equipment, ensure that the
design shell/tube differential pressure is not exceeded.
6. Air-cooled exchangers:
a. "Auto-variable" or "standard-pitch" fans, as specified.
b. Motor switches accessible from grade and located near the exchanger.
c. Fan pitch set correctly as determined by fan amperage draw.
d. Vibration switches on each fan.
e. Proper motor/fan rotation. Motors properly grounded.
f. Proper elevation and distances from connecting equipment.
g. Belt tension on motor drive pulleys is equal and correct.
h. Motor amperage can be easily checked.
i. Exchanger free to expand.
j. Manifold piping arrangements as shown on P&ID.
k. Split header design where specified.
l. Free draining requirements, as shown on P&ID.
m. Tube fin surfaces are in good condition with no construction debris on top of the fins.
7. Adequate space has been provided for pulling tube bundles.
5.6 PUMPS
A. Centrifugal Pumps
The design specifications should be reviewed against the pump curves and data given by the
vendor to confirm agreement on the following:
a. Head and capacity.
b. Pressure and temperature rating.

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c. Speed.
d. NPSH requirement.
e. Pump type, materials of construction, flange ratings, seals, bearings, number of
stages, lubrication and cooling systems, etc.
f. Type of driver.
g. Balancing lines for multistage pumps must have flanged joints (not unions).

The following items should be checked in the field:
a. Sight flow indicators, inlet/outlet shutoff valves on cooling water lines.
b. Thermometers/pressure gauges for gland seal and flushing oil manifolds.
c. Restriction orifices (if required) present in seal flush manifold piping.
d. Pedestals on pumps operating over 500F (260C) should be water cooled.
e. Cooling water to mechanical seals on pumps operating over 250F (121C).
f. Proper direction of rotation.
B. Reciprocating Pumps
The vendor information should be checked against the specifications to verify agreement on the
following:
1. Head and capacity (minimum, normal, maximum).
2. Materials of construction (body/glands, plungers, diaphragms, packing, internal check
valves).
3. Cooling/lubrication systems.
4. Pressure, temperature ratings.
5. Relief valve setting must be bench tested.
6. Pump speed and stroke.
7. Pulsation suppression devices, if required.
Means for calibrating the pump flow rate should be investigated.

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C. General
The following items should be checked for all pumps:
1. Piping to be arranged to permit removal or replacement of pump and driver.
2. Piping independently supported from pump; pump will not be pulled out of alignment when
lines get hot; no vapor pockets in piping.
3. Suction strainer easily removed for cleaning; strainers fit well so no bypassing can occur;
strainers have been installed.
4. Discharge pressure gauge readable from discharge block valve.
5. Suction/discharge valves easily accessible and operable, and near to the pump. Accessibility
of auxiliary piping and controls.
6. Check that NPSH requirements have been met.
7. Warm-up lines provided across discharge check valve when pumping hot fluids.
8. Base plate grouting complete.
9. Steam tracing and insulation provided on suction/discharge lines, pump casing, and process
seal flush lines, as required.
10. Minimum flow bypasses (with restriction orifice), if required.
11. All seal oil, warm-up, etc. lines have flanged connections and valves to permit removal of
pump.
12. Lubrication and cooling systems operate correctly.
13. Adequate means for venting and draining the pump casing are available.
14. Vacuum service pumps must have a discharge vent back to the system to allow filling the
pump with liquid.
15. Pumps and drivers are aligned correctly.
16. Check valves are of proper type and installed in the correct direction.
17. All drains from pumps and associated piping and instrumentation should be routed to a safe
location.

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5.7 COMPRESSORS
A. Centrifugal Compressors
The design specifications should be reviewed against the vendor information and drawings to
ensure agreement on the following:
a. Design capacity, temperature, pressure and specific gravity.
b. Compression ratio, number of stages.
c. Type of compressor, materials of construction, flange type, rating and facing.
d. Lube and seal oil systems, and estimated seal oil leakage.
e. Instrumentation, as supplied, must be in accordance with the design specifications.
f. Piping furnished with the compressor must conform to the same pipe class as
connecting lines.

The following items should be checked in the field.
a. Materials of construction; flange type, rating and facing; conformity of compressor
piping to applicable pipe specification.
b. Instrumentation for conformity to design specifications, location, operability and
access.
c. Lube/seal oil system; operability of all sight flow indicators, instrumentation, pumps
(including auto starts), filters, coolers, compressor trips, reservoir, seal oil pot, etc.
Check that addition and withdrawal of seal/lube oil to/from the reservoir can be
performed easily.
d. General cleanliness of all process and lube/seal oil systems, and of the general
compressor area.
e. Insulation as required for heat retention and personnel protection.
f. Check for access to sour oil and compressor casing drains, and that those drains are
routed to a safe location.
g. Proper supports on suction/discharge piping.

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B. Reciprocating Compressors
The vendor information and drawings should be compared with the UOP design specifications to
verify conformity on the following items:
a. Type of compressor, materials of construction, flange type, rating and facing.
b. Number of stages, compression ratio for each stage.
c. Design capacity, pressure, temperature and specific gravity for each cylinder.
d. Compressor speed; piston speed.
e. Lubricated or non-lubricated.
f. Single or double acting; balanced and opposed or dummy crosshead; fixed or variable
clearance pockets; auto or manual suction valve unloading.
g. Cooling to cylinder, packing, gearbox, lube oil.
h. Lube oil system operation.
i. Pulsation suppression devices; distance piece design; packing and distance piece vent
piping.

The following items should be checked in the field:
a. Materials of construction; flange type, rating, finish, gasketing.
b. Instrumentation for conformity to UOP design specifications, location, operability
and access.
c. Lube oil system/cooling water piping, including sight flow indicators.
d. Distance piece/packing vents piped correctly.
e. Adequate and accessible drains which are routed to a safe location.
f. Single strand steam tracing on the bottom of suction lines and snubbers, as specified;
insulation as specified for heat retention and personnel protection.
g. Automatic suction valve unloader operation.
h. Two compartment distance pieces, if required (greater than 30 mol percent hydrogen
in process gas).

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i. Acidizing requirements have been met and acidized piping is not in contact with the
atmosphere (under nitrogen blanket), includes both process and lube oil piping.
j. Provision for suction strainers, if required.
5.8 INSTRUMENTATION
All personnel on site should check to ensure that the instrumentation is provided as specified;
that it is functional; and that a minimum of instrumentation problems will occur when the unit is
commissioned. Some of the basic items which must be checked include the following:
1. Instrument type, range, and size.
2. Materials of construction and rating of instrument, accessories, and connecting
piping, flanges, and valves.
3. Accessibility of instrument for routine checks and maintenance; rigidly mounted.
4. Installation according to correct UOP drawing details.
5. Accessories (pulsation dampeners, filter/regulators, diaphragm seals, excess flow
checks, seal pots).
6. Location of local indicators so they are readable from grade platform or controller
assembly, as required.
7. Process requirements of flow, temperature, pressure, differential pressure, specific
gravity, etc.
8. Controller type, number of modes, chart type, range, cascades.
9. Power requirements of voltage, frequency; emergency power supply and connections.
10. Calibration of controllers, transmitters, analyzers, special instrumentation.
11. Control valve, block and bypass valve sizes for control valve assemblies.
5.9 CATALYST/CHEMICAL INVENTORY

A. Catalyst
1. It must be verified that sufficient quantities of catalyst, catalyst support material, and
other materials (such as ceramic fiber rope, etc.) are on site, are in good condition,

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and are properly stored (for example, in drums, indoors, and on pallets to prevent
contact with moisture).
2. It must be verified that all equipment required to load the catalyst is on site and in
good condition.
B. Chemicals
It must be verified that the proper type and quantity of chemicals (such as inhibitors, sulphiding
agent, soda ash, etc.) are on site and stored properly.
5.10 PRELIMINARY OPERATIONS

The preparation of the unit for startup must start as soon as construction of the various sections
of the unit is completed. Careful attention to detail will assure that a smooth startup can be
conducted and a safe operation is achieved. Pre-startup activities must be carefully planned and
should consist of the following items:
1. Vessel Inspection
2. Flow Check
3. Hydrostatic Pressure Test
4. Water Flushing and Pump Break-in
5. Utility Systems
6. Instruments
7. Acid Cleaning of Compressor Lines
8. Compressor Break-in
9. Dry-out
1. Vessel Inspection
Inspection of the vessels can be undertaken as soon as the UOP Chief Technical Advisor arrives
on site. Refer to the previous section on Pre-commissioning for a more detailed discussion on
vessel inspection.

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2. Flow Check
The actual arrangement of lines, vessels, pumps, etc., must conform to the UOP Piping and
Instrumentation (P&ID) drawing. As soon as construction is completed, and if possible even
before, the unit must be carefully checked against the P&ID and the appropriate UOP
specifications. This has been discussed in the previous section on Pre-commissioning.
3. Hydrostatic Pressure Test

A hydrostatic pressure test must be carried out in order to assure that the unit will be able to
withstand the normal operating pressures and temperatures. One exception to this rule is the
reactor, which can be excluded since it has already been shop tested. Special metallurgical
considerations must be taken into account whenever such a vessel is pressured at low
temperatures.
The unit can be divided into convenient sections for hydrotesting. In any given section, the
pressure test applied should be equal to the allowable test pressure of the lowest rate equipment
in the circuit.
The water used for the test must be at a temperature of at least 75F (25C), and when used in the
reactor circuit on austenitic stainless steel equipment, it must contain less than 50 wt-ppm
chlorides. Before any testing is done, all orifice plates must be removed from the lines, and relief
valves blinded off.
In the reactor section, special care must be exercised to avoid exceeding the design differential
pressure across the tube bundles. A temporary connection may have to be installed to assure that
both sides of the exchanger are pressured to the same level if the reactor is not included in the
test. Before the pressure test is concluded, the effluent exchangers must be tested at the design
differential pressure to assure that no cross leakage exists.
The test pressure must be held until it is assured that the unit is tight and all leaks have been
eliminated. In addition to process lines, utility lines (steam, air, etc.) should also be tested. It is
recommended that the pressure tests be carried out at the lower of the following two values:
1. 130 percent of the operating pressure of the lowest rated equipment in the circuit.

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2. 50 psi (3.5 kg/cm2) lower than the lowest shop test applied to any item on the circuit.
4. Water Flushing and Pump Break-In

The water left over from hydrostatic testing can be used to flush the lines and break in the
pumps. The reactor charge pump should not be run on water since it is a high head pump. Before
proceeding with water flushing, all orifice plates must be removed (if no already done so),
control valves rolled out to prevent the accumulation of dirt under the seats, and fine mesh
screens installed in all pump suctions. An effort should be made to run as many of the pumps and
use as many of the lines as possible to collect and remove all trash, solids, slag, etc. left over
from construction. Remember, when pumping water with centrifugal pumps intended for
hydrocarbon service, the suction valve must be fully open and the discharge throttled to avoid
overloading the motor. All pumps and drivers must be properly aligned by qualified personnel,
and the lubrication and cooling systems placed in service before any attempt is made to run
them. It is recommended that whenever possible the drivers be run prior to being coupled to the
pumps.
While running the pumps, the bearing should be checked often for signs of overheating and
vibration. An operator should be nearby to shut down a pump at the first indication of cavitation.
Suction strainers should be pulled and cleaned as often as needed until no more dirt accumulates
in them. In flushing through a reboiler be sure to do so one pass at a time to ascertain that the
tubes are clear. Do not flush into any exchanger until the lines leading to them have been flushed
clean.
The reactor section requires special attention since it will not be possible to use any pumps to
flush the combined feed exchanger, heaters, etc. The water left after hydrotesting can be drained
out under pressure, and this will remove most of the foreign material. High pressure steam can
also be used to blow through the lines. This procedure is especially recommended for the charge
heaters and effluent condensers to assure that all passes are clear. Advantage should also be
taken of the compressor run-in period when the air pumped by the compressors can be used
effectively to blow through the heater tubes and exchangers.

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5. Utility Systems
The various utility lines should be tested and placed into service as soon as the construction
schedule allows. Pressure tests should be carried out on the steam, condensate, air, fuel gas, fuel
oil, flare, and nitrogen lines. The steam lines should be warmed up gradually to prevent damage
by water hammer. At the same time, all steam traps and condensate lines should be placed into
service. Scale and construction debris can be conveniently removed from the steam lines by
blowing them as long as necessary with steam. The other utility lines can be cleaned by blowing
with steam or air, or by water flushing if possible. All utility lines, with the exception of fuel and
flare, can be put into service as soon as the construction schedule allows.
6. Instruments
All instruments should be checked as soon as possible so that any malfunctions or other faults
can be detected early. The instrument checkout should include the following items:
1. Pressure test of instrument air lines
2. Control valve action and calibration
3. Positioner calibration
4. Board calibration and loop check
5. Thermocouple calibration and identification
6. Level instrument calibration
7. Thermometers, pressure gauges, etc.
All orifice plate bores should be measured, recorded and compared with required sizes. The
orifice plates should also be checked to see if they were counter-bored wherever required. After
hydrotesting and water flushing have been completed, the orifice plates can be installed.
7. Acid Cleaning of Compressor Lines

Mill scale must be removed from the makeup compressor section by acid cleaning in order to
reduce the possibility of solids entering the compressors. The exact procedure to be followed
should be supplied by the contractor. The following items must be acid cleaned:
1. All makeup gas piping including spillback lines.

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2. Makeup compressor suction drum.

3. Makeup gas coolers and intercoolers.
8. Makeup and Recycle Compressor Break-In

The initial run-in of the makeup and recycle gas compressors should be carried out under the
supervision of the manufacturer's representatives. Before running any of the machines, the
operators should familiarize themselves with the pertinent operating instructions, including
lubrication, cooling and safety requirements.
Before running any of the makeup gas reciprocating compressors, the cooling and lubrication
systems must be placed in service. The drivers are run first separately, then coupled to the gear
boxes and compressors. The initial checkout of the compressors is done first with all valves out,
followed by unloaded and loaded operation on air. Before loading the compressor, be sure that
startup fine mesh suction filters have been installed and that all liquid has been drained from the
lines etc. (Do not use the makeup gas compressors to pump hydrogen unless the air is removed
from the entire reactor circuit by evacuation and purging with nitrogen.)
The run-in of the recycle gas compressor can be combined with the dry-out of the reactor circuit.
Consult with the manufacturer to determine the minimum compressor operating pressure.
9. Dryout
Excessive amounts of water must be driven out of the reactor circuit prior to catalyst loading.
Under most circumstances, free water can be adequately removed by allowing it to drain from
the lines, heaters, reactors, exchangers, etc. while blowing through the lines with air. However, it
might be convenient to perform the dry-out of the refractory in the charge heater with the run-in
of the recycle gas compressor. Evacuate the reactor section with the steam ejector.
1. Hold the vacuum for several hours and repair any leaks.
2. Break the vacuum with nitrogen to slight positive pressure.
3. Pull another vacuum and break it with nitrogen again to 75-100 psig (5.3-7 kg/cm2g),
or the lowest allowable for recycle compressor operation.

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4. Check the entire reactor section for leaks by taping all flanges and checking with a
soap solution through a pinhole in the tape.
5. Purge the recycle compressor with nitrogen and open the suction and discharge block
valves, taking suction from the cold separator.
6. Start the recycle gas compressor and gradually bring it up to full speed.
7. Steam out the recycle gas heater fire box and then remove the blinds from the fuel gas
line.
8. Light pilots in charge heater.
9. Light burners and fire the charge heater as required for refractory dryout. Circulate all
of the recycle gas through the charge heater. Start effluent condenser fans.
10. Drain water from the separator and all low point drains as it accumulates.
11. Raise the reactor inlet temperature to 700F (370C) as allowed by the heater dryout
procedure.
12. The reactor circuit will be considered dry when only a small amount of water collects
in the low point drains and separator.
13. Shut down the heater fires and cool the reactor to about 140F (60C) or less by
continuing gas circulation.
14. When the reactor is cool, shutdown and block in the recycle compressor.
15. Depressurize the system to the atmosphere. While depressurization, some of the gas
could be used to blow back through the reactor charge lines to remove any trapped
water.
16. Open the reactor for catalyst loading.

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SECTION 6
COMMISSIONING
The startup procedure must be reviewed / approved by the licensor before the start-up /
operation of the unit.
6.1 STARTUP PROCEDURE WITH FRESH CATALYST

The procedure has been prepared for a start-up with fresh catalyst. The purpose of this procedure
is to provide guidelines for the refiner when preparing specific procedures for an individual unit.
The promoter metals on hydrotreating catalysts are in the oxide state. This procedure includes
steps for sulphiding where the metal oxides react with H2S to form metal sulphides, which are
the most active form for hydrogenation, denitrification and desulfurization. The source of the
H2S is derived from native sulphur in the start-up feed or it can be from an easily decomposable
organic sulphur compound which is injected upstream of the catalyst beds.
The main objectives of the start-up procedure are:
To provide a safe and reliable way of getting the unit on stream.
To establish the maximum initial activity on the catalyst.
To establish the best flow patterns possible through the catalyst beds.
To protect the high pressure, high temperature equipment during the critical period of
initial pressuring and heating up.
A successful start-up of the hydrotreating unit requires that the unit be clean and the equipment
perform reliably. Pre-start-up activities usually include hydrostatic testing of pressure vessels and
piping, heater refractory dryout, inspection and testing of rotary equipment. The installation of
reactor internals should be carefully supervised and inspected to ensure proper assembly
according to the specifications. The pre-start-up activities and overall start-up critical path should
be carefully planned.
The start-up of the unit can be undertaken following the loading of catalyst or after catalyst
regeneration. All construction or maintenance work should be completed by this time. In general,
the start-up may be divided into the following phases:

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Pre-startup Checklist
Notification to other department.
Leak Test.
Catalyst drying and prewetting
Testing of emergency depressurizing system.
Catalyst sulphiding.
Establishing normal operation.
The start-up procedure outlined below assumes that all rotating equipment has been run in,
heater refractory and unit dry-out have been completed, and hydrogen is available.
6.2 PRESTARTUP CHECKLIST

Following checklist must be checked and recorded before the Start up.
1. The Blinds/ Specs position should be as per the Master blind list.
2. All the Relief Valves are checked, installed as per the PSVs list and taken in line.
3. All Sewers are in line.
4. Fuel Gas is commissioned.
5. Flare Headers are commissioned.
6. All the Instruments & Control systems are checked and kept ready.
7. All the Utilities are charged.
8. All the High point vents & Low point drains are closed as per high point vents and low
point drains list.
9. All the Control valves and bypasses are blocked in.
10. All pumps suction / discharge valves and maintenance spillback valves are closed.
11. Temporary 100 mesh strainers are provided in the suction of all the pumps.
12. Recycle Gas Compressor is blocked in.
13. Install temporary strainer at the suction of Recycle Gas Compressor.
14. All the flanges in Reactor section are taped & kept ready for Pressure testing.
15. Enough Quantity of Purge Nitrogen with O2 content less than 100 PPM is available.
16. Steam Ejector is kept ready for service.

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17. Make up Hydrogen is available for Start up.

18. Start up flushing oil is available.
19. Start up naphtha should be Straight Run Naphtha with properties
a. ASTM End Point: 205 C (max)
b. Total N2: 1 wt. PPM (max)
c. Total S: 100 wt ppm (max)
d. Bromine No. 1 (max)
20. Fire Water lines are charged and Fire Fighting Equipment kept ready.
21. Safety & Personnel Protective Equipment is kept ready.
22. Communication system i.e. Paging, Walkie-Talkie, CCTV etc are kept ready.
23. Ensure that Start up Audit and Safety Audit have been completed and audited points have
been liquidated.
24. Reactor internals are installed and inspected.
25. Reactor bed thermocouples and shell skin thermocouples are installed.
6.3 NOTIFICATION TO OTHER DEPARTMENTS

Before start up of Naphtha hydrotreater unit, interact with CPP & Utility for availability of
Power, steam, cooling water and other utilities. Ensure that start up naphtha is available at
battery limit and also confirm that product tank is ready to receive the product. Interact with
platformer unit for makeup hydrogen supply and ensure purity of Makeup Hydrogen. Inform
CDU & VB about the start up schedule so that necessary arrangements can be made at their end
for lining up hot feed once catalyst sulphiding is completed. Inform Sulphur about the start up
schedule so that necessary arrangements can be made at their end to receive sour water.
6.4 REACTOR LOOP

Line up reactor circuit as under:
I. Recycle gas Compressor Discharge 72-K-01 >> combined feed exchanger (72-E-01)
(shell) >> Charge Heater 72-F-01 (all Passes) >> Reactor 72-R-01 >> combined feed
exchanger (72-E-01) (tube) >> Product Condenser 72-A-01 >> Separator 72-V-04 >>

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Recycle compressor suction drum 72-V-05 >> Recycle gas Compressor Suction C01.
II. Carry out the leak test of the section by pressurizing the circuit and holding the pressure
for two hours.
III. Depressurize the circuit and prepare the circuit for evacuation.
IV. Deblind suction line to the ejector & line up the ejector for vacuum pulling. Keep
Recycle gas compressor isolated by closing both the isolation valves at suction /
discharge side and closing compressor bypass line. Isolate all instruments like PG/PT
before vacuum pulling. Line up MP steam to ejector and evacuate the section to (500-600
mm Hga).
V. Hold this vacuum for 30 mins. If rate of vacuum fall is more than 25-50 mm of Hg per
hour, break the vacuum by introducing nitrogen at Compressor discharge via line and
pressurize this section to 0.30 kg/cm2g. Identify the leakage and rectify. Repeat the
vacuum test until a good vacuum can be held.
VI. On completion of vacuum test purge the circuit by repeating this pressurization to 0.30
kg/cm2g and pulling vacuum until oxygen content, measured at Reactor downstream is
less than 0.5 mole %.
VII. Compressors are purged separately by pressurizing with nitrogen through nitrogen line in
the compressor suction via compressor discharge and finally depressurizing through
compressor bypass line back to atmospheric vents, located outside compressor shelter.
Repeat this pressurization & depressurization for at least three times to ensure oxygen
content from discharge side is less than 0.5 mole%. While vacuum pulling in the
reactor section being done ensure that compressor is not subjected to vacuum. After
purging, pressurize compressor with nitrogen.
VIII. After completion of purging, of the compressor & HP loop line up both the compressor &
start pressurizing with Hydrogen through the startup line at the compressor discharge.
IX. Start one of the compressors and establish hydrogen circulation across the reactor.
X. Pressurize the reactor to a pressure of 14 kg/cm2
XI. Once the hydrogen circulation is established, start lighting the pilots for charge heater

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6.5 STRIPPER, SPLITTER AND FEED PREHEATING SECTION

While purging of reactor section is carried out, steaming out of the Stripper, splitter & feed
section is to be done as per the following circuit.
Battery limit >> Feed Surge drum 72-V-01 >> Charge Pump 72-P-01 A/B >> Feed filter
72-X-01 >> Start up bypass control valve 72-FV-0702 >> Stripper Feed Naphtha Splitter
Bottom Exchanger Insulate 72-E-02 (shell) >> Stripper Feed Bottom Exchanger Insulate
72-E-03 A/B (shell) >> Stripper 72-C-01 >> Stripper Condenser 72-A-02 >> Stripper Receiver
72-V-06 >> Stripper Reflux Pumps 72-P-04 A/B >> Stripper Bottom >> Stripper Feed Bottom
Exchanger Insulate 72-E-03 A/B (tube) >> Splitter 72-C-02 >>Naphtha Splitter
Condenser 72-A-03 >> Naphtha Splitter Receiver 72-V-07 >>Naphtha Splitter Overhead Pump
72-P-06 A/B >> Naphtha Splitter Bottom Pumps 72-P-05 A/B >> Stripper Feed Naphtha Splitter
Bottom Exchanger Insulate 72-E-02 (tube) >> Naphtha Splitter Bottom Coolers 72-E-06
A/B/C/D >> Feed Surge drum 72-V-01
After steam out operation is complete (when oxygen content is less than 0.5 mole %), line up
nitrogen in order to avoid vacuum formation and subsequent air ingress. Ensure draining all the
condensate from all the points.
I. Before starting steam out ensure the following :
1. Battery limit de-blinding to be done as per list.
2. Fans of fin-fan coolers are stopped & push button switches are locked.
3. Crack open high point vents and low point drains on the vessels to be steam purged.
4. During the steam out of each operation, open vents on all dead legs in the system to purge
these lines free of air. Be sure to steam out feed and product lines all the way to the
battery limit.
5. Close all drain valves and vent connected to flare.
6. All Battery limit valves (Feed and Product) are closed. Feed filter banks are taken in line.
II. Provide LP steam connection to feed from tankage line & hot feed line ex Crude/ VB unit.

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III. Feed surge drum pressure control valve remains blocked in. Open charge pump suction and
discharge valve. Keep min. circulation control valves blocked in and its bypass isolation
valve closed. While providing steam out connection, utmost care should be taken to ensure
that steam / condensate does not enter the reactor circuit.
IV. Inhibitor dosing system is to be isolated by closing valve to the stripper overhead line.
Ensure steam out is done via PV 1801 upto battery limit block valve.
V. Steam out stripper bottom circuit till battery limit.
VI. Open steam to all steam out points mentioned above & stripper steam. Continue steam out
for 12 hours. Towards end of steam out start closing the open vents and line up fuel gas to
the Feed surge drum. After draining the condensate close the open drains and gradually
raise the pressure of the feed surge drum.
VII. Deblind nitrogen gas supply connection to stripper receiver. Pressurize stripper receiver to
by backing up nitrogen.
VIII. Receive SRN through battery limit line ex tank.
IX. Keep charge pump discharge isolation valves close & line up minimum circulation flow
control valves. Open pump suction isolation valve to fill the lines of this circuit, gradually
open the discharge isolation valve to fill the lines of this circuit. While filling the lines non-
condensable has to be vented through high points vents.
X. Start the feed charge pump. Take level in the stripper through reactor bypass line &
establish 60% level in stripper. Line up stripper bottom to Splitter & establish close
circulation through startup reactor bypass line by lining up back to feed surge drum through
different exchangers.
XI. Once the level in stripper and splitter has been established start the heat input to allow
sufficient heat reflux to remove essentially all water from the bottom products.
XII. Slowly heat up the column bottom at the rate of 20 oC /hr. When the temperature reaches
100 oC reduce the heat up rate to 10 oC /hr to allow any water in naphtha to expand slowly.
XIII. Change over the charge pump after 4 hrs. Clean the suction strainer. Make sure that all
bypass lines across control valves are flushed out with SRN.
XIV. Ensure that level and flow control instruments are taken into service.

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6.6 STARTUP NAPHTHA INTRODUCTION AND REACTOR PRESSURING

The promoter metals on fresh hydrotreating catalysts are in the oxidized state prior to sulphiding.
Care must be taken to make sure the catalyst does not become reduced before the sulphiding oil
is charged to the reactors. Reduction of the unsulfured catalyst occurs in a high hydrogen (and
low H2S) atmosphere at temperatures beginning around 205C. Reduction can cause loss of
catalyst activity for hydrotreating catalysts. Metal sulphides are the most active form for
hydrogenation, denitrification and desulfurization. These reactions consume hydrogen and
generate heat and water as by-products.
I. Pressure the unit with hydrogen to normal operating pressure at the product separator. Start
the product condenser fans and water trim cooler. Start the recycle gas compressor. Begin
circulating gas at maximum practical rate to the reactor inlet.
II. Begin firing the Combined Feed Heater according to practice and increase hydrotreating
reactor inlet temperature at no more than 15 C per hour to 150 C maximum.
III. With hydrotreating catalyst bed temperatures stabilized at 150C, begin sending SRN to the
hydrotreating reactor at a minimum 50% of design feed rate. Continue the bypass flow to
the Stripper section so the level in the Stripper bottom can be maintained. Carefully
monitor the operation of the recycle gas compressor and the reactor pressure drops as the
naphtha is first introduced. It is normal for a temperature rise to develop when naphtha is
first introduced through the catalyst beds due to the heat of adsorption. Watch all bed
temperatures in the hydrotreating reactor carefully. If the initial reactor temperatures rise is
very high, take the naphtha out and lower the reactor temperatures, while continuing to
circulate hydrogen.
IV. Establish a liquid level in the product separator and establish level control into the Stripper
section while discontinuing the SRN flow through to the Stripper section. Be sure that the
separator pressure control valve is in service and in the automatic position as liquid is
introduced to the system. Make the transition smoothly to avoid upsetting downstream
units. At this time begin sending the SRN to the reactor at about 50% of design feed rate.
V. The Splitter bottoms should be run to a slop system/tank for 4 hours in order to flush debris
from the unit.

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NOTE: At this time the internal circulation should be stopped. Depending on the heat exchange
provided, the stripper feed temperature may drop; adjust the steam flow to steam reboiler to
maintain steady tower operation.
VI. After the 4 hours of once through flushing, re-establish internal circulation from Splitter
bottoms back to the front end, and increase the feed rates through the reactor to the
maximum possible.
VII. Raise Stripper column reboiler temperature or adjust stripper feed preheat in order to
increase Stripper temperature to reject H2S during catalyst sulphiding. Stripper bottom
temperature should be increased to about 220 C before catalyst sulphiding.
VIII. Start naphtha splitter reboiler heater and establish the splitter column.
IX. Higher feed rates over the catalyst will shorten the time required to sulfide the catalyst.
Slowly begin to increase the reactor feed rate as much as possible.
X. As the reactor feed rate is increased, monitor the pressure drop across the reactor beds to
prevent reactor damage due to excessive pressure drop. At the same time increase the
amount of recycle gas in the system to maintain the design hydrogen to hydrocarbon ratio.
XI. Begin raising the hydrotreating reactor inlet temperature, by increasing firing at Combined
Feed Heater, to 230 C at about 30 C per hour maximum once the initial temperature wave
has passed through hydrotreating reactor and the SRN flow has been lined out.
XII. After the reactor inlet and outlet temperatures have been stabilized at 230 oC increase the
product separator pressure to the normal operating level or 28 kg/cm2 which ever is lower.
NOTE: When raising the reactor inlet temperature, monitor the reactor feed heater operation
closely to assure the design heater firebox and stack temperatures and design heater tubewall
temperatures are not exceeded.
6.7 CATALYST SULFIDING

The purpose of sulphiding is to convert the metal oxides on the hydrotreating catalysts to the
sulfide form. The naphtha used during the sulphiding step is same as the SRN, which is a straight
run, low nitrogen naphtha. The total amount of sulphur charged to catalyst should not exceed
0.25 wt % of naphtha charge at this point. To extend the sulphiding period for better control, the

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total amount of sulphur injected should be controlled at 0.08 0.10 wt % of naphtha charge,
depending on the catalyst metal loading. Before sulphiding begins, conditions in the fractionation
section should be established in order to assure the removal of H2S and light ends from the
reactor effluent. The stripper bottoms temperature should be raised by increasing the VHP steam
flow in the stripper reboiler. Increase stripper column reboiler temperature in order to reject H2S
during catalyst sulphiding. It will be necessary to rely on feed preheat to raise the stripper feed
temperature
Throughout the sulphiding procedure, maintain maximum recycle gas flow and normal operating
pressure with hydrogen. Note that the temperature controllers and transmitters may have to be
temporarily rearranged to control during the initial phases of the startup. Maintain the product
separator at normal operating pressure. Do not begin water injection to the reactor effluent until
after the sulphiding has been completed. The minimum time for this phase of the sulphiding will
be 1-2 hours. In practice, this is a reasonable minimum time required to sample feed, stripper
bottoms, and off gas streams while monitoring recycle gas H2S levels and sulfide chemical
injection rates, in order to perform a sulfur balance on the catalyst.
The objective is to conduct the sulphiding in a controlled, orderly fashion. If a lower sulfur
injection rate is required to accomplish this, the injection rate should be reduced accordingly.
Control the sulphiding within the following limits:
a. Do not exceed 450F (230C) maximum temperature in any catalyst bed.
b. Do not exceed 30F (17C) temperature rise across any catalyst bed.
Throughout this phase of the sulphiding, monitor the separator boot for water accumulation.
When water is detected, drain it from the separator water boot. Throughout the catalyst
sulphiding operation, the separator vent should be held at a minimum or zero to allow
establishing a high concentration of H2S in the recycle gas. After stable sulphiding condition is
established, then the hydrotreating catalyst bed peak temperature can be increased slowly at the
rate of 17 oC/hr up to 290 C. Continue sulphiding at these conditions until H2S in the recycle
gas stream increases abruptly to a higher concentration and stabilizes for a period of at least two
hours.

Doc No. Draft
NOTE: Do not proceed to the next step with higher sulphiding temperature level until the
calculated sulfur laid down on the catalyst system at this point is at least 75% of the catalyst
sulfur requirement.
Increase Charge Heater outlet temperature at 17 C per hour maximum and establish 290 C
peak temperature in hydrotreating catalyst bed. When hydrotreating catalyst bed peak
temperatures reach 290 C, begin a 4 hour hold. Adjust bed inlet temperature set points to
control peak catalyst bed temperature. Continue to analyze the recycle gas for H2S content and
product sulfur. Reduce Charge Heater firing to cool hydrotreating catalyst bed inlet temperature
to 230 C. Stop catalyst sulphiding and isolate the sulphiding facility.
6.8 ESTABLISH NORMAL FEED

Normal SRN feedstock can be brought into the unit after sulphiding is complete. Normal
operation can be established by raising the reactor temperatures to the level required to obtain the
desired product quality. The temperatures must be raised gradually over a period of time in order
to avoid over firing the heater and to allow time for adjusting the operation of compressor and
fractionation sections. It is preferred that design flow be maintained through the reactors to
assure good flow distribution. However, during the heating up period, the operation of the
reactor feed heater and the reactor pressure drop may limit the charge rate to lower values.
I. Adjust reactor inlet temperature to about 315 oC.
II. Upon introduction of SRN feed, reroute the splitter bottoms to slop or other storage tank.
III. Start the wash water injection system.
IV. Adjust the reactor effluent cooling to maintain the design temperature in the product
separator.
V. Continue to maintain system levels by the addition of feed to the front end.
VI. Add heat input to the splitter and stripper reboilers to meet product requirements.
VII. Establish level and pressure control in all towers and receivers.
VIII. Check recycle gas purity and rate and ensure operations are above minimum values. Bring
in make-up hydrogen as needed to maintain system pressure.

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IX. Allow the unit to line out for several hours. Sample all products and adjust reactor
temperature as needed to meet desired product quality. Make small adjustments in reactor
temperature and allow the unit to line out after each change. Operate the reactor at the
minimum required temperature necessary to achieve product specifications. Adjust profile
to operate at equal peak temperatures.
X. After stable reactor and fractionating conditions have been established, the fresh feed rate
can be increased to approach design. The reactor feed rate can thus be increased
simultaneously in small increments until the design feed rate is attained.
XI. Continue to monitor the feed heater to ensure that the design duty and maximum allowable
tube wall temperatures are not exceeded.
XII. Adjust the stripper section as needed to remove H2S from the bottoms product and establish
stable operation.
XIII. When cracked feedstock is introduced, the rate should be increased slowly.
6.9 STARTUP PROCEDURE FOR USED CATALYST

There may be occasions when feed is removed from the reactor and the catalyst is not
regenerated. Catalyst is considered to be used if it has been processing feed for more than 10 days.
A unit restart with "used" catalyst is simpler compared to startup with fresh or regenerated
catalyst. No sulphiding is required for a "used" catalyst startup.
A pressure testing and leak-checking program will be required during the restart even if no
flanges were opened during the shutdown period. Bolts can often loosen during cool down and
depressurizing during shutdown, or the subsequent reheating and re-pressuring during startup.
Hot bolting of flanges during restart may also be required.
I. Increase the reactor section to 14 kg/cm2 pressure with hydrogen and establish once
through or recycle gas flow at the maximum possible rate.
II. Maintain minimum hydrogen purity in the recycle gas of 70 mol percent.
III. Adjust reactor inlet temperature to 200C.

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IV. Establish a descending temperature profile in each reactor with the catalyst bed inlet
temperatures being controlled at about 3C below the inlet temperature of the preceding
bed.
V. Start SRN to the reactors at 50% of design feed rate.
VI. Monitor any temperature wave in the reactors caused by the heat of adsorption when oil is
first introduced. Exothermic hydrotreating reactions will also begin generating heat.
Maintain a descending temperature profile throughout the catalyst beds. Watch all
temperatures closely.
VII. Start wash water injection.
VIII. Establish VB naphtha feed flow to the reactor at 50% of design feed rate.
IX. After the adsorption heat waves have passed and a level appears in the product separator,
gradually increase the SRN and VB naphtha feed rates to design. At the same time,
increase the reactor temperature at a rate of about 30 C per hour to 315 oC.
X. Once the reactor temperature has reached 260 oC, increase the separator pressure to normal
operating level.
XI. Once the stripper & splitter operation is stable, sample all products and adjust reactor
temperature as needed to meet product specifications.
XII. Increase the feed flows to the desired rates while at the same time increasing the reactor
temperatures to maintain consistent product quality. If proper precautions were followed,
the catalyst activity should be nearly the same as before the shutdown. Adjust the inlet
temperatures to obtain roughly equal bed outlet temperatures.
XIII. Maintain the product separator pressure at the design level. As the hydrogen consumption
Increases, it may be necessary to adjust the loading on the makeup compressors or put
another compressor on line

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SECTION 7
NORMAL OPERATING PROCEDURES
7.1 INTRODUCTION
After the unit has been started up and lined out, the focus shifts to reaching and maintaining a
state of optimum operation. This state of optimum operation can be achieved by establishing a
few general operating rules and being aware of potential problems which can occur. First, a
means of judging performance must be defined.
Secondly, a list of operating variables is established. Using these operating variables, an
approach to operating the Isomar unit is outlined with respect to the performance indicators. This
procedure establishes a logical method for operating the plant, increasing yields and ensuring
longer catalyst cycles.
7.2 CONTROL PHILOSOPHY

The main operating parameters to control, in order to meet the required desulphurization /
denitrification rate, with an optimum catalyst life are:
The reactor inlet temperature
The hydrogen partial pressure
The space velocity
a. The reactor inlet temperature adjustment is performed in a conventional manner via a
temperature controller which resets the reactor heater fuel oil or fuel gas delivery pressure.
b. The hydrogen partial pressure at reactor outlet is a function of:
The total pressure (which is fixed at the design stage and is beyond the reach of
operators).
The hydrogen excess versus the chemical consumption which depends upon the
amount of hydrogen gas and the hydrogen purity (hydrogen purity is also beyond
operators reach)

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Hence, the hydrogen partial pressure is achieved:

By a flow control of the purge gas from the separator which enables operator to vary
the hydrogen excess. All other conditions being equal, an increase of the flow
controller set point means an increased hydrogen partial pressure.
By the recycle flow (if the unit is equipped with a recycle compressor) which is
generally maintained at the normal operating value (100% flow) for catalyst
preservation. But it can be reduced in proportion to the naphtha feed rate, if the latter
is noticeably reduced.
By feeding more or less make-up gas, to match the hydrogen consumption, through
the action of the separator pressure controller.
c. Space velocity
Space velocity coupled with reactor inlet temperature defines the severity of the hydrotreatment.
Severity is increased when either the space velocity is decreased or the temperature is increased.
Space velocity can be varied by changing the naphtha feed flow. Space velocity is reduced;
when the naphtha feed flow is reduced.
7.3 NORMAL OPERATING PARAMETER

DESCRIPTION TAG No. UNIT VALUE
Cold naphtha feed FIC-0601 m3/hr 199.0
Hot Feed FI-0602 m3/hr 199.0
FCC Heart Cut Naphtha FI-0603 m3/hr NNF
Feed surge drum 72-V-01 PIC-0601 Kg/cm2 2.0
Cold Feed to Surge Drum PI-0602 Kg/cm2 4.5
Hot Feed PI-0604 Kg/cm2 4.5
Feed surge drum 72-V-01 PI-0605 Kg/cm2 2.0
VBU Naphtha Feed PI-0606 Kg/cm2 4.5
o
Hot Feed TI0603 C 75.0
Charge pump discharge FIC-0701 m3/hr 214.6

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o
Charge pump suction TI-0701 C 75.0
Charge heater inlet PI-0801A Kg/cm2 30.0
Charge heater inlet PI-0801B Kg/cm2 30.0
Charge heater inlet PI-0803 Kg/cm2 30.0
2
Charge heater outlet to reactor PT-0802 Kg/cm 24.9
Charge heater outlet to reactor PT-0804 Kg/cm2 24.9
o
Charge heater outlet to reactor TI-0808 C 332.0
o
Charge heater outlet to reactor TIC-0809 C 332.0
Reactor inlet PI-0904 Kg/cm2 24.9
Reactor outlet PI-0905 Kg/cm2 24.4
o
Reactor outlet TI-0901 C 343.0
72-E-01 A-G shell inlet FIC-1003 Kg/hr 151835.0
FT-1002
Recycle gas to 72-E-01 m3/hr 1531.0
A/B/C
Recycle gas to 72-E-01 PI-1001 Kg/cm2 32.8
Recycle gas to 72-E-01 PI-1002 Kg/cm2 32.8
72-E-01 A-G shell inlet PI-1003 Kg/cm2 32.7
72-E-01 A-G tube outlet PI-1004 Kg/cm2 21.8
o
72-E-01 A-G shell outlet to heater TI-1001 C 287.0
o
Recycle gas to 72-E-01 TI-1002 C 107.0
o
72-E-01 A-G shell inlet TI-1003 C 79.0
o
72-E-01 A-G tube outlet TI-1004 C 128.0
Wash water injection pump discharge FIC-1101 m3/hr 6.0
Cold condensate PIC-1101 Kg/cm2 4.0
Wash water to product condenser FIC-1202 m3/hr 6.0
Make-up gas from platformer FI-1203 m3/hr 99.1
Make-up gas from platformer PI-1201 Kg/cm2 23.6

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o
Make-up gas from platformer TI-1201 C 40.0
o
Product condenser 72-A-01 outlet TI-1202 C 55.0
Separator overhead to stripper receiver offgas
FT-1302 m3/hr NNF
line
Sour water to sour water stripping unit FT-1304 Kg/hr 5898.0
Separator 72-V-04 PIC-1301 Kg/cm2 21.1
Sour water to sour water stripping unit PI-1303 Kg/cm2 5.11
Separator 72-V-04 PI-1304 Kg/cm2 21.1
Compressor 72-K-01A discharge PI-1502 Kg/cm2 32.8
Compressor 72-K-01B discharge PI-1504 Kg/cm2 32.8
o
Compressor 72-K-01A suction TI-1505 C 55.0
o
Compressor 72-K-01A discharge TI-1521 C 107.0
o
Compressor 72-K-01B suction TI-1506 C 55.0
o
Compressor 72-K-01B discharge TI-1522 C 107.0
Naphtha to storage (CCR feed tank) FIC-1601 m3/hr NNF
72-E-03 A/B tube outlet FI-1602 m3/hr 231.9
Naphtha to storage (CCR feed tank) PI-1601 Kg/cm2 9.6
Naphtha to platformer PI-1603 Kg/cm2 141.1
Sweet naphtha from storage PI-1604 Kg/cm2 4.5
72-E-03 A/B shell outlet PI-1606 Kg/cm2 12.3
72-E-03 A/B shell inlet PI-1607 Kg/cm2 13.1
2
72-E-03 A/B tube outlet PI-1609 Kg/cm 10.5
72-E-03 A/B tube inlet PI-1608 Kg/cm2 11.6
72-E-02 shell inlet PI-1610 Kg/cm2 14.0
72-E-02 tube inlet PI-1611 Kg/cm2 10.3
o
Naphtha to storage (CCR feed tank) TI-1601 C 40.0
o
72-E-02 shell outlet TI-1605 C 93.0

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o
72-E-03 A/B tube outlet TI-1606 C 132.0
o
72-E-02 shell inlet TI-1607 C 55.0
o
72-E-02 tube inlet TI-1608 C 146.0
o
72-E-03 A/B tube outlet TI-1609 C 132.0
Reboiler condensate stream FIC-1701 Kg/hr 21812.0
Naphtha stripper bottom PI-1701 Kg/cm2 11.6
Naphtha stripper overhead PI-1702 Kg/cm2 10.9
Stripper reboiler 72-E-04 shell outlet PI-1706 Kg/cm2 11.1
Stripper reboiler 72-E-04 shell inlet PI-1707 Kg/cm2 11.6
o
Stripper feed TI-1701 C 166.0
o
Stripper overhead TI-1702 C 122.0
o
Stripper bottom TI-1703 C 200.0
o
Stripper reboiler 72-E-04 shell outlet TI-1704 C 206.0
Stripper reflux pump 72-P-04 A/B discharge FI-1801 m3/hr 97.4
3
Stripper receiver overhead gases FI-1802 m /hr 168.2
Unstabilized net overhead liquid to CBD FI-1803 m3/hr NNF
Stripper receiver pressure PIC-1801 Kg/cm2 10.6
Stripper reflux pumps 72-P-04 A discharge PI-1804 Kg/cm2 14.5
Stripper reflux pumps 72-P-04 B discharge PI-1805 Kg/cm2 14.5
Stripper receiver pressure PI-1809 Kg/cm2 10.6
o
Stripper receiver inlet TI-1801 C 55.0
Naphtha splitter bottom pumps discharge FIC-1901 m3/hr 152.8
Naphtha splitter bottom PI-1901 Kg/cm2 1.6
72-P-05A discharge PI-1905 Kg/cm2 12.5
2
72-P-05B discharge PI-1906 Kg/cm 12.5
72-P-07 A discharge PI-1909 Kg/cm2 9.2
72-P-07 B discharge PI-1910 Kg/cm2 9.2

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Naphtha splitter bottom PI-1911 Kg/cm2 1.6
o
Naphtha splitter feed TI-1901 C 118.0
o
Naphtha Splitter overhead TI-1903 C 92.0
o
Naphtha splitter bottom TI-1905 C 146.0
3
72-F-02 inlet convection section FIC-2001A-F m /hr 655.2
72-F-02 inlet PI-2002A-F Kg/cm2 9.4
72-F-02 combined outlet for all passes PI-2005 Kg/cm2 1.7
o
72-F-02 combined outlet for all passes TI-2002 C 156.0
Feed to Isomerisation unit FIC-2101 m3/hr 71.2
72-P-06 A/B pump discharge to 72-C-02 FI-2102 m3/hr 240.1
72-P-06 A/B pump discharge to 72-C-02 FIC-2103 m3/hr 240.1
Light isomerate to storage FIC-2104 m3/hr NNF
Feed to Isomerisation unit PI-2101 Kg/cm2 6.1
Light isomerate to storage PI-2102 Kg/cm2 6.1
2
72-P-06 A/B suction PI-2103/04 Kg/cm 1.1
72-P-06 A/B suction PI-2105/06 Kg/cm2 8.4
72-E-05 A/B/C/D shell outlet PI-2107 Kg/cm2 6.1
o
72-E-05 A/B/C/D shell outlet TI-2101 C 40.0
o
72-E-05 A/B/C/D shell inlet TI-2104 C 76.0
Naphtha splitter overhead to condenser PIC-2201 Kg/cm2 1.1
Naphtha splitter receiver pressure PI-2204 Kg/cm2 0.7
o
Naphtha splitter condenser outlet TI-2202 C 76.0
7.4 SET VALUES OF ALARM

DESCRIPTION TAG No. VALUE
Feed surge drum interface LIC-0601 LAH-90%, LAL-10%
Feed surge drum LIC-0602 LAH-80%, LAL-20%

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Feed surge drum interface LI-0603 LAL-60%
Feed surge drum interface LI-0603 LALL-50%
Feed surge drum LI-0604 LAH-80%
Charge pump A suction strainer
PDI-0701 PDAH-0.1 Kg/cm2
differential pressure
Charge pump A suction strainer
Charge pump discharge FIC-0701 FAL-142 m3/hr
Feed filter differential pressure PDI-0703 PDAH-1.0 Kg/cm2
TXE-0801A
Charge heater tube skin Pass A TXAH-645 oC
0806A
TXE-0801B
Charge heater tube skin Pass B TXAH-645 oC
0806B
Charge heater Pass A outlet TI-0807A TAH-355 oC
Charge heater Pass B outlet TI-0807B TAH-355 oC
Reactor differential pressure PDI-0903 PDAH- 3.5 Kg/cm2
Reactor outlet TI-0901 TAH-353 oC
Fresh feed to combined feed
FI-1001 A/B/C FAL-78 m3/hr
exchanger
Fresh feed to combined feed
FI-1001 D FALL 65 m3/hr
exchanger low flow shutdown
Recycle gas to combined feed
FI-1002 A/B/C FAL20,000 Nm3/hr
exchanger
Recycle gas to combined feed
FI-1002 D FALL 15,000 Nm3/hr
exchanger low flow shutdown
Water break tank LIC-1101 LAH-80%, LAL-20%
Wash water injection pumps
FIC-1101 FAL-3.9 m3/hr
discharge

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Wash water to CFE FI-1201 FAL-3.2 m3/hr
Wash water to CFE FI-1201D FALL-2.4 m3/hr
Wash water to CFE FIC-1202 FAL-3.2 m3/hr
Separator interface LIC-1301 LAH-80%, LAL-20%
Separator LIC-1302 LAH-80%, LAL-20%
Separator interface LI-1303 LAL-60%
Separator interface LI-1303 LALL-50%
Separator LI-1304 A/B/C LAL-60%
Separator LI-1304 D LALL-50%
Recycle compressor suction drum LI-1401 A/B/C LAH-40%
Recycle compressor suction drum LI-1401 D LAHH-50%
Recycle compressor suction LIC-1402 LAH-90%, LAL-10%
RG compressor A discharge TI-1502A TAH-135 oC
Recycle compressor A suction
strainer differential pressure
RG compressor B discharge TI-1503A TAH-135 oC
Recycle compressor B suction
strainer differential pressure
Naphtha splitter bottom to storage TI-1601 TAH-45 oC
Stripper LI-1701 LAH-80%, LAL-20%
Stripper condenser outlet TI-1801 TAH-60 oC
Stripper receiver interface LIC-1801 LAH-90%, LAL-10%
Stripper receiver LI-1802 LAH-80%, LAL-20%
Stripper receiver interface LI-1803 LAL-60%
Stripper receiver low level
LI-1803D LALL-50%
shutdown
Naphtha splitter LIC-1901 LAH-80%, LAL-20%

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Naphtha splitter bottom pump
FIC-1901 FAL-64 m3/hr
discharge
Naphtha splitter reboiler heater pass
FIC-2001 A-F FAL-52 m3/hr
inlet
FI-2002 D FALL-39 m3/hr
inlet
TI-2001 A-F TAH-161 oC
outlet
Naphtha splitter reboiler outlet PDIC-2001 PDAL-20%
Naphtha splitter net overhead liquid
TI-2101 TAH-45 oC
to Isomerisation
Naphtha splitter receiver LIC-2201 LAH-80%, LAL-20%
Neutralisation storage tank LI-2301 LAH-80%, LAL-20%
Fuel gas KOD LI-22401 LAH-80%
Fuel gas basket strainer differential
pressure
Fuel gas to charge heater PIC-2506A PAH-1.7 Kg/cm2, PAL-0.2 Kg/cm2
Fuel oil to charge heater PI-2504 PALL-1.8 Kg/cm2
Fuel gas to charge heater PI-2507 PAL-0.1 Kg/cm2
Fuel gas to charge heater PI-2507 D PALL-0.07 Kg/cm2
Pilot gas to charge heater PI-2509 A/B/C PAL-0.6 Kg/cm2
Pilot gas to charge heater low
PI-2509 D PALL-0.5 Kg/cm2
pressure shutdown
Fuel oil to charge heater PDI-2505 PDAH-0.1 Kg/cm2
Fuel oil to charge heater PI-2504 PAL-2.0 Kg/cm2
Atomisation steam to charge heater PI-2501 PAL-4.5 Kg/cm2
Charge heater atomising stream / PDIC-2501 PDAL-1.0 Kg/cm2

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fuel oil differential pressure
Charge heater atomising stream / PDAH- 3.2 Kg/cm2, PDAL-1.0
PDI-2502
fuel oil differential pressure Kg/cm2
Charge heater atomising stream /
PDI-2502 PDALL-0.4 Kg/cm2
fuel oil differential pressure
Charge heater firebox PI-2510 PAH- 3mm H2O
Charge heater firebox TI-2501 TAH-853 oC
Naphtha splitter reboiler heater
atomising stream / fuel oil PDI-2602 PDALL-0.4 Kg/cm2
Fuel oil to naphtha splitter reboiler
PI-2604 PALL-1.8 Kg/cm2
heater
Fuel gas to naphtha splitter reboiler
PIC-2606A PAH-1.7 Kg/cm2, PAL-0.2 Kg/cm2
heater
PI-2607 PAL-0.1 Kg/cm2
heater
heater
Pilot gas to naphtha splitter reboiler
PI-2609 A/B/C PAL-0.6 Kg/cm2
heater
Pilot gas to naphtha splitter reboiler
heater low pressure shutdown
heater
PIC-2603A PAH-7.0 Kg/cm2 , PAL-2.4 Kg/cm2
heater
heater

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Atomisation steam to naphtha
splitter reboiler heater

atomising stream / fuel oil PDIC-2601 PDAL-1.0 Kg/cm2

PDAH-3.2 Kg/cm2, PDAL-1.0
atomising stream / fuel oil PDI-2602
Kg/cm2
PI-2610 PAH-3 mm H2O
firebox
TI-2603 TAH-743 oC
firebox
Combined flue gas to naphtha
TI-2601 TAH-745 oC
splitter reboiler convection section
7.5 LIST OF CONTROL VALVES

Sr. No. DESCRIPTION TAG
1 Fresh feed from storage 72-FV-0601
2 Feed surge drum split range control 72-PV-0601A/B
3 Feed surge drum boot water level control 72-LV-0601
4 Charge pump spillback 72-FV-0701
5 Startup bypass 72-FV-0702
6 Feed to CFE shutoff 72-UV-0701
7 Fresh feed to combined feed exchanger 72-FV-1003
8 Wash water injection pumps spillback 72-FV-1101
9 Condensate to water break tank 72-LV-1101
10 Condensate to condensate coolers 72-PV-1101

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11 Wash water to combined feed exchanger 72-FV-1202
12 Make up hydrogen from platformer 72-PV-1301
13 Regeneration waste gas to atmosphere 72-PV-1302
14 Plant air to recycle compressor suction drum 72-FV-1301
15 Separator boot water level control 72-LV-1301
16 Separator hydrocarbon level control 72-LV-1302
Separator hydrocarbon to stripper feed bottom
17 72-UV-1302
exchanger shutoff
18 Recycle compressor suction drum 72-LV-1402
19 Naphtha splitter bottom to storage 72-FV-1601
20 Condensate from stripper reboiler 72-FV-1701
21 VHP steam to stripper shutoff 72-UV-1701
22 Stripper receiver boot level control 72-LV-1801
23 Stripper reflux pump discharge 72-LV-1802
24 Stripper reflux pumps spillback 72-FV-1804
25 Stripper receiver pressure control 72-PV-1801
26 Naphtha splitter feed 72-LV-1701
27 Naphtha splitter bottom pump spillback 72-FV-1901
28 Naphtha splitter reboiler heater pass inlet 72-FV-2001 A-F
Naphtha splitter net overhead liquid to
29 72-FV-2101
isomerization unit
30 Naphtha splitter overhead pump discharge 72-FV-2103
31 Light naphtha to storage 72-FV-2104
32 Naphtha splitter overhead vapor 72-PV-2201
33 Naphtha splitter hot vapor bypass 72-PDV-2202
34 Steam condensate from fuel gas heater insulate 72-UV-2401
35 Steam condensate from fuel gas heater insulate 72-UV-2402

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36 Atomisation steam to charge heater 72-PDV-2501
37 Pilot gas to charge heater 72-PCV-2519
38 Fuel oil to charge heater 72-PV-2503
39 Fuel gas to charge heater 72-PV-2506
40 Charge heater fuel oil supply shutoff 72-UV-2501A
41 Charge heater fuel oil return shutoff 72-UV-2501B
42 Charge heater fuel oil supply shutoff secondary 72-UV-2502
43 Charge heater fuel gas supply shutoff 72-UV-2503
44 Charge heater fuel gas supply shutoff secondary 72-UV-2504
45 Charge heater pilot gas supply shutoff 72-UV-2505
46 Charge heater pilot gas supply shutoff secondary 72-UV-2506
47 Pilot gas to naphtha splitter reboiler heater 72-PCV-2608
Atomisation steam to naphtha splitter reboiler
48 72-PDV-2601
heater
49 Fuel oil to naphtha splitter reboiler heater 72-PV-2603
50 Fuel gas to naphtha splitter reboiler heater 72-PV-2606
Naphtha splitter reboiler heater fuel oil supply
51 72-UV-2601A
shutoff
Naphtha splitter reboiler heater fuel oil return
52 72-UV-2601B
shutoff
Naphtha splitter reboiler heater fuel oil supply
53 72-UV-2602
shutoff secondary
Naphtha splitter reboiler heater fuel gas supply
54 72-UV-2603
shutoff
Naphtha splitter reboiler heater fuel gas supply
55 72-UV-2604
shutoff secondary
Naphtha splitter reboiler heater pilot gas supply
56 72-UV-2605
shutoff

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Naphtha splitter reboiler heater pilot gas supply
57 72-UV-2606
shutoff secondary
7.6 LIST OF PSV

Sr. No. DESCRIPTION PSV No. P&ID No.
1 Sulphiding pump 72-P-09 PSV-074 120-05
2 Caustic injection pump 72-P-10 PSV-075 120-05
3 Feed surge drum 72-V-01 PSV-01 A/B 120-06
4 Feed filter 72-X-01 PSV-013 120-07
5 Charge pump seal balancing system PSV-20 A/B 120-07
6 Condensate coolers 72-E-07 A/B tube side PSV-049 / 050 120-11
7 Condensate coolers 72-E-07 A/B shell side PSV-053 / 054 120-11
8 Spent caustic pump 72-P13 PSV-018 120-12
9 Separator 72-V-04 PSV-02 A/B 120-13
10 Regeneration water return pump 72-P-11 PSV-019 120-14
11 RG compressor A discharge PSV-03 / 31 120-15
12 RG compressor B discharge PSV-04 / 32 120-15
Naphtha splitter reboiler coolers 72-E-06
13 PSV 09 / 010 120-16
A/B/C/D shell side
Naphtha splitter reboiler coolers 72-E-06
14 PSV-011 / 012 120-16
A/B/C/D tube side
15 Stripper 72-C-01 PSV-05 A/B 120-17
16 Naphtha splitter 72-C-02 PSV-06 A/B/C 120-19
Naphtha splitter overhead coolers 72-E-05
17 PSV-051 / 052 120-21
A/B/C/D tube side
18 Naphtha splitter receiver 72-V-07 PSV-07 120-22
19 Inhibitor injection pump 72-P-12 A/B PSV-072 / 073 120-23

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Sr. No. DESCRIPTION PSV No. P&ID No.

20 Fuel gas KOD 72-V-08 PSV-08 120-24
21 Fuel gas coalescer insulate 72-M-02 PSV-015 120-24
22 Charge pump fuel oil return header PSV-055 120-25
Naphtha splitter reboiler heater fuel oil
23 PSV-056 120-26
return header

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SECTION-8
NORMAL SHUTDOWN
The shutdown procedure must be reviewed / approved by the licensor before the start-up /
operation of the unit.
8.1 FEED REMOVAL FOR CATALYST TURNAROUND

The time it takes to shut down will depend on the experience of the operating personnel. Precise
control of reactor temperatures must be maintained throughout the shutdown.
I. Increase or maintain recycle gas flows hydrotreating reactors to 100% design.
II. First lower the reactor temperatures then lower the fresh feed rate gradually. When
bringing feed rate and temperature down in gradual increments, always decrease
temperature before decreasing feed rate.
III. The Charge Heater should be kept in service for as long as possible while the reactor
temperatures are being lowered, so the cool down rates will be controllable.
IV. As the feed rate is reduced and the reactor temperatures are lowered, the amount of heat
released and temperature rise in the catalyst beds will decrease.
V. Lower reactor inlet temperatures slowly, at a maximum of 15 C per hour. Lower the
reactor inlet temperatures to 316C.
VI. After the reactor inlet temperature has been reduced to 316 oC, the feed rate should be
gradually lowered to 50% before it is completely removed. While lowering the feed rate,
also lower the levels in the splitter and feed surge drum by further reducing fresh feed
entering the unit.
VII. Reduce the steam flow to the stripper reboiler and cool down naphtha splitter reboiler
heater and divert products to slop as they go off spec. Lower levels in all vessels. This will
minimize the amount of liquid to be drained or pumped out of the unit after it is shut down.
VIII. Immediately after the feed has been stopped, use recycle gas to sweep residual naphtha
from the catalyst beds, transfer lines and exchangers. Continue to circulate recycle gas for 1
hour at full pressure and temperature of 260 oC. Stop water injection to the product

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condenser at the start of cooling. Remove as much water as possible from the product
separator.
NOTE: Heat exchanger temperatures may be higher at this time than normal operations. Make
sure the exchanger design temperatures are not exceeded. In order to avoid the possibility of
nickel carbonyl formation, all gas streams containing carbon monoxide must be excluded from
the system when cooling below 260 C.
IX. Continue cooling the reactors with recycle gas to as low a temperature as is possible.
Cooling should be continued till the catalyst bed temperatures reach 65 C to allow time for
removal of heat from the reactor walls. Otherwise, after stopping the recycle compressor,
the catalyst beds will heat up again from the heat remaining in the reactor walls. If the
catalyst is to be skimmed or dumped unregenerated, reduce the reactor temperature to
38C.
X. Completely depressurize the unit to flare.
XI. Purge the reactor section with nitrogen until the system contains less than 1 mol percent
hydrogen plus hydrocarbons.
UNDER NO CIRCUMSTANCES SHOULD AIR BE PULLED THROUGH THE
CATALYST BED WHEN THE CATALYST BEDS ARE ABOVE 80 C. (This is to
prevent burning in the catalyst bed that could lead to high localized temperatures inside
the reactor and the formation of nickel carbonyl).
XII. The Splitter and Stabilizer columns should be cooled down by stopping reboiler heat input,
and should be left under positive fuel gas pressure. De-inventory Splitter and Stabilizer
columns if so desired. Divert products to slop as they go off-spec. Lower levels in all
vessels to minimize the amount of liquid to be drained or pumped out of the unit after it is
shut down. If entry into the columns is required, at a minimum, they must be drained,
steamed out, blinded off from other equipment, and air purged for safe entry.

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8.2 TEMPORARY SHUTDOWN

These procedures are intended for those cases in which the unit may have to be shutdown for a
short duration. The intent is to cool the catalyst beds safely below reaction temperature and leave
them wet with oil.
Follow the Shutdown for Catalyst Removal procedure, steps 1 through 3 above.
I. Continue circulation of feed and recycle gas to cool the catalyst bed at no more than
30C/hr in order to cool reactor inlet temperatures to 205 C.
II. Stop wash water injection to the reactor effluent when the reactor temperature drops below
260C.
III. After the reactor inlet temperature has been reduced to 205 C, the feed rate should be
gradually lowered to 50%. When all catalyst bed temperatures reach the desired
temperature, stop naphtha circulation and continue recycle gas circulation long enough to
sweep the bulk of the naphtha off of the catalyst and over to the separator. Then shut down
the recycle gas compressor.
IV. The surge drum may be placed on recirculation with the Stripper & Splitter may be placed
on total reflux for the duration of the shutdown
UNDER NO CIRCUMSTANCES SHOULD AIR BE PULLED THROUGH THE

CATALYST BED WHEN THE CATALYST BEDS ARE ABOVE 175F (80C) in order to
prevent burning in the catalyst bed and the possible formation of nickel carbonyl (for
catalyst containing nickel).
V. Maintain a positive nitrogen flow on both sides of any flanges that are to be opened for
blinding.
VI. During the entire shutdown period the charge heater firebox temperatures must be
maintained at 205C for the protection of the heater tubes or they must be neutralized as
discussed in the Special Procedures section.
VII. Any austenitic stainless steel equipment to be opened to the atmosphere should be
neutralized with a soda ash solution as described in the Special Procedures section.

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VIII. The Stripper and Splitter columns and feed surge drum must be drained and steamed out
prior to opening any of the equipment. It is also recommended that the towers and receivers
be washed thoroughly with water before admitting air to prevent the ignition of the iron
sulfide scale on the walls.
NOTE: Special care must be taken during shutdown and maintenance to avoid personnel
entering an atmosphere contaminated with hydrogen sulfide or blanketed with nitrogen. All
vessels that are opened must be thoroughly tested to insure the safety of entry.

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SECTION-9
TROUBLE SHOOTING
9.1 GENERAL
The main cause of concern for the operator of the hydrotreating unit is sulphur breakthrough into
the hydrotreated naphtha, contaminating platformer and isomerization unit feed. If an upset
occurs, the operator must be knowledgeable and experienced enough to take the proper
corrective actions immediately and to know if he should shut-off feed to the downstream units
before any catalytic activity loss occurs. It is advisable to even shutdown the downstream units.
The seriousness of the upset and the level of contaminant breakthrough will dictate the necessary
course of action to take.
This section offers some guidelines for troubleshooting various problems that may be
encountered over the course of normal operation of a hydrotreating unit. The information is
organized under the following general subject areas of the unit:
Reactor Temperature Increases
Reactor Pressure Drop
Reactor Catalyst Bed Maldistribution
Reactor Section Operation
Reactor Hydrogen Partial Pressure
Reactor Effluent Condensers
Product Separator Level Control
Corrosion Problems
Stabilizer Bottoms Product
9.2 REACTOR TEMPERATURE INCREASES
Symptom: On normal operation, the reactor top catalyst bed differential temperature
increases.
Possible Cause Remedies
A. Feed composition a. Check the operation of the upstream units.
changes from hot feed b. Check relative feed rates from upstream units to determine if

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sources causing a more cracked stock is being fed to the hydrotreating unit.
higher content of c. Reduce firing on lead reactor charge heater, if necessary, to
olefins and aromatics in control the top bed temperature rise.
the feed. d. Increase, if necessary, the reactor bed quenches to control the
catalyst bed temperature rise.
e. If catalyst bed temperatures can not be brought under
control, begin decreasing reactor temperatures and unit
charge after temperature adjustment.
f. If catalyst bed temperatures can not be brought under
control, and unit is equipped with depressurizing system,
activate the emergency depressurizing system.
B. Feed composition from a. Decrease the cold feed charge to the unit if possible.
cold feed source has b. Begin checking sources to cold feed tankage. Possibility that
changed. Unit is line up in tank farm area is allowing other material to be
receiving imported routed to unit cold feed tank.
stock. c. Check any piping that may be connected to unit feed supply
for correct isolation.
C. The reactor charge a. Check operation of reactor charge heater. Determine the
heater has become cause and correct, if possible, while maintaining the safe
unstable allowing a operation of the unit.
higher process outlet b. If heater operation can not be restored, to safely control the
temperature to the reactor inlet temperature, begin shutdown of the reactor
reactor inlet. charge heater.
c. Increase, if necessary, the reactor bed quenches to control the
catalyst bed temperature rise.
d. If catalyst bed temperatures can not be brought under
control, and unit is equipped with depressurizing system,
activate the emergency depressurizing system.

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D. Less heat removal is a. Check the operation of the recycle gas compressor.
available and residence b. Check the position of the recycle gas control valves.
time for feed in contact c. If the recycle gas control valves are equipped with solenoids,
with the catalyst has check their operation.
increased due to low
flow of recycle gas.
9.3 REACTOR PRESSURE DROP

Symptom: Reactor catalyst bed delta pressure begins to increase.
A. Scale is depositing on a. If feed to unit is filtered, check operation of feed filters.
the reactor catalyst bed. b. Check feed filter internals for damage.
c. Check size of filter internals. Should be capable of removing
50 micron particulates
B. Differential Pressure a. Check DP instrument for damage.
instrument is plugged
or damaged, giving
incorrect reading.
C. Feed filter bypass line a. Check block valves on filter bypass line, if applicable.
installed is passing, Repair and or replace at next unit shutdown.
causing unfiltered feed b. Chain lock closed the filter bypass line block valves, if
to be sent to reactors. necessary.
D. Cold feed from storage a. May be necessary to install filter on cold feed stream.
is not filtered, b. If possible route cold feed through existing feed filters if
particulate is depositing equipped.
on catalyst c. At convenient time remove cold feed tank from service for
cleaning.
d. Decrease cold feed supply to unit if possible.

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e. Stop cold feed to unit, if necessary, before pressure drop
becomes excessive.
E. Unit is feeding a. Imported feedstocks contacting air can form gums from the
imported feedstock that oxidation of olefinic hydrocarbons. Check feed source for
has not been re- contamination.
processed through b. Check imported feedstock storage for correct blanketing.
crude unit. c. Check imported feed stock transport tankers, trucks, for
contamination.
d. Reduce imported feedstock to unit and process at a slower
rate.
e. Re-process imported feed stock in crude unit.
Symptom: Unit experience temperature excursion, which increase pressure drop in

reactors.
A. High catalyst temperatures a. Unit should be shutdown and the catalyst dumped and
have caused coke to be formed screened and or regenerated, depending on the extent
in the reactor catalyst bed. of the excursion and pressure drop.
b. Depending on pressure drop, decrease unit
throughput to reduce pressure drop in system.
9.4 REACTOR BED MALDISTRIBUTION

Symptom: Catalyst bed radial temperature profile indicating flow channeling.
A. Catalyst bed was not properly a. At next unit turnaround dump catalyst and re-load
loaded, causing distribution using proper loading techniques.
flow problems. b. If severe maldistribution is occurring and catalyst
radial temperature spread can not be safely

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controlled, the unit should be shutdown and the
catalyst dumped, screened, and regenerated.
c. Properly load the catalyst at the next convenient unit
turnaround.
9.5 REACTOR SECTION OPERATION

Symptom: Product Separator pressure begins to decrease.
A. Feed composition change is a. Monitor incoming feed for composition changes

causing increased hydrogen b. Check upstream units supplying feed to unit for
consumption. operational changes.
c. Reduce reactor severity to regain control of unit
pressure.
d. Adjust reactor temperatures for feed composition
change and available hydrogen supply.
B. The hydrogen make-up a. If available, place spare compressor in service.

compressor has shutdown b. With spare compressor on line adjust unit operating
causing no flow to be sent to conditions for one compressor operation if possible.
the reactor section. c. If unit is not equipped with spare makeup compressor
or if spare is not available, begin unit shutdown.
d. Check the operation of the compressor cylinder
loading and unloading system.
e. Check the discharge temperature of the compressor.
Increasing temperature may indicate a compressor
valve that is not working.
C. Hydrogen makeup compressor a. Check spillback control valves for correct operation.
spillback system has b. Check Product Separator pressure control system

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malfunctioned. instrumentation.
D. Hydrogen makeup compressor a. Check the PSV's on each compressor suction drum, if
suction drums pressure safety passing.
valves passing. b. Check the PSV pressure setting in relation to the
actual operating pressure of the suction drums.
E. Hydrogen supply from a. Check and correct, if possible, the upstream supply
upstream hydrogen plant has problem.
decreased. b. If Hydrogen Plant is equipped with PSA unit, check
operation of PSA absorption cycles.
c. Check the Hydrogen Plant tail end pressure control
system.
d. Check the hydrogen supply pressure from the
Hydrogen Plant. Adjust if, possible, to correct
delivery pressure.
F. Product Separator control a. Check the HIC control valve to flare, if equipped.
valves to flare passing, or b. Check the pressure safety valves on the HPS for
leaking pressure relief valves. leakage.
Symptom: Product separator pressure decreases as catalyst temperatures increase.

A. Reactor charge heater is not a. Check the operation of the charge heater.
controlling the heater outlet b. Check the fuel control system for proper operation.
temperature, causing higher c. Reduce the reactor charge heater outlet temperature
catalyst bed temperatures and to reduce the catalyst bed temperatures.
increased hydrogen d. Ensure that the reactor hydrogen quench facilities are
consumption. controlling the catalyst bed temperatures.
e. If reactor charge heater cannot be controlled, shut

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down the heater and begin unit shutdown.
Symptom: Product Separator pressure begins to increase.

A. Hydrogen makeup compressor a. Check the operation of the hydrogen makeup
control system not controlling compressor's spillback control system.
the separator pressure. b. Check the product separator pressure control system.
9.6 REACTOR HYDROGEN PARTIAL PRESSURE

Symptom: H2 partial pressure is decreasing due to increasing Product Separator
temperature.
A. Product separator temperature a. Check the operation of the product condenser.
is too high, due to problem in b. Are any fans shut down, restart as necessary.
the product condenser, causing c. Are all fans operating at best efficiency
higher light hydrocarbons d. If belt driven fin fans, do the belts need changing or
content in the recycle gas adjusting to give optimum driver performance.
stream
B. Product separator temperature a. Check water wash injection for correct injection rate.
is too high because product b. Check wash water quality. Be sure wash water is
condenser efficiency is within contaminant specifications.
decreasing, due to fouling.

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9.7 PRODUCT CONDENSERS

Symptom: The product condenser outlet temperature begins to increase.
A. Wash water injection is too a. Check wash water injection pumps for mechanical
low to remove ammonium problems. Repair as necessary.
bisulfide being deposited in the b. Check pumps pressure safety valve for correct lifting
condenser tubes. Heat transfer pressure setting.
in the condenser has decreased c. Be sure wash water rate is as designed or above.
d. Monitor product condenser bundle outlet
temperatures after washing.
B. Wash water injection point is a. Check the installation of the wash water injection
not installed properly. quill.
b. Is wash water quill sized properly. Slot size should
provide water velocity of 3-5 ft/sec.
c. Is wash water quill installed in the direction of flow.
d. Is the wash water quill installed in a vertical run of
piping, upstream of the product condenser to give
sufficient mixing?
C. Wash water pumps not a. Check and calculate the pump capacity, Pump may
pumping required flow and be operating at upper limit.
discharge pressure. b. Check the reactor section pressure. May be higher
than indicating, causing pump to operate above
design conditions.
D. Makeup gas supply is from off a. If Platformer is equipped with chloride guard bed,
gas of Platformer, containing check outlet of guard bed for chloride breakthrough.
chloride, resulting in NH4Cl b. Inject wash water at inlet of last reactor effluent
formation upstream of wash exchanger temporarily to remove NH4Cl deposit.
water injection point. c. Install alumina treaters, if necessary, to remove
chlorides from makeup gas.

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Symptom: Product condenser outlet temperature has increased.

A. Outlet temperature is a. Check the fin fan blades for damage, replace as
controlled by fin fans which necessary.
are having mechanical b. Check the fin fan blades for correct blade pitch.
problems. Adjust pitch for maximum cooling within limitations
of fan driver.
c. If fans are equipped with variable pitch controllers,
check mechanical integrity of the variable pitch hub.
d. If fans are belt driven, check fan belt tension for
damage. Replace as necessary.
B. Atmospheric conditions are a. At next unit turnaround, hydro-blast condenser tube
causing sand, dirt to deposit on fins externally.
condenser external tube fins,
decreasing cooling efficiency.
9.8 PRODUCT SEPARATOR LEVEL CONTROL

Symptom: Failure of the Product Separator Hydrocarbon Level control valve.
A. Possible wrong type of valve a. Install valves with internals of 316SS.
metallurgy and/or the wrong
type of valve.
B. The amount of solids coming a. Try to correct the upstream feed supply unit
into the Product Separator operation. If feeding from Coker, verify feed source
could be causing erosion and quality for coke dust and fines.
plugging.

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C. Higher feed rate above design a. If the unit operation dictates continued operation at
causing increased velocity higher rates, possibility that the Product Separator
through control valve. control valve will need to be changed to
accommodate the increased rate.
Symptom: Failure of the Product Separator sour water level control valve.
A. Possibly wrong type of valve a. Change valve internals metallurgy to 316SS.
metallurgy or wrong type of
valve.
9.9 NAPHTHA SPLITTER BOTTOM PRODUCT

Symptom: Stabilizer Bottoms product color is going off-spec
A. Change in feedstock quality a. Check for change in crude source since color can be
crude source dependent.
B. Increased amount of VB a. Reduce VB naphtha component of feed, if necessary.
naphtha in feed blend. Cracked
stock tends to have more
nitrogen compounds that have
been linked to color stability.
C. Feedstock endpoint has a. Check upstream unit operations and lower the
increased. hydrotreating unit feed endpoint, if necessary.
D. Leak in stripper feed naphtha I. Check naphtha splitter product streams for unusually
splitter bottom exchangers that high sulfur or nitrogen levels.
may allow contamination of
product with color-producing
contaminants.

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Symptom: Naphtha splitter bottom product is off-spec on sulfur or nitrogen content.

A. Error in the sampling a. Check that the sample bottle or container has been
technique has resulted in false properly cleaned.
analysis of the naphtha b. Observe the laboratory testing method and confirm
product. that the method is current and correct.
c. Observe that the sample is being taken at the correct
sampling point.
d. If operations personnel are taking the sample, provide
adequate training in the sample analysis technique.
B. Leak in stripper feed naphtha a. Introduce a chemical species into the feed which may
splitter bottom exchangers that be traced in order to determine if there is a leak.
may allow contamination of
product.
C. Change in Feedstock a. Check that the new feedstock does not have above
design values of nitrogen or sulfur.
b. Increase the reactor inlet temperatures as necessary to
remove all of the sulfur and nitrogen (if there is room
to do so within temperature limitations of
equipment).
c. If the above is not successful, reduce feed rates of
feed stream with higher nitrogen and/or sulfur levels
until blended stream falls within design values.
d. Consider revamping the unit if feedstock change will
be permanent.

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SECTION-10
SPECIAL PROCEDURES
This section contains information on various special procedures that may be required in the
operation or maintenance of a hydrotreating unit. This information is organized under the
following subjects:
10.1 PRESSURE TESTING AND LEAK CHECKING GUIDELINES

Pressure testing, leak checking and leak repairing prior to commissioning are an essential part of
any refinery unit start-up. The high pressure hydrogen environment found in hydroprocessing
units requires a thorough, well executed pressure testing plan. Failure to properly detect even
small leaks at low pressure levels can lead to catastrophic problems when pressures are
increased. It is important that all personnel involved in unit pressure testing and leak detection
understand the serious nature of the work and its importance to a safe and timely unit start-up.
Sufficient time should be allowed to conduct leak testing in a methodical, stepwise manner.
Pressure testing and leak checking of the unit should be an on-going process throughout the start-
up. Multiple tests will need to be conducted when pressures are raised, when unit environment is
changed from nitrogen to hydrogen, and when equipment temperatures are raised. It is important
to remember that molecular differences between hydrogen and nitrogen mean that hydrogen is
much more likely to discover any path for system leaks. Because of the hazardous nature of
leaking hydrogen, it is important that extra care be taken when switching from a nitrogen
environment to a hydrogen environment.
An overview of the pressure testing and leak checking procedures is outlined below. It should be
noted that the procedures actually used are the refiners responsibility. The overview below is
offered as a general guideline only, to aid in developing a more detailed plan. It should also be
noted that the pressure testing and leak testing efforts outlined below may be incorporated at
different stages of the start-up depending on whether a Depressurizing Test is performed or not.
Performing a vacuum test during air-freeing of the reactor section is the first indication as to how
well the unit will subsequently hold pressure. Obvious leaks can often be detected and fixed at

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this time. After completion of unit air-freeing, a low pressure leak test should be performed using
nitrogen. As mentioned in the Pre-startup Checklist, all flanges in the high pressure section
(reactor and make-up gas sections) should have been taped. This allows for easy flange checking
with the use of soapy water solution. In addition to all flanges, all instrumentation fittings and
valve packing need to be thoroughly checked.
Upon completion of a successful pressure test at low pressure with nitrogen, the system pressure
should be raised using nitrogen. A second pressure test and leak testing effort should be
conducted at typical nitrogen supply header pressure.
The next step would typically be to start using hydrogen from the makeup gas compressors to
boost system pressure. Reactor pressure should be increased in increments with sufficient hold
time at each pressure level to allow a detailed leak check on all flanges, fittings and valves to be
performed. Suggested pressure increments are between 200-400 psi (15-25 kg/cm2). The
pressure can be held at each level by placing the make-up compressor into full spillback mode.
Further into the startup, reactor temperatures will be increased as part of the Catalyst Activation
and Establish Normal Feed procedures. At this time hot bolting may be required. Further leak
testing of flanges should be included as part of this work. Several methods can be utilized to
check for leaks. Any of these can be effective, if used properly.
As described above, a soapy water solution can be applied to taped flanges. This is the most
common method used by refiners. However, it will not be effective if the tape will not adhere
to the flange. Tape may not adhere to hot flanges or to flanges in some environments such as
high humidity conditions.
An ultrasonic listening device can be employed. This can be useful for identifying most
leaks. However, it might not be applicable for steam leaks due to low sensitivity.
A hydrogen analyzer or combustibles meter can be used to test all flanges. Using this in
conjunction with taped flanges can increase the ability to detect leaks. This method will not
work if combustibles are not in the unit. For example, during initial pressurization with
nitrogen, a hydrogen analyzer or combustibles meter will not detect a leak. If a leak is
detected, reduce pressure until the leaking stops and then tighten the flange.
a. Non-sparking tools should be used to prevent the possible ignition of hydrogen.

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b. A steam hose should be ready and available near the flange to smother any potential fire
that might occur.
c. If a major leak is detected, it will be necessary to completely depressurize the system,
isolate the leaking flange and purge the piping with nitrogen to remove any hydrogen.
d. After a section of piping is hydrogen-free (as shown on combustibles meter), open the
flange and replace the gasket.
e. Re-purge section with nitrogen after performing work and ensure that the affected section
is oxygen-free (<0.5 mol %).
10.2 TESTING THE EMERGENCY DEPRESSURING SYSTEM

Some units are designed with one or more restriction orifices in the emergency depressurizing
line to control the rate of depressurizing. For the initial startup of a new unit, it is necessary to
check that the restriction orifice(s) in the emergency depressurizing line have been properly
sized. The procedures below describe how to conduct the required testing. For subsequent
startups following turnarounds, it is only necessary to check that the depressurizing system is
functioning properly; actual depressurizing tests are not required unless revamp work has
significantly affected the system volume.
The initial tests will determine the depressurizing rates at the test conditions. From these tests,
the depressurizing rate under normal operating conditions can be calculated. The tests will ensure
that the restriction orifice has been properly sized and that there are no unusual restrictions in the
lines. It is important that the corrected depressurizing rate for normal operating conditions match
the design rate. Too high a depressurizing rate during normal operation could lead to excessive
forces being exerted on the reactor internals. Too low a depressurizing rate could limit the ability
of the unit operator to bring any unit upset safely under control.
The depressurizing tests can be done with either nitrogen or hydrogen. If nitrogen is used, the
flare may be extinguished. This may make using nitrogen impractical if other operating units are
using the same flare. Testing with hydrogen will provide an atmosphere closer to the normal
operation and will thus reduce the corrections needed to get the correct depressurizing rates.

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10.3 EMERGENCY DEPRESSURIZING TEST

The reactor section should be pressured with nitrogen or makeup gas so that the product
separator is at or near the maximum pressure (~30% of normal operating pressure) allowed for
vessels below the MPT. System temperatures should be steady. The recycle gas compressor
should be in operation.
Sample gas off the product separator and determine its composition. Record average
temperatures of all equipment in the high pressure system
Open the emergency depressurizing valve fully open. Record pressures at 15-second intervals
at three locations preferably at the product separator and at the reactor inlets. Compare
control board readings with those obtained from field mounted pressure gauges.
After testing the system for 6 minutes, the depressurizing can be stopped. Again, record
temperatures of all equipment in the high pressure system. Sample gas off the product
separator if the composition has possibly changed.
Check if all shutdown interlocks responded properly. Reset them as required.
Re-pressurize the system and prepare for the next step.
10.4 CALCULATION OF DEPRESSURIZING RATES

A plot of the natural logarithm of the system pressure (psia or kg/cm2 abs) versus time (minutes)
will be very close to a straight line. The equation for the pressure decay is:
P = P0 emt
where:
P = pressure at any time
Po = pressure at time zero
m = constant = slope of natural logarithm P versus time
t = time
Determine the slope of this line by graphical means or by linear regression of the pressure and
time data. For any two points, 1 and 2, on the plotted line, the slope is:

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(ln P2 - ln P1)
m=
(t2 - t1)
The target depressurizing rate is the rate that will decrease the pressure to 20% of normal
operating pressure in 15 minutes. Use the following equation to determine that drop in pressure:
dp
= Po (1 - em)
min
where:
dP/min = decrease in pressure in first minute
Correct the test depressurizing rate to middle-of-run (MOR) operating conditions and gas
properties:
V ZTsMN
0.5

ZT k
dp dp

Test

Test
=
minMOR minTest V ZTsMN

ZT MOR k MOR
where:
(k + 1)
k + 1 (k - 1)
N =
2
dP/min = initial depressurizing rate, psi/min or kg/cm2/min.

(V/ZT) = the sum of the vapor volume divided by temperature and compressibility
factor for all equipment and lines in the high pressure circuit, ft3/R or m3/K. Assume the
reactor volume is the volume of the reactor when empty. Assume normal liquid levels for
middle-of-run.
K = ratio of specific heats for the separator flash gas, Cp/Cv at separator temperature.
Z = compressibility factor of separator flash gas.
M= molecular weight of the separator flash gas. For middle-of-run, use molecular weight
at initiation of depressurizing.
Ts= temperature of the separator, R or K. For middle-of-run, use temperature at
initiation of depressurizing.

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If the results of the depressurizing test indicate that the orifice size is incorrect, a new diameter is
calculated with the following expression:
dp 0.5
min
D2 = D1 2
dp
min1
where:
D1 = existing orifice diameter.
10.5 PREPARATION FOR REACTOR LOADING

10.5.1. Reactor Dry-Out
Before loading catalyst, lines and equipment should be dried to remove excess water remaining
from construction and pressure testing. Drying is best effected by circulating heated gas through
the normal process flow and draining condensate from the separator and all lines.
It is not necessary for the reactor circuit to be bone dry, but any free water should be removed.
Drain all low points in the system and air blow the lines as dry as possible. Individual charge
heater passes should be blown clear separately to ensure than no liquid pockets are present.
Small amounts of moisture are not harmful to the catalyst, but care must be taken so it does not
become wet.
Air blowing of the lines to remove trash left from construction is also recommended. All dirt,
scraps and foreign materials must be removed from the reactors.
10.5.2. Reactor Internals Inspection

All pre-assembled internal components of the reactors should be closely inspected to ensure
compliance with all process and mechanical design features. Any inadequacies should be
remedied prior to start of catalyst loading.
Manway tray sections should be inserted into the reactors and placed to the side so as not to
interfere with the catalyst loading operation.

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10.5.3. Catalyst Handling

Presulfurized hydrotreating unit catalysts are classified as self-heating substances and must be
transported and stored in proper locations. Presulfurized catalysts should not be exposed to air
for extended periods as long term exposure to air could cause the material to generate sulphur
dioxide and heat. These catalysts should be stored in a cool, dry place. Therefore, outside storage
is not recommended. Exposure to air and water may cause discoloration and agglomeration of
the material. If the material does get wet or generates heat, the drums or flow bins should be
purged with nitrogen or dry ice and resealed.
Personal protective equipment must be worn when the material is loaded. The sulphur and
hydrocarbon dust from the material can be irritating to the eyes, skin and respiratory system. The
Occupational Safety and Health Administration (OSHA) of the United States government
requires that workers exposure to nickel dust inhalation be limited to a concentration of 1
milligram of nickel compounds (as Ni) per cubic meter of air averaged over an 8-hour day.
Inhalation of catalyst dust in concentrations above permitted levels may cause irritation and
inflammation of the respiratory tract.
If the catalyst loading is interrupted, monitor SO2 and reactor bed thermocouples closely for
signs of reaction. If the loading will be interrupted for an extended period of time (more than 12
hours), purge the reactor with nitrogen. Appropriate measures need to be taken to protect
personnel when the reactor is being purged or has been purged with nitrogen. Once the catalyst is
loaded, blanket the reactor with nitrogen and seal the reactor. Do not allow air to flow through
the catalyst bed. If the catalyst bed begins to self-heat, purge the reactor with nitrogen
immediately.
People working in the reactor during loading or unloading operations must wear self-contained
breathing apparatus with positive pressure in full face piece or a combination pressure demand
type supplied air respirator with an auxiliary self-contained air supply. Full protection clothing
must also be worn. If dust is present and it is not certain that concentrations are below the limit, a
dust respirator should be worn.
Clean up catalyst spills and remove dust promptly. Do not wash catalyst spills or settled dust into
any public water system. Notify local authorities at once if contamination occurs.

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Catalyst is typically received in sealed steel drums and/or flow bins. For destinations in North
America, the catalyst can also be transported in DOT approved supersacks. The reactors and the
loading equipment should be free of water and purged with nitrogen prior to and during loading
operations.
10.6 CATALYST LOADING

It is not necessary for the reactor circuit to be bone dry, but any free water should be removed.
Drain all low points in the system and air blow the lines as dry as possible. Individual charge
heater passes should be blown clear separately to ensure than no liquid pockets are present.
Small amounts of moisture are not harmful to the catalyst, but care must be taken so it does not
become wet. Loading of the reactor(s) is normally the last item attended to before unit starts up.
Reactor loading consists of the following:
Planning and preparation including a target loading diagram
Installation and inspection of the bottom internals
Loading of the catalyst support material and catalyst
Installation and inspection of the vapor/liquid re-distributor tray and support grid
Loading of the catalyst support material and catalyst
Installation of the catalyst hold down material
Installation of the inlet distributor and bolting up of the reactor
10.6.1. Discussion
It must first be decided how the catalyst is to be lifted to the top of the reactors. It could be lifted
in its original drums by a monorail or pulley system, but the quickest and probably best way is to
lift the catalyst by a crane. If a crane is used, the loading time can be greatly reduced by
constructing two large transfer hoppers to move the catalyst from the ground level to the top of
the reactors. In this case, a transfer-hopper loading platform must be constructed in a convenient
place close to the reactors. The loading platform can be constructed of scaffolding and wooden
planks or of any other convenient material. The platform area should be at least large enough to

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accommodate enough drums to load one hopper and to allow working room for the personnel
who will do the loading.
Regardless of the way the catalyst will be lifted, a convenient, temporary storage place near the
reactor must be found for the catalyst. The catalyst should be stored on pallets and completely
covered by canvas to give a certain measure of protection against the elements. A forklift or
some other means of moving the catalyst from this site to the loading platform (or to any other
place) should be available.
The catalyst loading path, both on the ground and through the air, must be checked so that it is
entirely free from obstruction. To assure this, it may be necessary to remove or modify the
reactor superstructure, the piping support, or the piping itself. Failure to obtain a clear loading
path could result in a slow and hazardous loading procedure. A typical lay-out for the catalyst
loading is shown in Figure XIII-1.

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Figure XIII-1
Typical Lay-out for Catalyst Loading

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A list must be made of all the accessory equipment that will be needed to do the loading. A
partial list of some of the items that will be needed follows:
c. One crane (not necessary, but very helpful if available) and safety hitch for the crane hook.
d. One forklift.
e. Two large transfer hoppers (also not necessary, but desirable) and separate lifting cables for
each hopper.
f. One transfer hopper loading platform if transfer hoppers are to be used. One loading hopper
to rest above the reactor.
g. Explosion-proof lights inside the reactor (and also flashlights).
h. Ceramic rope to protect the manway ring joint and to fill crevices created between reactor
internals.
i. Ceramic gasket or wooden cover to protect the reactor manway and elbow flange gasket
surfaces.
j. Canvas for covering the catalyst drums and for covering the reactor inlets between loading
intervals as protection against rain, snow, etc.
k. A safe ladder to enter and leave the reactor.
l. Loading socks of correct diameter and sufficient length to do the loading in the manner
planned.
m. Wooden boards to stand on while inside the reactor and to level the catalyst and catalyst
support material.
n. A vacuum eductor to remove catalyst dust.
o. Dust masks for the personnel who will be working with the catalyst. Fresh air masks may be
desirable for the personnel who will be doing the actual loading inside the reactors.
p. Measuring tapes for both small and large measurements (such as catalyst loading outages).
q. Chalk, crayons, or other types of markers to mark the reactor walls.
r. Miscellaneous hand tools such as pliers, screwdriver, etc.
s. Air hose to supply air to the dense loading machine (for dense loaded catalysts).
t. A planned loading diagram is prepared and supplied to the loading supervisor.

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10.6.2. Procedure
The bottom reactor internals consist of the catalyst support outlet cover stool and the catalyst
unloading support plate. The catalyst support stool is typically constructed of profile wire screen.
The entire support grid should be inspected for deviations from the project specification (slot
widths, metallurgy, fit-up, etc.) and for structural weaknesses. Near the base of the catalyst
unloading nozzle the catalyst support plate is installed. A ceramic rope must be placed on top of
the plate to plug the unloading nozzle. The removable support plate rests on three equally spaced
lugs. This support plate allows the removal of the nozzle blank flange and the installation of an
external unloading spout prior to the actual removal of any catalyst.
Once the bottom internals are in place, the loading may be started, beginning with the catalyst
support material as follows:
a. A level layer of 3/4" (19mm) diameter ceramic support material (CSM) is loaded to a level
height above the outlet support grids.
b. A level layer of 1/4" (6mm) CSM is placed on top of the 3/4" (19mm) CSM.
c. A level layer of 1/8" (3mm) CSM is placed on top of the 1/4" (6mm) CSM.
d. When loading each layer of the catalyst support material, care must be taken so that the
previous layer of balls is not disturbed. Cratering of any layer may cause migration of the
balls, resulting in the migration of the catalyst bed.
e. The catalyst should be dense loaded by using UOP's dense loading equipment. Dense loading
has the primary advantage of allowing more catalyst to be loaded into the same reactor
volume. In general, there are only a few differences in the typical sock loading and dense
loading procedures. In dense loading, the loading machine is anchored either on the vapor-
liquid distribution tray manway or inside the reactor. A loading sock attached to the loading
hopper feeds the loading machine with catalyst. The operator of the machine regulates it so
that the catalyst is loaded uniformly and so that the level rises flatly. Even when dense
loading, it will probably be necessary to level the bed after reaching the desired catalyst
height. Afterwards, an outage measurement should be taken and recorded.
f. If the sock loading method is used, the sock should extend to the bottom of the reactor when
connected to the hopper in the reactor inlet manway. The catalyst must be loaded slowly at

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first to prevent cratering of the support material. The sock should be kept moving in a figure-
eight pattern to prevent the catalyst from forming hills. It is important to keep the catalyst
bed as level as possible during loading so the loaded catalyst density is uniform throughout
the bed. The sock should be cut off as the catalyst level rises.
g. During the loading of the catalyst, an accurate count of the drums loaded and the drum lot
numbers must be recorded. It is advisable to retain a composite catalyst sample for future
reference composed of about 5cc from each drum loaded.
h. The reactor will be topped off by placing a layer of 1/4" (6mm) ceramic balls and a layer of
3/4" (19mm) ceramic balls on top of the catalyst bed. A catalyst loading diagram depicting
the actual loading should be drawn and retained for future reference (See FigureXIII-2).

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Figure XIII-2
Loading Diagram
uo p DENSE LOADING
Customer Page No.
Subject Date
Project
By
Total Catalyst Loaded

3
Lbs. ft
Drums
Loaded Density
UOP 3055-34
II.

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10.7 CATALYST UNLOADING

In unloading used catalyst that has not been regenerated, special precautions must be taken to
prevent the ignition of pyrophoric iron sulphide scale deposits that can be found in the reactor
and catalyst beds. The temperature generated by this combustion can be quite high, and if left
unchecked, can result in severe damage to the catalyst, reactor internals, and catalyst handling
equipment. In addition, if the coke on the catalysts were allowed to contact air, it could burn at
an uncontrolled rate. Some catalysts, if overheated in an uncontrolled coke burn, could have a
change in the catalyst base structure, rendering it unusable. For these reasons, the entire catalyst
dumping and screening operations should be conducted under a nitrogen blanket. All personnel
involved with the unloading should be properly informed of the dangers involved, and of the
proper safety precautions to be followed.
10.7.1. Catalyst Preparation

After oil has been cut out of the reactor and the catalyst has been thoroughly flushed in
accordance with the Normal Shutdown procedures, raise the reactor inlet temperature to 400 C
to dry the catalyst. Throughout the catalyst drying operation continually drain hydrocarbons from
low points and dead-ended lines. Continue maximum hydrogen circulation for a minimum of two
hours after the reactor outlet and all catalyst temperatures have been heated to above 370 C, and
have been stabilized. Then cool the catalyst, depressurize and purge. The catalyst should be
cooled to less than 65 C, and preferably to 40-50 C. At temperatures above this level, the
combustion of iron sulfide scale in air is greatly accelerated, and, in addition, as the catalyst in
the drums cools there will be a greater tendency to draw air into the drums.
10.7.2. Catalyst Unloading

Maintain a nitrogen blanket in the reactor at all times to prevent any air from entering the system
and contacting the catalyst. Make sure that personnel entering the top of the reactor wear the
proper safety equipment and follow all safety precautions for entering a contaminated
atmosphere. Remove enough of the hold-down ceramic balls to reach the balls/catalyst interface.
If any hard crust is present in the balls or at the balls/catalyst interface that might be self-

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supporting if the catalyst below were removed, then break up this crust and remove the material
before dumping the catalyst from the bottom of the reactor.
Continue to maintain a nitrogen blanket in the reactor, and unload the catalyst from the bottom.
If the catalyst is to be reused, it should first be screened to remove dust and fines that could cause
excessive pressure drop in the reactor, resulting in maldistribution. This can be conveniently
done during unloading by dumping the catalyst from the reactor directly into the screening
apparatus. Figure XIII-3 depicts a typical layout for this operation.
Figure XIII-3
Unloading Used Catalyst
UOP 2032-08
UOP-3054-26
For the upper beds in a multi-bed reactor, it will be necessary to use the side unloading nozzles
provided for each bed. If the reactor is equipped with angle unloading nozzles, the catalyst

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should flow freely from the unloading nozzles. If the reactor is equipped with horizontal
unloading nozzles it may be necessary to use a catalyst auger or a vacuum system to induce flow
of the catalyst. Figure XIII-Figure 4 depicts an auger device for catalyst unloading.
Figure XIII-4
Catalyst Unloading Auger
B To Suit
3 5/16 1-1/2 6 2-0
3/16 PL
1/2PL
2 2
C 1/8
1/8
1/8
1/8
Grind Bolt Heads
C 1b
Lifting Lug
3/16 PL (TYP)
as Reqd to Insert
in Top Holes
2 9/16 Hole B Section C-C
(4) 9/16 Holes for 1/2x 1/2 Bolts
CTSK. Far Side 7/8 Dia. 4
4 3/16 PL Lifting Lug
Section B-B A
2 1
1b 6 SCH. 10 Pipe 1b Cut Corners
CL 1 Hole and Fair in
1/4 Pitch
6
A Discharge
BILL OF MATERIAL
ITEM DESCRIPTION
1 Rotary catalyst rake complete
1d and consisting of the following=
1a Air Motor Mounting PL a Air motor-Gast no. 8AM-FRV-2A
Guard Mounting Clip Reversible rotation, base mounted
b Gast muffler # AC 990 (for above)
1f
c Link-Belt type C shaft mounted
1c screw conveyor drive # 107D15
Provide 20 Ga. Steel
Belt Drive Guard for trough end mounting w/1 1/2
1e type B output shaft for 6 dia.
screw complete with motor bracket
Guard Mounting Clip for # 107D15 reducer to mount air
motor (item 1a above) adapter kit
2x2x1/4 Angle on Dump Funnel for # 107D15 reducer with felt seals
(See drawing #E-544-P--3) to suit output shaft. Shaft kit with
type B output shaft complete with
Section A-A retainer and self locking cap screws.
(For arrangement IT)
1g Screw Conveyer Flight
Conveyer Trough d V belt drive sheave 4.75 O.D. - 3/4
Air Hose bore . Standard keyway, single groove
1a Air Motor Worthington #3V-4.75
1d Pulley (4.75 O.D.)
e V belt drive sheave 6.50 O.D. - 3/4
1f V-Belt bore . Standard keyway, single groove
1a Pulley (6.50 O.D.) Worthington #3V-6.50
Hopper
Belt Drive Guard Platform f V belt - 3/8 x 45 Goodyear HY-T
1c Conveyor Drive Reactor C
L wedge belt #3V-450
Adjustable Legs
g Screw conveyer flight, 6 dia. right
To Standpipe hand with nominal 2 pipe shaft.
Link-belt helicoid type,
NOTE: Cat. # 6H-312-E
This drawing is presented for concept purposes only. h 6 SCH.10 (0.134 Wall) black wrought
Specific dimensions and equipment are for a device steel pipe.
designed by Unocal 76 Oil Company at its Los
Angeles refinery. UOP 3055-35

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The screening apparatus should be enclosed and maintained under a nitrogen blanket to prevent
air from entering. Use the proper size screens to separate the catalyst from the ceramic balls, and
from the dust and fines. The catalyst should be dumped directly from the screening apparatus
into nitrogen blanketed metal drums. This can be accomplished by using a copper tubing line at
the unloading site to fill each drum with nitrogen before putting in catalyst. Allow the tubing to
remain in the drum as catalyst is being dumped into it to keep a steady stream of nitrogen
flowing over the catalyst.
After each drum is filled, remove the nitrogen purge line and immediately cover and tightly seal
the drum. Have CO2-type fire extinguishers and steam hoses available to quench any burning if it
should happen to occur. The CO2 is preferable if the catalyst is to be used again because it will
not wet the catalyst, and the catalyst will not, therefore, require a subsequent drying operation.
It is expected that some of the "sparking" of the pyrites will take place in any event. Therefore,
all workmen in the area must be supplied with face and eye protection. In addition, they should
wear long sleeve shirts with the collars and cuffs tightly buttoned.
Maintain a positive flow of nitrogen out of the unloading nozzle throughout the unloading. If the
catalyst becomes bridged in the unloading nozzle or is not free flowing, break the plug with a
blast of nitrogen. Do not allow air to be drawn into the reactor.
If ignition of pyrites takes place inside a reactor, stop unloading in that reactor and increase the
nitrogen purge to maximum until burning has stopped.
10.7.3. Catalyst Sampling

As the catalyst is dumped and screened, take samples of every 5 percent of the catalyst load and
make a composite (in a nitrogen-blanketed sample can) to use for analytical work, as required. If
more than one reactor of catalyst is dumped, obtain separate composite samples from each
reactor.

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10.8 AUSTENITIC STAINLESS STEEL PROTECTION

Proper precautions should be taken during the shutdown and dumping operation to protect
austenitic stainless steel equipment against conditions that could lead to stress corrosion
cracking. This is especially critical for reactor charge heater tubes.
After dumping the catalyst, flood the reactor with soda ash solution according to the austenitic
stainless steel procedure. Air out the reactor and inspect and clean. Any catalyst that has
remained at the bottom of the reactor during the soda ash wash operation must be considered
contaminated and should not be reused. Since corrosion cracking of austenitic stainless steel can
lead to failure of the equipment involved, it is of the utmost importance that this equipment be
properly protected to prevent corrosive environments from occurring. Therefore, all operating
personnel, and especially the supervisory personnel, must be familiar with the locations of piping
and equipment fabricated from austenitic stainless steel. They should also recognize the need for
special handling of these sections of the unit during startup, shutdown, flushing, cleaning,
maintenance and inspection, and should be thoroughly familiar with the procedures to be used
for the proper protection of the equipment.
Austenitic stainless steels are those of the "300 series," the compositions of which are nominally
18 percent chromium and 8 percent nickel. The most common types used in the petroleum
industry are Types 304, 316, 321 and 347. Because of their inherent high temperature strength
properties and high corrosion resistance, they are particularly suitable for use in hydrocracking
units in areas of moderate and high temperature, and where substantial resistance to hydrogen
sulphide corrosion is required, such as in heater tubes, reactors, reactor combined feed
exchangers and piping. Types 321 and 347 are stabilized to minimize intergranular carbide
precipitation and are preferred because they are more resistant to the intergranular corrosion
cracking caused by polythionic acid attack, which can occur particularly during downtime
periods when exposed to air and moisture. Since these stabilized grades are not completely
immune to intergranular corrosion cracking, special handling procedures are recommended for
the protection of these materials as well as the unstabilized grades.

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10.8.1. Chloride Attack

The presence of halides (chlorides are usually the most serious offenders) along with an aqueous
phase and tensile stresses can result in stress corrosion cracking of austenitic stainless steels.
This type of cracking is predominantly trans-granular and is somewhat dependent on time,
temperature and chloride concentration.
Therefore, precautions should be taken to minimize the amount of chloride in the process
material that will come in contact with austenitic stainless steel equipment. Under normal
shutdown period conditions, chloride cracking is not likely to be a problem as long as chlorides
are not allowed to accumulate and concentrate in hot equipment, and as long as precautions are
taken to limit the chloride content to low levels in any flushing, purging or neutralizing agents
used in the system.
10.8.2. Polythionic Acid Attack

Once a unit has been placed on stream, even if the sulfur content of the feed stock is low, all
items made of austenitic stainless steel should be considered to contain a layer of iron sulfide
scale. Even though these layers of scale in many cases may be very thin, they represent a
potential hazard to the underlying steel. The action of water and oxygen on this sulfide scale
forms weak sulfurous type acids, commonly referred to as polythionic acids, which can attack
austenitic stainless steels and cause intergranular corrosion and cracking. These stainless steels
are vulnerable to this type of corrosion, particularly in areas of residual tensile stresses and in
areas where intergranular carbides may exist, such as the heat-affected zones adjacent to welds.
Therefore, special precautions should be taken to protect austenitic stainless steel from this
corrosive environment.
10.8.3. Protection Against Polythionic Acid Attack

Protection against polythionic acid attack can be accomplished by preventing the corrosive
environment from forming or by providing an agent that will neutralize any corrosive acids as
they are formed:

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Preventing the Formation of Polythionic Acids

Since these acids are formed by the action of water and oxygen with hydrogen sulfide or sulfide
scale, elimination of either liquid phase water or oxygen will prevent these acids from being
formed. Since there will usually be an equilibrium amount of water vapor present during the
normal operation of a unit, during shutdown periods this water vapor can be prevented from
condensing by maintaining the temperature of the austenitic stainless steel equipment above the
dew point of water.
Under normal operations (other than a startup immediately following a catalyst regeneration,
where there may be significant amounts of oxygen present before purging), there should be
essentially no oxygen present in the system. The only other time any significant amount of
oxygen might enter the system would be during a shutdown period when the system is
depressurized and the equipment is opened and exposed to air. Under these conditions a suitable
purge of nitrogen should be established through the equipment involved to prevent any air from
entering the system, and maintained until the system is again closed. If possible, the equipment
should be blinded or blanked-off during this period and kept under a slight positive pressure of
nitrogen.
10.8.4. Purging & Neutralizing

Whenever austenitic stainless steel cannot be adequately protected by maintaining temperatures
above the dew point of water or by an adequate nitrogen purge, a protective neutralizing
environment should be established in this equipment prior to exposure to air. An effective
neutralizing environment can be provided by purging with and maintaining an ammoniated
nitrogen blanket, or by washing with a dilute soda ash solution.
Purging Nitrogen
Nitrogen used for the purging and protection of austenitic stainless steels should be dry and the
oxygen content should be limited to a maximum of 1000 mol-ppm. The oxygen content of the
nitrogen used should be specified by the supplier, since the analysis for oxygen in this low
concentration range requires elaborate analytical equipment which may not normally be

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available in the refinery laboratory. If the only nitrogen available has oxygen content in excess of
1000 mol-ppm, or if the oxygen content is unknown, then as a safeguard, ammoniated nitrogen
should be used where possible. However, for this case, catalyst safety considerations might be
necessary.
Ammoniated Nitrogen
To prepare ammoniated nitrogen for use in purging or blanketing an austenitic stainless steel
system, sufficient ammonia is added to the nitrogen to provide a minimum concentration of 5000
mol-ppm of ammonia. Whenever ammonia is added to the reactor system, the ammonia content
of the recycle gas should be checked frequently. It is expected that the catalyst will absorb a
considerable amount of ammonia, and, therefore, additional ammonia makeup will be required to
maintain the 5000-ppm ammonia concentration until the system reaches equilibrium. One
convenient method of adding ammonia to the system, especially when the system is at high
pressure, is to use a high pressure "blow case." With this type of arrangement liquid ammonia is
pressured into the blow case at low pressure from the ammonia cylinder, and then the blow case
is isolated. High pressure gas from the discharge of the recycle gas compressor is then used to
pressure up the blow case and to force the ammonia into the system at a location of lower
pressure.
All personnel working in the unit should be familiar with the toxic nature of ammonia, and must
follow proper safety precautions in working with the system when it contains ammonia. For
example, workers opening flanges or manways in a system containing ammonia should be
equipped with fresh air masks or other oxygen breathing equipment.
In order to preserve the activity of the catalyst in the reactors, ammonia is not to be passed over
the catalyst when it is in its oxidized form, that is, whenever the catalyst is either fresh or freshly
regenerated.
Brass and most other copper alloys are subject to corrosion attack from ammonia. Therefore,
arrangements should be made to isolate this equipment from the system before admitting any
ammonia.

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Soda Ash Solutions

Aqueous neutralizing solutions of soda ash (Na2CO3) should be prepared in the range of 2 to 5
wt%. Preheating the water to about 40C will facilitate dissolving all the soda ash. In this range a
sufficiently high level of alkalinity will be provided to affect neutralization of any reasonable
amount of polythionic acids which may be formed. To avoid exposing the austenitic stainless
steel equipment to a concentration of chlorides, the chloride content of the soda ash used to
prepare the solution should be limited to a maximum of 500 wt-ppm while the chloride content
of the water should not exceed 50 wt-ppm. As added protection against chloride attack from the
small amount of chloride present in the neutralizing solution, 0.5 percent by weight of sodium
nitrate should be added to the soda ash solution. Sodium nitrate concentrations much above 0.5
wt% should not be used, however, in order to avoid the possibility of stress corrosion cracking of
carbon steel piping and equipment in the system.
Soda Ash Neutralization Techniques

Whenever a soda ash solution is used for neutralizing and protecting austenitic stainless steel, the
piping or piece of equipment involved should be filled completely full with the solution.
The equipment should then be allowed to soak for a minimum of two hours before the soda ash
solution is drained and the equipment is exposed to the air. If there are any pockets of unvented
high areas in the equipment that cannot be reached by filling with the soda ash solution, then the
solution should be vigorously circulated through the equipment to assure thorough contact of all
austenitic stainless steel surfaces. This circulation should be continued for a minimum period of
two hours before draining and exposing the equipment to air. For extremely large surfaces, such
as reactor or large vessel walls and internals, where filling with soda ash solution is impossible
because of foundation load limitations, it is recommended to wash the areas very thoroughly by
means of a high pressure hose equipped with a spray nozzle. This type of washing will have to
be done after the vessel has been opened to allow entry. Until the soda ash washing has been
completed, the vessel should be maintained under a nitrogen blanket to prevent the entry of air.

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Soda Ash Protective Film

In all cases of flushing or washing with soda ash solution, after the solution is drained from the
equipment, the surfaces should be allowed to dry so that a film or fine deposit of soda ash
remains on all surfaces for added protection against polythionic acid formation. Therefore, after
draining the soda ash solution, do not rinse the system with steam or water.
For large accessible surfaces, such as vessels or reactor walls and internals, the excess dried soda
ash can be removed just prior to startup with a brush or dry cloths; do not use wet cloths and do
not flush with steam or water. The small amount of soda ash remaining on the reactor surfaces,
even if it were all deposited on the catalyst, would not have any significant effect on the activity
of all but the platinum-type catalysts under consideration in this paper.
10.8.5. Hydrotesting New Austenitic Stainless Steel

When conducting hydrostatic tests on new austenitic stainless steel equipment, the water used
should have a chloride content not exceeding 50 wt-ppm, in order to reduce the possibility of
concentrating chlorides in pockets or dead areas of the system. If chlorides were allowed to
accumulate and concentrate (such as during subsequent heating operations) in such areas, stress
corrosion cracking could result. If the only water available has a chloride content in excess of 50
wt-ppm, then 0.5 wt% of sodium nitrate should be used.
Hydrotesting Used Austenitic Stainless Steel

Whenever a piece of equipment has been used for the processing of hydrocarbons in
hydrodesulufization service, it must be assumed that some degree of sulfide scale can be present.
Therefore, even if this sulfide scale is so slight that it is difficult to detect, the possibility of
polythionic acid formation with resulting intergranular corrosion cracking exists. Even if the
equipment has been cleaned by mechanical means, burning or acidizing, it is difficult to assure
that no traces of sulfide scale remain. Therefore, any hydrostatic testing (and any cleaning by
hydroblasting) operations on used equipment should be conducted using the dilute soda ash
solution specified for neutralizing this equipment. Here again, a protective film of dried soda ash
should be allowed to remain on the surfaces of the equipment while it is exposed to the air.

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10.8.6. Reactor Charge Heater Tubes

Maintaining Small Fires
The austenitic stainless steel tubes in a reactor charge heater can best be protected by
maintaining a balanced set of small fires (or pilots, as applicable) in the heater box at all times,
even when there is no circulation of process material through the tubes. These small fires should
be adjusted to keep the tubes warm and dry, to maintain the environment inside the tubes above
the dew point of water. As a general rule, about 205 C, as measured by thermocouples placed in
the hip sections of the heater and directly below any convection coils that may exist, will usually
be sufficient for this purpose. The dew point, however, should be determined for each specific
condition involved and the temperature should be adjusted as necessary. Only fuel gas firing
should be used for this operation because of the difficulty in controlling and maintaining
sufficiently small flames when burning fuel oil. It is important during these periods of heater
operation that the heater firing be kept under strict control and that the firing pattern be properly
established to provide good heat distribution. Sufficient thermocouples should be installed
throughout the hip sections of the heater to provide a good measurement of the firebox
temperatures and to monitor the distribution of heat in the firebox. These thermocouples should
be located below any convection bank in the heater, and should be connected to a continuous
recorder provided with high and low alarm points. The low alarm point should be set at about
150 C and the high alarm point at about 230C.
CAUTION: Stack temperatures should never be used to control firebox temperatures.
To Shut Down Fires

If it should be necessary for any reason to shut down the fires in charge heater containing
austenitic stainless steel tubes, then this should be done only when it is absolutely certain that the
environment within the tubes does not contain both oxygen and water (or water vapor). As a
result of the operation of the reactor effluent water wash facilities in units so equipped, there will
normally be an equilibrium amount of water present in the entire reactor circuit both during
normal operation and during or after a period of in situ catalyst regeneration. If the heater fires
must be shut down during a period of normal operation, it is required only that no oxygen is

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present, which is usually the case during normal processing periods. As the heater tubes cool
there will be small amounts of water condensing inside the tubes; however, this water should not
be harmful in the absence of oxygen.
If the heater must be cooled down and it is suspected that trace quantities of oxygen might be
present, then before cooling the heater the system should be depressurized completely, but do not
evacuate. Evacuation at this point is perhaps possible, but not recommended because it
introduces the possibility of allowing air to enter the system. Continue to maintain the 205 C
firebox temperatures while depressurizing and purging. After the system has been depressurized,
pressure with nitrogen to any convenient pressure level. Repeat this depressurizing/pressuring
procedure as many times as required to reduce the oxygen concentration, by dilution, to as much
below 100 mol-ppm as is possible and reasonable. Then the fires can be shut down and the heater
allowed to cool.
Neutralization
If neutralization is necessary, such as when a tube or tubes are cut out of the coil, or any time
when exposure to air at temperatures below the dew point of water cannot be avoided, the tubes
should be filled with soda ash solution and allowed to soak for a minimum of two hours. With
vertical coils, where it is not possible to completely fill the unvented upper return bends, it is
necessary instead to vigorously circulate the soda ash solution through the tubes for a minimum
of two hours to assure contact of all surfaces. After draining the soda ash solution, do not flush
with steam or water but instead allow a film of protective soda ash to remain in the tubes.
Exterior Surfaces
Whenever heater fires must be shut down and the tubes are allowed to cool, it is recommended
that the exterior tube surfaces be protected, especially in heaters where fuel oil or high sulfur
content fuel gas is employed. As a result of the sulfur in the fuel, a sulfide scale can build up on
the exterior tube surfaces as well as on the inside tube surfaces. If moisture is allowed to
condense on the tubes as the heater box is cooled, the action of oxygen and moisture on the scale
can form polythionic acids which can attack the austenitic stainless steel tube surfaces and lead

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to intergranular stress corrosion cracking. There are two recommended procedures that can be
followed to prevent this from occurring: First, it is possible to prevent any moisture from
condensing on the tubes, and thus prevent the formation of polythionic acids, by purging the
firebox with copious amounts of dry air. Normal instrument air is prepared by processing
through a set of driers where the dew point is reduced to a sufficiently low level to prevent
condensation from occurring at ambient conditions. This air can be effectively used to maintain a
dry air blanket in the heater box both during cooling and throughout the entire period the fires
are out. In order to minimize the consumption of instrument air, and to prevent moist air from
entering the heater box, the stack damper, all burner air registers, and all doors and ports in the
heater box should be kept closed.
Second, an alternate method of protecting the tubes from polythionic acid attack is to cover the
exterior tube surfaces with a protective film of soda ash, which will act to neutralize any
polythionic acids as they are formed. The neutralizing soda ash should be the same dilute
solution recommended for general neutralization, and should be applied to the tube surfaces as
soon as the heater box has cooled sufficiently to prevent vaporizing the soda ash solution, and
preferably before any moisture has begun to condense out on the tube surfaces. A fairly efficient
and effective method of applying the soda ash solution is to utilize a vat or tank with a small
portable pump which can pump the solution through a hose fitted with a spray nozzle which will
produce a fairly fine mist.
NOTE: A low pressure spray is advisable as high pressure may erode the refractory.
Small diameter pipe extensions can be fitted to the hose to allow reaching up to the tube areas at
the top of the heater box. This type of spray equipment will minimize the soda ash consumption
and provide a reasonable means to reach all tube surfaces that are exposed to the heater flames.
Once the soda ash solution has been applied, it should be allowed to dry to form a protective film
on the surfaces of the tubes; do not wash off this protective film.
If the exterior tube surfaces are heavily coated with an oxide or carbonaceous material, it should
be removed by wire brushing or sandblasting. This cleaning, however, will also remove any
protective soda ash film that may have been applied. In this case, the tube surfaces should be
further protected by applying another film of soda ash without delay.

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On the occasions when the heater fires are shut down, it is convenient to also schedule inspection
of the tubes. Inspection should include measuring the tube outside diameters for comparison to
the original new tube ODs, dye penetrate checking of welds and heat affected zones for cracks,
and random ultrasonic flaw detection of the heat affected zones around welds. Periodic
radiographic inspection should be conducted to check for scale or deposits inside the tubes.
10.8.7. Heat Exchangers

If lines leading to or from heat exchangers containing austenitic stainless steel are to be opened,
blinds can be rapidly inserted to isolate the exchanger, while maintaining a nitrogen purge
through the exchanger involved preventing air from entering. A nitrogen blanket or continuous
nitrogen purge should then be maintained in the exchanger during this maintenance period.
If shell and tube exchangers containing austenitic stainless steel are to be opened and inspected,
or if the tube bundles are to be pulled, then before exposing this equipment to air, both shell and
tube sides should be flooded with soda ash solution and allowed to soak for a minimum of two
hours. If there are any pockets or high areas which cannot be reached with the soda ash solution,
then the soda ash solution should be vigorously circulated through the exchanger for a minimum
of two hours. Do not rinse with water, but instead allow a film of soda to remain on the surfaces.
If tube bundles of austenitic stainless steel are to be cleaned by hydroblasting, then soda ash
solution should be used for this purpose instead of just water.
10.8.8. Reactor Internals

Any time a reactor is to be opened, maintain sufficient nitrogen purges to prevent the entry of air
into any part of the system and isolate the charge heater coils and the reactor effluent system
with blinds. A blanket of nitrogen should also be maintained in the reactor, especially if it
contains unregenerated catalyst. A slight amount of air coming in contact with the reactor
internals for relatively short periods of time is normally not considered to be harmful to the
metal; however, precautions should be taken to prevent contact with water or moisture,
especially in the presence of air. If any exposure to air has occurred, the air should be purged out
with nitrogen as soon as possible.

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When the reactor internals are to be exposed to air for a prolonged period of time, such as during
a catalyst change, the reactor walls and internals should be washed very thoroughly as soon as
possible with a high pressure hose, using copious amounts of soda ash solution. A portable pump
and a vat of soda ash solution on skids is typically used for this operation. In order to do this
washing properly, a workman equipped with a fresh air mask and following all other proper
safety precautions, might have to enter the vessel to make sure all surfaces, including the
underside of the top head, are thoroughly wetted. Be especially careful to thoroughly soak
welded areas with particular emphasis on welds normally required to support heavy loads, such
as those on support beams, grids and trays.
When the reactor contains trays, which would make wetting all surfaces with soda ash solution
difficult, a sufficient amount of soda ash solution should be sprayed around the top of the reactor,
and allowed to rain down through the reactor to wet as much of the surfaces as possible in the
areas below the top tray. Be sure to thoroughly soak and keep wetted any used catalyst remaining
in the reactor, and then air can be drawn through the reactor so that personnel can enter. During
this time, a small flow of soda ash solution to the reactor should be maintained, and as each tray
manway is removed, the vessel area beneath that tray and the underside of the tray should be
thoroughly washed with soda ash solution.
Whenever spent, unregenerated catalyst is unloaded from the reactor; some amounts of catalyst
will inadvertently remain on the trays and in the bottom of the reactor. This catalyst must be kept
wet to prevent ignition of sulfide scale when air is admitted, which is another reason for
conducting a thorough washing operation with the soda ash solution.
After washing with soda ash solution, allow the surfaces to dry with a fine deposit of soda ash.
Do not rinse this residue off with water. Later, just prior to reloading catalyst, wipe as much
excess soda ash residue from the surfaces as possible with brushes or dry cloths; do not use water
or wet cloths.
10.8.9. Cooling Catalyst After Regeneration

When it is necessary to reduce the temperature in an austenitic stainless steel charge heater coil
below the dew point of water when oxygen is present, such as during the procedure of cooling

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the catalyst bed to a temperature which would allow entering the reactor following a catalyst
regeneration, the oxygen must first be reduced to an acceptable level. Maintain the final reactor
temperature used in the regeneration and continue gas circulation; and depressurize to the
minimum allowable for recycle compressor operation. Then pressure with nitrogen. Conduct this
procedure at least three times, or as necessary to reduce oxygen concentration in the circulating
gas by dilution to as much below 100 mol-ppm as is possible and reasonable. Maintain reactor
temperatures and gas circulation, after shutting down and draining the caustic and water systems,
until the reactor system is dry and no more water collects in the separator.
Then the system can be cooled to about 150F (65C) at the reactor outlet. At this point shut
down the recycle gas compressor but maintain heater fires sufficient to maintain about 400F
(205C) firebox temperatures throughout the shutdown period.

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SECTION-11
SAMPLING PROCEDURE AND LABORATORY ANALYSIS REQUIREMENT
11.1 GENERAL
Control tests provide the information to the operating staff for making necessary adjustments to
get the maximum output and on-spec quality products. The control tests are to be made at all
steps to monitor the intermediate and final products whether or not they are at the desired
specification. Samples are taken and analyzed at regular intervals such that the operation of the
plant are monitored and any deviation (from specification will indicate some maloperation /
malfunction of the plant which can be spotted and rectified in time without undue loss of time
and product. Sometimes, samples are taken to find out the effect of certain changes brought
about in the operating conditions. The samples are to be taken with great care so that the samples
are representative samples. The frequency of sampling, the type of analysis and points where
samples are to be taken are generally specified by t he process licensor. During guarantee tests
some additional samples can be taken at higher frequencies, which will be specified, in the
technical procedures prior to test run. The following guidelines should be followed while
collecting samples.
11.2 SAMPLING PROCEDURE

a) Liquid Sampling Procedure (Non-Flashing Type)
i) The person taking samples should wear proper or appropriate safety clothing like face
shields, aprons, rubber gloves etc. to protect face, hands and body.
ii) Whenever hot samples are taken, check cooling water flow in the sample cooler is
circulating properly.
iii) Sample points usually have two valves in series. One gate valve for isolation (tight
shutoff) and other globe valve for regulating the flow. Open gate valve first and then
slowly open the globe valve after properly placing the sample containers. After the
sampling is over, close the globe valve first and then the gate. Then again open the globe

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valve and drain the hold up between the gate and globe valve in case of congealing
liquid.
iv) Sample valve should be slowly opened, first slightly to check for plugging. If the
plugging is released suddenly, the liquid will escape at a dangerously uncontrolled rate.
Never tap the line to release the plugging. Call the maintenance gang to properly unplug
the line. In case of congealing type samples, sample point should be equipped with
copper coil type steam tracer. It should be ensured that steam-tracing line is functioning
normally.
v) The operator taking the sample should be careful to stand in a position such that the
liquid does not splash on him and he has unobstructed way out from the sample point in
case of accident.
vi) While taking dangerous toxic material for sampling, it will act as an observer for safety.
Proper gas mask is to be used. It is advisable to stand opposite to wind direction in case
of volatile toxic liquid.
vii) Sample should be collected in clean, dry and stoppered bottle. In case of congealing
samples use clean dry ladle.
viii) Rinsing of the bottle should be thorough before actual collection.
ix) Before collecting, ensure that the line content has been drained and fresh sample is
coming.
x) Gradually warm up the sample bottle / metallic can by repeated rinsing before collecting
the sample.
xi) Stopper the bottle immediately after collection of sample.
xii) Attach a tag to the bottle indicating date, time, and name of the product and tests to be
carried out.
xiii) A few products suffer deterioration with time.
xiv) For example, the colour of the heavier distillates slowly deteriorates with time. So these
samples should be sent to laboratory at the earliest after collection.

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The samples after collection should be kept away from any source of ignition to minimize fire
hazard.
Volatile samples (e.g. naphtha) should be collected in bottles and kept in ice particularly for
some critical test like RVP.
b) High Pressure Hydrocarbon Liquid Samples (Flashing Type)
i) The person taking sample should use personal protection appliances like apron, gas mask
and hand gloves to protect himself.
ii) Ensure that sample bomb is empty, clean and dry.
iii) Connect the sample bomb inlet valve to the sample point with a flexible hose.
iv) Open the inlet and outlet valves of the sample bomb. Hold the sample bomb. Hold the
sample bomb outlet away from person. Keep face away from hydrocarbon vapour and
stand in such a way that prevalent wind should blow hydrocarbon vapour away. Open the
gate valve of sample point slowly till full open. Then slowly cracks open the regulating
valve. One should be careful at the time of draining, because chance of icing is there. As
a result, the formation of solid hydrates is a continuing process, which leads to the
plugging of valves.
v) When all the air in the hose and bomb are displaced as seen by the hydrocarbon vapour
rising from the outlet of sample bomb close the sample outlet valve. Allow a little
quantity of liquid to spill to make sure that the bomb is receiving liquid. Frosting will be
an indication of liquid spillage.
vi) Allow liquid hydrocarbon to fill the bomb. When the bomb is full up to the specified
level, close both the valves on sample point. Close inlet valve on the sample point.
vii) Carefully disconnect the hose from the sample bomb. To allow for some vapor space in
the bomb for thermal expansion in case of overfilling, crack open the outlet valve of
bomb and discharge a small part of the liquid. Close outlet valve.
viii) Closed sampling facilities are provided at some locations where it is not desirable to
waste the costly product or if the material is toxic. For filling the sampling bomb,

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pressure drop across a control valve is usually utilized or across pump discharge &
suction. Air is expelled from the bomb after it is connected to upstream of control valve
or pump discharge side. The sample is then collected and bomb is detached after closing
valves on both sides.
ix) Send sample bomb to laboratory for analysis. Protect the bomb from heat exposure.
c) Gas Sample
For collection of gas sample, which are not under high pressure and temperature, rubber bladders
are used. For the operations under vacuum or low pressure, aspirator is used. For representative
sample, purge the bladder 3 to 4 times with the gas and then take t he final sample. Use of 3
ways valve with bladder / aspirator will facilitate purging and sampling.
Sample bombs are to be used for taking gas samples from high pressure and high temperature
source. Procedure mentioned under high-pressure liquid sampling (flashing type) is to be used.
11.3 LABORATORY TEST METHOD AND SCHEDULE

Recommended Methods and Frequency
The frequencies given below are routine related to a normal operation. During start-up and test
runs more analysis will be required.
Charge to NHT
PROPERTY METHOD FREQUENCY

Gravity ASTM D 4052 or ASTM D 1298 1 per day
API ASTM D 287 1 per day
Distillation ASTN D 86 1 per day
Colour ASTM D 156 3 per day
Sulphur ASTM D 4045 1 per day
Chloride UOP 588 Occasionally
Nitrogen ASTM D 4629 Occasionally

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Composition (PONA) UOP 880 Occasionally
Arsenic UOP 946 Occasionally
Lead UOP 952 Occasionally
Bromine No. UOP 304 Occasionally
Dissolved Oxygen UOP 678 Occasionally
Trace Metals UOP 389 Occasionally
Mercury UOP 938 Occasionally
Recycle Gas (Separator off gas)

Relative density UOP 114 1 per day
Composition UOP 539 3 per week
Stripper Off gas

Relative density UOP 114 1 per day
Composition UOP 539 3 per week
Stripper Overhead Liquid

Composition (requires high
UOP 551 Occasionally
pressure sampler)
H2S UOP 212 Occasionally

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Stripper Bottom

Relative Density ASTM D 4052 or ASTM D 1298 3 per day
Distillation ASTN D 86 3 per day
Colour ASTM D 156 3 per day
Sulphur ASTM D 4045 1 per day
Chloride UOP 395 1 per week
Nitrogen ASTM D 4629 1 per week
Composition (PONA) UOP 880 1 per week
Composition (C6-) UOP 551 Occasionally
Arsenic UOP 296 1 per month
Lead UOP 350 1 per month
Copper UOP 144 1 per month
Water Content UOP 481 Occasionally
Bromine No. UOP 304 1 per month
Silicones UOP 787 1 per week
Fluorides UOP 619 1 per month
Naphtha Splitter Overhead

Composition UOP 551 As Required
Distillation ASTM D 86 3 per day

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Naphtha Splitter Bottoms

Composition UOP 880 As Required
Distillation ASTM D 86 3 per day
Nitrogen ASTM D 4629 As Required
Make-Up Hydrogen

Composition UOP 539 1 per day
Relative Density UO P 114 1 per day
Charge Heater Flue Gas

Oxygen content Orsat Occasionally
Naphtha-Splitter Reboiler Heater Flue Gas

Oxygen content Orsat Occasionally
Product Separator Water

pH, iron, Copper UOP 314 Occasionally
NH3 UOP 740 Occasionally
H2S UOP 683 Occasionally
Chlorides UOP 456 Occasionally

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Stripper Overhead Receiver Water

pH, iron, Copper UOP 314 Occasionally
REGENERATION CASE
Recycle Gas

CO2 by Orsat UOP 172 As Required
O2 Portable Analyser As Required
H2S Detector Tube As Required
SO2 Detector Tube As Required
Reactor Effluent Gas

CO2 by Orsat UOP 172 As Required
O2 Portable Analyser As Required
Spent Caustic

% NaOH UOP 210 As Required
pH ASTM D 1293 As Required
pH Litmus Paper As Required
Total Solids APHA 2540-A 1 per week
Settleable solids APHA 2540-F 1 per week

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Circulation Caustic

% NaOH UOP 210 As Required
pH ASTM D 1293 As Required
pH Litmus Paper As Required
Total Solids APHA 2540-A 1 per week
Settleable solids APHA 2540-F 1 per week

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SECTION -12
EMERGENCY PROCEDURES
12.1 GENERAL
Emergencies that occur in hydrotreating units must be recognized and acted upon immediately.
The operators and supervisory personnel should carefully study in advance, and become
thoroughly familiar with, the proper steps to be taken in such situations. Some of the emergency
conditions described here will not only result in a unit shutdown, but if the situation is not
handled properly, can lead to serious damage to the catalyst and equipment.
In general, the objective of the emergency procedures is to avoid damage to equipment and
catalyst. This is accomplished by rapid cooling of the catalyst beds below reaction temperature
and by reducing the pressure whenever there is a possibility of a temperature excursion.
In addition, specific rules cannot be made to cover all situations that might arise. Therefore, the
following procedures cover only those emergency situations that are the most common and, for
the most part, only the immediate steps to be taken are listed. It should be noted that the
procedures outlined here concentrate on the reactor section. In most cases, the corrective actions
will result in upsets in the Splitter and Stabilizer columns. It is advised that care be taken to
adjust the Stripper and Splitter columns operation whenever flows and/or severity are reduced.
It should also be noted that the protection of austenitic stainless steel equipment must always be
kept in mind. The proper precautionary measures must be taken to prevent oxygen and liquid
water from coming into contact with any austenitic material that has sulfide scale. These
measures should not conflict with the immediate steps required as a result of the emergency
condition.
Any time an emergency situation occurs, especially when a reduction in space velocity or
capability of removing the heat of reaction from the catalyst is involved, a condition exists which
could lead to the generation of localized high temperatures. Therefore, if during any type of
emergency there is a rapid temperature rise in the reactor or catalyst bed; immediate steps should
be taken to depressurize the system to suppress the reactions. The objective is to prevent a

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further rise in temperature and minimize the danger of damage to the reactor and other
equipment.
12.2 CHARGE PUMP FAILURE

Objective: Maintain hydrogen pressure to minimize coke formation and cool the catalyst with
recycle gas.
CAUTION: Be aware of the possibility that high temperatures could be generated rapidly in the
catalyst bed, and be prepared to take appropriate action as per the instructions in part H of this
section.
I. Lower the reactor temperatures to 28 C below their normal operating level as rapidly as
possible.
II. Hold the system pressure at the normal level.
III. If available, put the spare charge pump on line as quickly as possible. Maintain water
injection to the reactor effluent at the same rate as before the emergency.
IV. Maintain liquid levels in all vessels.
V. After the spare charge pump is on line, continue with a normal startup. If a pump is not
available, maintain hydrogen circulation and continue lowering Hydrotreating Reactor inlet
temperature to 205C until a charge pump becomes available. Then, line out catalyst
temperatures and proceed with normal startup.
12.3 LOSS OF STRAIGHT RUN NAPHTHA FEEDSTOCK

Objective: Maintain hydrogen pressure to minimize coke formation and cool the catalyst with
recycle gas.
section.
I. Lower the reactor temperatures to 28 oC below their normal operating level as rapidly as
possible.
II. Shut down and block-in the charge pump to stop the flow of to the system.

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III. Hold the system pressure at the normal level.

IV. Maintain water injection to the reactor effluent at the same level as before the emergency.
V. Maintain liquid levels in all vessels.
VI. Maintain hydrogen circulation and continue to cool the hydrotreating reactor inlet
temperature to 205 C until the straight run naphtha (SRN) feed becomes available. Then,
line out catalyst temperatures and proceed with normal startup.
12.4 RECYCLE GAS COMPRESSOR FAILURE

Objective: Maintain hydrogen pressure to minimize coke formation and cool the catalyst as
much as possible by sweeping with makeup gas once-through the reactor.
section.
I. The charge pump should shut down automatically on loss of recycle gas flow.
II. The charge heater should shut down automatically on loss of recycle gas flow.
III. Shut down and block in the water injection pump.
IV. Increase the makeup gas rate to its maximum and maintain normal operating pressure by
venting from the product separator. If the makeup gas is normally sent to the suction of the
recycle gas compressor, it will be necessary to vent gas from the reactor circuit first, to
lower the unit pressure. Then switch the makeup gas destination to the discharge of the
recycle gas compressor and send makeup gas once-through the reactor to the separator.
V. Continue makeup gas injection to remove the oil from the reactors and push it over to the
separator and cool the catalyst as much as possible.
VI. When the recycle gas compressor becomes available, reestablish recycle gas flow and line
out Hydrotreating Reactor inlet temperature to 205C. Then, continue with normal
procedure for startup with used catalyst.

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12.5 LOSS OF MAKEUP GAS

Objective: The system pressure will drop as a result of continued reactions. Therefore, to reduce
hydrogen consumption and minimize coke formation, stop the liquid feed and cool the catalyst
rapidly with recycle gas to below reaction temperatures.
The loss of any portion of makeup gas hydrogen will require a feed rate reduction. The fresh feed
reduction should be proportional to the makeup gas loss. If there is a substantial loss in makeup
gas, pressure will decrease rapidly while hydrogen consumption exceeds makeup capacity. As
the system pressure declines, the capacity of the recycle gas compressor will be reduced and
control of reactor temperatures will become more difficult.
I. Lower reactor temperature sufficiently to reduce hydrogen consumption. Restore reactor
pressure as quickly as possible. After the pressure has returned to normal, adjust reactor
temperature to obtain as much desulfurization as is possible with the available hydrogen.
II. If there is a total loss of makeup hydrogen, it will be necessary to shutdown. Lower
hydrotreating reactor inlet temperature to 205C and follow normal shutdown procedures.
III. If the makeup compressors shut down (i.e. due to a dip in power) and can be immediately
restarted, a shutdown may not be necessary. Lower temperatures and feed rate as quickly as
possible to minimize hydrogen consumption. Restart the makeup gas compressors and
restore system pressure as soon as possible. If the product separator pressure drops to less
than 70 percent of its normal pressure before the compressor can be restarted, the unit must
be shut down to prevent excessive catalyst coking and deactivation.
12.6 LOSS OF WASH WATER

Objective: Prevent formation of salts and the resultant fouling of the reactor effluent cooler.
Loss of wash water for an extended period will force a shutdown. Ammonia will no longer be
removed from the reactor effluent and will begin to build up in the recycle gas causing
ammonium salts to deposit in the products condenser. Rapid fouling and tube plugging can
occur. If neither wash water pump can be started within 30 minutes, follow the shutdown
procedure presented in Normal Shutdown Procedures.

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12.7 TEMPERATURE EXCURSION

Objective: Prevent catalyst temperatures from exceeding design limits.
A temperature excursion is a serious situation that requires immediate attention. During a
temperature excursion, highly exothermic cracking reactions can take place. These temperatures
can rise rapidly to well above the equipment design temperature. A temperature excursion can be
brought about by equipment or utility failures that result in any one of the following problems:
A significant reduction in space velocity over the catalyst.
A reduction of the capability of removing the heat of reaction from the catalyst.
By overheating during a startup or during normal operation.
The period during a fresh catalyst startup, before the catalyst has been thoroughly sulphided, is
perhaps the most critical time when very special care should be taken to control the reactor
temperatures, as outlined in the startup procedure.
During a temperature excursion, highly exothermic demethylation reactions can take place. It is
not necessary, however, to have demethylation occurring in order to have a temperature
excursion. When there is a significant increase in residence time of feedstock on the catalyst, and
especially when this is coupled with the loss or reduction of a large heat removal stream such as
recycle gas, excessive cracking reactions can take place, resulting in severe overheating. Catalyst
temperatures can rise rapidly to well above the reactor design temperature in such a situation,
even though the cracking has not progressed to the point of demethylation. Hydrotreating
catalysts have been formulated to provide a high desulfurization activity with very little
hydrocracking activity, and therefore they are much less susceptible to temperature excursions
than a hydrocracking catalyst. The possibility of a temperature runaway still does exist, however,
and all appropriate precautions should be taken.
In order to sustain a temperature excursion, both hydrocarbons and heat must be available.
Therefore, removing one or the other will cause the reactions to stop. The quickest way to
achieve this, and still maintain hydrogen pressure in order to minimize coke formation, is to
remove the feed from the unit and to cool the catalyst with recycle gas. However, if the
temperature rise cannot be controlled, then the unit should be rapidly depressurized to suppress
the reactions and to minimize the danger of damage to the reactors and other equipment.

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If a temperature in the reactor starts to rise above normal, the following steps should be taken:
I. Reduce the inlet temperature of the bed in which the high temperature occurs. Also, reduce
inlet temperatures to the catalyst beds below.
II. If the temperatures are not controlled by the corrective action of step (1), reduce the reactor
inlet temperature by reducing firing rate of the charge heater.
III. If the temperatures continue to rise 28 C above normal, remove feed from the unit.
IV. If the catalyst bed temperatures are 28C above normal and continue to rise despite the
above corrective actions, or if the temperatures exceed the maximum allowable operating
temperature of the reactor, then depressurizing will be necessary to regain control of the
reactor. If the operator decides to manually depressurize the unit via the manual emergency
depressurizing system, the following should occur automatically:
The feed pump shuts down.
The shutoff control valves in the fuel gas and fuel oil lines to the charge heaters
close, the pilots will stay lit..
The wash water pump will shut down.
NOTE: If the manual depressurizing system is activated, the recycle gas compressor will
continue to operate.
V. Verify that the charge heater burners are out. Open the stack damper and all air registers to
the full open position to establish the maximum flow of cooling air through the box. Add
snuffing steam to the heater box to aid in cooling. Be sure the steam is dry before admitting
it to the heater box.
VI. Put the product condenser fans on maximum cooling. Be careful not to exceed the reactor
product condenser maximum design temperature.
VII. The depressurizing valve may be closed when all reactor temperatures are at least 28C
below normal operating temperatures. If temperatures remain high after the unit has been
depressurized, then begin purging the reactor with nitrogen at the maximum rate possible.
VIII. If recycle compressor operation can be maintained, continue maximum gas circulation and
cool all catalyst temperature points and hydrotreating reactor outlet temperature to 205C.
IX. Hold until ready for startup.

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NOTE: In the event of a serious temperature excursion, the hydrotreating unit should be
completely shut down and the affected catalyst removed, screened and reloaded. In addition, the
reactor and other affected equipment should be carefully inspected for damage.
12.8 INSTRUMENT AIR FAILURE

Objective: The pressure will maintain as the emergency depressurizing valve fails closed.
Therefore, stop feed and cool the catalyst rapidly with recycle gas to below reaction temperatures
to reduce hydrogen consumption and to minimize coke formation.
I. The emergency depressurizing valve will typically be a fail closed valve and the unit
should not begin to depressurize upon loss of instrument air. If the emergency
depressurizing valve is supplied with an air volume bottle, the operator may still open it if
required.
II. Shut down all heaters fires and maintain maximum recycle gas circulation as long as
possible to cool the catalyst rapidly. Be careful not to exceed the reactor product condenser
maximum temperature. Put the fans on maximum cooling.
III. Cut in auxiliary or plant air as soon as possible to supplement the normal instrument air.
Do not attempt to continue operations if the auxiliary air fails also. Shut down and block in
the charge pump and shut down the reactor effluent wash water injection pump.
IV. The makeup gas control valve will fail closed, or the spillback valve in the last stage of
makeup gas compression will fully open, which will stop the flow of makeup gas to the
unit.
V. After instrument air is restored, continue to reduce all reactor temperatures to 28C below
their normal operating level.
VI. Once recycle gas circulation is resumed, and all catalyst bed temperatures are stable,
pressure up the unit and continue with the normal startup procedure.
12.9 CHARGE HEATER TUBE RUPTURE

Objective: Stop all hydrogen and hydrocarbons going to the unit. Stop the fire, and then purge
the process lines with steam or nitrogen at the rupture to prevent air from entering the unit.

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I. Depressurize the unit with the manual emergency depressurizing system.

II. Shut off all fuel supply and return lines to the heaters and open snuffing steam to the box.
III. Open the stack dampers completely.
IV. Shut down and block in any of the following equipment that has not already been
automatically shut down by the depressurizing interlocks: the makeup and recycle gas
compressors, the feed pump, and the reactor effluent water injection pump.
V. After the system is depressurized, hook up steam hoses to both sides of the heater and
purge through to the rupture to prevent air from backflowing through the rupture and
forming an explosive mixture with hydrocarbons in the system. If purging must pass
through the reactor, the purging material should be nitrogen instead of steam. In any case,
nitrogen is preferred for catalyst protection and for the protection of the austenitic stainless
steel piping or equipment in the circuit.
12.10 EXTERNAL FIRE

Objective: Rapidly shut down the unit and depressurize if necessary to prevent further damage.
I. Rapidly shut down the unit and depressurize to prevent further damage. Keep the recycle
gas compressor running, if practical, to cool the reactor and sweep oil from the high
pressure system. Do the following if possible, as applicable.
II. Shut down and block in the fresh feed.
III. Shut off all fuel supply and return lines to all heaters.
IV. Shut down and block in the makeup gas compressor, but maintain the recycle gas
compressor operation as long as possible.
V. Cool the catalyst inlet temperature to 400F (205C) with recycle gas circulation.
VI. Shut down and block in the reactor effluent water injection pump.
VII. Depressurize to flare and purge with nitrogen as applicable to the situation.

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SECTION -13
SAFETY PROCEDURE
13.1 INTRODUCTION
Safety of personnel and equipment is very important. Ignorance of the details of the unit or the
techniques of safe and efficient operation reduces the margin of safety of personnel and subjects the
equipment to more hazardous conditions. All the operating and maintenance crew therefore must
be fully familiar with the equipment and materials being handled in the unit, and recognize the
hazards involved in handling them and the measures taken to ensure safe operations.
Since the unit handles with one of the most potential source of fire and explosion, H2, Naphtha and
chemical like caustic, therefore adherence of safety rules should be given uphill importance.
13.2 SAFETY OF PERSONNEL

General safety rules which shall be practiced and enforces for all personnel who enter the unit are
summarized below:
a. Safety helmets and boots shall be worn by all personnel at all times in the plant. They may be
removed when inside rooms or buildings which do not have overhead or other hazards.
b. Smoking shall be permitted only in specified areas which are clad as non-hazardous and are
pressurized through a ventilation system. Failure of the ventilation system automatically
cancels the smoking privilege until the system is repaired, inspected and authorized operation.
c. Each employees assigned to work in the unit shall know where the safety and fire suppression
equipment is located and how to operate this equipment.
d. Safety glasses, goggles or face shields shall be worn while performing work which could result
in eye or face injury.
e. Operations personnel golden rule
Do not open or close any valve without first determining the effect.
Note:-Treat each piece of equipment or piping as if it is under pressure.

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13.3 WORK PERMIT PROCEDURE

A work permit system must be issued by the appropriate operations group before commencing
any maintenance work affecting the operation of the unit. The work permit is issued for Hot
and Cold work. The Hot work permit must include as a minimum, a precise description and
mode of execution of Hot works, the equipment to be used, the expected time which Hot
works is scheduled to start and expected completion, an exact location of the Hot works and
precautions to be taken.
Unit areas are generally identified as hazardous areas as far as the threat of fire is concerned.
Therefore, in order to carryout works within these areas, a written work permit is required. The
work permit, when approved, indicates that a specific work can be carried out in safe conditions
provided that all safety precautions are observed.
a) Permit for Hot work

Permits of hot works are required for any work involving the use of or generation of heat sufficient
to ignite flammable substances. Typical sources of ignition are:
Electric and gas welding
Any machine capable of producing a spark
Not explosion-proof electrical equipment
Internal combustion engines
Ferrous tools, both hand operated and pneumatic or other type
b) Permits for Cold-Work

Permits for cold-work are required for any work not involving the use of a local ignition source.
Typical examples of cold-work are:
Disconnecting of lines for the insertion of blinds etc.
Opening of any equipment such as vessels, filters, etc.

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c) Entry permits
Entry permits are required for entering enclosed spaces such as vessels, sewer, pits, trenches, etc.
The use of any tool or machinery, which could provide a source of ignition, is forbidden. Also,
prior to entry it should be ensured that area is well ventilated and the oxygen content in air is
about 20.9% by volume. Fresh air flow is to be ensured in the enclosed space through out the
duration of work. A gas test for H2S and flammable gases should also be performed before entry.
A person should also be on alert outside the enclosed space for rescue in case of emergency.
Procedure for carrying out work and rescue plan shall be formulated before commencement of
work.
d) Guidelines for release of permits

The equipment item, on which works have to be carried out, shall be clearly indicated.
During the shutdown of any system, permits covering the whole section with above
mentioned item shall be issued, if possible. The type of work permitted shall be clearly
indicated.
The date and the period of validity of the permit shall also be indicated. If the work does not
get over within the period of validity of the permit, the permit can be extended provided that,
at each start of the works the safety conditions are checked again and signed by the operator
in-charge and by safety officer. Beyond this extended period, a next permit will have to be
issued. The explosiveness test and the check of toxic gases shall be performed always at the
last moment before each start of the work and subsequently every time the work is resumed
or whenever doubts arise.
The validity of the permit can be cancelled at any moment by the operator or by safety
officer; in case they deem that the conditions are not safe.
The conditions to be complied with shall include special precautions, such as the use of
protective clothing, breathing apparatus, safety equipment and the tools to be used etc.
No one shall be allowed to enter the vessel or other enclosed spaces without suitable
protective clothing and until the vessels or the enclosed spaces become safe for entry by

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means of proper isolation, proper ventilation and suitable check of the atmosphere inside and
availability of rescue person outside the enclosed equipment.
If welding or hot work is to be done ensure that:-

Fire fighting system is ready
Close the neighbouring surface drains with wet gunny bags
Keep water flowing in the neighbouring area to cool down any spark.
Responsible operation supervisor should be present at the place of hot work till the first
torch is lighted.
13.4 PREPARATION OF EQUIPMENT FOR MAINTENANCE

a) Process Equipment: Towers, Vessels etc.
Before opening any equipment, it should be purged to render the internal atmosphere non-explosive
and breathable. Operations to be carried out are: -
Isolation with valves and blinds.
Draining and depressurization.
Replacement of vapors or gas by steam, water or inert gas.
Take care about instrument tapping.
Washing of towers and vessels with water.
Ventilation of equipment.
Opening of top manhole.
Testing of inside atmosphere with explosive meter.
Complete opening if inside atmosphere is satisfactory.
Analyze the atmosphere inside for O2 content and any poisonous gas.
Note: Open a vent on the upper part of the vessel to allow gases to escape during filling and to
allow air inside the vessel during draining. Ensure proper ventilation inside the vessel by
opening all manholes. For hydrocarbon or other gases, pressurize the vessel with N2 or gas

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and fill in the liquid and drain under pressure. This is to avoid hydrocarbon going to
atmosphere.
b) Precautions Before Handing Over Equipment

Following items should be checked by a responsible operating supervisor before the equipment is
handed over for maintenance after it has been purged.
Ascertain that equipment is isolated by proper valves and blinds.
Ascertain that there is no pressure of hydrocarbons in the lines, vessels and equipment.
Purge the system with N2 first and later by air and check for O2 content at vent and drain to
ensure that the vessel is full of air.
Check that steam injection lines and any inert line connections are disconnected or isolated
from the equipment.
Provide tags on the various blinds to avoid mistakes. Maintain a register for blinds.
Check for pyrophoric iron and if existing, keep this wet with water.
Keep the surrounding area cleaned up.
Get explosive meter test done in vessels, lines, equipment and surrounding areas.
If welding or hot work is to be done, also:

Keep fire fighting devices ready for use nearby.
Close the neighbouring surface drains with wet gunny bags.
Keep water flowing in the neighbouring area to cool down any spark bits etc.
Keep stem lancers ready for use.
After the above operations have been made, a safety permit should be issued for carrying out the
work. A responsible operating supervisor should be personally present at the place of hot work till
the first torch is lighted. Hot work should be immediately suspended if instructed by the supervisor
or on detecting any unsafe condition. When people have to enter a vessel for inspection or other
work, one person should stand outside near the manhole of the vessel for any help needed by the
persons working inside. The person entering the vessel should have tied on his waist a rope to

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enable pulling him out in case of urgency. Detail procedure for preparation for vessel entry is given
in next sub-section.
13.5 PREPARATION FOR VESSEL ENTRY

The most common potential hazards in vessel entry are:
Unit Checkout Prior to Start-up
Turnaround Inspections
Reactor Loading
Reactor Unloading
The precautions apply equally to entry into all forms of vessels, including those enclosed areas
which might not normally be considered vessels. Examples include: Reactors, Columns,
Separators, Receivers, Clay Treater, Fired heaters, Sumps
Positive Vessel Isolation

Every line connecting to a nozzle on the vessel to be entered must be blinded at the vessel. This
includes drains connecting to a closed sewer, utility connections and all process lines. The
location of each blind should be marked on a master piping and instrumentation diagram
(P&ID), each blind should be tagged with a number and a list of all blinds and their locations
should be maintained. One person should be given responsibility for the all blinds in the unit to
avoid errors.
The area around the vessel manways should also be surveyed for possible sources of dangerous
gases which might enter the vessel while the person is inside. Examples include acetylene
cylinders for welding and process vent or drain connections in the same or adjoining units. Any
hazards found in the survey should be isolated or removed.
Vessel Access
Safe access must be provided both to the exterior and interior of the vessel to be entered. The
exterior access should be a solid, permanent ladder and platform or scaffolding strong enough to
support the people and equipment who will be involved in the work to be performed.

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Access to the interior should also the strong and solid. Scaffolding is preferred when the vessel
is large enough. The scaffolding base should rest firmly on the bottom of the vessel and be
solidly anchored.
If the scaffolding is tall, the scaffolding should be supported in several places to prevent sway.
The platform boards should be sturdy and capable of supporting several people and equipment at
the same time and also be firmly fastened down. Rungs should be provided on the scaffolding
spaced at a comfortable distance for climbing on the structure.
If scaffolding will not fit in the vessel a ladder can be used. A rigid ladder is always preferred
over a rope ladder and is essential to avoid fatigue during lengthy periods of work inside a
vessel. The bottom and top of the ladder should be solidly anchored. If additional support is
available, then the ladder should also be anchored at intermediate locations. When possible, a
solid support should pass through the ladder under a rung, thereby providing support for the
entire weight should the bottom support fail. Only one person at a time should be allowed on the
ladder.
When a rope ladder is used, the ropes should be thoroughly inspected prior to each new job. All
rungs should be tested for strength, whether they be made of metal or wood. Each rope must be
individually secured to an immovable support. If possible, a solid support should pass through
the ladder so that a rung can help support the weight and the bottom of the ladder should be
fastened to a support to prevent the ladder from swinging. As with the rigid ladder, only one
person should climb the ladder at a time.
Wearing of a Safety Harness

Any person entering a vessel should wear a safety harness with an attached safety line. The
harness is not complete without the safety line. The harness should be strong and fastened in such
a manner that it can prevent a fall in the event the man slips and so that it can be used to extricate
the man from the vessel in the event he encounters difficulty. A parachute type harness is
preferred over a belt because it allows an unconscious person to be lifted from the shoulders,
making it easier to remove him from a tight place such as an internal manway. A minimum of one

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harness for each person entering the vessel and at least one spare harness for the people watching
the manway should be provided at the vessel entry.
Providing a Manway Watch

Before a person enters a vessel, there should be a minimum of two people available outside of
the vessel, one of whom should be specifically assigned responsibility to observe the activity of
the people inside of the vessel. The other person must remain available in close proximity to the
person watching the manway so that he can assist the person or go for help, if necessary. He
must also be alert for events outside of the vessel which might require the people inside to come
out of the vessel, for example, a nearby leak or fire. These people should not leave their post
until the people inside have safely evacuated the vessel.
A communication system should be provided for the man way watch so that they can quickly call
for help in the event that the personnel inside of the vessel encounter difficulty. A radio,
telephone, or public address system is necessary for that purpose.
Providing Fresh Air

The vessel must be purged completely free of any noxious or poisonous gases and inventoried
with fresh air before permitting anyone to enter. The responsible department, usually the safety
department, must test the atmosphere within the vessel for toxic gases, oxygen and explosive
gases before entry. This must be repeated every 4 hours while there are people inside the vessel.
Each point of entry and any dead areas inside of the vessel, such as receiver boots or areas
behind internal baffles, where there is little air circulation should be checked.
Fresh air can be circulated through the vessel suing an air mover, a fan, or, for the cases where
moisture is ca concern, the vessel can be purged using dry certified instrument air from a hose or
hard piped connection. When an air mover is used, make certain that the gas driver uses plant
air, not nitrogen, and direct the exhaust of the driver out of the vessel to guarantee that this gas
does not enter the vessel. When instrument air is used, it must be confirmed that a check of the
supply header is made to ensure that it is properly lined up and that there are no connections
where nitrogen can enter the system (nitrogen improperly used as a backup for instrument air by

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some refiners). The fresh air purge should be continued throughout the time that people are
inside of the vessel. The responsible control room should be informed that instrument air is
being used for breathing so that if a change to nitrogen is required the people are removed from
the affected vessel.
A minimum of one fresh air mask for each person entering the vessel and at least one spare mask
for the hole watcher should be provided at the vessel entry. These masks should completely
cover the face, including the eyes, and have a second seal around the mouth and nose. When use
of the mask is required, it must first be donned outside of the vessel where it is easy to render
assistance in order to confirm that the air supply is safe. Each mask must have a backup air
supply that is completely independent of the main supply. It must also be independent of
electrical power. This supply is typically a small, certified cylinder fastened to the safety harness
and connected to the main supply line via a special regulator that activates when the air pressure
to the mask drops below normal. The auxiliary supply should have an alarm which alerts the
user that he is on backup supply and it should be sufficiently large to give the user 5 minutes to
escape from danger.
Preparation of Vessel Entry Permit

Before entering the vessel a vessel entry permit must be obtained. A vessel entry permit ensures
that all responsible parties know that work is being conducted inside of a vessel and establishes a
safe preparation procedure to follow in order to prevent mistakes which could result in an
accident. The permit is typically issued by the safety engineer or by the shift supervisor. The
permit should be based on a safety checklist to be completed before it is issued. The permit
should also require the signatures of the safety engineer, the shift supervisor, and the person that
preformed the oxygen toxic and explosive gas check on the vessel atmosphere. Four copies of
the permit should be provided. One copy goes to the safety engineer, one to the shift supervisor,
one to the control room, and one copy should be posted prominently on the man way through
which the personnel will enter the vessel. The permit should be renewed before each shift and
all copies of the permit should be returned to the safety engineer when the work is complete.

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Additional requirements or procedures may be imposed by the refiner, but the foregoing is
considered the minimum acceptable for good safety practice.
Checkout Prior to New Unit Start-up

The risk of exposure to hydrocarbon, toxic or poisonous gases, and catalyst dust is low during a
new unit checkout; the primary danger is nitrogen. There will be pressure testing, line flushing,
hydrotesting, and possibly chemical cleaning being conducted in the unit and nitrogen may be
used during any of these activities. Some of the equipment may have been inventoried with
nitrogen to protect the internals from corrosion. An additional hazard is posed by operations in
other parts of the plant which may be beyond the control of the people entering the vessel so that
action taken at a remote location could admit nitrogen, fuel gas, steam, or other dangerous
material through a connecting process line into the vessel which is being entered. For these
reasons vessel entry procedures must still be rigorously followed during the checkout of a new
unit.
The oxygen content of the atmosphere inside of the vessel should be checked before every entry
and the vessel should be blinded. Independent blinds at each vessel nozzle are preferred.
However, in the event that many vessels are to be entered in a new unit which is separate from
the rest of the plant, the entire unit can be isolated by installing blinds at the battery limits rather
than by individually isolating every vessel nozzle.
Inspections During Turnarounds

In turnaround inspections, the possibility that vessels will contain dangerous gases is much
higher. Equipment which has been in service must be thoroughly purged before entry. The
vessel should have been steamed out unless steam presents a hazard o the internals and then fresh
air circulated through it until all traces of hydrocarbons are gone. If liquid hydrocarbon remains
or if odours persist afterwards, repeat the purging procedure until the vessel is clean. The service
history of the vessel must also be investigated before entry so that appropriate precautions may
be taken. The service may require a neutralization step or a special cleaning step to make the
vessel safe. Internal scale can trap poisonous gases such as hydrogen sulphide or hydrogen

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fluoride which may be released when the scale is disturbed. If this sort of danger is present,
fresh air masks and protective clothing may be required to be worn while working inside of the
equipment.
In a turnaround inspection, every vessel nozzle must be blinded at the vessel with absolutely no
exceptions. There will always be process material at the low and high points in the lines
connecting to the vessel because it is not possible to purge them completely clean. The blinds
must all be in place before the vessel is purge.
Another factor to be cautious of, especially if entering a vessel immediately after the unit has
been shut down, is heat stress. The internals of the vessels can still be very hot from the steam-
out procedure or from operations prior to the shutdown. If that is the case, the period of time
spent working inside of the vessel should be limited and frequent breaks should be taken outside
of the vessel.
13.6 HAZARDOUS CHEMICAL HANDLING

Hazardous properties of chemicals and their handling procedure are available in Material Safety
Datasheet. Hazards and handling procedure of some the material is discussed below.
13.6.1. HYDROGEN SULFIDE (H2S)

A hazard and handling procedures of H2S is as follows:
A) Potential for Exposure
The existence of H2S concentration with the fluids normally handled in this unit constitutes an
additional hazard to operating personnel that demands special attention. The properties of H2S make
exposure to even very low concentrations extremely dangerous. However, many years of industry
experience in handling the problems associated with H2S have resulted in procedures which, if
properly implemented, permit a reasonable level of safety for unit personnel.
The danger of exposure of H2S cannot be lessened. The potential for exposure can only be
minimized. The procedures and precautions contained within this section and elsewhere in this
manual constitute minimal requirements for dealing with H2S only. The implementation of
additional safety measures which can be found in various industry manuals is encouraged.

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B) Properties of H2S (Hydrogen Sulphide)

The chemical formula H2S represents a compound which is made up of two hydrogen atoms and
one sulphur atom. H2S (Hydrogen Sulphide) is a colorless (transparent), gas heavier than air.
Hydrogen sulphide is a poisonous gas that can paralyze the breathing system and kill a person in
minutes. In small amounts it is dangerous to health. This risk is increased by heat or hot weather. At
low concentrations (small amounts) H2S has an offensive odour similar to rotten eggs. At slightly
higher concentrations (small amounts), H2S may have a sick-sweet odour. At high concentrations no
smell can be detected, because H2S rapidly deadens the sense of smell by paralysis of the Olfactory-
Nerve. Consequently the sense of smell cannot be depended upon to detect H2S.
Characteristics of H2S
Hydrogen sulphide has the following characteristics:
Deadly-extremely toxic gas.
Colourless.
Heavier than air tends to settle in low lying areas.
Readily dispersed by wind movement of air currents.
Burns with a blue flame, producing Sulphur Di-oxide (SO2), which is also a toxic gas.
Odour of rotten eggs. Only in low concentrations rapidly deadens the sense of smell. Do
not depend on the sense of smell to detect H2S
Highly corrosive to certain metals.
More deadly than Carbon Monoxide (CO), and almost as toxic as Hydrogen Cyanide
(HCN) gas.
Property table OF H2S

- Auto ignition Temperature 500F(260C)
- Boiling Point @ 1 atm -76.6F(-60.33C)
- Critical Density 0.349 g/ml
- Critical Pressure 1309 psig (89.05 atm)
92 kg/cm2, absolute

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- Critical Temperature 212.7F (100.4C)

- Density, gas @ 0C 1 atm 1.5392 g/l
- Density, Liquid @ b.p. 0.993 g/l
- Flammable Limits in Air 4.3-4.5% (by volume)
- Freezing Point @ 1 atm -121.9F (-85.49C)
- Latent Heat of Fusion @ m.p. 508cal/mole (16.7 cal/g)
- Latent Heat of Vaporization @ b.p. 4.463kcal/mole (131 cal/g)
- Molecular Weight 34.08
- Solubility in Water @0C 1 atm 0.672 g/100 ml water
- Specific Heat, Gas @ 25C 1 atm
Cp = 0.240 cal/ (g) (C)
Cv = 0.181 cal/ (g) (C)
- Specific Gravity Gas 1.1895 15C, 1atm (Air = 1)
- Specific Heat Ratio, Gas 1.32@25C, 1 atm, Cp/Cv
- Thermal Conductivity @ 0C 0.305 cal/(Sec)(Cm2) (C/cm)
- Vapour Pressure @ 70F 252 psig (17.7 kg/cm2g)
- Specific Volume @ 70F, 1 atm 11.23 cu ft/lb (701 ml/g)
- Viscosity of Gas @ 0C 1 atm 0.01166 centipoise
- Explosive limits:
- Lower 4% volume in air upper 44% volume in air
C) Effects of H2S on Personnel

Itemized concentrations of Hydrogen Sulphide as prepared by American National Standards
Institute (ANSI Standard No. Z37.2-1972) are tabled below:
0.13 ppm Minimal perceptible odour

4.60 ppm Easily detectable, moderate odour
10 ppm Beginning eye irritation
27.0 ppm Strong, unpleasant odour, but not intolerable

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100 ppm Coughing, eye irritation, loss of sense of smell after 2-15
minutes.
200-300 ppm Marked conjunctivitis (eye inflammation) and
respiratory tact irritation after one hour of exposure.
500-700 ppm Loss of consciousness, possible death in 30 minutes to 1
hour.
700-1000 ppm Rapid unconsciousness, cessation (stopping or
pausing) of respiration and death.
1000-2000 ppm Unconsciousness at once, with early cessation of respiration
and death in few minutes. Death may occur even if individual
is removed to fresh air at once.
ppm parts of gas per million part of air by volume.
D) H2S handling procedure

General Procedures:
Industry practice mandates that the following precautions procedures should be followed by all
personnel:
When approaching the work area it is necessary to take the following precautions to insure
safe entry
1. Observe Condition signs and observe for audio/visual alarms.
2. Check for wind direction.
3. Look for personnel and their activity.
4. Enter work area slowly.
Maintain mental image of two (at least) escape routes preferably cross wind.
Continuous atmosphere monitoring or detecting equipment is required along with an
adequate audio/visual alarm warning system. Portable detectors and combustible gas meters
give an additional degree of safety.
Gas ignition hazard must be eliminated and No Smoking regulations strictly enforced.

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Continued observation of wind indicators, windsocks and streamers is a must. During

atmospheric contamination by H2S, move upwind/cross wind from source, not downwind.
Select a partner and use the Buddy System for mutual safety.
Maintain and observe warning signs.
Post emergency numbers in a conspicuous place. Maintain reliable communication systems.
Locate emergency stations a minimum of 250 feet or as far from the H2S source as practical.
During an emergency all personnel will assemble at the briefing stations for instructions and
for refilling air bottles.
Hazardous concentrations of H2S can be disposed of by discharging through flare stacks
with automatic ignitions.
Note: Burning H2S produces Sulphur Dioxide (SO2), a deadly toxic gas that is heavier than H2S.
Because of the heat it rises and disperses into the upper atmosphere.
Maintenance Procedure:
There are two basic areas of maintenance operations which are inherently dangerous from
the standpoint of H2S exposure. These are venting / draining of piping and confined space
entry.
Depressurization of piping, valves, fittings, strainers, etc. in H2S service represents a safety
hazard in the unit, since the vent and drain valves are not hard-piped to a closed vent or
drain header.
Without exception, breathing air respirators are to be worn when opening piping, removing
valves or performing any operation which might permit vapours to enter the immediate area.
When valves are removed, install blind flanges.
Confined space entry is entrance into areas such as tanks, vessels, etc. This is one of the
most dangerous activities of the unit and should be avoided whenever possible.
When it is absolutely necessary that a confined entry be made, entry should be made only after the
following safety conditions have been met.
Entry permit form has been filled out and signed.

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Space contains at least 19.5% of oxygen by volume.

Sample does not contain combustible vapours above L.E.L.
Space does not contain toxic gas contaminants above the limit of appropriate threshold
values for the substance.
Even if the above mentioned conditions are met, personnel entering such enclosed spaces
shall be equipped with self contained breathing apparatus (SCBA) pressure demand type.
Rescue equipment must be in close vicinity of the confined space.
All personnel entering the confined space must wear safety harness and reflective tape.
An adequate number of personnel must be stationed outside for emergency assistance.
Communications must be clearly established and a system of safety signs and signals
understood by all.
Any battery operated or electrical communications system such as hand-held walkie-talkie
or throat type microphone, if used in a hazardous environment must be intrinsically safe.
There are a number of other safety precautions and equipment to be considered when a confined
space entry must be made such as:
Resuscitation equipment, litter, safety lanterns or chemical lights, tripped for hoisting over hatches,
instrument calibration, mechanical ventilation, cascade systems, continuous monitoring, houseline
units, separate means of access where possible, emergency team and plan and proper training.
Remember the fact that any entry into a confined space is inherently dangerous.
E) Emergency Procedures
If all the above procedures have been adhered to strictly, a catastrophic release of H2S should never
occur. In the unlikely event such a release does occur, the emergency procedures detailed in this
section should be followed.
a) Egress
H2S is a dangerous, deadly gas; however serious injury or death can be avoided by simply
evacuating the contaminated area and moving to a safe area upwind. Therefore, the most important
things to remember are to Stay Claim and Get Away.

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Precise emergency escape procedures will be defined by the operations management of the
complex; however the following general procedures should be followed:
Remain Calm-Do Not Panic
Hold your breath
Extinguish all fires
Alert the rest of the crew
Make a quick, cursory check of the area to see if the source of the gas is obvious.
Do not spend time looking for a leak
Observe windsock to determine wind direction. Move upwind or crosswind, not downwind,
until the safe breathing area is reached.
Active alarms if not already done.
Once assembled at the safe briefing area, the foreman will make a head count to determine if
all personnel have evacuated safely.
b) Rescue and First Aid

Although H2S is a dangerous, deadly gas, its effects are readily reversible provided the appropriate
action is taken in a timely manner. In the event of, a fellow worker is down or overcome by H2S, the
necessity of an immediate and effective rescue effort is or utmost importance. A natural reaction is
to unthinkingly rush to the side of the downed victim, which could be a fatal action.
Instead, before proceeding into the hazardous area to rescue a downed victim, stop, think and:
Put on an appropriate safe breathing apparatus.
Move quickly, but carefully to the victim, side. Move the victim to a safe area; either
upwind or crosswind from the hazardous area. Do not evacuate in a downwind direction.
Begin mouth-to-mouth artificial respiration if the victim has stopped breathing. Check the
victims pulse periodically to ensure that the victims heart is still beating. If the victims
heart stops beating, administer CPR. Artificial respiration or CPR should be continued until:
The victim begins to breathe and, if applicable, the heart begins to beat.
He is pronounced dead by a doctor.
He is dead beyond any doubt.

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Seek assistance at the first opportunity and make arrangements for transportation to
a medical facility to seek medical attention by a physician.
c) Abatement Procedure
Once the safety of all personnel has been determined, the next order or business is to determine the
source of H2S and stop it, if possible.
Control Room Personnel

Control Room personnel Stay in the Control Room since it is equipped with a positive
ventilation system pulling suction from a higher elevation. Since H2S is heavier than air, the
Control Room should be safe.
If leak can be located, activate the deluge system for that area.
Field Personnel
Use breathing apparatus (Respirator).
Establish communication with Control Room.
Communicate with first personnel to sound alarm/notice of the H2S.
To determine the general area of the source, slowly begin searching the source from the
upwind side.
13.6.2. HYDROGEN
Hydrogen is a colourless, tasteless, odourless and highly flammable gas and is the lightest
element. Since hydrogen is lighter than air, less danger exists of it collecting in pockets in low
areas. However, the potential danger from fire or explosion is high. Gaseous fuels such as
hydrogen can mix with air or oxygen in all proportions. However, the proportions must be within
certain limits before those mixtures will burn. The limiting proportions are referred to as
flammable limits or explosive limits and are expressed as the percentage by volume of the
fuel in the air-fuel mixture. Fuel-air mixtures outside of the flammable range will not explode.
Hydrogen has a very wide range (4-75%) of flammability or explosive limits in air at

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atmospheric pressure. In addition to, the flammability range becomes wider at higher pressure or
if oxygen is substituted for air. Thus, explosions can occur over a very wide range of hydrogen
concentrations in air. The safest approach to safeguard against possible fires or explosions is to
make sure that hydrogen leaks do not develop.
The auto ignition temperature of a substance is the lowest temperature required to initiate or
cause self-sustained combustion in the absence of a spark or flame. The auto ignition
temperature of hydrogen in air is 580C at atmospheric conditions. However, other factors such
as the nature, size, and shape of the igniting surface can affect this temperature.
Unlike most gases, which cool when expanded or bled off, hydrogen heats up when expanded
and great care must be exercised when bleeding down lines or compressors to the atmosphere. In
its pure state, hydrogen burns with a bluish white flame (almost invisible) that is extremely hot.
Such a hot flame can weaken any support beams or lines on which it may impinge. Any leaks
should be put under a steam blanket immediately to prevent the possibility of a fire. Be aware,
however, that many leaks can auto ignite and will be difficult to see. Replacing the source of the
hydrogen with a nitrogen or steam purge is the most effective way of combating a hydrogen fire.
Hydrogen, although a not a poisonous gas itself, is an asphyxiant (i.e. cuts off oxygen supply to
the body by displacing air in the lungs) and can cause unconsciousness and even death if the
victim falls and remains in a high hydrogen atmosphere.
Because of the small size of hydrogen molecules, a pressure check with air or nitrogen or a
hydrostatic test will not always show all leaks that will occur with hydrogen.
13.7 FIRE FIGHTING SYSTEM

The operating personnel should be fully conversant with Fire Fighting system provided in the unit.
All of them should have adequate fire fighting training and will serve as an auxiliary Fire Squad in
the event of a fire breakout. It will be the primary responsibility of unit personnel to fight the fire at
the very initial stage and, at the least, localize it.
Major Fire fighting facilities provided in the unit comprise the following:

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i) Fire Water System

Water is most important fire fighting medium. Water is used for fire extinguishment, control,
equipment cooling & exposure protection of equipment/personnel from heat radiation.
An elaborate fire water distribution network is provided around unit. Fire Water Hydrants/Monitors
are provided around unit, which give coverage to most of equipment.
ii) Foam System
For containing large Hydrocarbon fires, foam systems are useful. They have inherent blanketing
ability, heat resistance and security against burn back. Low expansion foam is used for hydrocarbon
oil fire. Foam can be applied over burning oil pool with the help of foam tenders/foam delivery
system.
iii) Portable Fire Extinguishers
Fire should be killed at the incipient stage. Portable fire extinguishers are very useful in fighting
small fires. All extinguishers in the unit must be located in specified places only. The operating
crew should be acquainted with exact location of the extinguishers. They also must know most
suitable type, which, when and how to use an extinguisher. For example, electrical fires should be
put out with CO2 or dry power extinguishers; water and foam should not be used. The used
extinguishers should be checked and restored by fire station personnel.
iv) Fire Signal
Break Glasses have been provided at strategic locations of unit to see fire alarm in fire station. if a
fire is sighted, glass of window should be smashed, causing fire alarm switch to actuate. This is an
emergency call & should be periodically tested for proper functioning.
v) Steam Smothering
LP Steam hose connections have been provided at every convenient point inside unit. Steam lances
of standard 15M length can be fitted with these hose stations. Where ever hydrocarbon leakage is
detected which is likely to catch fire, Steam blanketing may be done. Apart from diluting
combustible hydrocarbons, steam prevents atmospheric oxygen from taking part in combustion,
thus help in extinguishing fire. However, steam should never be applied on large pool of
hydrocarbon fire. Direct application of steam on burning oil may result in spillage of burning

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hydrocarbon & spread of fire. Similarly use of fire water on hot oil surfaces may cause sputtering &
spread of fire.
13.8 USE OF LIFE SAVING DEVICE

Safety of the personnel should the prime concern. Life saving device is to be used for personnel
protection. Important life saving devices which are required to be used are given below:
Head protection:- Safety helmets shall be worn by all personnel at all times in the plant for protection
of the head. They may be removed when inside rooms or buildings which do not have overhead or
other hazards.
Eye and face protection:- Safety glasses, goggles or face shields shall be worn while performing
work, which could result in eye or face injury.
Hand Protection: - Proper hand protective gloves should be worn.
Foot protection: - Safety shoes are to be worn for foot protection.
Ear protection: - Whenever personnel are required to be work in noisy areas proper ear protection
device such as ear plug etc, is to be used.
Breathing apparatus: - Whenever persons are required to work or enter an area of high
toxic/aromatic/hydrocarbon vapor concentration, wear appropriate respiratory protection, such as
self-contained breathing apparatus or an air mask with an external air supply.

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SECTION -14
GENERAL OPERATING INSTRUCTIONS FOR EQUIPMENT
14.1 GENERAL
This section covers the general procedure for operation and trouble shooting of commonly used
equipment like pumps, heat exchangers and furnace etc. For specific information and more detail
refer to vendor's manuals.
14.2 CENTRIFUGAL PUMPS

14.2.1. Start-up
Inspect and see if all the mechanical jobs are completed.
Establish cooling water flow where there is such provision. Also open steam for seal
quenching in pumps having such facilities.
Check oil level in the bearing housing, flushing may be necessary if oil is dirty or contains
some foreign material.
Rotate the shaft by hand to ensure that it is free and coupling is secure. Coupling guard
should be in position and secured properly.
Open suction valve. Ensure that the casing is full of liquid. Bleed, if necessary, from the
bleeder valve.
Energize the motor. Start the pump and check the direction of rotation. Rectify the direction
of rotation if it is not right.
Check the discharge pressure. Bleed if necessary to avoid vapour locking.
Open the discharge valve slowly. Keep watch on the current drawn by the motor, if
ammeter is provided. In other cases check at motor control centre.
In some pumps a by-pass has been provided across the check valve and discharge valve to keep the
idle pump hot. In such pumps, the by-pass valve should be closed before starting the pump. It
should be ensured that casing of these pumps are heated up sufficiently prior to starting of the pump
to guard against damage of the equipment and associated piping due to thermal shock.

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14.2.2. Shutdown
Close discharge valve fully.
Stop the pump
a) If pump is going to remain as standby and has provision for keeping the pump hot, proceed
as follows:
Open the valve in the by-pass line across the discharge valve and check valve.
The circulation rate should not be so high to cause reverse rotation of idle pump and also
overloading of the running pump.
b) If pump is to be prepared for maintenance, proceed as follows:

Close suction and discharge valves.
Close valve on check valve by-pass line, if provided.
Close cooling water to bearing, if provided. Also shut off steam for seal quenching, if
provided.
Slowly open pump bleeder and drain liquid from pump if the liquid is very hot allow
sufficient time before draining is started. Ensure that there is no pressure in the pump. Also
drain pump casing.
Blind suction and discharge and check valve by-pass line and flare connection if any.
Cut-off electrical supply to pump motor prior to handling over for maintenance.
14.2.3. Trouble Shooting

i. Pump not developing pressure
Bleed to expel vapor/air
Check the lining up in the suction side.
Check the suction strainer.
Check the liquid level from where the pump is taking suction.
Check pump coupling and rotation.
Get the pump checked by a technician.

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ii. Unusual Noise

Check the coupling guard if it is touching.
Check for proper fixing of fan and fan cover.,
Check for pump cavitation.
Get the pump checked by a technician.
iii. Rise of Bearing Temperature

Generally the bearing oil temperature upto 80C or 50C above ambient whichever is lower, can be
tolerated.
Arrange lubrication if bearing is running dry or oil level is low.
Adjust cooling water to the bearing housing, if there is such provision.
Stop the pump, if temperature is too high, call the pump technician.
iv. Hot Gland

Adjust cooling water if facility exists.
Slightly loosen the gland nut, if possible.
Stop the pump and hand over to maintenance.
Arrange external cooling if pump has to be run for sometime.
v. Unusual Vibration
Check the foundation bolts.
Check the fan cover for looseness.
vi. Leaky Gland

Check the pump discharge pressure.
Tighten the gland nut slowly, if possible.
Prepare the pump for gland packing or adjustment/replacement of mechanical seal as the
case may be.

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vii. Mechanical Seal Leak

Stop and isolate the pump and hand over to maintenance.
14.3 POSITIVE DISPLACEMENT PUMPS

14.3.1. Start-up
i. Check if all mechanical jobs are completed.
ii. Flush and renew oil in pump gear box.
iii. Check whether suction strainer is installed.
iv. Check for proper lining up including the pressure safety valve in the discharge. Open
suction valve fully.
v. Check that the motor shaft is reasonably free and coupling secured. Coupling guard should
be in position.
vi. Energize motor. Open discharge valve. Start the motor and check direction of rotation. Stop
and rectify if direction of rotation is wrong.
vii. Adjust the pump stroke and run the pump at different settings. Watch discharge pressure and
check the rate of pumping using the flow meter or by taking suction from the calibration
pot. In case the pumps is provided with a pressure controller adjust it to obtain the required
discharge pressure.
viii. Care should be taken to avoid dry running of pump and back flow of liquid. Bleed if
necessary to expel vapor/air.
ix. Check for unusual noise, vibrations, rise of temperature of both motor and gears.
14.3.2. Shutdown
Stop the pump.
Close the suction and discharge valves.
Drain the liquid if maintenance jobs are to be carried out on the pump.

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i. Insufficient Discharge Pressure
Check the lining up in the suction side.
Check the functioning of the safety valve and pressure control valve on discharge to suction.
Check the strainer on the suction side.
Check for insufficient liquid level in the tank.
Check pump coupling and rotation.
Get the pump checked by pump technician.
ii. High Discharge Pressure

Check the line up on the discharge side.
Check pressure control valve opening.
iii. Leak Gland

Check for normal pump discharge pressure.
Tighten the gland nut slowly if possible.
Hand over the pump for replacing gland packing.
iv. Unusual Vibrations

Check the foundation bolts.
Check motor fan cover for looseness.
14.4 CENTRIFUGAL COMPRESSOR

The pre-commissioning of the centrifugal compressor should follow the equipment manufacturers
recommended procedures. The following general procedures shall not be construed as a
replacement for the manufacturer procedures.

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Verify that the lubrication, seal gas, and coolant systems are clean and free of contamination and
that all control systems function properly. The pre-commissioning of these package units should
follow the manufacturers recommended procedures.
Verify that the shutdown system on the compressor function according to design. The temporary
strainers on the suction should be removed prior to full-time operation.
Verify that the compressor rotate freely.
14.4.1. Start-up
i. Ensure all mechanical jobs have been completed on the compressor that is to be started
including suction line passivation.
ii. No load run of the motor to be completed before the compressor is coupled. After no load
run, de-energize the electrical supply. Couple the motor and compressor. Check the
rotating element of the compressor for free rotation turning slowly by hand. If the rotor
rubs, rotation should be stopped immediately and the difficulty located and repaired.
iii. Check oil level in lube oil tank and refill as required bringing the oil level to the high
mark on the sight glass. Do not overfill.
iv. Line-up and start seal and lube oil circulation to make certain that bearings of the
compressor and driver are well lubricated.
v. Establish the pressure of lubricating oil in bearings and seal oil to seal.
Note: Seal system is to be in operation whenever any pressure is in the compressor, even
though the machine is idle.
vi. Bar the unit over once to be sure all moving parts are clear.
vii. Make sure that water cooler and air coolers coming in compressor circuit are in
operation.
viii. Ensure that compressor casing has also been purged with inert gas. Pressurise the
compressor with nitrogen and leak test.
ix. Open suction valve/discharge valve and line up to the system. Remove any accumulated
liquid from the casing by opening casing drain.
x. Start the drive as per the vendors recommendations and run the compressor.

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xi. Allow the oil to warm up to 40o C. Watch compressor motor amperage. Listen for
unusual noise or vibration during the warm up period.
xii. Auxiliary motor driven lube oil pump will be stopped when shaft-driven pump develops
normal oil pressure and kept ready for auto start.
xiii. When the unit is warmed up and determined to be operating satisfactorily, gradually start
throttling the valve beyond surge requirements of the compressor.
xiv. Load the compressor to the required capacity in the above mentioned manner.
Note: The compressor before trial run on the actual medium may be tried on air with suction and
discharge open to atmosphere. While attempting to run the Compressor on air, Vendor's
instructions and recommendations are to be followed. It is to be noted that scaling
arrangement may be required to be changed to suit the machine running on air.
14.4.2. Shutdown
i. Stop the drive.
ii. Start the oil pump to lubricate the bearing till required.
iii. Close the discharge valve.
iv. Close the suction valve.
v. Turn off cooling water to oil cooler as applicable.
vi. If the compressor is to be given for maintenance, isolate, depressurise and purge with
inert gas to make the compressor free of hydrocarbons.
14.4.3. Normal Operation

i. Check oil level in lube oil tank and add oil as required to maintain the proper level as
indicated on sight glass. Periodically check level in emergency lubricating oil overhead
tank.
ii. Log all temperatures, pressures, levels, flows.
iii. Adjust cooling water flows to compensate for changes in inlet water temperature or
ambient temperature.

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iv. Listen for any unusual noise while the machine is operating. These should be
investigated immediately.
v. Periodically drain from suction pot etc.
vi. Watch differential pressure across oil filter to check cleanliness; change over filter, if
necessary and arrange cleaning of choked filter.
vii. Keep the exterior of the compressor and the compressor room floor clean.

Follow vendor's recommendations. However, some general guide lines are given below:
i. SURGING
Restricted flow due to plant operating at partial load or throttling at discharge.
Blocked suction due to strainer choking or line choking if a permanent strainer is not
provided.
Liquid carry over from suction K.O. drum.
ii. HEAVY VIBRATIONS IN MACHINE

Misalignment
Bent rotor
Damaged rotor
Imbalance
Weak foundation
Mechanical Loosening etc.
Bearing damage
14.5 HEAT EXCHANGERS

GENERAL
The unit has a number of heat exchangers, air coolers. Suitable valve arrangement for bypassing
and isolation is provided wherever necessary to offer the required operational flexibility.

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The exchangers have been provided with draining and flushing connections. The coolers and
condensers have been provided with TSV's on the cooling water side to guard against possible rise
of pressure due to faulty operations with the safety release to atmosphere. Temperature gauges or
thermo wells have been provided at the inlet and outlet of exchangers. Where water is the cooling
medium, no temperature measurement is provided for water inlet temperature which is the same as
cooling water supply header temperature.
AIR COOLERS
The air coolers/condensers comprise of a fin tube assembly running parallel between the inlet
and outlet headers. These are of the forced draft type. The forced draft fans provided have auto
variable speed rotors in which the fan speeds are adjusted during rotation. This allows variation
in air flow as per the cooling requirements. A high vibration switch is provided with alarm to
indicate any mechanical damage.
EXCHANGERS
Shell and Tube type heat exchangers can be broadly classified into following types: -
Water Coolers/condensers
Steam heaters (reboiler)
Exchangers
Start-up /shut down procedures for each unit shall vary slightly from case to case. However,
general start-up /shut-down procedures are discussed in the following paragraphs.
14.5.1. Start-Up
After the heat exchanger has been pressure tested and all blinds removed, proceed as follows:
i. Open cooling medium vent valve to displace non-condensable (air, fuel gas, inert gas
etc.) from the system. Ensure the drain valves are capped. For high pressure system,
drain valves should be flanged. This activity is not required if gas is the medium.

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ii. Open cooling medium inlet valve. Close vent valve when liquid starts coming out
through it, then open cold medium outlet valve and fully open the inlet valve also. Where
cold medium is also hot, warming up of cold medium side gradually is also essential.
iii. Open hot medium side vent valve to displace non condensable (air, fuel inert gas etc.).
Check that the drain is closed and capped. This activity is not required if gas is the
medium.
iv. Crack open hot medium inlet valve. When liquid starts coming out from the vent valve,
close it. Open hot medium inlet valve and then open the outlet valve fully. In case of
steam heaters, initially the condensate shall be drained to sewer till pressure in the
system builds up to a level where it can be lined up to the return condensate header.
v. In case by passes are provided across shells and tube side, gradually close the bypass on
the cold medium side and then the bypass across the hot medium side.
vi. Check for normal inlet and outlet temperatures. Check that TSVs are not popping.
vii. The operation of inlet and outlet valves should be done carefully ensuring that the
exchangers are not subjected to thermal shock.
viii. In case of coolers/condensers, adjust the water flow to maintain the required temperatures
at the outlet.
ix. For avoiding fouling, velocity of water should be at least 1 m/sec in a cooler/condenser.
14.5.2. Shutdown
Shut down of an exchanger, coolers, condenser is considered when the equipment is to be isolated
for handling over to maintenance while the main plant is in operation. The following is the
suggested procedure for isolation of the piece of equipment
i. Isolate the hot medium first. In case both hot and cold medium are from process streams,
exchanger shall remain in service till the hot stream has cooled down enough.
ii. In case of a cooler, adjust cooling water flow to the cooler which is in line so that product
temperature is within allowable unit.
iii. Isolate the cold medium next.

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iv. Drain out the shell and tube sides to OWS/Sewer/Closed blow down system as
applicable. In case flushing oil connection is given flush the exchanger to CBD. Ensure that
the CBD drum has sufficient level to receive the flushing of the exchanger
v. Depressurize the system to atmosphere/flare/blow down system as applicable.
vi. Purge/flush if required. This is particularly important in congealing services.
vii. Blind inlet and outlet lines before handing over the equipment for maintenance.

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NAPHTHA HYDROTREATING UNIT

VISAKH REFINERY CLEAN FUEL PROJECT

A Issued for comments

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4.2 PROCESS FLOW DESCRIPTION ............................................................................... 42

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7.3 NORMAL OPERATING PARAMETER...................................................................... 90

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SECTION-11 .............................................................................................................................. 149

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14.1 GENERAL ................................................................................................................... 187

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2.2 UNIT CAPACITY

2.3 TURNDOWN CAPABILITY

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2.4.1. Feeds specification

FEED, mass fraction FBR Naphtha % Case-I FBR Naphtha % Case-I

i-Pentane 2.83 7.45

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223-Mbutane 0.00 0.06

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1M2-EBenzene 0.11 0.12

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Total oxygen wt ppm 2.0 max

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2.6 BATTERY LIMIT CONDITIONS FOR NHDT

Incoming Stream Source Temperature ( C) Pressure ( Kg/cm2 g)

SR Light Naphtha CDU 1,2,3 75 4.5

Outgoing Stream Destination Temperature ( C) Pressure ( Kg/cm2 g)

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Outgoing Stream Destination Temperature ( C) Pressure ( Kg/cm2 g)

2.7 UTILITY CONDITION

Minimum (for Mech.

2.7.2. Condensate Return System

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2.7.3. Process Water and Boiler Feed water

2.7.4. Cooling Water

2.7.5. Fuel Oil System

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2.7.6. Fuel gas System

2.7.7. Plant and Instrument Air

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2.7.10. Spent Caustic

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3.1 PROCESS CHEMISTRY

3.2 SULFUR REMOVAL

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3.3 NITROGEN REMOVAL

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3.4 OXYGEN REMOVAL

3.5 OLEFIN SATURATION

C-C=C-C-C-C + H2 C-C-C-C-C-C (and isomers)

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3.6 AROMATIC SATURATION

3.7 METALS REMOVAL

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3.8 HALIDES REMOVAL

HCl + NH3 NH4Cl

3.9 REACTION RATES

Hydroprocessing reaction Relative heat of reaction