J-826 10 AREA 2500 AMINE UNIT INTRODUCTION This manual covers the basic procedures for the commissioning, preparation, start-up, ormal operation, normal shutdown, and emergency shutdown of the Amine Unit, Area 2500. Since the Amine Unit forms only a part of the overall system, it is not possible for the basic procedures presented to cover all operational contingencies. The information presented should be carefully reviewed by operating personnel with respect to proper operator reactions to deviations and difficulties that will arise. For interconnection between Phase one and Phase two, reference the “Interconnections” sections at the beginning of this manualAREA 2500 Page 2 - J-826 2.0 PROCESS DESCRIPTION ‘The process description can be better followed by referring to the P&l D's, 826-D-5102-1 through 826-D-5102-13 The Amine Unit is designed to treat approximately 3.0 MM SCMID of gas from 5.0 mole % CO; to less than 100 ppm CO2. 24 22 Feed Knock Out System The inlet gas flow to the amine unit is controlled by FV-21405 in the 2100 area FV-21405 has a minimum stop that will prevent the valve from closing and sending too much gas to the amine unit. The raw gas enters the amine unit and flows to the Inlet Separator, V-2501, to knock out any entrained liquids in the stream. Hydrocarbon carryover causes foaming and decreases efficiency of the amine system. The vessel is equipped with a coalescing vane pack at the outlet {0 aid in minimizing the liquid carryover. Entrained liquids are accumulated and sent to the Condensate Flash Drum, V-2601, by a level controller LIC-25101, which operates LV-25101. An independent low level switch, LSLL-25103 is provided as a safeguard. Activation of the low-level switch will close a secondary valve, NV-25501, to prevent gas blow -by to the condensate stabilization unit The vessel is also equipped with local level gauge, LG-2501, and a local pressure gauge, PI-2501, for monitoring purposes. An inlet CO» analyzer (AE- 25602) is provided to monitor inlet CO, concentrations. Gas Contactor Gas from V-2501 then flows to the Gas Contactor where a specialty amine (Dow Gas/Spec now owned by INEOS) removes. the carbon dioxide that is present in the gas. The contactor contains 21 valve type trays. The gas flows up the tower and is contacted with the amine, which flows down the tower. The CO» isAREA 2500 Page 3 ~ J-826 2.0 PRE = continued - chemically reacted with and adsorbed by the amine. The reaction is later reversed by high temperatures and low pressures in the stripper, to regenerate the amine. The treated gas from the contactor is then sent to the Outlet Separator, V-2503. To aid in trouble shooting the unit, the contactor is equipped with a differential pressure measurement PDI-25302 across the trays. An increase in pressure drop usually indicates foaming ‘The rich amine solution flows from the bottom of T-2501 to the Rich Amine Fiash ow level switch is provided as a safeguard. Activation of LLSL-25106 will close a secondary valve, NV-25503. Local level gauges, LG-2503 A/B, and a local pressure gauge, PI-2503 are also provided for monitoring. A relief valve, PSV- 2501 protects V-2501, V-2503, and 7-2501 from overpressure. 2.3 Outlet Separator Entrained amine is knocked out in the Outlet Separator, V-2503. The vessel contains a coalescing Vane pack at the outlet to minimize any liquid carryover in the treated gas. Entrained liquids are collected in the bottom of the vessel, and sent to the Rich Amine Flash Drum, V-2505, by a level controller, LIC-25102. An independent low level switch is provided as a safeguard. Activation of LSLL- 25104 will close a secondary valve, NV-25502. A local level gauge, LG-2502, and a local pressure gauge, P1-2502, are provided for monitoring the vessel. An outlet CO; analyzer (AE-25601) is provided to monitor treated gas CO, concentrations. | Drum, V-2505, on level contol using LIC-25105 and LV-25108. An independent | i eee : PETROPACAREA 2500 Page 4 ~ J-826 2.0 PROCESS DESCRIPTION — continued - 2.4 Rich Amine Flash Drum The rich amine flows from the contactor to the Rich Amine Flash Drum, V-2505. Entrained gases and hydrocarbons are flashed from amine solution. The relatively small amount of flashed gas is sent to the Hot Oil Heaters, H-2701 A/B, {for disposal. Pressure is maintained on the vessel by PIC-25303 and PV-25303. \V-2508 also has adequate residence time to separate liquid oil from the aqueous {amine/water) solution. The oil will overflow the oil side baffle, and is manually drained from the system. ‘The amine flows through the underflow/overfiow weir assembly to maintain an aqueous seal and prevent the carry over of oil. Level in the amine side of the vessel is maintained by LIC-25107 and LV-25107. Local level gauges are provided for the amine section LG-2504, and the oil section LG-2508, for local monitoring of the vesse! levels. 2.5 Amine Regeneration The rich amine from V-2505 is heated by cross exchange with the lean amine in the Lean/Rich Amine Exchangers, £-2501 A/B (two 50% operating exchangers), and is then sent to Amine Stripper, T-2502, for regeneration of the amine. Local temperature gauges are provided for monitoring the performance ofthe plate and frame exchangers. TI-25203 provides a DCS temperature measurement also. 17-2502 is a trayed tower with twenty-one valve trays and one chimney tray. The feed enters just above the top tray of the tower through an inlet distributor. A small amount of the feed will be vapor, and travels out of the top of the tower. ‘The liquid is evenly distributed on to the deck of the top tray. | | i2.0 PROCESS DESCRIPTION — continued - The Amine Stripper Reboilers, £-2502 AJB, are once-through horizontal thermosyphon type rebollers. In a thermosyphon type reboiler, the density difference between the two phase retum line and the liquid inlet line provides the pressure driving force to allow circulation through the exchanger. The particular configuration of this reboiler also allows for simple gravity flow through the ‘exchangers. Hot oil is used as the heat source for the reboilers. In the reboilers, portion of the solution is vaporized. The vapor, mostly steam, travels up through the tower. The combination of heat and low pressure reverses the acid gas absorption reaction, and the steam strips the acid gas components from the amine solution. The amount of heat and the amount of stripping are controlled by controlling the amount of hot oil to the reboiler via FIC-25403/FIC-25404 and FV- 25403/FV-25404, The overhead vapor from T-2502 flows to the Amine Stripper Overhead Condenser, AC-2502. The overhead vapor consists mostly of water vapor, CO>, and small amounts of hydrocarbons and other components. Most of the water vapor is condensed in AC-2502, which is an air-cooled heat exchanger. Manually operated louvers are provided on AC-2502 for controlling the outlet temperature from the air cooler. The two-phase mixture from AC-2502 is separated in V-2502, the Amine Stripper Reflux drum, V-2502 contains a wire mesh mist pad to minimize liquid carryover. The acid gas is vented to the atmosphere through PV-25305, which maintains the operating pressure of T-2502 at the pressure controller PIC-25305 set point. The liquid is accumulated in the bottom of the vessel, liquid level is controlled by LIC-25110 and LV-25110. An independent low level switch is provided as a safeguard, Activation of the low-level switch, LSLL-25111, wil shut off P-2502 A/B, the Amine Stripper Reflux Pumps to prevent damage to these pumps from loss of suction. A local level gauge, LG-2507, and a local pressure gauge, Pl-2509, are provided for monitoring the vessel ® PETROFAC r > AREA 2500 Page 5 J-826AREA 2500 Page 6 ~ J-826 2.0 PROCESS DESCRIPTION — continued - 28 ‘The liquid from V-2502 enters the suction of the Amine Stripper Reflux Pumps, P-2502 A/B, and is pumped back to T-2502 as reflux. One pump is operational, and the other is a 100% standby spare, \V-2502 also contains a oil weir. If an oil layer is present as evidenced by the local interface level gauge, LG-2508, the oil can be decanted. The regenerated hot amine leaves the bottom of T-2502 and flows through E- 2501 AVB to the suction of the Lean Amine Circulation Pumps, P-2501 A/B/C. The level in the bottom of T-2502 is indicated by LT-25108 on the DCS. The bottom section of T-2502 is the surge compartment for the unit. An independent low level switch is provided as a safeguard. Activation of the low-level switch, LSLL-25109, will shut off the Lean Amine Circulation Pumps (P-2501 A/B/C) as well as the Lean Amine Booster Pumps (P-2506 A/B/C) to prevent damage to. these pumps from loss of suction. The activation of this low level switch also causes a secondary valve (NV-25523) at the gas contactor to close. This will prevent the high pressure gases in the contactor from entering the amine circuit when the amine circulation pumps are not running. Local level gauges, LG-2506 ‘AB are provided to monitor the liquid level as well ADCS pressure differential gauge, PDI-25304, is also provided to monitor the pressure drop across the tower. A significant increase in pressure drop is a sign of foaming in the system. A pressure relief valve, PSV-2508, provides pressure relief for the regeneration system. | Lean Amine Circulation, Filtration, and Cooling i The hot lean amine from the stripper, exchanges heat with the rich amine in the | Leanv/Rich Amine Exchangers E-2501 A/B. The Lean Amine Circulation Pumps | (P-2501 A/BIC) are designed such that two pumps are operational and one is aAREA 2500 Page 7 ~ J-826 2.0 PROCESS DESCRIPTION - continued 50% standby spare. P-2501 A/B/C pumps the lean amine to the Lean Amine Cooler (AC-2501). Flow from AC-2501 then splits, the majority flows to the Lean ‘Amine Booster Pumps (P-2506 A/B/C) and a controlled amount flows to the Lean ‘Amine Mechanical Filters (F-2501 AJB) and on to the Amine Carbon Filters (F- 2502 AJB). These flows blend back at the suction of P-2506 A/B/C. The Lean ‘Amine Booster Pumps (P-2508 A/B/C) are designed such that two pumps are operational and one is a 50% standby. P-2506 A/B/C pumps the lean amine to T- 2501 Gas Contactor. ‘The Lean/Rich Amine Exchangers (E-2501 A/B) are plate frame exchangers that are sized for 50% of the total required duly each. Local temperature gauges provide monitoring of each LeaniRich Exchanger. ‘The Lean Amine Cooler (AC-2501) is an air cooled exchanger that consists of three (3) bays. One of the bays have automatic louvers which are controlled with TIC-25206, while the other two bays do not have louvers. Local thermowells provide the ability to monitor the performance of each bay. A local temperature ‘gauge (TI-2508) provides monitoring of the air cooler. ‘The Lean Amine Mechanical Filters (F-2501 A/B) process a slipstream (10%) of the total amine flow. The filters are equipped with local pressure differential indication, PDI-25306 and PDI-25307, to determine when the filter elements have become clogged and changeout is necessary. The filters can be blocked in while on-stream for changeout of the elements. PSV-2510 and PSV-2511 provide pressure relief protection of the filters. |AREA 2500 Page 8 ~ J-826 2.0 PROCESS DESCRIPTION - continued - ‘The Amine Carbon Fillers (F-2502 A/B) process the stream of amine that has been filtered in the mechanical flters. F-2502 A/B are filled with activated carbon, which removes hydrocarbons and other impurities in the amine stream. PDI- 25308 and PDI-25309 provide differential pressure measurement across the carbon beds to determine when changeout of the carbon is necessary. The filters can be blocked in while on-stream for changeout of the carbon beds. PSV-2512 and PSV-2513 provide pressure relief protection for the two vessels. The Lean Amine Booster Pumps (P-2506 A/B/C) pump lean amine to the top of the Gas Contactor (T-2501). Lean Amine flow to the Contactor is controlled by FIC-25402, while FIC-25409 provides minimum flow protection for the pumps by | retuming flow to suction of the Lean Amine Circulation Pumps (P-2501 A/BIC). 27 — Drained Amine System All of the amine drains in the unit gravity flow to V-2504, the Drained Amine Vessel. This material is pumped back to the Rich Amine Flash Drum, V-2508, by the Drained Amine Pump, P-2504. If an oil layer is known to be in V-2504, it can be decanted to the oil side of the vessel and pumped out by P-2503, the Slop Oil Pump. This pumps the oil either to V-2508 or to the closed drain header. DCS level indicators, LI-25114B (amine side) and LI-25115B (cil side), are provided for monitoring the liquid levels in the vessel. A small flow of sweet fuel gas is provided as a sweep gas to prevent a build up of high concentrations of H2S | and/or any oxygen that may have entered the system from venting/purging of ‘equipment during maintenance. The flow of this gas is regulated by PCV-2506AREA 2500 Page 9 — J-826 2.0 PROCESS DESCRIPTION — continued - 2.8 Amine Storage Area ‘The amine storage area consist of two main parts: Tankage and Pumpage. 2.8.4 Tanks The combined capacity of TK-2501 and TK-2502 is sufficient to hold the {ull inventory of the system. However, it wil normally be the case that TK- 2501 will be used as a tank of makeup amine and TK-2502 will be used as temporary storage capacity of drained amine. The Drained Amine Tank (TK-2502) has sufficient capacity to hold the system inventory with the exception of V-2505. Under most circumstances, which require the Unit to be drained, it is likely that V-2505 will be blinded off with its inventory of amine and the rest of the system will be drained via V-2504 and into TK-2502. Should maintenance be required on V-2505, then this, vessel should be drained independently of the rest of the system to insure that sufficient storage volume is available in TK-2502. The Amine Storage Tank, TK-2501, is supplied to provide the means of filing, diluting, and makeup of amine to the unit. Over time, amine ‘makeup will be required. The tank has local level indication via LI-25113, The tank is blanketed with fuel gas to minimize oxygen migration in the tanks, which accelerates the degradation of the amine. The fuel gas is regulated by PCV-2505. The tank is protected from overpressure by PSV- 2515. These relief devices also provide vacuum protection. Normal breathing losses in the tank are vented to the atmosphere. A local pressure gauge, PI-2517, is provided for monitoring Makeup water for dilution of amine and normal water makeup requirements is controlled by FQIC-25407and FV-25407. This. meterivalve arrangement allows a certain amount of water to be added to the system, The water can be routed to either V-2505 or V-2502,AREA 2500 Page 10 - J-826 2.0 PROCESS DESCRIPTION — continued - 2.8.2 Amine Makeup Pump The Amine Makeup Pump, P-2505, is provided to charge amine to the system, circulate the inventory in the tanks, transfer inventory to the other tank, or can be used for off-loading amine from the unit. Piping and valves. are supplied so that the pump can take suction from either of the two tanks, TK-2501 or TK-2502. The discharge can then be routed to (a) the unit, (b) the same tank as suction, (c) the opposite tank as suction, (d) the Phase 1 tanks, (e) a hose connection. Restcto orffces, FO-2503 and FO-2504 are supplied to provide | minimum flow protection for the pump if needed, The minimum flow | recirculation lines are routed back to both of the tanks. FQIC-25408 controls a totazer valve, FV-25408, which allows a certain amount of artne to be added to V-2505. 29 — Antifoam Injection System ‘The antifoam injection system consists of the Antifoam injection Pump (P-2507) and a drum rack enabling the antifoam chemical to be pumped directly from the 55-gallon drum in which it is supplied. A calibration gauge is also furnished with the system. The pump is a small proportioning pump, and is furnished with a relief valve, ‘The antifoam can be injected into the suction of either P-2506 A/BIC or P-2502 AB,AREA 2500 Page 11 — J-826 344 B42 3.0 PREPARATION FOR INITIAL START-UP 3.4 System Checkout Following the completion of mechanical installation and electrica/instrument interconnections to controls, the systems should be checked out and all deficiencies corected, Inspect vessels intemally as well as possible from manways and hand holes. Remove any weld slag, dirt, debris, or any other foreign material, Check out all piping against the Petrofac P&ID's and verity 3.1.2.1 All items are installed. All items and piping are of proper sizes and pressure ratings, 3.1.2.2 Control valves and check valves are installed in the proper flow direction. 3.1.2.3 Relief valve nameplate settings are correct. 3.1.2.4 Free operation and travel of manual valves. 3.1.2.5 Removal of temporary braces and tie downs, if any. Verify all fiter media is on hand. Remove filter media from all fiters. These will be reinstalled after cleaning Using compressed air, blow scale and dirt from piping as well as possible. Pressure the system to 0.5 to 0.7 kg/cm?(g) (7-10 psig). Check all flanges and connections for leaks with soap solution or other suitable means of detection. Correct any leaks.AREA 2500 Page 12 - J-826 3.0 PREPARATION FOR INITIAL START-UP ~ continued - 3.1.5 Install lubricants in pumps and motors as required. Verity electric power supply to motors. Disconnect drivers and verify free movement of pump shafts. “Bump " motors to verily correct rotation. Reinstall shaft couplings and verify correct alignment. 3.4.6 Check out instrumentation and controls 3.1.6.1 Verify proper installation and ranges for local pressure gauges land temperature gauges. 3.1.6.2 Verify proper installation of orifice plates and thermocouples. 3.1.6.3 Verify installation and continuity of all interconnections between the unit and control room, 3.1.6.4 Establish instrument air supply to all users. 3.1.6.5Commission control loops and verify proper controller action, calibrations, and control valve actionitravel : 3.1.6.6Verify alarms and interlock actions, ESD system, ESD | instruments, and action of ESD valves and instrumentation. 3.1.7 Remove all unnecessary construction debris, scaffolding, and the lke from the unit area | 3.2 System Cleaning Any rust, ditt, oils or grease left inside the system after installation can contribute to serious foaming and fouling problems during startup and operation of the unit, | In sufficient degree, these problems can cause inability to achieve the required removal of carbon dioxide from the product gas stream, high amine losses, and | chronic system upsets. Therefore, the unit should be thoroughly cleaned prior to | amine charge and start-up. A suggested procedure for the washing of the unit is as follows: iAREA 2500 Page 13 — J-826 3.0 PREPARATIOI IAL START-UP — continued - 3.24 3.22 3.23 3.24 ‘A substantial amount of treated water, as well as a means of disposal of cleaning solutions will be required. It may be necessary to start storing water in TK-2501 andlor TK-2502 prior to cleaning, to insure sufficient water is available. It is also suggested that disposal of the cleaning and Finsing solutions be arranged. All solutions and chemicals should be made with demineralized water and low chloride chemicals to prevent potential chloride stress corrosion of stainless steel components This boiloutiflushing should be done prior to the installation of the filter elements and filter media. P-2501 A/B/C and P-2506 A/B/C will be utilized | to circulate the solution. P-2504 can be used to pump drained liquids to TK-2502. Using treated water, establish levels in V-2505, T-2501, and T-2502. This ‘can be done by using hose connections and utility connections for these vessels. Establish circulation of water, add water as necessary, but keep 2 relatively low level in T-2502 so that cleaning solution can be added Keep records of the total amount of water added to the system using the counters on FCIC-25407. T-2501 may need to be pressurized to about 1 | to 2 kgiom? (15-30 PSIG) with inert gas so that the solution can flow to V- 2505. Do not overfill system inventory so that cleaning solution can later be added. ‘The preferred solution for the cleaning is a 3 wt% solution of the GASISPEC amine solvent. This has the advantage of not having to be water washed after cleaning, Optionally a solution of 3 w1% caustic soda (NaOH) combined with 2 wi% soda ash (Na;CO,) can be used. PETROPAcAREA 2500 Page 14 - J-826 3.0 PREPARATION FOR INITIAL START-UP - continued - 3.25 3.26 3.27 ‘Add enough amine to the unit, while circulating, to bring the solution to approximately 3 wi%, or add the caustic soda and soda ash to the circulating water to achieve the 3wt% and 2wt% concentrations respectively. Reference Appendix 3 for estimated quantities of Boil out materials. Introduce hot oil to the reboiler, E-2502 A/B and heat the solution to 65°C- 85°C (149°F - 185°F), Circulate the warm solution for a minimum of 12 hours. A small amount of water vapor may go overhead at T-2502. Use the overhead condenser and reflux pumps (P-2502 A/B) when needed to minimize water losses. It should not be necessary to start any of the fans for the air cooler. If fans are used, be sure to close the louvers on AC- 2501, because it is desired to keep the circulating solution warm over the entire unit. Be sure to open all available circuits for flow, such as the filters, spare pumps, exchangers, etc, so that they are all cleaned. Run spare pumps and clean suction strainers of the offline pumps. This is particularly important during the initial running of the pumps. when most of the debris will be caught in the strainers. After 12 hours, stop the heating of the solution and allow to cool to approximately 48°C (118°F), The fans for AC-2501 can be used if necessary to cool the solution. Drain the solution to V-2504, pump to TK- 2502, and drain to appropriate facilites.AREA 2500 Page 15 - J-826 3.0 PREPARATION FOR INITIAL START-UP ~ continued - 33 3.2.8 IF CAUSTIC AND SODA ASH ARE USED AS THE CLEANING SOLUTION: After draining the solution, refil the unit with treated water. Circulate the water through the system for a minimum of two hours to clean as much of the solution as possible from the system. Again, make sure that all circuits, such as spare pumps, exchangers, filters, etc., are flushed. AMter flushing, drain the system. Continue flushing unit until the sodium content of the water is less than 100 ppm. 3.29 Open the manways of T-2501, T-2502, and V-2505. Inspect for cleanliness. If they do not appear clean, redo procedure until unit is clean. 3.2.10 After completion of the water flush and draining, install the filer elements in F-2501 A/B, and fill F-2502 A/B with the carbon bed media. The amine system is now ready to purge for removal of oxygen Purging The System [At this point, itis necessary to purge the air from the system. Before hydrocarbon {928 oF amine is introduced to the unit, itis important that oxygen be purged with an inert gas. This prevents oxidation of the amine and also protects against the formation of an explosive mixture. Due to length of time required to purge the unit, purging should be undertaken as quickly as possible to minimize oxidation. 3.3.1. A supply of inert gas for purging the unit must be available. 3.3.2. Make sure all hydrocarbon lines to the unit are blocked in. (é PeraoracAREA 2500 Page 16 - J-826 3.3.3 3.3.4 335 341 | i 3.4 Preparation of Ar 3.0 PREPARATION FOR INITIAL START-UP — continued - Introduce inert gas slowly to the equipment at convenient points Pressure the unit up to about 1.25 kg/cm*(g) (18 psig). Vent the inert gas from all available equipment and piping extremities, so that all of the ‘equipment and piping are purged as well as possible. When venting the inert gas/air, vent down to about 0.1 kg/cm*(g) (1.5 psig). Close all vents, repeat inert gas pressurization/depressurization. Continue purging until oxygen content is below 1%, as measured with portable analyzers. It will take approximately 4 to 6 purges to reduce the oxygen to less than 1%. If desired, the unit can be separated into several sections, and each section purged individually. WARNING - Do not vent the purge gases to the flare, as this could produce an explosive or flammable mixture in the flare line. When purging is complete, maintain the system at a certain pressure for a pre-determined amount of time for a leak test. If pressure decreases, look for and correct any leaks. Note that ambient temperature fluctuations can ‘also cause slight pressure fluctuations in the system After leak test is complete, the equipment can be maintained at about 0.7 kg/em?(g) (10 psig). 1e Solution Prior to charging amine, remove any blinds as necessary to allow normal system flows. Purge air from any equipment that may be opened to the atmosphere. PETROPAC ®AREA 2500 Page 24 - J-826 amine circulation. Also make proportional increases in the hot oil rate to the reboiler. Observe CO, content of treated gas and differential pressure across T-2501. At design rates, analyses should be performed on the inlet gas, outlet gas, rich amine, lean amine, and acid gas. This is necessary to determine operating conditions, loadings, and optimization of the unit The amine unit should now be commissioned and operational.5.0 AREA 2500 Page 25 ~ J-826 NORMAL OPERATION It is important to monitor the unit regularly to make sure that all the temperatures, pressures, flows, and levels are at their normal conditions. Regular analyses of the amine solution and of the inlet and outlet gases are vitally important to the operation of the unit. Prompt corrective action to any abnormal condition will result in increased safety, less downtime, and more on-spec product. Under normal operation conditions, the amine unit will be controlled from the control room with a few exceptions. However, the unit should be visited on a periodic basis by a qualified operator who will take readings of locally indicated instruments and observe that all of the equipment is functioning correctly. The raw gas feed, treated gas, and off gas should be tested on a routine basis, Also, samples of the rich amine and lean amine should be tested to determine the COz loading of the amine to monitor the effectiveness of the stripping and regeneration cycle, Lean amine solution strength should be checked at least once every twenty-four hours. A listing of expected operating conditions at design capacity is included in Section 5.1 ‘Some of the major items to be monitored by the operators are: 5.1 Amine Circulation Rate - Adjusted to provide approximately 100 ppmv CO; in the sweet gas. At reduced rates or lower than design acid gas content of the feed gas, the circulation rate can be lowered to save operating costs. 5.2 Reboiler - The amount of reboiling in E-2502 A/B is the key variable for the degree of acid gas stripping achieved in the Amine Stripper, and is generally controlled by setting the flow rate through FV-25403 and FV-25404. If amine circulation rate is reduced, the hot oil rate can also be reduced, but generally not as much. Py