Qatar Petroleum Ngl-1 Operating Manual

QATAR PETROLEUM VOL : 1
SEC. : 1
NGL-1 OPERATING MANUAL PAGE : 1
PROCESS DESCRIPTION
1. DESCRIPTION OF FACILITY
2. DESCRIPTION OF PROCESS
3. BASIS OF DESIGN
4. OPERATING BASIS AND EQUIPMENT
a) Operating Basis
b) Operating Equipment
5. OBJECTIVES
6. CONTROL PHILOSOPHY
a) Operating Variables
b) Control signal location & Parameter changes
7. PRODUCT SPECIFICATIONS
a) Propane Liquid Product

b) Butane Liquid Product
c) Gasoline Product
d) Product Composition & Rates
e) Fractionation Capacity
f) Product Treating Facilities
8. UTILITIES AND COMMON FACILITIES
a) Cooling Water
b) Fresh Water
c) Fuel gas System
d) Instrument Air/Tool Air System
e) Merox Air System
f) Electric Power
g) Auxiliary Systems
9. CHEMICAL FACILITIES
10. PROTECTIVE AND SAFETY FEATURES

a) Protective Design Features
b) Safety Features
SEC. : 1
11. GUIDELINES TO PRECOMMISSIONING
a) Columns And Vessels

b) Furnaces
c) Equipment
d) Instrumentation
e) Electrical
f) Utilities, Auxiliaries and Fire & Safety Equipment
g) Hydrostatic Pressure Testing
h) Flushing
i) Draining
j) Blowing
k) Drying Out
l) Drying Out of Furnaces
m) Drying Out of Furnace Refractory
n) Purging
o) Displacement
p) Pressurizing
q) Commissioning of Equipment
r) Running in of Pumps & Compressors
s) Pump and Compressor Checks
t) Initial Start-up of Utilities & Refrigeration
u) Start-up
SEC. : 1
1. DESCRIPTION OF FACILITY
The Fractionation plant is designed to receive raw NGL from the demethaniser column
in the North Field Gas Plant (NFGP is also called as NGL-3).
Facilities exist to process feedstocks from Fahahil and NGL-2 plants.
The Fractionation unit comprises the Surge Drum V-1360, the Deethaniser Column C-
1301, the Depropaniser Column C-1302, the Debutaniser Column C-1303 and their
associated reboilers and reflux systems.
The ethane rich gas from the Deethaniser Column is used to cool the untreated liquid
LPG and gasoline products. Provision is kept to compress the ethane rich gas in the
ethane rich gas compressor K-1360 and either export to QAPCO, or feed into the lean
gas system in NFGP (NGL-3). Ethane rich gas compressor K-1360 was included
primarily to provide the recycle reflux stream to NFGP (NGL-3) at the required pressure.
The NFGP (NGL-3) has been subsequently revamped to generate its own internal reflux
and therefore the need to send ethane rich gas from NGL-1 no longer exists. Therefore
ethane rich gas compressor K-1360 is not operational and this gas is sent to QAPCO
without compression.
Normally fuel gas for NGL-1 is supplied from NFGP (NGL-3) which has got less H 2S
content. But provision is available to receive gas from Government Gas Grid (Point-S)
or methane rich steam form NGL-2.
The liquid propane produced from the Depropaniser column is treated in the ADIP unit
to remove hydrogen sulphide and carbonyl sulphide. The Unit comprises of an extractor,
a series of mixer/settlers, ADIP regeneration system and ADIP storage.
The propane product, Butane product and gasoline products are treated in Merox units
to remove mercaptans prior to the drying of the propane and butane in molecular sieves.
The gasoline product within the Merox unit is treated to 'sweeten' mercaptans.
Propane and butane products, after molecular sieves, are chilled with propane
refrigerant prior to routing to the storage facilities.
The gasoline product from the Merox unit is heated and the lighter ends are separated in
the RVP correction unit to bring its vapour pressure within product specifications (this
facility is used as per operational requirements only ) prior to cooling against ethane rich
gas and routing to storage.
The lighter ends are condensed and blended into the naphtha product rundown.
The propane Refrigeration Unit comprises two gas turbine driven centrifugal
compressors, suction drums and surge drum.
SEC. : 1
2. DESCRIPTION OF PROCESS
Raw NGL is received from North Field Gas Project (NGL-3) into a feed Surge Drum,
which provides surge/hold up capacity to facilitate the handling of flow variations in the
feed. The raw NGL feed is pumped on flow control to the Deethaniser Column in the
fractionation plant.
Facilities exist to process alternative feed supply from Fahahil or NGL-2 directly into the
Deethaniser Column.
The overhead gas from the Deethaniser Column (ethane rich gas) is partially condensed
against propane refrigerant. The condensed liquid serves as reflux for the Deethaniser
Column.
Provision is available to compress the ethane gas in the Ethane Rich Gas Compressor
and deliver to NFGP (NGL-3), to QAPCO or can be used as Fuel gas. Since NFGP
(NGL-3) is not using ethane rich gas, the Ethane Rich Gas Compressor is not
operational and the ethane rich gas is supplied to QAPCO without compression.
The bottom liquid in the Deethaniser Column is heated in hot oil reboiler. Bottom product
flows by pressure difference to the Depropaniser Column.
The overhead vapour from Depropaniser Column is condensed in cooling water

condensers. Condensed propane is partly used as reflux. The propane product is then
pumped to the ADIP unit where hydrogen sulphide (H2S) and carbonyl sulphide (COS)
removed and send to merox unit for further treatment.
The bottom liquid in the Depropaniser Column, is heated in a hot oil reboiler and
product flows by pressure difference to the Debutaniser Column.
The overhead vapour from the Debutaniser Column is condensed in air and cooling
water Condenser. Condensed butane is partly used as reflux and the rest is sent to
Merox unit after cooling. The bottom liquid in the Debutaniser Column is heated in hot oil
reboiler And bottom product (gasoline) is cooled and sent to merox unit.
The gasoline merox unit is a mercaptan extraction/sweetening unit. The treated gasoline
is then heated to correct RVP in the RVP Correction Unit in Merox.
The lighter ends, mostly pentane rich vapour, are condensed and pumped to naphtha
storage and facility exist to send the naphtha to burn pit.
The gasoline product is cooled against ethane rich gas and sent to storage.
In the propane merox unit mercaptan from the propane is removed and sent to
molecular sieve driers prior to chilling and routing to storage.
In the butane merox unit mercaptan in the butane is removed and sent to molecular
sieve driers prior to chilling and routing to storage.
SEC. : 1
Rich caustic is regenerated in Merox Unit Oxidizers and the disulfide oil is separated in
the Disulphide Separator. The regenerated caustic is flashed in Evaporator to remove
water and gases. Part of regenerated caustic is sent back to the gasoline extractor, the
other part is washed with butane to clean it from dissolved disulfide oil before being sent
back to propane and butane extraction.
Washed butane containing disulfide oil is routed to Debutaniser Column in NGL-1.

Provision exists to route the washed butane to the Butane Extractor in Merox Unit.
3. BASIC OF DESIGN
Reference Drawings
F11W-0080-01 - Fractionation Unit PFD

F11W-0120-01 - Propane Adip Treating PFD
F11W-0120-02 - Gas Adip Treating and Regeneration PFD
F11W-0120-03 - Third Stage Propane Adip Treating PFD
F11W-0050-01 - Propane Merox Unit PFD
F11W-0050-02 - Butane Merox Unit PFD
F11W-0050-03 - Gasoline Merox Unit PFD
F11W-0050-04 - Caustic Regeneration System PFD
F11W-0050-05 – Caustic Effluent Neutralization System PFD
F11W-0050-06 – Gasoline RVP Correction Unit PFD
Design feed to NGL-1 is Raw NGL from the NFGP (NGL-3) and NGL from FSP/Arab-D.
Provision available to receive feed from various other sources also, they are:
- C3-ex QAPCO
- C4-ex Refinery and
- Raw NGL from NGL-2
SEC. : 1
The design NFGP (NGL-3) feed composition (NGL-3 Acid Gas Removal Unit (AGRU)
not in operation), rate, temperature and pressure are as follows:
BASE LEAN RICH

K mol/hr Mol % K mol/hr Mol % K mol/hr Mol %
COS 1.2 0.04 1.2 0.04 1.5 0.05
CO2 184.4 6.17 164.7 5.81 239.0 7.60
H2S 121.6 4.07 112.1 3.96 156.9 4.99
C1 164.0 5.49 156.3 5.51 173.6 5.52
C2 1116.8 37.38 1101.3 38.86 1091.1 34.69
C3 776.1 25.98 714.5 25.21 826.5 26.28
iC4 165.0 5.52 157.7 5.56 180.8 5.75
nC4 265.0 8.87 241.5 8.52 279.7 8.89
iC5 67.4 2.26 68.4 2.41 73.9 2.35
nC5 57.2 1.91 52.9 1.87 56.5 1.80
C6 37.7 1.26 30.8 1.09 35.8 1.14
C7 16.9 0.57 17.5 0.62 16.3 0.52
C8 5.6 0.19 6.1 0.22 5.5 0.17
C9 1.2 0.04 1.3 0.05 1.1 0.03
C10 0.3 0.01 0.4 0.01 0.3 0.01
Organic Sulphur 6.9 0.23 7.4 0.26 6.8 0.22
TOTAL 2987.3 100.0 2834.1 100.0 3145.3 100.0
t/d 2950 2784 3122

Temperature °C 7 7 7
Pressure bara 31.9 31.9 31.9
SEC. : 1
The COS content is based on using molecular sieves for dehydrating feed gas to the
NGL-3.
The current Feed Composition, Rate, Temperature and Pressure are as follows:
(with AGRU in operation).
COMPONENT NGL-3(with AGRU/TEG in operation) FSP/ARAB – D

Mol % Mol %
COS 0.01
N2 0.01
CO2 2.60 2.86
H2S 0.00 2.49
C1 5.51 6.02
C2 36.37 27.47
C3 29.39 33.68
iC4 6.94 7.84
nC4 10.81 15.55
iC5 2.94 1.81
nC5 2.24 2.02
C6 2.04 0.15
C7 1.15 0.09
C8 0.01
TOTAL 100.0 100.00
t/d (about) 3200 700 – 800

Temperature °C -7 Amb
Pressure bara 26 to 27 38
The design yield rates for NFGP (NGL-3) feed only are as follows:
1165 t/d - ethane rich gas

829 t/d - commercial grade propane
598 t/d - commercial grade butane
129 t/d - light gasoline
214 t/d - pentane rich liquid.
Other evaluation basis items are as follows:
- Fractionation: Minimum fractionation requirements are based on meeting GPA

specifications for LPG products and on debutanising gasoline as required for safe
storage.
- Mercaptan Extraction: To process deethanised NGL for mercaptan extraction by

separate Merox units on each product.
- Gasoline Sweetening: In accordance with the project specification, the gasoline

product is sweetened to reduce its mercaptan sulphur content to less than 550
SEC. : 1
PPMW as sulphur. The current mercaptan sulphur in gasoline is below 10 PPMW.
This process does not reduce total sulphur.
- Propane Treating: Propane is treated in the ADIP unit modified to process high
COS content feed and reduce the COS sulphur content to 5 PPMW or less.
- Product Cooling: Propane and butane LPG products are chilled against propane
refrigerant for storage in atmospheric tanks. Gasoline is flashed (as and when
required) to reduce its vapour pressure to about 12 psia RVP and cooled against
ethane rich gas for storage. Pentane rich liquid joins naphtha from NGL-3 for
storage.
The design product storage temperatures are as follows:
DESIGN CURRENT
PROPANE - 45°C - 42°C
BUTANE - 7°C - 8°C
GASOLINE 21°C 15°C
NAPHTHA 21-25°C 21-25°C
Normal or Base Case: When QAPCO's requirements are low, the surplus ethane rich
gas either used partially as fuel gas or diverted to flare.
4. OPERATING BASIS AND EQUIPMENT
a) Operating Basis
Raw NGL stream is first deethanised to produce an ethane-rich gas for either direct
transmission to QAPCO, or for injection into the booster compressor system in
NFGP (NGL-3).
Deethanising is followed by depropanising and debutanising whereby propane,

butane and gasoline product streams are separate. The propane product is treated
to remove hydrogen sulphide (H2S) and carbonyl sulphide (COS) in ADIP unit, and
mercaptans in a Merox extraction unit. The propane product is treated and dried in
molsieves, chilled and then stored at slightly above absorption pressure storage
tanks T3/T4.
Butane is treated to remove mercaptans in Merox extraction unit, then , treated and
dried in molsieves; chilled and stored at slightly above atmospheric pressure storage
tanks T1/T2.
SEC. : 1
Gasoline is treated for partial removal of mercaptans in Merox extraction unit and the
lighter ends are removed to meet the gasoline RVP specification in the RVP
correction unit. The pentane rich stream is blended into the naphtha product
rundown line or can be sent to burnpit when designed C5/naphtha ratio (1:5) is
exceeded.
1) Feed
Raw NGL feed is pumped from the bottom of NFGP (NGL-3) Demethaniser to
Deethaniser feed Surge Drum, which provides surge NGL-1 (HOLD-UP) capacity
to permit handling flow variations from NFGP (NGL-3).
The new feed is pumped to the Deethaniser Column (C-1301) on flow control to
provide smoother operation.
FSP/Arab D feed directly flows to the Deethaniser Column under pipeline

pressure control.
2) Deethaniser, C-1301
The Debutaniser Column overhead gas is partially condensed in E-1302 propane

refrigerant condenser. Provision is kept to compress ethane rich gas in the
Ethane Rich Gas Compression K-1360. The compressed gas can either be sent
to any of the two destinations as per process requirement.
a) Direct transmission on flow control to the existing QAPCO facilities.
b) Excess gas is either flared or partially used in fuel gas system.

Deethaniser Column (C-1302) is operated at 27 to 29 barg.
Ethane rich gas compressor is not in operation and the ethane rich gas is sent to
QAPCO directly as NFGP (NGL-3) is not using ethane rich gas as reflux.
Deethaniser bottoms flows under level control and pressure difference to the
Depropaniser Column (C-1302) operating at about 17 barg.
3) Depropaniser, C-1302
The overhead gas from Depropaniser Column (C-1302) is condensed in E-1304

A/B/C/D in cooling water condenser.
The propane product is partially pumped as reflux by P-1302/A and pumped as

product by P-1308/A to the ADIP unit for hydrogen sulphide (H 2S) and carbonyl
sulphide (COS) removal. It is cooled to about 25°C with the ethane rich gas in E-
1324 required for treating in the Merox unit for mercaptan extraction. Then the
propane is dried in molsieves C-1307A/B and chilled to -42°C to store in for
atmospheric pressure storage tank T3/T4.
SEC. : 1
Depropaniser bottoms under level control pressure flows to the Debutaniser

Column C-1303, operating at 7.5 barg.
4) Debutaniser, C-1303
The overhead gas from Debutaniser (C-1303) is condensed in Air Cooler E-1308
and cooling water condenser E-1308S operating in series.
The butane product is further cooled to about 25°C with cooling water E-1322
and ethane rich gas in E-1323 prior to treating in the Merox unit for mercaptan
extraction. Then, the butane is treated/dried in molsieves C-1308A/B and chilled
to about -7°C for storing in atmospheric pressure storage tank T1/T2.
Debutaniser bottoms (gasoline) is cooled to 44°C in E-1306A/B cooling water

cooler and pumped by P-1361A/B to the Merox extraction/sweetening unit.
The treated gasoline is heated to remove light ends by flashing in RVP

Correction unit cooled to 21°C (current 15°C) with ethane rich gas in E-1305 and
stored in floating storage tanks T-5/T-6.
The flashed pentane rich vapour is condensed in E-1742 A/B and flows to
Pentane rich Separator V-1745. The separated pentane rich liquid is pumped by
P-1742 A/B either to Naphtha Storage Tanks T-7/T-8 or to burnpit if the
C5/Naphtha ration exceeds 1:5 ratio.
b) Operating Equipment
The facilities and equipment required controlling process separate and store the
produced NGL products are covered in full within the complete NGL-1 manual.
This section will cover the basic outline of the plant equipment.
1) Deethaniser Feed Surge Drum V-1360
Provides surge/hold up capacity to accommodate the variations from NFGP

(NGL-3).
2) Fractionation Unit
Comprises Deethaniser Column C-1301, Depropaniser Column C-1302 and

Debutaniser Column C-1303 with their associated reboilers and reflux systems.
3) Ethane Rich Gas Compressor K-1360
Provided to compress and deliver the ethane rich overhead gas from C-1301 to
NFGP (NGL-3) AND QAPCO with subsequent modifications in NFGP (NGL-3),
ethane rich gas is not required, so this compressor (K-1360) is not in operation
and ethane rich gas flows to QAPCO directly.
SEC. : 1
4) ADIP Unit
Liquid propane from V-1302 is pumped by P-1308/A to ADIP unit for removal of
hydrogen sulphide (H2S) in Propane Extractor (C-1304) and carbonyl sulphide
(COS) in three stage merox unit.
The ADIP unit consists of mainly Propane Extractor, three stage mixers, sittlers,
Coalescer and charcoal absorbers.
5) Merox Unit
Liquid propane, butane and gasoline are treated in U.O.P.'s (Universal Oil
Products) Merox unit. The unit consists of two types of process namely
extraction and sweetening.
a) Extraction
In the extraction process, the feed is contacted with aqueous caustic in a

multi-stage tower (counter current) where mercaptans are absorbed by the
caustic and form sodium mercaptide.
Caustic is withdrawn from the extractor and regenerated by catalytic air

oxidation of the sodium mercaptide to sodium disulphide and water.
The disulphide is separated from the caustic by phase separation.
Regenerated caustic is recycled to the extractor.
b) Sweetening
In the sweetening unit, the mercaptans are directly converted to disulfides,

which remain in the product. There is no reduction in the total sulfur content.
Absorption of mercaptans as sodium mercaptide and oxidation to disulphide

and water takes place within the caustic hydrocarbon mixture.
The resulting disulphide is reabsorbed by the hydrocarbon. The sulphur

content is not removed but only changed from mercaptan to disulphide.
The sweetening process is effective for treating heavier hydrocarbon

fractions.
The merox unit system consists of extractors, vessels, sand filters, settlers,
disulphide separator, flash evaporator, reactor, butane wash vessels,
exchangers/coolers, pumps, tank eductors, mixer, vacuum compressor and
air system.
SEC. : 1
6) Gasoline RVP Correction Unit
The gasoline from fractionation unit and the merox unit can have a relatively high
vapour pressure due to the dissolved nitrogen and high pentane content.
To meet gasoline specification and overcome storage problems with the high
vapour pressure, the gasoline cut is flashed to remove the pentane (as and when
required).
Gasoline from merox is preheated (as and when required) to 85°C ~ 89°C and
flashed to 2.0 barg. The gasoline is sent to gasoline storage, the pentane to RVP
corrected Naphtha storage as per process requirement and the non-condensable
nitrogen to flare.
7) Molecular Sieve Units
The main function of the propane and butane molecular sieve units will be as
dryers.
The molecular sieve would also remove mercaptan and residual sulphur but
depends on the merox unit efficiency.
The frequency of change of the MOL sieves will depend upon the efficiency of
the ADIP and Merox units. Currently the MOL sieves' absorption cycle is about 5
days, which could vary depending process requirement.
The equipment comprises molecular sieve beds, and control system.
8) Refrigeration Unit and Product Cooling
The system comprises two refrigerant compressors (Dresser Rand), driven by

gas turbines (AEG Frame 3).
Propane is used as refrigerant by flash evaporation, compression and cooling.

Product cooling is carried out at different pressure levels to achieve the required
product cooling as mentioned below:
The overhead vapours of the Deethaniser are condensed.
 Products are chilled.
 The boil off vapours from propane and butane tanks are compressed by Boil
off compressor and the chilled and reclaimed.
The system comprises compressors, turbines, chillers, coolers, vessels and

dedicated control and protection systems.
SEC. : 1
9) Vapour Recovery
The tank vapour recovery system is incorporated in the product cooling system.
1) Propane tank vapours from Propane Boil off compressor.
These vapours are condensed with low stage propane refrigerant. Liquid
from the receiver is pumped back into the propane product line to storage.
The non-condensibles flow to the LP flare system.
2) Butane tank vapours from Butane Boil off compressor.
These vapours are condensed with high stage propane refrigerant. Liquid
from the receiver is pumped back into the butane product line to storage.
The non-condensibles flow to the LP flare.
The system comprises compressors, chillers (condenser), receiver, pumps

and control system.
10) Liquid Propane/Butane Recovery unit
Liquid streams from mol. sieve absorbers (during displacement to flare/burnpit

or purging/cooling) are recovered and recycled back to fractionation system
for reprocessing.
The system comprises Propane/Butane separators and Butane transfer

pump.
5. OBJECTIVES
a) The objective of the operational variables and control system in of the NGL-1 unit is
to enable the plant to operate safely and efficiently in accordance with design and
process requirements.
This must be done in order to process the specified feedstock into its various
products as defined in product specification.
b) The objective is to meet the product’s specification, safely and economically,

without upset or overstress.
By constant monitoring to the dedicated control system, the plant operation is

maintained steadily to prevent process upset of NGL-1, upstream and downstream
units.
SEC. : 1
c) The plant design incorporates instrumentation and safety devices, which will protect
the plant. The unit is protected against unsafe operating conditions from unsafe
conditions arising from plant upsets or abnormal operations.
d) In addition, equipment and components in the plant are designed to 'fail safe' i.e. to
shutdown safely or to go into a safe operating mode if a failure or breakdown occurs.
e) Systems devised by Operations Department with the co-operation of others helps to

promote the position of reliability within the plant e.g. valve identification, cleanliness
and discipline.
f) Guidelines such as operating procedures, standing instructions, operating manuals

etc have the objective of creating, understanding and reliability in the operation.
This has the effect of increasing efficiency and safety.
g) The associated and interconnecting facilities should always be considered i.e. hot oil
systems, Utility systems, Flares and Burn pits.
6. CONTROL PHILOSOPHY
The NGL-1 process control is designed systematically to create progressive and

associated stable conditions from section to section.
Small operational upsets in one section can escalate into large upsets in another
section.
The initial stage of the process starts with the supply of raw NGL from the NFGP (NGL-
3) plant and is dependent on a constant controlled line pressure and feed consistency.
If conditions change then unsteady conditions could prevail in the fractionation unit.
Each section has its own control system maintaining the process parameters within the
specified range.
SEC. : 1
a) Operating Variables
The operating conditions shown below shows the design conditions and the present
operating conditions based on present feed composition and higher thruput. In
future with the commissioning of NGL-4 the operating parameters will be varying
depending on NGL-4 feed composition.
PROCESS CONDITIONS CONTROLLED BY

DESIGN (OPERATING)
1) Deethaniser surge drum V-1360
Feed pressure 30.9 barg 13-PIC-609

Drum level 50% 13-LIC-601
Feed flow 6060 m³/d (6500 m³/d) 13-FIC-601A

DESIGN (OPERATING)
2) Deethaniser C-1301
Pressure 30.8 barg (27.0 barg) 13-PRC-3

Temperature 106°C (101°C) 13-TRC-1
Overhead reflux
flow 4369 m³/d (4680 m³/d) 13-LRCA-002/
13-FIC-002
Note:
C-1301 Temperature is controlled by the hot oil 13-TIC-2/13-FRC-005.
13-TI-1-4 will indicate tray 4 temperature at 106°C.

DESIGN (OPERATING)
3) Depropaniser C-1302

Temperature 115°C (108°C) 13-TRC-3
Overhead reflux flow 5367 m³/d (6200 m³/d) 13-FIC-10
SEC. : 1

DESIGN (OPERATING)
4) Debutaniser C-1303

Split Range
Temperature 125°C (127°C) 13-TIC-608/
13-FIC-015
Overhead reflux
flow 1565 m³/d (2500 m³/d) 13-FRC-14

DESIGN (OPERATING)
5) ADIP Treating
Lean ADIP to Propane

Extractor 250 t/d 13-FRC-20
Lean ADIP to gas
extractor 1611 t/d (1542 t/d) 13-FRC-26
ADIP regenerator
pressure 0.45 barg 13-PIC-14
ADIP regenerator
Temperature 95°C (106°C) 13-TRC-6/
13-FIC-027

DESIGN (OPERATING)
6) Merox Unit
Propane System
Feed to C-1720 1645 m³/d (2750 m³/d) 13-LRCA-11/

13-FIC-012
Extractor
level C-1720 50% 17-LIC-007
Caustic flow
to C-1720 1044 kg/hr (900 kg/hr) 17-FRC-003
SEC. : 1
Butane-System
Feed to C-1730 A/B 536/536 m³/d (820/820 m³/d) 17-FRC-011/

17-FRC-013
Extractors level
C-1730 A/B 50% 17-LIC-015/
17-LIC-016
Caustic flow to
C-1730 A/B 1090/1090 kg/hr 17-FRC-012/
1090/1090 kg/hr 17-FRC-014
Gasoline System
Feed to C-1740 530 m³/d (970 m³/d) 13-FRC-613

Caustic
flow to C-1740 3303 kg/hr 17-FRC-015
Pressure in V-1743 6.0 barg (6.3 barg) 17-PIC-016

DESIGN (OPERATING)
7) Gasoline RVP correction
V-1744 Inlet
temperature 89°C 17-TIC-005
Pentane recovery
flow ex V-1745 333 m3/d 17-FRC-002

DESIGN (OPERATING)
8) Molecular Sieve Unit
Regeneration
gas flow 8500/8500 kg/hr 13-FIC-30/
4500/4500 kg/hr 13-FIC-32
Regeneration gas
temperature 316°C 310°C 13-TRCA-12
Regeneration gas
pressure (*) 20.0/6.0 barg 17.5/5.5 barg 13-PICA-23/
13-PICA-29
(*) Different for Propane and Butane Molsieves.
SEC. : 1
9) Product cooling section
Propane product
temperature -43°C -43°C 13-TRC-17
Butane product
temperature - 6°C -7°C 13-TRC-18
10) Refrigerant System
K-1301/K-1302
normal speed Individual KT-1301/KT-1302
6400 RPM Speed indicator
High stage
Refrigerant -14°C 2.0 barg V-1308 outlet
Low stage
Refrigerant -49°C 0.76 bara V-1307 outlet
b) Control signal location/parameter changes
The following is an outline of the effects that a change of parameters will have on the
various systems.
1) Deethaniser C-1301
a) Pressure
Controlled by 13-PRC-3 on V-1301 vapour outlet.
If pressure rises, C2 and H2S will increase in the C3+ from bottom outlet. If
pressure falls, amount of C3 in overheads will increase.
SEC. : 1
b) Temperature
Controlled by 13-TIC-2/13-FRC-5 on Hot Oil) .
If temperature rises, C3 and H2S will increase in overheads. If temperature

falls, amount of C2 and H2S will increase in the bottom.
c) Reflux
Controlled by 13-FIC-002 and cascaded with 13-LRCA-002.
If reflux increases, C3 will reduce in overheads and C2 content in the

bottoms will reduce. If reflux decreases, C3 will increase in overheads and
C2 content in the bottoms will increase. The sudden increase/decrease in
the reflux will change temperature gradient and upset Deethaniser Column
operations.
2) Depropaniser, C-1302
a) Pressure
Controlled by 13-PRC-5 on Tray 4.
If pressure rises, C3 content of bottom outlet will increase.
If pressure falls, C4 content of overheads will increase.
b) Temperature
Controlled by 13-TRC-3 on Tray 4.
If temperature rises, C4 content of overheads will increase
If temperature falls, C3 content of bottom outlet will increase.
c) Reflux Controlled by 13-FIC-10
If reflux increases, C4 content in overheads will reduce.
If reflux decreases, C4 content of in overheads will increase.
3) Debutaniser, C-1303
a) Pressure
Controlled by 13-PRC-607 from Tray 7.
If pressure rises, C4 content of bottom outlet will increase.
If pressure falls, C5 content of overheads will increase.

SEC. : 1
b) Temperature
Controlled by 13-TIC-608 from Tray 7.
If temperature rises, C5 content of overheads will increase.
If temperature falls, C4 content of bottom outlet will increase.
c) Reflux
Controlled by 13-FRC-14.
If reflux increases, C5 content of overheads will reduce.
If reflux decreases, C5 content of overheads will increase.
4) ADIP Treating
a) Propane extractor C-1304
Lean ADIP solution flow rate controlled by 13-FRC-20.
If flow increases, H2S content in propane will reduce.
If flow decreases, H2S content in propane will increase.
b) ADIP gas absorber C-1305
Lean ADIP solution flow rate controlled by 13-FRC-26.
If flow increases, H2S and CO2 will decrease in regeneration gas.
If flow decreases, H2S and CO2 will increase in regeneration gas.
c) ADIP regenerator C-1306
Temperature controlled by 13-TRC-6 cascaded with 13-FIC-027 (hot oil flow).
If temperature increase, H2S and CO2 will be removed. But if temperature

increase is too severe then decomposition of the ADIP will take place.
If temperature decreases, H2S and CO2 will remain in loan ADIP.

SEC. : 1
5) Merox Unit
a) Prewash vessel V-1720
Caustic strength in V-1720 is maintained @ 6%. If caustic strength of 6%

falls then H2S traces will remain in the propane.
If propane pressure falls then H2S traces will remain.
b) Extractor C-1720
Propane flow recorded by 17-FR-021 and 12 to 14% caustic flow controlled

by 17-FRC-003
If caustic flow increases then mercaptan in propane is decreased.
If caustic purity increases then mercaptan in propane decreases.
If temperature increases the mercaptan in propane increases.
c) Extractors C-1730 A/B
Butane flow controlled by 17-FRC-011/ 17-FRC-013 and 12-14% caustic flow

controlled by 17-FRC-012/17-FRC-014.
If caustic flow increases then mercaptan in butane decreases.
If caustic purity increases then mercaptan in butane decreases.
If temperature increases the mercaptan in butane increases.
d) Extractor C-1740
Gasoline flow recorded by 17-FR-030
12-14% caustic flow controlled by 17-FRC-015. If caustic flow increases then

mercaptan in gasoline decreases.
If caustic purity increases then mercaptan in gasoline decreases.
e) Merox Reactor V-1741
Reaction is improved by: Raising temperature, increasing air-flow and

increasing mixing rate.
SEC. : 1
f) Oxidizer V-1702
Poor oxidization will result if: Temperature is Lean caustic flow

(17-FIC-008), and Air flow is too low (17-FIC-005)
6) Gasoline R.V.P. Correction
1) Gasoline knockout drum V-1744
Gasoline temperature controlled by 17-TIC-005 at 89°C. if temperature is low

then gasoline RVP will be high. If temperature is high the gasoline RVP will
be low.
2) Pentane Rich Separator V-1745
Pressure is controlled by pressure control to the flare. If pressure is high,

inert will remain with pentane rich cut. If pressure is too low, pentane rich cut
pumps will not be able to pump.
7) Molecular Sieves
1) Regeneration Gas Flow
Controlled by 13-FIC-30 Propane

Controlled by 13-FIC-32 Butane
If flow is low, regeneration of molsieves will be poor. H2S and H2O may
remain the molsieve beds.
2) Regeneration Gas Temperature
Controlled by 13-TRCA-12 on F-1301 regeneration furnace outlet. If

temperature is low, regeneration will be poor. If temperature is excessively
high, the molecular sieve will be degraded.
3) Regeneration Gas Pressure
Controlled by 13-PICA-23 Propane

Controlled by 13-PICA-29 Butane
If pressure is high, regeneration will be poor.
Product will become entrained with the regeneration gas if one of the orbit
valves of online molsieves is passing.
SEC. : 1
8) Product Cooling
1) Propane
Temperature is controlled by 13-TRC-17 on outlet of E-1327.
If rundown temperature rises, the storage tank pressure will rise producing
increased boil off from tankage.
2) Butane
Temperature is controlled by 13-TRC-18 on outlet of E-1316.
If butane rundown temperature rises, the storage tank pressure will rise
producing increased boil off from tankage.
7. PRODUCT SPECIFICATIONS
Reference Drawings:

F11W-0120-01 - Propane Adip Treating PFD
F11W-0120-02 - Gas Adip Treating and Regeneration PFD
F11W-0120-03 - Third Stage Propane Adip Treating PFD
F11W-0050-01 - Propane Merox Unit PFD
F11W-0050-02 - Butane Merox Unit PFD
F11W-0050-03 - Gasoline Merox Unit PFD
F11W-0050-04 - Caustic Regeneration System PFD
F11W-0050-05 - Caustic Effluent Neutralization System PFD
F11W-0050-06 - Gasoline RVP Correction Unit PFD and
6304-00-004
6304-00-005
6304-00-007
6304-00-008
The configuration of the NGL-1 plant, the sections, equipment and control parameters
are all based on the ultimate objective of producing on specified products safely and
economically. The product specifications will confirm the standard test methods usually
A.S.T.M. (American Standard Test Methods) specifications from QP, specifications from
G.P.A. (Gas Processor Association) and those within the project technical definition.
Some guidelines are provided by the licensor for special sections.
SEC. : 1
The following tables and information will illustrate the range and alternatives within the
design specifications and the marketable products.
a) Propane Liquid Product
PROJECT G.P.A.
COMPOSITION SPECIFICATION SPECIFICATION
Propane 95.0 vol. % (min)
Butanes and heavier 2.5 vol. (max)
Hydrogen sulphide Negative No. 1 copper strip
Mercaptan } 15 gr/100 SCF as

sulphur ) 30.0 ppmw(max) sulphur (max)
COS as sulphur ) (185 ppmw)
Water cobalt bromide test
Vapour pressure 14.3 barg max at 38°C
b) Butane Liquid Product
PROJECT G.P.A.
Butanes 96.0 vol (min)
Pentanes and heavier 2.0 vol (max)
Hydrogen sulphide Negative No. 1 copper strip
Mercaptans ) 15 gr/100 SCF as

) 30.0 ppmw (max) sulphur (max)
COS as sulphur ) (140 ppmw)
Water No free water

Vapour pressure 4.8 barg max at 38°C
SEC. : 1
c) Gasoline Product
PROJECT G.P.A.
Hydrogen sulphide Negative, sweet
Total sulphur 1000 ppmw (max)
Water (Ex Merox)

Saturated
Vapour pressure 0.83 bar RVP 0.7 - 2.3 bar RVP
Saybolt colour Not less than +25
% evaporated at 140°F 25 - 85%
% evaporated at 275°F Not less than 90%
End point Not more than 375°F
Corrosion Not more than

classification 1
d) Product Compositions and Rates (Base Case)
COMPOSITION PROPANE BUTANE GASOLINE
Mol % (LV%)
C2 2.3(2.2)
C3 95.9 (95.6) 1.8 (1.6)
C4’s 1.8 (2.2) 96.7(96.7) 0.2 (0.1)
C5's 1.5 (1.7) 45.6 (40.6)
C6-plus 54.2 (59.3)
Vapour Pressure
at 380C, bara 13.9 4.3 0.72
Sulphur Content
Mercaptan PPMW 5 5 550
Total PPMW 25 20 1000
Quantity, t/d 829 598 129
Quantity, t/d(present) 1300 950 650
SEC. : 1
Following are the findings of adequacy check of NGL-1 facilities for processing
NFGP feed.
Note:
All equipment loading in the fractionation facilities are within the capacities
demonstrated during the July 16, 1985 test run. Although specific test run data are
not available for the ADIP unit, LPG molecular sieves and product cooling facilities,
the equipment loading is well within the original design capacity. A third stage mixer
settler has been added to process the high COS content in the propane feed.
e) Fractionation Capacity
The fractionation facilities are capable of producing on spec. LPG products and
debutanised gasoline product. Propane recovery in the deethaniser is estimated to
be 98%.
Estimated light and heavy component concentrations in each product are tabulated
below:
Mol% LV%
Propane
C2 2.31 2.23
iC4 1.64 1.95
nC4 0.18 0.20
Butane
C3 1.84 1.59
iC5 1.35 1.55
nC5 0.16 0.18
Gasoline
iC4 0 0
nC4 0.16 0.12
Ethane in the propane product is well below the concentration corresponding to the
maximum vapour pressure specification of 14.34 barg at 38°C. The butanes and
heavier content is sufficiently within the GPA specification of 2.5 LV%, maximum.
SEC. : 1
Propane in the butane product is below the concentration corresponding to the

maximum vapour pressure specification of 4.83 barg at 38°C. Pentanes and heavier
are within the GPA specification of 2.0 LV% maximum.
f) Product Treating Facilities
The product treating facilities are integrated with the NGL fractionation plant, which
recovers raw propane, butane and gasoline products. Propane and butane are
treated and dried to meet GPA LPG and project specifications. Gasoline is treated
to reduce its mercaptan in merox unit to meet the product specification Gasoline is
flashed in the vapour pressure correction facilities to meet the GPA gasoline and
project specifications.
Proprietary treating processes are utilized: Shell's ADIP process for removing
hydrogen sulphide (H2S) and carbonyl sulphide (COS) from the propane product and
UOP's Merox process for extracting mercaptans from the propane, butane and
gasoline products. In addition UOP's merox sweetening process is used for further
gasoline treatment following mercaptan extraction.
The product treating facilities comprise the following units:
Unit 1300 Propane ADIP
Unit 1700 Propane Merox (including Caustic Regeneration)
Unit 1700 Butane Merox
Unit 1700 Gasoline Merox
Design Basis
The following tables present the design basis for the product treating facilities.
As indicated, the raw propane, butane and gasoline quantities are based on a
wellstream rate of 22.7 MMm³ per day plus 6.8 MMm³/d added from Qatar Gas
(presently the to total gas is about 30 MMm³/d).
Sulfur contents in the raw products were calculated based on the limited well stream
composition and the best available vapour liquid equilibrium data. However, there is
considerable uncertainty in the sulphur compound distribution. The "design" sulphur
contents were specified in conjunction with QP to provide margins for mercaptan
distribution variations.
Propane and butane product quality meets both the GPA LPG specifications and
Project Technical Definition (PTD) specifications shown in the tables under product
characteristics. Sulphur contents correspond to those that the Licensors are willing
to guarantee.
SEC. : 1
1) Capacity
- Feed rates are based on a wellstream rate of 22.7 mmm³/day plus 6.8
mmm³/d (presently feed rate is 30 mmm³/d).
- Raw (untreated) product rates are as follows:
CASE PROPANE BUTANE GASOLINE
t/d m3/d t/d m3/d t/d m3/d

Base 834 1649 613 1062 346 531
Lean 767 1516 571 989 331 507
Rich 891 1761 655 1137 349 537
Design 930 660 375
Present
operation 1300 2750 950 1540 650 970
(Merox Unit)
2) Feed Sulphur Contents
a) Propane - all figures PPMW as sulphur
Base Lean Rich Design
H2S 3179 2954 4468 4500
COs 875 889 1018 1100
Methyl Mercaptan 943 1025 886 1000
Ethyl Mercaptan 25 27 23 200
Propyl Mercaptan - - - -
Butyl Mercaptan - - - -
Other Sulphur - - - -
Total 5022 4895 6395 6800

SEC. : 1
b) Butane - all figures PPMW as sulphur
H2S - - - -
COs 0.9 0.9 1 -
Methyl Mercaptan 458 502 425 900
Propyl Mercaptan 0.1 0.1 - -
Butyl Mercaptan - - - -
Other Sulphur 1.2 1.2 1.2 -
Total 5895 6709 5459 7400
c) Gasoline - all figures PPMW as sulphur
H2S - - - -
COs - - - -
Methyl Mercaptan - - - -
Propyl Mercaptan 1943 2464 1797 3700
Butyl Mercaptan 386 528 348 1320
Other Sulphur 19 24 19 -
Total 2494 3183 2293 7780

SEC. : 1
d) Product Specifications – all figures PPMW as sulphur.
PROPANE BUTANE GASOLINE
COS 5 - -
Mercaptans 5 5 550 *
Disulphides 15 15 450
Total PPMW
As Sulphur 25 20 1000
Water content
PPMW 0.5 0.5 no Spec.
e) Product characteristics
PROPANE BUTANE TEST METHODS
Composition Liquid ASTM D-2163

Vol. %
Ethane 2.5 max Trace
Propane 95.0 min 2.0 max
i – Butane } )
} } 96.0 min
n – Butane ) ) 2.5 max
)
Pentane & heavier 2.0 max
Volatile Sulphur 30 ppm wt 30 ppm wt. ASTM D-2784

max max
Hydrogen Sulphide Negative Negative ASTM

D-2420 (mod)
Copper Corrosion No. 1 max No. 1 max ASTM

D-1838
Residual matter 0.05 ml max - ASTM D-2158
S.G To be To be ASTM D-1657

reported reported
Vapour pressure 14.3 max 4.8 max) ASTM D-1267

(38°C barg)
SEC. : 1
Moisture content Pass - } GPA-Propane

) Dryness Test
) (Cobalt Bromide
)
} or ASTM
D-2713
Free Water Content - None )
8. UTILITIES AND COMMON FACILITIES
To facilitate the safe and controlled operation of the NGL-1 plant many services such as
water, power, air and heat are required.
Protective features such as relief systems, blowdown systems and fire protection
systems are required.
The Services of the laboratory, engineering departments of all disciplines, Medical

department, Administration and many others are all required for stability, safety and
control.
The utility systems supplying services are independent but are an integral part of the
system.
Failure of any of the utility systems is extremely critical. Because of this the vital
important ones have sophisticated back up facilities and failure systems. Nevertheless,
failure can still occur. Reference is made to these situations in the emergency shutdown
sections throughout the manual.
The following is a brief outline of the facilities available. More detailed information will be
given in the more comprehensive description within their own section in the manual.
Reference should be made to the appropriate P&ID in each case.
a) Cooling Water
The on plot cooling water system is shown on the P&ID.
Cooling water is pumped from the jetty to the users and returns to the sea by a
gravity flow system. The outlet from each user is piped to a tundish.
SEC. : 1
The water is chlorinated to prevent marine growth in the system.
The estimated consumption is 7300 m3/hr (excluding future ERU).

SEC. : 1
b) Fresh Water
Fresh water is supplied from the desalination plants at two pressure levels.
Fresh water is also supplied from the Government.
High pressure at 39 barg for the Propane ADIP unit.
Low pressure at 2.5 barg for potable water and service water.
c) Fuel Gas System
Fuel gas distribution is done on a dual system basis - low pressure and high
pressure.
1. Low Pressure Fuel Gas System
Gas is supplied from used regeneration gas from the molecular sieves, make up
bypass around the treaters from H.P. system and a let-down system from other
suppliers.
The system operates at 4.2 barg.
The LP fuel gas supplies the gas to regeneration

gas heater F-1301 and hot oil heater F-1305.
2. High Pressure Fuel Gas System
Gas is supplied from dry sour gas from NGL-2 or from the Government gas
supply.
SEC. : 1
The H.P. fuel gas supplies the gas to the gas turbines KT-1301/KT-1302,
passing through a gas scrubber and heater before supplying the turbine.
The H.P. fuel gas also supplies pilot’s igniters, purges and regeneration gas to
ADIP treating.
SEC. : 1
d) Instrument Air/Tool Air System
1. Instrument Air
The system consists of four air compressors. K-3201, K-3201S, K-1603 are
electrically driven and K-3201E is diesel driven.
They supply air for NGL-1 and NGL-2.
The diesel driven compressor acts if all three electrically driven compressors are
unavailable e.g. in a power failure.
The diesel compressor starts when pressure is 5.0 barg and will also start at that
pressure, even when electrically driven compressors are on line.
A secured air system is available allowing for an air supply to valves for
depressurization purposes at 6.0 barg.
Supply to other sources is at 6.0 barg.
2. Tool Air
Tool air is provided from a portable compressor.

SEC. : 1
e) Merox Air System
The Merox unit has its own air package A-1750. It consists of two compressors,
Atlas Copco K-1750 A/B, complete with all accessories. One compressor is on line
with the other as standby.
f) Electrical Power
Electricity is supplied at 33 kV from the Industrial area sub-station at Mesaieed.
The incoming voltage steps down through transformers to 11 kV.
The power is again stepped down to 3.3 kV for motor drivers up to 400 kW and feed
to the distribution board for NGL offices and workshops.
Various other step downs and facilities will be described in Volume 2 section 3 of the
manual.
One important point is the 415 V essential services switch board located in
sub-station 3400.
This switch board is backed up by an alternative supply from a diesel generator in

the event of a main failure.
SEC. : 1
g) Auxiliary Systems
The following text gives a brief outline of the systems of the NGL-1 plant. Fuller
details will be given in Volume 3 of the manual.
SEC. : 1
The purpose of the introduction is to enable the reader to accept certain facilities.
1. Blowdown Relief and Flares System
The relief and flare facilities dispose of the following.
a) Deethaniser overheads in extreme emergency.
b) Off-specification products.
c) Acid gas from treating sections.
d) Vapour discharge from safety relief valves.
e) Vapour discharge from depressurising valves.
f) Vapour discharge from vent valves.
g) Blowdown liquids.
Four separate disposal facilities are incorporated into the design.
a) Low pressure relief and flare header.
b) High pressure flare header joins the LP flare, after K.O. Drum V-1319.
c) c) Main liquid disposal to burnpit.
d) d)Acid gas flare.
All flares are provided with pilots and automatic ignition systems.
Pilot gas is from the H.P. fuel gas.
Flare heights are at 91m elevation for disposal of sulphur dioxide.

SEC. : 1
2. Hot Oil System
Hot oil is circulated to heaters and reboilers in the fractionation, ADIP and merox
units.
The oil is circulated by hot oil circulating pumps P-1314/A at 8.0 barg to the
users.
The oil is heated in heater F-1305 to 232°C and returns from the users at 149°C.
Some of the returning oil at the lower temperature is used for the ADIP
regeneration reboiler. In some cases combinations of the hot oil and return oil is
used thereby creating a warm oil system.
h) Interconnecting Systems and Facilities
Reference should be made to the P&ID's F11W-0002-01 and F11W-0003-01.
Within the NGL complex consisting of NGL-1 and NGL-2, utility services, auxiliary
services, storage and loading systems, feed and gas supplies there are many
interconnections.
SEC. : 1
The following will give some clarification of the function and services in this category.
1) Facilities exist to supply feed to NGL-1 from the NGL producing wells at Fahahil.
Facilities also exist to supply feed to NGL-1 from the NGL-2 feed supply from
the offshore source.
2) Butane from NODCO can be supplied to Depropaniser C-1302 and propane ex

ERU (QAPCO) can be received and processed in Deethaniser C-1301.
Washed butane from the Merox unit can be returned to Debutaniser C-1303.
Facility exists to route washed butane return to Merox Butane Extractor C-1730
A/B.
3) Facilities exist for the ethane rich gas compressor K-1360 to be used to
compress gas from NGL-2. This would be used to supply NFGP in the
eventuality of an NGL-1 shutdown with NFGP running. As NGL-3 does use
ethane as reflux K-1360 is not in operation nowadays.
4) Gas from NGL-1, NGL-2 and government supply is supplied to the HP and LP
fuel gas systems.
HP fuel gas is supplied to NGL-1 turbines and also to NFGP.
5) Within the flare system, the common flare elevated structure contains both
NGL-1 and NGL-2 flares although lines are individual.
SEC. : 1
6) The facility exists to interconnect cooling water between NGL-1 and NGL-2.
7) Fresh water is a common facility between NGL-1, NGL-2 and Services.
8) Instrument air is a common facility between NGL-1 and NGL-2.
Merox unit has its own process air supply for Merox Reactor, but facilities exist to
rout the process air to the instrument air header. Similarly instrument air can be
routed to the process air.
A connection exists between NGL instrument air and NFGP.
The secured air system is also an interconnected system between NGL-1 and
NGL-2
9) The nitrogen system is a common facility between NGL-1 and NGL-2.
10) Methanol supply for injection facility is common to both NGL-1 and NGL-2.
11) The fire water system is a common facility between NGL-1 and NGL-2.
12) Electrical supply is from the government supply. NGL-1, NGL-2, Merox, Storage
and Loading and cooling water pumps have separate sub-stations.
13) Telephone, Radio and closed circuit television are common facilities.
14) Storage and loading facilities are common.
9. CHEMICAL FACILITIES
Various chemicals - acids, alkalines inhibitors etc are used within the NGL-1 and
associated systems. They will be dealt with in their respective sections but are detailed
briefly here for guidance.
a) ADIP: Di-isopropanolamine (CH3-CHOR-CH2)2 NH
Used as an absorption agent for hydrogen sulphide, carbonyl sulphide and carbon
dioxide.
It is used as a solution of 27% (currently 20-22%) with water.
b) Methanol CH3 OH
Used as an emergency dehydration agent in situations where water tends to freeze

and form hydrates.
SEC. : 1
c) Water Treatment
The chemicals used are an anti-scale formation agent Belgard 'EVN', corrosion inhibitor,
sodium hypochlorite and lime.
d) Alumina Desiccant
Used in gas dryers.
e) Bromo-chloro-fluoro Methane (B.C.F)
Used as a fire fighting agent on gas turbines, floating roof tanks etc. Trade name
HALON. BCF system is gradually being phased out with environment friendly fire
fishing agents.
f) Anti Foaming Agent
Used in ADIP treating to suppress foaming tendency of ADIP and heavy

hydrocarbons. Various trade names such as OCENOL.
SEC. : 1
g) Molecular Sieves
Crystalline solids with adsorbent properties. Trade name UNION CARBIDE.
h) Merox Unit
The Merox unit has by far the greatest number of chemicals.
Reference should be made to drawing LEPC scope 6000-00-006 for full details.
The following will identify by name some of the chemicals/catalyst used.
Sulphuric Acid T-1752

Glacial Acetic Acid V-1741
Liquid Ammonia V-1741
Merox (U.O.P.) W.S. Reagent Catalyst V-1701
Corrosion Inhibitor Petrolite
Vector V.N. 6000K Hot Water
Activated Charcoal V-1741
Sand Sand Filters
Anthracite Coal V-1703
Raschig Rings V-1702/3/4
Caustic 30% and 50% wt Normal usage 14 %
SEC. : 1
10. PROTECTIVE AND SAFETY FEATURES
The major factor in all operations wether in the petrochemical industry or in any other
industry is SAFETY.
When contemplating and designing a plant such as NGL-1, safety is the prime factor.
The facilities and equipment may be treated as a section or as an individual item, but
each function is a vital part of a complex protection and safeguarding system.
a) Protective Design Features
1) Process relief valves
2) Emergency shutdown valves

SEC. : 1
3) ESD valves and systems
4) PSV isolation - self draining facility
5) Valve isolations
6) Tight shut off valves
7) Action of control valves
8) Protected valve reset features
9) Hand jack systems
10) Override systems
11) Alarm and trip settings
12) Alarm testing
13) Anti surge control systems
14) Low and high operating parameters
15) Heat/Cold protection.
16) Secured air for depressurizing
NOTE: No repressuring of unit is allowed following emergency rapid

depressurizing until temperatures have recovered.
SEC. : 1
17) Furnace lighting equipment
18) Access to equipment
19) Drain and utility lines capped.
20) Correct procedure for gas freeing and inerting.
b) Safety Features
In addition to the above listed features all personnel should be aware of the safety
procedures.
All Operations personnel should be fully familiar with normal and emergency
operating procedures.
Standing Instructions should strictly complied with.
In addition to the many protective features there are also a number of important
safety systems and functions.
1) Flares and burnpits
2) Fire fighting systems

SEC. : 1
3) Fire water pump system
4) Fire water main
5) Sprinklers
6) B.C.F.
7) Foam
8) Extinguishers
9) Alarms and Sirens
10) Fire/Gas/H2S/smoke alarms
11) Permit procedures
12) Equipment isolation procedures
13) Power and air back up systems.
14) Safety equipment - Personnel Safety

SEC. : 1
15) Safety clothing.
All aspects of this outline will be dealt with progressively in later sections.
Your own response to all instructions is of prime importance.
Your knowledge of standing instructions, rules for permits, operating instructions etc
are all mandatory.
11. GUIDELINES TO PRECOMMISSIONING
The commissioning of a new plant or modified plant is usually a more complicated and
potentially a more hazardous situation than the start up of an established plant.
To ensure organized and safe progression of the start up, a detailed format should be
prepared.
The use of arrow diagrams and critical path directions has proved to be an excellent
method during the precommissioning and start up of a new plant or system. In this
system the sequence and chain of responsibility and the sequence of all the required
steps would be indicated.
The advance preparation of ordering materials, chemicals, equipment etc should be

organized some time prior to start up.
Filling of vessels such as desiccants etc. should be supervised by operations personnel.
Sets of P&ID's should be available for final checks for flushing, blowing, testing, drying
and purging.
The understanding of what is on the P&ID, what should be installed on the plant and the
connected facilities is vitally important.
Always read and observe very carefully any covering notes and appendages on the
P&ID's.
Copies of data sheets and engineering specifications should be available for a full
understanding of the equipment and what the facilities should be.
SEC. : 1
Checks should always be made with construction and engineering sections for
mechanical completion.
The intensive and detailed checking of the P&ID’s, PFD’s and UEFS is vital. Make a list
of defects, often called ‘PUNCH ’ lists, ensuring that the defects and omissions listed are
rectified.
SEC. : 1
All systems should be checked, pipelines identified, internals checked etc normally with
the co-operation of inspection department.
Guidelines are as follows:
a) Columns and Vessels
Check for cleanliness
Position of nozzles and spiders
Check that level gauges are easily readable from one position.
Check that level gauge illuminators have been properly installed.
Installation of vortex breakers.
Completion of trays and downcomers. Check that valves in valve trays can move
freely and cannot be pushed out.
Position of draw-offs and relative position of trays.
Check position of thermowells
Check proper installation of internals.

SEC. : 1
b) Furnaces
Inspect refractory for damage.
Check that furnace tubes are free to expand.
Check dimensions of burner throats and position of burners against drawings.
Check air louvers for smooth operation and correct air rotation. Burners in the same
cell should be checked for correct air rotation.
Moving parts of the air registers should be lubricated with flake graphite before
assembling. This would be carried out by mechanical maintenance department.
Check manually and automatically operated dampers for smooth operation.
Check that no foreign matter is left behind before boxing up.
Check that gas burners can easily be reached and handled.

SEC. : 1
Check that gas valves are located in such a position that lighting of burners can be
done from the side of the furnace by one operator.
Install posters, indicating proper sequence of start-up and shutdown of furnaces.
Ensure that scaffolding materials, tools and surplus materials are removed from the
operating area. They present a safety hazard during start up.
SEC. : 1
c) Equipment
Check all items of equipment such as valves, pumps, filters, sight glasses, flanges,
non return valves, gauges, sample points, vents, drains, switches etc.
Every item, no matter how small, should be checked for cleanliness, safety and
correct operation. Ensure that all drains and vents are capped.
d) Instrumentation
Checks should be made on instrument loops, actions, indications, air supply and
identification as a means of verification.
This would normally be a combined effort between instrument department and

operations.
Orifices should be retained until flushing is complete.
e) Electrical
All electrical circuits, supplies and correct loading, lights, tracing, reset facilities and
rules should be checked and verified.
This would normally be a combined effort between electrical department and

operations.
f) Utilities, Auxiliaries and Fire & Safety Equipment
All should be available and listed. Checks should be made for cleanliness, safety
and correct operation.
Cooling water system can be circulated, vented and checked for cleanliness.
Potable water, instrument air and nitrogen should also be checked in this way.
SEC. : 1
g) Hydrostatic Pressure Testing
A hydrostatic pressure test is performed to detect cracks in materials/welds and to

check that the system is tight. Therefore flanges, joints, pump casings must NOT be
hydrotested.
When testing specified circuits, pump valves and connections must be broken and
blanked off in order to check that leaks are from defects and not from valves or
joints.
The procedure would normally be supervised by inspection department.
Records of all activities should be kept.
It is not allowed to hydro test austenitic steel piping and equipment with water
containing more than 2 ppm of chlorine.
h) Flushing
Carried out with potable/plant water.
All lines should be flushed with water to free the system of dust, scale, sand and
other matter.
The procedure and method should be compiled in arrow diagram form.
Vessels should be filled to reasonable levels to act as reservoirs and used for
flushing their sections of the plant.
SEC. : 1
P&ID's should be marked off and records kept of any valves or spools removed
during flushing. Ensure that the valves etc are replaced properly together with
orifices, gaskets, filters, plugs, spools etc.
Mechanical department should be in attendance when any rotating equipment is to

be initially started in order to check direction and mechanical features of the
equipment.
NOTE TO REMEMBER - If a pimp is used for water, in many cases a check must be
kept on the electrical load (amps). No flushing of low temperature sections
refrigerant.
i) Draining
After ensuring that all systems are clean allow as long as possible for draining. This
applies especially to columns.
Select the low points.
Remember to cap of` drain lines after blowing.

SEC. : 1
j) Blowing
Because of the high velocities and high quantities of air used, vessels should be
used as air storage vessels where possible.
A portable compressor with dryer is advised.
Procedure for section blowing should be organized as for flushing etc. i.e. marking of
P&IDs.
When shock or piston blowing, care should be taken with regard to column internals.
SEC. : 1
When blowing, noise warnings should be posted and staff involved must be wearing
ear defenders.
Suction lines to gas compressors should be manually cleaned then chemically

cleaned. This also applies to the gas lines to the turbines.
Seal oil and lube oil systems will be cleaned by the vendor.
k) Drying out
Drying out initially can be done by a continuous purge of air through vents.
A portable air compressor with dryer can be used.
A stepwise procedure should be prepared.
For systems where low temperatures will be encountered it is advisable for

instrument air to be used. In this way the dryness of the air can be relied on.
Portable moisture analyzers are an advantage.
l) Drying out of Furnaces
It is important that water from flushing through systems and within the tubes should
be vigorously removed.
Water left in the hot oil system could be a trouble factor later.
Water left in the reactivation furnace (gas) could create critical problems.
SEC. : 1
When drying out, temperatures should be increased slowly with manufacturers

recommended procedures being closely followed.
SEC. : 1
m) Drying out of Furnace Refractory
All checks should be made on hangers, tubes, debris, burner throats, inspection
glasses.
Ignitor should be prepared.
This activity is carried out in combination with hot oil circulation through the furnace
coils.
It is emphasized that special attention should be paid to the safety aspects when
starting up fired equipment. In this respect it is recommended to prepare separate
start up instructions, which should be in accordance with the information issued on
operation and control of fired equipment.
Refer to Volume 3 Section 2.
Test emergency alarms and cutouts of the furnace (s).
Take gas test in furnace before lighting gas burners. (See also dry-out procedure of
refractory manufacturer).
n) Purging
Again, as with flushing, blowing and drying, procedure should be recorded and
P&IDs’ marked up.
A step wise procedure should be compiled.
Systems in all sections should be purged until oxygen content is below 1.0%.
SEC. : 1
The inert gas system should be prepared for the continuous use of nitrogen.
Ensure that all dead pockets and low points are purged.
Purging should be done at low pressure and speed.
Safety precautions must be taken.
o) Displacement
Flares and burnpit should be commissioned.
Fuel gas from fuel gas main will be routed via V-1304 A/B to V-1302 and then to
purge all systems to flare and blowdown pit.
Systems should be purged thoroughly to remove all inert.

SEC. : 1
p) Pressurizing
Stepwise pressurizing should take place.
All safety aspects should be observed.
Constant vigilance must be maintained for any leaks in the system.
When satisfied, then increase pressure gradually at about 3.0 barg every hour.
q) Commissioning of Equipment
Commissioning of all equipment should be done gradually and progressively.

SEC. : 1
Initially and whenever practicable, vender representative and relevant engineering

department representative should be in attendance.
r) Running in of Pumps and Compressors
The following rules should be observed before starting a pump.
i) The pump and drive must be properly lubricated.
ii) The shaft should turn readily by hand.
iii) Pump's requiring gland cooling water must always be operated with an adequate
cooling water supply.
Pumps may be run-in directly after-pressure testing when lines are flushed with
sweet water. Once they have been found to operate satisfactorily, they may be
stopped and the filters inspected and cleaned and the pumps thoroughly drained of
water. Turbines must be run-in separately to check performance and settings of
trips.
s) Pump and Compressor Checks
Check that the recommended lube oil and greases have been used.
Check that filters have been installed in the suction lines of all pumps and
compressors.
Strainers above 4" dia. should have drain valves on the lower part of the blind
flange.
SEC. : 1
Cooling water - for a closed circulating cooling water system the isolation valves in
return lines should be downstream of cooling water flow indicator of particular pump.
SEC. : 1
Check for drain located in lowest part of suction line downstream of suction valve.
Vent lines of pumps in LPG service should be lined up to the flare.
Drain lines should preferably not be connected to the pump body, for safety reasons.
Drains should be lined up to the oily drain system.
Check rotation of drives. Would be carried out by Mechanical maintenance

department.
Check warming up facilities, e.g. small-diameter by pass line around check valve for
pumps on high temperature duty (above 230C).
Check that piping to and from pump is free from strain.
Check that "Blood" line on ammeter corresponds to specifications on electric motor.

Would be carried out by electrical department.
t) Initial Start up of Utilities and Refrigeration
1) Before initial start-up the following utilities are assumed to be already

operational:
All flare systems
All fire fighting facilities
The cooling water system
For details of the start up of the cooling water system see Volume 3 - Section 4
and the cooling water pumps manufacturer's-operating manual. As at initial start
up no instrument air is available, the control of the system, especially the control
of the sea water filters, must be done manually and be monitored regularly.
SEC. : 1
The instrument air system.
For start up see Volume 2 section 2 and vendors Books. The instrument air
should be started up as soon as possible after the cooling water system has
been started up.
The inert gas system.
2) After fuel gas has been made available, the fuel gas system can be started up.
The hot oil system can now be started up.
The refrigeration unit can now be started up. Initial filling of the refrigeration unit
is made possible via the tank facilities.
3) Prior to starting up the gas and product treating facilities the fresh water facilities
should have been started up and sufficient fresh water should have been
accumulated in the fresh water storage tanks.
SEC. : 1
u) Start Up
For progressive start up of the NGL-1 system reference should be made to the
individual sections. Each section contains its own start up instruction.
The main directive for a good start up should come from arrow diagrams compiled
for the initial start up.
Reference should be made to drawing NG-087 which gives a guide line to the
progression required.

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QATAR PETROLEUM VOL : 1

4. OPERATING BASIS AND EQUIPMENT

a) Propane Liquid Product

8. UTILITIES AND COMMON FACILITIES

10. PROTECTIVE AND SAFETY FEATURES

11. GUIDELINES TO PRECOMMISSIONING

a) Columns And Vessels

Facilities exist to process feedstocks from Fahahil and NGL-2 plants.

The overhead vapour from Depropaniser Column is condensed in cooling water

Washed butane containing disulfide oil is routed to Debutaniser Column in NGL-1.

F11W-0080-01 - Fractionation Unit PFD

BASE LEAN RICH

t/d 2950 2784 3122

COMPONENT NGL-3(with AGRU/TEG in operation) FSP/ARAB – D

t/d (about) 3200 700 – 800

1165 t/d - ethane rich gas

Other evaluation basis items are as follows:

- Fractionation: Minimum fractionation requirements are based on meeting GPA

- Mercaptan Extraction: To process deethanised NGL for mercaptan extraction by

- Gasoline Sweetening: In accordance with the project specification, the gasoline

PPMW as sulphur. The current mercaptan sulphur in gasoline is below 10 PPMW.

This process does not reduce total sulphur.

The design product storage temperatures are as follows:

4. OPERATING BASIS AND EQUIPMENT

Deethanising is followed by depropanising and debutanising whereby propane,

FSP/Arab D feed directly flows to the Deethaniser Column under pipeline

The Debutaniser Column overhead gas is partially condensed in E-1302 propane

a) Direct transmission on flow control to the existing QAPCO facilities.

b) Excess gas is either flared or partially used in fuel gas system.

The overhead gas from Depropaniser Column (C-1302) is condensed in E-1304

The propane product is partially pumped as reflux by P-1302/A and pumped as

Depropaniser bottoms under level control pressure flows to the Debutaniser

Debutaniser bottoms (gasoline) is cooled to 44°C in E-1306A/B cooling water

The treated gasoline is heated to remove light ends by flashing in RVP

1) Deethaniser Feed Surge Drum V-1360

Provides surge/hold up capacity to accommodate the variations from NFGP

Comprises Deethaniser Column C-1301, Depropaniser Column C-1302 and

3) Ethane Rich Gas Compressor K-1360

In the extraction process, the feed is contacted with aqueous caustic in a

Caustic is withdrawn from the extractor and regenerated by catalytic air

The disulphide is separated from the caustic by phase separation.

Regenerated caustic is recycled to the extractor.

In the sweetening unit, the mercaptans are directly converted to disulfides,

Absorption of mercaptans as sodium mercaptide and oxidation to disulphide

The resulting disulphide is reabsorbed by the hydrocarbon. The sulphur

The sweetening process is effective for treating heavier hydrocarbon

6) Gasoline RVP Correction Unit

7) Molecular Sieve Units

The equipment comprises molecular sieve beds, and control system.

8) Refrigeration Unit and Product Cooling

The system comprises two refrigerant compressors (Dresser Rand), driven by

Propane is used as refrigerant by flash evaporation, compression and cooling.

The overhead vapours of the Deethaniser are condensed.

 Products are chilled.

The system comprises compressors, turbines, chillers, coolers, vessels and

1) Propane tank vapours from Propane Boil off compressor.

The non-condensibles flow to the LP flare system.