Unit 52 Operating Manual

SOCAR HAOR MODERNIZATION AND RECONSTRUCTION PROJECT
BAKU- AZERBAIJAN REPUBLIC

EPC CONTRACT PACKAGE A
OPERATING MANUAL – UNIT 52
PROJECT : SOCAR HAOR MODERNIZATION AND

RECONSTRUCTION PROJECT-PACKAGE A
SITE : SOCAR HAOR REFINERY-BAKU- AZERBAIJAN
REPUBLIC
EMPLOYER : STATE OIL COMPANY OF AZERBAIJAN
REPUBLIC OIL REFINERY NAMED AFTER
HEYDAR ALIYEV (SOCAR HAOR)
SFW CONTRACT NUMBER : 1SD0020A
CONTRACTOR JOB. NO : TK01
DOCUMENT DESCRIPTION : OPERATING MANUAL – UNIT 52
CONTRACTOR DOC. NUMBER : TK01-VZ-MP-520001
EMPLOYER DOC.NUMBER : HS84218-52-PR-OG-0001-0000
1 30-Nov-2020 Re-Issued for Design - Issued for IP Register change S. Barde A. Trentin G. Dodoros
0 13-Nov-2019 Issued for Design (IFD) K. Bayraktar M. Farrokhi M. Farrokhi
A 25-Sep-2019 Issued for Review (IFR) K. Bayraktar M. Farrokhi M. Farrokhi
Rev. Date Purpose of Issue By Check Approved
Page 1 of 118
Document Title Document No. Rev.
OPERATING MANUAL – UNIT 52 TK01-VZ-MP-520001 1
TABLE OF CONTENTS
1 BASIS OF DESIGN........................................................................................................................ 5
1.1 INTRODUCTION ..................................................................................................................... 5
1.2 PURPOSE OF THE FACILITY .............................................................................................. 6
1.3 PROCESS OVERVIEW ........................................................................................................... 6
1.4 FEED CHARACTERISTICS. ................................................................................................. 7
1.5 PRODUCT SPECIFICATION .............................................................................................. 11
1.6 MATERIAL BALANCE ........................................................................................................ 11
1.7 BATTERY LIMIT CONDITIONS........................................................................................ 12
1.8 GLOSSARY OF TERMS ....................................................................................................... 14
2 DESCRIPTION OF PROCESS .................................................................................................. 16
2.1 PROCESS CHEMISTRY ....................................................................................................... 16
2.2 PROCESS FLOW DESCRIPTION ...................................................................................... 18
2.3 OPERATING CONDITIONS ................................................................................................ 18
2.4 MAIN PROCESS VARIABLES ............................................................................................ 21
2.5 DRAWINGS ............................................................................................................................ 24
2.6 UTILITY, PROCESS CHEMICALS AND EFFLUENT .................................................... 24
2.7 CATALYST AND CATALYST OPERATION.................................................................... 24
3 DESCRIPTION OF PLANT CONTROL .................................................................................. 29
3.1 DCS / ESD CONTROL LOGIC NARRATIVE ................................................................... 29
3.2 DCS / ESD CAUSE AND EFFECT DIAGRAMS ................................................................ 29
3.3 DCS / ESD PROCESS ALARM LIST & SETTINGS ......................................................... 29
4 DRAWINGS.................................................................................................................................. 30
4.1 ELECTRICAL ONE LINE DIAGRAMS ............................................................................. 30
4.2 AREA CLASSIFICATIONS DRAWINGS .......................................................................... 30
4.3 MATERIAL SELECTION DIAGRAM................................................................................ 30
5 PLANT PROTECTIVE EQUIPMENT ..................................................................................... 31
5.1 PRESSURE RELIEF DEVICE LIST ................................................................................... 31
5.2 FIRE AND GAS SYSTEM ..................................................................................................... 31
5.3 FIREFIGHTING EQUIPMENT ........................................................................................... 32
5.4 MATERIAL SAFETY DATA SHEETS ............................................................................... 32
5.5 OPERATIONAL SAFETY ISSUES...................................................................................... 32
6 START UP & SHUTDOWN ....................................................................................................... 33
6.1 PREPARATIONS FOR START UP ..................................................................................... 33
6.2 START UP PROCEDURE ..................................................................................................... 56
6.3 ROUTINE OPERATION ....................................................................................................... 71
6.4 TROUBLESHOOTING ......................................................................................................... 80
6.5 SHUTDOWN PROCEDURE ................................................................................................. 83
6.6 SPECIAL PROCEDURES ..................................................................................................... 88
7 EMERGENCIES .......................................................................................................................... 99
7.1 EMERGENCY SHUTDOWN................................................................................................ 99
7.2 PROCESS FLOW FAILURES ............................................................................................ 104
7.3 EQUIPMENT FAILURE ..................................................................................................... 105
7.4 UTILITY FAILURES ........................................................................................................... 105
8 HAZARDS .................................................................................................................................. 110
8.1 FACILITIES HAZARDS REQUIRING SPECIAL PRECUATIONS ............................ 110
Page 2 of 118
9 SUMMARY OF MAJOR EQUIPMENT ................................................................................. 111

9.1 LINE LIST ............................................................................................................................. 111
9.2 EQUIPMENT LIST .............................................................................................................. 111
9.3 INSTRUMENT LIST............................................................................................................ 111
9.4 EQUIPMENT BLIND LIST ................................................................................................ 111
10 PACKAGE EQUIPMENT DESCRIPTION ............................................................................ 112
10.1 COALESCER PACKAGE ................................................................................................... 112
11 PLANT SAFETY ........................................................................................................................ 113
11.1 MEASURES TO AVOID CORROSION ............................................................................ 113
11.2 MEASURES TO AVOID FIRE ........................................................................................... 113
11.3 MEASURES TO AVOID LEAKS ....................................................................................... 114
11.4 MEASURES TO AVOID EXPLOSION ............................................................................. 114
11.5 MEASURES TO AVOID CATALYST DAMAGE............................................................ 115
11.6 SAFE SAMPLING ................................................................................................................ 115
11.7 GENERAL PRECAUTIONS ............................................................................................... 115
12 ATTACHMENTS ....................................................................................................................... 116
List of Tables
Table 1.1: Inlet Feed Composition to C4 Hydrogenation unit 7

Table 1.2: Allowable Impurities level in the Feed (Design and Check Case) 8
Table 1.3: Allowable Contaminants level in the Feed (for both Design and Check Cases) 8
Table 1.4: Hydrogen Make Up Composition 9
Table 1.5: Start-up Hydrogen Specification 10
Table 1.6: Wash Water Specification 10
Table 1.7: Product Specification 11
Table 1.8: Feed Conditions at C4 Hydrogenation Unit Battery Limit 12
Table 1.9: Products Conditions at C4 Hydrogenation Unit Battery Limit 12
Table 1.10: Utility Conditions at C4 Hydrogenation Unit Battery Limit 12
Table 2.1: Catalyst Contaminants Summary Table for Raw C4 Cut 27
Table 2.2: Catalyst Contaminants Summary Table for Hydrogen Make-Up 28
Table 5.1: Pressure Relief device list 31
Table 6.1: Sample Catalyst Loading Report Summary 54
Table 6.2: Summary of operating conditions for Design Case 71
Table 6.3: Summary of operating conditions for Check Case 72
Table 6.4: Recycle Flowrate for each Operational Case 74
Table 6.5: Reactor Catalyst Specifications 88
Table 6.6: Catalyst Activation conditions 91
Table 6.7: Catalyst Reactivation conditions 94
Table 6.8: Catalyst Hot Hydrogen Stripping conditions 96
List of Figures
Figure 1.1: Block flow diagram 11

Figure 6.1: Sequence of events for the first start-up 34
Figure 6.2: Catalyst Handling–Loading with use of Hopper 46
Figure 6.3: Stationary Hopper 47
Figure 6.4: Filling up of the Shuttle Hopper at ground level 48
Figure 6.5: Shuttle Hopper 49
Figure 6.6: Catalyst Loading–Slide Valve 50
Page 3 of 118
Figure 6.7: CATAPAC™ – Utilities and equipment requirements 51

Figure 6.8: CATAPACTM - Loading Hopper for CATAPACTM feeding 52
Figure 6.9: First Start-Up Schedule 57
Figure 6.10: Solubility of water in Raw C4 Cut and Hydrogenated C4 Cut 79
Figure 6.11: Reactor Temperature Profiles 81
Figure 6.12: Catalyst activation procedure 93
Figure 6.13: Catalyst Reactivation Procedure 95
Figure 6.14: Catalyst Hot Hydrogen Stripping procedure 97
Figure 6.1: Block flow diagram 11
Figure 6.2: Sequence of events for the first start-up 35
Figure 6.3: Catalyst Handling–Loading with use of Hopper 47
Figure 6.4: Stationary Hopper 48
Figure 6.5: Filling up of the Shuttle Hopper at ground level 49
Figure 6.6: Shuttle Hopper 50
Figure 6.7: Catalyst Loading–Slide Valve 51
Figure 6.8: CATAPAC™ – Utilities and equipment requirements 52
Figure 6.9: CATAPACTM - Loading Hopper for CATAPACTM feeding 53
Figure 6.10: First Start-Up Schedule 58
Figure 6.11: Solubility of water in Raw C4 Cut and Hydrogenated C4 Cut 80
Figure 6.12: Reactor Temperature Profiles 82
Figure 6.13: Catalyst activation procedure 94
Figure 6.14: Catalyst Reactivation Procedure 96
Figure 6.15: Catalyst Hot Hydrogen Stripping procedure 98
The changes referred to IP Register change are identified by <1IP> indication
Page 4 of 118
1 BASIS OF DESIGN
1.1 INTRODUCTION
The Heydar Aliyev Oil Refinery plant of SOCAR is currently undergoing a modernization project with
the final aim to upgrade the refinery facilities to be capable of processing 7.5 MMTPA of crude oil,
whilst meeting quantity and quality requirements of products to feed Azerikimya revamped
petrochemical plant and producing EuroV quality automotive transportation fuels.
The project envisages the installation of new grass root units, revamping of existing process units,
upgrading of utilities and off-site systems and upgrading of infrastructures.
The present document provides the operating instruction for the new C4 Hydrogenation Unit (Unit–52),
to be provided as part of the HAOR Modernization Project in Baku in the Republic of Azerbaijan.
The process study of this unit has been carried out in accordance with the agreement signed between
SOCAR and Axens. The unit is designed to treat 39.1 t/h of C4 cut with a turndown ratio of 30% and a
stream factor of 7920 h/y.
The instructions given in this operating manual are referred to the start-up, the operation and the shut-
down of the C4 Hydrogenation Unit (Unit–52) that is foreseen within the HAOR Modernization
Project.
The instructions can be improved and/or modified in case of particular requirements or on the basis of
the experience that will be gathered during the start-up, shut-down and the plant operation.
1.1.1 Purpose of the Document
The aim of this “OPERATING MANUAL” is to provide Operation staff with the necessary background
and information to understand the process, prepare the unit for start-up, operate it and shut it down and
prevent or correct operation upsets. Special procedures for catalyst handling or treatment prior to start-
up as well as the relevant list of analyses and specific safety recommendations are also included.
This section will also justify the use of special equipment, if any, required by temporary operations.
Some of the instructions given herein can be considered as a reminder. This is the case of the
instructions of a general nature such as those pertaining to the pre-commissioning and commissioning
of the equipment, except where Axens issues specific requirements clearly identified. All and every
instruction, which relate to the operation of the unit and have an impact on the responsibilities of the
licensor must be strictly followed and can be altered only by Axens’ representative within the range of
the unit operating conditions.
Page 5 of 118
1.2 PURPOSE OF THE FACILITY
The purpose of the unit is to convert all the unsaturated components (mainly 1,3-butadiene: 13BD, and
olefins) present in the Raw C4 feed coming from FCC/MTBE units, into saturated products by
hydrogenation, to meet the required product specifications which can be sent to the LPG Sales or to the
Azerkimya Steam Cracker Unit.
Since hydrogenation reactions are exothermic (approximately 30 kcal/mol of H2) and diolefins are gum
precursors, one of the problems with diolefins hydrogenation is the potential risk of polymers formation.
Axens’ answer to this problem is liquid phase hydrogenation. Liquid phase enables a better and more
homogeneous heat removal through a partial vaporization and reduces the risk of hot spots. The large
liquid fraction washes the catalyst continuously and prevents polymerization, avoids deposits and
pressure build-up on the catalyst bed.
1.3 PROCESS OVERVIEW
The C4 Hydrogenation unit consist of:
• Feed Section
• Reaction section
• Stabilizer section
The C4 Feed from FCC unit (during Diesel Phase) [MTBE unit (during Gasoline Phase)] is mixed with
Demineralized Water, to be washed from its sodium content.
Since the C4 feed is free from sodium content during gasoline phase there is no need to wash the C4
stream during this phase and the relevant section will be by-passed.
The washed C4 feed is pumped to the reaction section and after mixing with liquid recycle from reactor
and Hydrogen Make-Up gas from Diesel Hydrotreating Unit is finally routed to the Hydrogenation
Reactor where diolefins and olefins are hydrogenated to reach the required specifications. The
hydrogenation reactions are highly exothermic. Therefore, the liquid recycle stream is required to dilute
the fresh feed in order to prevent excessive temperatures within the catalyst bed and to ensure an
appropriate hydraulic distribution through the catalyst bed.
Saturation reactions involved in reactor are:

1) C3H6 + H2 = C3H8
2) C4H8 + H2 = C4H10
3) C4H6 + 2H2 = C4H10
4) C4H6 + H2 = C4H8
Page 6 of 118
The hydrogenated stream flows to the Recycle Drum where the Reactor Off-Gas is separated from the
hydrogenated C4 liquid. Part of the liquid from the Recycle Drum is cooled and pumped back to the
Reactor to control the reaction temperature and the rest is sent to the stabilizer. The stabilizer is equipped
with overhead condenser and a vertical thermosiphon reboiler to ensure to meet product specification.
1.4 FEED CHARACTERISTICS.
1.4.1 C4 Cut Composition
The following feedstock characterization has been used for the design of C4 Hydrogenation Unit:
Table 1.1: Inlet Feed Composition to C4 Hydrogenation unit
FCC unit (Design Case) MTBE unit (Check Case)

Origin
(%mol) (%mol)
Propylene 0.24 0.17
Propane 0.68 1.12
Butene-1 13.8 17.23
Butene-2 (cis+trans) 26.2 32.67
Isobutylene 17.72 0.30
Butadiene 0.32 0.39
i-Butane 24.32 29.83
n-Butane 15.0 18.14
Isopentane 1.74 0.14
Total 100.00 100.00
1.4.2 Unit Capacity
The C4 Hydrogenation Unit is designed to treat 39.1 t/h of C4 Cut with a stream factor of 7920 h/y.
1.4.3 Turndown Case FeedStock
The turn down ratio of the unit is considered 30% (by Axens) of its design capacity.
1.4.4 Impurities
The impurities and contaminants level in the inlet feed to C4 Hydrogenation Unit is as per following
tables.
Page 7 of 118
Table 1.2: Allowable Impurities level in the Feed (Design and Check Case)
Unit Design Case Check Case
Sulphur ppmwt 10 max 10 max
1 ppmw max 1 ppmw max

Sodium (Na+) ppmwt
(expected 0.5) (expected 0)
DME ppmwt – 1000 max
Methanol ppmwt – 25 max
MTBE ppmwt – 25 max
Table 1.3: Allowable Contaminants level in the Feed (for both Design and Check Cases)
Unit Value
Free water - Nil
H2S+COS wppm < 0.1
NH3 + Amines wppm <1
Tertiary Butyl Catechol (TBC) wppm < 50
Acetonitrile wppm < 10
NMP wppm < 10
DMF wppm < 10
C8+ and oligomers wppm < 100
Methanol and other alcohol wppm < 50

Max value as reported
Other oxygenates
In feed definition above
Mercury wppb <2
As wppb <4
-
Si, Pb Nil
Organic Chlorides - Nil
Caustic wtppm < 0.1
Page 8 of 118
1.4.5 Hydrogen Make-Up
The hydrogen make-up gas for the unit is supplied from Diesel Hydrotreating Unit Hydrogen Make-up
Gas Compressors which is originated from high purity hydrogen header (CCR PSA / H2 Production
Unit). The hydrogen make-up composition is given in following table.
Table 1.4: Hydrogen Make Up Composition
Composition Value (mol%=vol%)

Hydrogen 99.9
Methane balance
Ethane –
Propane –
Butane –
C5+ –
Nitrogen –
Other (please specify) –
Total 100
Origin Steam Reformer / PSA (1)
Maximum available amount
–
(Nm3/hr or ton/hr)
Impurities: Vol ppm
H2S 0.1 max
HCl Nil
CO 1 max
CO+CO2 10 max
COS Nil
O2 Nil
H2O (Free Water) Nil
Nitrogen 100 max
Mercury Nil
Note 1: The origin of the hydrogen to C4 Hydrogenation Unit is the PSA in H2 Production Unit (Unit–33), however it will
be routed to C4 Hydrogenation Unit via DHT Unit (Unit–32) after pressure increment.
1.4.6 Hydrogen for Start-Up
Hydrogen will be used for activation of catalyst during plant start-up. Both High purity and low purity
hydrogen can be used for this purpose. The activation conditions with a hydrogen rich stream, are
summarized in the following table, depending on the activation gas type taken into consideration.
Page 9 of 118
Table 1.5: Start-up Hydrogen Specification
Unit
Gas components H2 from PSA / H2 from CCR
H2 content mol % 99.9 / 92.2
Gas Flowrate (kg/h) kg/h 1357 / 3224
1.4.7 C4 Feed for Start-Up
An ideal composition of the start-up feed is a 100% butane feed. The highly recommended procedure (by
Axens) for start-up is to fill the unit with a C4 cut, essentially free of unsaturated hydrocarbons, however
a typical composition of the Start-up feed is:
► Olefins: 5 wt.% maximum
► Diolefins: 500 wt ppm maximum
The C4 feed for Start-up will be supplied from Unit–59 (New LPG Storage Facilities) via saturated C4
loading pumps (59-P-103 A/B).
1.4.8 Wash Water
The wash water is used to reduce the sodium content of the C4 cut from FCC to the 1 ppmw max as
reported in Table 1.2. The selected water should be demineralized meaning to correspond to the water
prior to addition of basic compounds (i.e. oxygen scavengers like hydrazine, neutralizing amines, filming
amines, etc.).
Table 1.6: Wash Water Specification
Unit Desirable Target
Oxygen scavenger + Basic compounds Nil
pH 6.0-9.5 max
Conductivity µS/cm Preferred < 10
Dissolved oxygen ppmw <3
Chloride ppmw <1
Page 10 of 118
1.5 PRODUCT SPECIFICATION
The specification of C4 cut as the unit product for all cases is presented in the following table.
Table 1.7: Product Specification
Unit Desirable Target
Diolefins content in product wt ppm <1000
Olefins content in product %wt <5
Sodium content ppb wt <100
Methane and lighter compounds (incl. H2) wt ppm <50
For sampling test method refer to Attachment XXV “Sampling Schedule and Specific Laboratory
Equipment” (doc no. HS84218-00-PR-PL-0002-0000).
1.6 MATERIAL BALANCE
For Material Balance of the C4 Hydrogenation Unit refer to Attachment I “HEAT AND MATERIAL
BALANCE–UNIT 52” (Doc. No: HS84218-52-PR-HM-0001-0000).
Figure 1.1: Block flow diagram
Page 11 of 118
1.7 BATTERY LIMIT CONDITIONS
The following tables present the C4 Hydrogenation Unit Feeds/Products conditions at the unit battery
limit.
Table 1.8: Feed Conditions at C4 Hydrogenation Unit Battery Limit

Normal
Normal Operating
Stream Description Source Operating Phase
Pressure barg
Temperature oC
C4 FCC/MTBE Unit 40 7.7 Liquid
H2 make-up (High Purity) DHT Unit 48 32.7 Gas
Washing water
DMW Network 20 6(1) Liquid
(Demin water)
Note 1: As per BEDG document, minimum reported pressure is 5 barg.
Table 1.9: Products Conditions at C4 Hydrogenation Unit Battery Limit

Normal
Normal Operating
Stream Description Destination Operating Phase
Pressure barg
Temperature oC
To
C4 Product storageASCU 40 9 Liquid
<1IP>
Off-gas (reaction section) Fuel Gas 40 6.23 <1IP>17 Gas
Off-gas
Fuel Gas 40 6.19 <1IP>17 Gas
(stabilizer section)
Waste water WWTU 41 4 Liquid
The utility conditions for the C4 Hydrogenation Unit are summarized in following table (refer to Basic
Engineering Design Basis, Doc. No: HS84218-00-PEN-BD-0001-0000)
Table 1.10: Utility Conditions at C4 Hydrogenation Unit Battery Limit

Utility Service Normal Operating Minimum Operating Maximum Operating Mechanical Design
Conditions @ Users Conditions @ Users B.L. Conditions @ User B.L.
B.L.(Grade Note 11) (Grade Note 11) (Grade Note 11)
Barg °C Barg °C Barg °C Barg °C
High pressure Steam(8) 44 400 43 390 45 410 50/FV 450
Medium Pressure Steam(8) 10.5 240 8 185 12 320 15/FV 425
Low Pressure Steam(8) 4 162 3.5 158 4.5 166 6.5/FV 200
HP Boiler feed water 60 110 56 105 64 115 87 150
MP Boiler feed water 21.5 110(1) 20 105 23 115 34 150
Page 12 of 118
Utility Service Normal Operating Minimum Operating Maximum Operating Mechanical Design
Conditions @ Users Conditions @ Users B.L. Conditions @ User B.L.
B.L.(Grade Note 11) (Grade Note 11) (Grade Note 11)
Barg °C Barg °C Barg °C Barg °C
Pumped Condensate from units
6 110 n.a. n.a. n.a. n.a. 14 170
to condensate treatment(2)
Demin Water 6 20 5 15 7 25 10 80
Process Condensate to Users(7) 5 42 4 32 6 42 8 80
Cooling Water Supply 4 32 3.5 32 4.5 32 7 80
Cooling Water Return 2 42 2 42 2 42 7 80
Raw water(6) 2.5 20 2 5 5 25 7 80
Technical water 4 20 3.5 5 5 25 7 80
Potable Water 2.5 20 2 5 5 25 7 80
Fire Water 10 20 7(12) 5 12 25 14 80
Plant Air 6.5 25 6 15 7 35 8.8 80
Instrument Air(3) 6.5 25 6 15 7 35 8.8 80
LP Nitrogen(9) 4 25 3 15 8 35 8.8 80
High Purity Nitrogen(10) 4 25 3 15 8 35 8.8 80
Natural gas 6.5(4) 20 6 15 7 25 12 80
Fuel Gas 5 30 4 15 6 40(5) 8 80
Fresh Caustic 4 25 3 10 6 35 10 80
Flushing Oil Supply for
10 75 - - - - 15 170
BBU(Diesel Phase)
Flushing Oil Return for
4 60 - - - - 15 170
BBU(Diesel Phase)
Flushing Oil Supply for BBU
- - 3 80 5 95 15 170
(BBU Phase)
Flushing Oil Return for BBU
4 125 - - - - 15 170
(BBU Phase)
Note 1: Per HP BFW from same Deaerator.

Note 2: Fouling factor: 0.00017 m2/(°C*W).
Note 3: Dewpoint minus 40 °C at header max pressure, Oil free.
Note 4: Pressure in the refinery after the reduction station.
Note 5: Users do not have to cool amine-treated gas at reasonable T.
Note 6: Source of the raw water is from the Jeyranbatan Lake. The raw water after appropriate pre-treatments is
used to feed the following HAOR services:
Firewater storage and network;
Technical water;
Page 13 of 118
Note 7: Clean condensate after polishing unit.

Note 8: HP/MP/LP Steam Fouling Factor: 0.000086 m2/(°C*W).
Note 9: Maximum Oxygen Content:
- 5 ppm vol. for ISOM, MTBE, FCC GHT, DHT, LPG Merox, C4H and ATU units
- 100 ppm vol. for other units.
Note 10: High Purity Nitrogen with the following quality:
Nitrogen purity: >99.99 %vol.
O2 content: <5 ppm vol.
CO2 content: <1 ppm vol.
Oil content: Nil.
Note 11: Values are referred to ground level at TBM2 elevation (i.e. 100 m).
Note 12: As per relevant EPC Hydraulic Calculation report, U/G.
1.8 GLOSSARY OF TERMS
ASCU Azerkimiya Steam Cracking Unit

BEDG Basic Engineering Design Guidelines
BFW Boiler Feed Water
BL Battery Limit
CCR Continuous Catalytic Reformer
CDU Crude Distillation Unit
DHT Diesel Hydro-Treater
DMW Demineralized Water
EOR End Of Run
ESD Emergency Shutdown System
FC Fail Close
FCC Fluid Catalytic Cracking
FEED Front End Engineering Design
FL Fail Lock
FO Fail Open
HAOR Heydar Aliyev Oil Refinery
HDT Hydro-treated
HHS Hot Hydrogen Stripping
HP High Pressure
ISOM Isomerization Unit
LP Low Pressure
Page 14 of 118
MM TPA Million Metric Tons Per Annum

MP Medium Pressure
MTBE Methyl Tertiary Butyl Ether
PID Piping and Instrumentation Diagram
PSA Pressure Swing Adsorption
SFW SOCAR Foster Wheeler
SOR Start Of Run
SOCAR State Oil Company of Azerbaijan Republic
TCM-KT Tecnimont
TBM Temporary Bench Mark
WWTU Waste Water Treatment Unit
Page 15 of 118
2 DESCRIPTION OF PROCESS
The aim of the information given in this chapter is to provide enough theoretical basic background to
support the instructions given in the sections that follow: Start-up, Shutdown and Restart of the unit,
Emergencies, Package Equipment Description and Plant Safety.
The objective is to provide the operation team with a better understanding of the operating instructions
and enable them to make wise decisions, should the circumstances deviate from what is covered in the
Operating Instructions.
The different chapters of this Section describe the following:
- The Process Chemistry including various chemical reactions involved in the process.
- Process Flow Description.
- Operating Conditions
- Main Process Variables.
- Drawings
- Utility and Process Chemicals.
- The Catalyst Characteristics, Mechanism, and Contaminants.
2.1 PROCESS CHEMISTRY
2.1.1 Thermodynamics and Kinetics
For any chemical reaction the thermodynamic dictates the possibility of its occurrence and the amount of
products and unconverted reactants. Under certain conditions (P, T) some reactions are 100% completed
meaning that all the reactants are converted into products. Others are in equilibrium so that part of the
reactants is only converted. Thermodynamic dictates the equilibrium. Thermodynamic does not predict
the time required to reach equilibrium or the full completion of a reaction.
Kinetic dictates the rate of a chemical reaction or the amount of feed that disappears in a specified amount
of time say, one second. Kinetic, which dictated the rate of reaction, is dependent on operating conditions
but can also be widely modified with properly selected catalysts. One reaction or a family of reactions is
generally enhanced by a specific catalyst.
In other words thermodynamic dictates the ultimate equilibrium composition assuming the time is
infinite. Kinetic enables the prediction of the composition after a finite time. Since time is always limited,
kinetic is generally predominant when reactions are competing.
Page 16 of 118
A catalyst generally consists of a support (earth oxide, alumina, silica, magnesia…) on which (a) finely
divided metal(s) is (are) deposited. The metal is responsible for the catalytic action, but very often the
support has also a catalytic action related to its chemical nature.
A catalyst is not completely consumed but can be deactivated either by impurities in the feed or by some
of the products of the chemical reactions involved, resulting in polymers or coke deposits on the catalyst.
2.1.2 Chemical Reactions
2.1.2.1 Hydrogenation reactions
These reactions are exothermic.
• Hydrogenation of propylene
The reaction can be represented as follows:
Propylene + H2 → Propane
CH2 = CH – CH3 CH3 - CH – CH3
• Hydrogenation of butadiene and butenes
This is the main reaction:
C C C C + H2
C C C C + H2 BUTENE 1 C C C C
BUTADIENE BUTENE 2 + BUTENE 2+ H2

C4 H6 BUTANE
CIS TRANS
CH3 CH3 H CH3
C C C C
H H CH3 H
Page 17 of 118
• Hydrogenation of iso-butene
This reaction is the most difficult to achieve:
C C
C C C + H2 C C C
Iso-butene iso-butane
2.1.2.2 Overall reaction scheme
No diolefins will be left in the product and the main part of the olefins contained in the unit feed will be
hydrogenated to n-butane or iso-butane.
Considering the relative rate of reactions, the residual olefins in the product will be mainly iso-butene.
2.2 PROCESS FLOW DESCRIPTION
The C4 hydrogenation Unit process flow is described in section 2.3 “OPERATING CONDITIONS”.
2.2.1 Block Flow Diagram
The C4 Hydrogenation Unit block flow diagram is represented in Attachment III “BLOCK FLOW
DIAGRAM–UNIT 52. (Doc. No: HS84218-52-PR-BF-0001-0000).
2.3 OPERATING CONDITIONS
2.3.1 Feed Section
The C4 Feed from FCC unit (during Diesel Phase) [MTBE unit (during Gasoline Phase)] is mixed with
Demineralized Water, which is pumped from the battery limit by Wash Water Pumps (52-P-001 A/B).
The water flow rate is controlled under flow ratio of the hydrocarbon flow rate.
The mixture is routed to the Wash Water Drum (52-V-001), which operates at 5.5 barg, where the C4 cut
is washed from its sodium content. Waste water is sent to the Waste Water Degassing Drum (52-V-006)
under Wash Water Drum interface level control, while hydrocarbons are sent to the Feed Surge Drum
(52-V-002), which operates at 4.5 barg. Since the C4 feed is free from sodium content during gasoline
phase so water pump will not be in operation during this phase therefore the C4 feed directly will be
routed to the Feed Surge Drum (52-V-002) bypassing 52-V-001.
Page 18 of 118
Feed Surge Drum (52-V-002) is equipped with a boot to collect possible free water, which is temporary
poison for the reactor catalyst. The pressure in the vessel is controlled by Hydrogen/Flare blanketing.
The washed C4 feed is pumped to the reaction section by the Feed Pumps (52-P-002 A/B) under flow
control reset by Feed Surge Drum level control.
The Waste Water Degassing Drum (52-V-006), which operates at 0.3 barg, is collecting the waste water
from drums inside the unit and Wash Water Drum (52-V-001), Feed Surge Drum (52-V-002), the
Coalescer Package (52-PU-001), the Recycle Drum (52-V-003), the Reactor Off-Gas Separator Drum
(52-V-004), and the Stabilizer Reflux Drum (52-V-005). The degassed waste water is sent to the Waste
Water Treatment via the Waste Water Pumps (52-P-005 A/B) under level/flow cascade control.
The Catalyst Treatment Gas Electrical Heater (52-EH-001), operating at 3.9 barg, is used during catalyst
activation, catalyst re-activation and during hot hydrogen stripping (HHS) by heating up a high purity
hydrogen stream coming from the unit battery limit. The hydrogen is afterward sent to the Reaction
Section.
2.3.2 Reaction Section
The C4 feed is mixed with liquid recycle and Hydrogen Make-Up gas from Diesel Hydrotreating unit in
the Static Mixer (52-MX-001).
The hydrocarbon/hydrogen mixture enters the top of the Reactor (52-R-001), which operates at 30 barg,
and flows downwards through the catalyst fixed bed, where diolefins and olefins are hydrogenated to
reach the required specifications. The hydrogenation reactions are highly exothermic. Therefore, the
liquid recycle stream is required to dilute the fresh feed in order to prevent excessive temperatures within
the catalyst bed and to ensure an appropriate hydraulic distribution through the catalyst bed.
Saturation reactions involved in reactor are:
1) C3H6 + H2 = C3H8
2) C4H8 + H2 = C4H10
3) C4H6 + 2H2 = C4H10
4) C4H6 + H2 = C4H8
Page 19 of 118
As the catalyst activity reduces during the run life, the feed temperature is increased from 55°C at start of
run (SOR) to 80°C at end of run (EOR). Steam preheating by the Start-Up Heater (52-EX-001) is
necessary during start-up in order to reach reactor inlet temperature and initiate reactions.
The hydrogenated stream flows from the Reactor bottom to the Recycle Drum (52-V-003) which operates
at 27.1 barg during SOR and 24.2 barg during EOR. The vapor phase is cooled in the Reactor Off-Gas Air
Condenser (52-EA-001) and Reactor Off-Gas Trim Cooler (52-WX-001) down to 41oC. Vapor, liquid and
water phases are then separated in the Reactor Off-Gas Separator Drum (52-V-004), which operates at
26.6 barg. Liquid hydrocarbons are sent back to the Recycle Drum while hydrogen-rich reactor off-gas is
purged to Fuel Gas system. Condensed water is sent to Waste Water Degassing Drum (52-V-006) under
water level control.
During normal operation, the hydrogen make-up gas rate is under pressure control while the Reactor off-
gas rate is under flow control. This arrangement allows maintaining the reactor inlet pressure while
keeping a small hydrogen excess at any time, which is necessary to bring reactions to completion. (Refer
to Attachment V “CONTROL NARRATIVE–UNIT 52” (Doc. No: HS84218-52-PR-LN-0001-0000) for
the details of control loop).
Part of the liquid from the Recycle Drum (52-V-003) is pumped by the Recycle Pumps (52-P-003 A/B)
and sent to the Recycle Air Cooler (52-EA-002), which cools the recycle stream down to 53oC. The
bypass of this cooling section allows controlling the Reactor inlet temperature, which shall be kept in
55oC in SOR and 80oC in EOR conditions, the remaining part is routed to stabilizer section.
The Coalescer Package (52-PU-001) is installed downstream the Recycle Air Cooler to remove any free
water that may poison the hydrogenation catalyst.
The global recycle is sent to the Reactor as a stream to be mixed with the fresh feed, as described above
under the flow control.
2.3.3 Stabilizer Section
Remaining part of the hydrocarbon liquid from the Recycle Drum is routed to the Stabilizer (52-K-001)
under level-flowrate control.
The Stabilizer overhead is partially condensed in the Stabilizer Overhead Air Condenser (52-EA-003) and
in the Stabilizer Overhead Trim Cooler (52-WX-002) prior to flowing to the Stabilizer Reflux Drum (52-
Page 20 of 118
V-005), which operates at 18.6 barg. In the Stabilizer Reflux Drum, the vapor, hydrocarbon liquid and
water phases are separated.
The Stabilizer pressure, which is 19.2 barg at the top, is controlled by the Stabilizer Off-Gas flow from
the Stabilizer Reflux Drum to Fuel Gas System.
The decanted water is routed to Waste Water Degassing Drum (52-V-006) under level control of the drum
boot.
The liquid hydrocarbon is pumped by the Stabilizer Reflux Pumps (52-P-004 A/B) and sent back to the
top of the column as reflux under flow control reset by the Stabilizer Reflux Drum level control.
The reboiling is ensured by a vertical thermosiphon reboiler. A part of the Stabilizer bottoms flows
through the Stabilizer Reboiler (52-EX-002) heated by low pressure steam under flow control.
The Stabilizer bottom product is cooled down in the Product Air Cooler (52-EA-004) and in the Product
Trim Cooler (52-WX-003) down to 40oC. This C4 hydrogenated product is finally sent to LPG Sales /
Steam Cracker unit in Azerkimiya.
2.4 MAIN PROCESS VARIABLES
2.4.1 Independent Variables
The independent process variables are:
- The hydrogen excess,
- The liquid recycle flowrates,
- The space velocity (or residence time),
- The temperature,
- The pressure.
These are independent variables since each of them can be set, in theory, independently from all the
others.
The feed quality is also an independent variable, although it is generally beyond the reach of operators.
Operating parameters are defined as process variables on which operators can actually act. They will be
described in more details later as well as the ways to adjust them in function of feed characteristics and
Page 21 of 118
required products specifications. Refer to the section 6.3 “ROUTINE OPERATION”. The effect of each
independent variable taken separately is discussed below.
2.4.2 Hydrogen Excess
The make-up hydrogen flowrate must satisfy the hydrogen consumption. In a total hydrogenation process,
most of the unsaturated hydrocarbons must be converted into saturated hydrocarbons. For kinetics
reasons, this requires a hydrogen excess.
2.4.3 Liquid Recycle Flowrate
The liquid recycle is used as a diluent of the feed for the high unsaturated content. It absorbs the heat
released by the reactions, limits the temperature gradient across the Reactor and the vaporization rate.
An important effect is to ensure that a satisfactory hydrodynamic regime prevails in the Reactor, to avoid
channeling and hot spots. It is highly recommended to keep the recycle flowrate at its normal operating
value. Refer to section 6.3.1 "Summary of Operating Conditions".
2.4.4 Liquid Hourly Space Velocity (LHSV) and Residence Time
The LHSV is defined as follows.
Liquid fresh feed volume flow rate (at 15C) per hours -1
LHSV = (h )
Catalyst volume
Both volumes must be expressed with the same unit.
The LHSV is related to the residence time of the feed in the Reactor.
Catalyst volume
RT = x 60
Volume per hour of (fresh feed + recycle)
RT: Residence Time (in min.)
Typically, an increase of the residence time (i.e. a decrease of the LHSV) means a higher conversion:
more time is left for the reaction to proceed.
However, the recycle must be kept constant for hydrodynamic purpose, whatever the feed flowrate may
be; hence the residence time is not an operating parameter.
Page 22 of 118
2.4.5 Temperature
The operating temperature is a trade-off between thermodynamics and kinetics:
- Thermodynamically all the reactions involved are exothermic, hence at low temperature, the
equilibrium is displaced towards the hydrogenated product.
- Kinetically rates of reaction are increased when temperature rises.
In addition one must also remember that high temperatures favor the formation and deposit of undesirable
polymers, thus reducing catalyst cycle duration.
Therefore the unit will have:
a. to operate at the lowest inlet temperature compatible with a sufficient catalyst activity,
b. to take advantage of the liquid recycle to limit the exotherm (temperature increase) in the Reactor.
However, as catalyst ages, polymers deposits progressively coat the active sites and catalyst activity
decreases (i. e. at the same temperature, unsaturated conversion drops). A slight progressive increase
temperature is used to compensate for this loss of activity. The limit corresponds to the End Of Run
(EOR) temperature.
The normal Reactor inlet temperature for a feed composition, ranges from the Start Of Run (SOR) figure
to the End Of Run (EOR) figure. Refer to section 6.3.1 "Summary of Operating Conditions".
2.4.6 Pressure
Pressure affects the process performance:
- A higher pressure increases the hydrogen partial pressure and favors the hydrogenation reactions,
- A higher pressure concurs to maintain a large liquid fraction and improves the catalyst working
conditions.
The unit must be operated at the maximum pressure compatible with the equipment design pressure and
available battery limit pressure of make-up hydrogen.
Page 23 of 118
2.5 DRAWINGS
2.5.1 Process Flow Diagrams
The Process flow diagram of C4 Hydrogenation Unit is given in Attachment II “PROCESS FLOW
DIAGRAMS–UNIT 52” (Doc. No: HS84218-52-PR-PF-0001-0000).
2.6 UTILITY, AND PROCESS CHEMICALS AND EFFLUENT
2.6.1 Utility
For detail Utility conditions available at the battery limit refer to section 1.7 “BATTERY LIMIT
CONDITIONS”.
For dDetail utility consumption refer Attachment XXIV “UTILITY CONSUMPTION SUMMARY”
(doc. No. HS84218-52-PR-UB-0001-0000).
2.6.2 Process Chemicals
For the consumption of Chemicals in C4 Hydrogenation Unit refer to Attachment IV “CHEMICALS

AND CATALYST SUMMARY–UNIT 52” (Doc. No: HS84218-52-PR-CC-0001-0000).
2.6.3 Effluent
For detail list refer to Attachment XXVI “EMISSIONS AND EFFLUENTS SUMMARY” (doc.
no. HS84218-52-PR-EB-0001-0000).
2.7 CATALYST AND CATALYST OPERATION
For the catalyst detail and quantity refer to Attachment IV “CHEMICALS AND CATALYST
SUMMARY–UNIT 52” (Doc. No: HS84218-52-PR-CC-0001-0000).
2.7.1 Catalyst Characteristics
It is the choice of the catalyst and the associated operating conditions which are essential to the
performance of any catalytic process.
Catalyst to be used in C4 Hydrogenation unit must meet the following criteria :
- A high hydrogenation activity to fully hydrogenate the diolefins and the olefins, at the lowest
possible temperature.
- A low polymerization activity to reduce gum formation to a minimum and allow long operating
cycles.
Page 24 of 118
- A high mechanical and thermal resistance to withstand the high temperature required during
regeneration.
Considering the above, the selected catalyst is Axens LD 485 which consists of Palladium metal highly
dispersed on high purity alumina beads.
2.7.2 Catalyst Activity, Selectivity, Stability
The main characteristics of a catalyst other than its physical and mechanical properties are:
- The activity which is the catalyst ability to increase the rate of the reactions involved. It is
measured by the temperature at which the catalyst must be operated to produce a product on-
specification, for a given feed, all other operating conditions being equal.
- The selectivity expresses the catalyst ability to favour desirable reactions rather than others. It is
measured by the quantity of desired product.
- The stability characterizes the change with time of the catalyst performance (i.e., activity,
selectivity) when operating conditions and feed are stable. It is chiefly polymers or coke deposits
that affect stability since they decrease the metal contact area. Traces of some metals in the feed
also adversely affect stability.
2.7.3 Catalyst Mechanism
A catalyst consists of a support (earth oxide, alumina, silica...) on which a finely dispersed metal is
deposited. Depending upon their chemical nature, catalys supports exhibit either an acidic or alkaline
function.
The metal is responsible for the hydrogenation activity and the selectivity of the catalyst. Palladium has
been selected for LD 485 because of its high activity.
The support must meet the following criteria:
- Favor the appropriate metal dispersion within its structure as well as the reactants diffusion to the
active sites,
- Be mechanically resistant,
- Inhibit polymerization reaction by a low acidic function,
- Withstand steam, hydrogen, air treatments at temperatures higher than 400oC, (these treatments are
required for catalyst regeneration).
Considering the above, the choice has been an alumina having a specific structure, with a medium area
that has been improved.
Page 25 of 118
Its main properties are a weak acidity, close to an alpha-alumina and much weaker than a standard gamma
cubic alumina, with good texture properties, high porous volume, no micro porosity, and an excellent
behavior towards thermal shocks and steam during the course of regenerations.
It is the selection of the right catalyst together with the operating conditions which determines the rate of
the various reactions and enables to meet the required product specification. Concerning the side reactions
of dimerization or trimerization, their effect is a production of dimers and trimers depending on the
temperature. The higher the temperature, the higher the amount of oligomers.
2.7.4 Catalyst Contaminants
2.7.4.1 Temporary poisons
Temporary poisons are contaminants which are so strongly adsorbed that they accumulate over the active
surface. A specific treatment (applicable in-situ or ex-situ) is needed to remove the temporary poisons and
restore activity. Free water is a typical temporary poison and Hot Hydrogen Stripping enables to recover
the catalyst activity.
2.7.4.2 Permanent poisons
Permanent poisons are not removable by procedures available on site, i e. usually steam-and-air decoking
and Hot Hydrogen Stripping: Silicon from antifoaming additives is a typical permanent poison. When
permanent poisoning occurs, the catalyst must be dumped and replaced by a fresh load.
2.7.5 Catalyst Contaminants Summary Tables
The list of contaminants, their effect, their origin and means of removal, are presented in the following
table.
Before using this list some important remarks must be made:
a. This table is valid only for the catalyst, the feed and the hydrogenation reaction specified. Any
extrapolation to another case, which appears similar, can lead to false interpretations.
b. This table presents a non-exhaustive list of the most commonly encountered impurities in the given
type of application. Impurities not listed here, and related to other feeds, may have a detrimental
effect on catalyst performance.
Page 26 of 118
c. Regeneration of mercury contaminated catalysts will produce mercury containing effluents (Steam
and air). There is no simple and safe process for the decontamination of such effluents and Axens
does not propose any process for this purpose.
However, Axens proposes a process for complete removal of mercury and arsenic from the steam
cracker feed itself.
Also note that continued contact with mercury contaminated feeds will lead to some irreversible loss
in activity due to metal sintering.
d. When maximum content is stated as nil, it means:
- Below the detection limit of the most sensitive analytical method,
- Or, that the contaminant presence can only arise from an external source and therefore
eliminating the source would imply no presence.
e. C4 cut non listed impurities are considered as not present.
• Catalyst : LD 485
• Feed origin and description : C4 Feed from FCC / MTBE
• Reaction : Total Hydrogenation
Table 2.1: Catalyst Contaminants Summary Table for Raw C4 Cut

Maximum
Impurities Contaminant type Origin Means of removal
content
RAW C4 CUT (wt.)
Free water nil temporary poison C4 cut Reactivation
Sulfur
0.1 ppm inhibitor C4 cut Restore feed spec.
(Other than H2S+COS)
upstream
H2S + COS 0.1 ppm temporary poison Regeneration
misoperation
Oxygenates (excluding
50 ppm inhibitor C4 cut Restore feed spec.
antioxidant)
Nitrogen as NH3/Amines
1 ppm temporary poison C4 cut Regeneration
(excluding antioxidant)
Total chlorides nil permanent poison external pollution
C8+ and Oligomers 100 ppm temporary poison C4 cut Regeneration
Antioxidants
Amine type 20 ppm

Inhibitor storage Restore spec.
Phenol type 20 ppm
Silicon nil permanent poison external pollution
Mercury 2 ppb temporary poison cracker feed Regeneration
Lead nil permanent poison external pollution
Page 27 of 118
Arsenic 2 ppb temporary poison cracker feed Regeneration
Caustic (Sodium) 0.1 ppm temporary poison caustic wash Hot water wash(1)
Note 1: Uncertain outcome of the treatment.
Table 2.2: Catalyst Contaminants Summary Table for Hydrogen Make-Up
H2 MAKE-UP (vol.) Contaminant type Origin Means of removal
Free water nil temporary poison H2 gas Reactivation

Cold H2 stripping or
CO + CO2 10 ppm inhibitor methanator upsets
restore H2 spec.
O2 5 ppm temporary poison H2 gas Regeneration
HCl Nil permanent poison H2 gas
H2S 1 ppm temporary poison H2 gas Regeneration
Mercury nil temporary poison H2 gas Regeneration
Page 28 of 118
3 DESCRIPTION OF PLANT CONTROL
3.1 DCS / ESD CONTROL LOGIC NARRATIVE
For Detail interlocks and logic refer to Attachment V “CONTROL NARRATIVE–UNIT 52” (Doc. No:
HS84218-52-PR-LN-0001-0000).
3.2 DCS / ESD CAUSE AND EFFECT DIAGRAMS
For Detail Cause & Effect Diagrams refer to Attachment VI “CAUSE & EFFECT DIAGRAMS–UNIT
52” (Doc. No: HS84218-52-PR-CE-0001-0000).
3.3 DCS / ESD PROCESS ALARM LIST & SETTINGS
For Detail Alarm list & Settings refer to Attachment VII & VIII “DCS POINT CONFIGURATION
DATABASE–UNIT 52” & “ESD & FGS POINT CONFIGURATION DATABASE–UNIT 52” (Doc.
No: HS84218-52-INS-ILT-0004-0000 & HS84218-52-INS-ILT-0005-0000).
Page 29 of 118
4 DRAWINGS
4.1 ELECTRICAL ONE LINE DIAGRAMS
For Electrical One Line Diagrams refer to Attachment XXII “ONE LINE DIAGRAM SUBSTATION”
(Doc. No: HS84218-00-ELE-SLD-7201-0001).
4.2 AREA CLASSIFICATIONS DRAWINGS
For Area Classification Diagrams refer to Attachment IX “HAZARDOUS AREA CLASSIFICATION

LAYOUT–UNIT 52” (Doc. No: HS84218-52-PSE-HAD-9001-0000).
4.3 MATERIAL SELECTION DIAGRAM
For Material Selection Diagram refer to Attachment X “MATERIAL SELECTION DIAGRAMS–UNIT

52” (Doc. No. HS84218-52-MT-MS-0001-0000).
Page 30 of 118
5 PLANT PROTECTIVE EQUIPMENT
5.1 PRESSURE RELIEF DEVICE LIST
For Pressure Relief Devices refer to following table.
Table 5.1: Pressure Relief device list
Orifice Pressure Connections

Protected Size Governing Relief
Tag Number Type Area Set Back
Equipment Case Inlet Outlet
(cm2) (barg) (barg)
52-PSV-0001 A/B 52-V-001 Balanced 4M6 23.2258 Fire 6.2 1.75 4 in Flg 300# 6 in Flg 150#
Liquid Blocked
52-PSV-0002 A/B 52-V-002 Balanced 3K4 11.858 6.1 1.75 3 in Flg 150# 4 in Flg 150#
outlet
52-PSV-0004 52-EX-001 Conventional 1D2 0.7097 Thermal expansion 50.6 1.75 1 in Flg 600# 2 in Flg 150#
52-V-00752-
52-PSV-0005 Balanced 1D2 0.7097 Fire 39 3.9 1 in Flg 300# 2 in Flg 150#
DT-0002
52-PSV-0006 A/B 52-EA-002 Conventional 1D2 0.7097 Thermal Expansion 50.3 1.75 1 in Flg 600# 2 in Flg 150#
52-PSV-0007 A/B 52-PU-001 Conventional 1.5G3 3.2452 Fire 50.6 1.75 1.5 in Flg 600# 3 in Flg 150#
52-PSV-0008 A/B 52-R-001 Conventional 1.5F2 1.9806 Fire 50.6 1.75 1.5 in Flg 600# 2 in Flg 150#
Liquid Blocked
52-PSV-0009 A/B 52-V-003 Conventional 6Q8 71.2902 31.2 1.75 6 in Flg 600# 8 in Flg 150#
outlet
Liquid Blocked
52-PSV-0010 A/B 52-V-004 Conventional 3K4 11.858 30.8 1.75 3 in Flg 300# 4 in Flg 150#
outlet
52-PSV-0011 A/B 52-K-001 Conventional 3K4 11.858 Gas Blowby 21.4 1.75 3 in Flg 300# 4 in Flg 150#
52-DTV-
52-PSV-0012 A/B Conventional 1E2 1.2645 Fire 17.5 1.75 1 in Flg 300# 2 in Flg 150#
00038
52-XV-0028 Full
52-PSV-0013 A/B 52-V-006 Pilot 4P6 41.1612 2.1 1.75 4 in Flg 150# 6 in Flg 150#
Open
Vapor blocked
52-PSV-0014 52-EH-001 Balanced 4L6 18.4064 5.9 1.75 4 in Flg 300# 6 in Flg 150#
outlet
52-PSV-0015 52-WX-001 Conventional 1D2 0.7097 Thermal Expansion 24 2.4 1 in Flg 300# 2 in Flg 150#
52-PSV-0016 52-WX-002 Conventional 1D2 0.7097 Thermal Expansion 16.5 1.65 1 in Flg 150# 2 in Flg 150#
52-PSV-0017 52-WX-003 Balanced 1D2 0.7097 Fire 16.5 1.65 1 in Flg 150# 2 in Flg 150#
52-PSV-9001 52-V-910 Balanced 6Q8 71.2902 Tube Rupture 2.4 0.24 6 in Flg 150# 8 in Flg 150#
5.2 FIRE AND GAS SYSTEM
For Fire and Gas Detection system refer to Attachment XI “INSTRUMENT INDEX FOR FIRE AND
GAS DETECTION SYSTEM–UNIT 52 C4H” (Doc No: HS84218-52-INS-ILT-0003-0000) and
Attachment XII “FIRE AND GAS DETECTION LOCATION LAYOUT–UNIT 52 C4H” (Doc No:
HS84218-52-INS-ILD-0004-0000 & HS84218-52-INS-ILD-0005-0000).
Page 31 of 118
5.3 FIREFIGHTING EQUIPMENT
For Firefighting Equipment list and locations refer to Attachment XXIII “FIRE FIGHTING AND
SAFETY EQUIPMENT LAYOUT–UNIT 52” (Doc. No: HS84218-52-PSE-APD-9002-0000).
5.4 MATERIAL SAFETY DATA SHEETS
For detail of Material Safety Data Sheets refer to section 8.1.1 “Various hazardous and toxic substances
are present in this process”.
5.5 OPERATIONAL SAFETY ISSUES
Safety is the first consideration for all operations in all of the plant. Procedures, practices, and rules have
been established as guides to assure a safe working environment. Safety also plays a major role in the
efficient operation of the Refinery facilities.
The safety rules and instructions also emphasize safety hazards. Safe attitudes, practices and habits are
necessary for safe and efficient operation of the unit.
Refinery General safety procedures must be followed in C4 Hydrogenation Unit.
Page 32 of 118
6 START UP & SHUTDOWN
6.1 PREPARATIONS FOR START UP
6.1.1 Chronology of Operations
A typical bar chart sequence of events for the first start-up is given in Figure 6.1. It includes the phases of
start-up preparation in which Axens’ representatives are involved. No time scale has been provided since
the completion of these tasks depends on site manpower, local facilities and contractual provisions
between the Unit Owner and his Contractors.
It is recommended that the Axens' representative(s) is (are) present on site at least a week earlier to enable
them:
• To inspect the unit (mandatory attendance from the first day of unit check-out and vessel
inspection)
• To witness the leak test (optional for the 1st leak test and mandatory attendance for the 2nd leak test)
For the Detailed Engineering schedule, the above period should coincide with the end of the
commissioning of the utilities (utilities systems available) and the completion of the commissioning of the
unit (water wash, hydro-test, etc.).
Page 33 of 118
Then a typical chronology of operations is indicated on the following figure.
TIME AXENS TEAM READY FOR

ON SITE START-UP
TASKS
- UTILITIES COMMISSIONING
- VESSELS HYDRO TESTS
- EQUIPMENT INSPECTION
(REACTOR, VESSELS)
- UNIT COMMISSIONING
(WASHING, FLUSHINGPUMP
RUNNING-IN)
- UNIT INSPECTION
(PID's, OPERABILITY CHECKS)
- LEAK TESTS
- CATALYST LOADING
- SECOND LEAK TEST AND

NITROGEN PURGES
- INSTRUMENT SAFETY DEVICE

CHECKS
Figure 6.1: Sequence of events for the first start-up
Page 34 of 118
6.1.2 Equipment and Unit Inspection
The first inspection activity takes place towards the end of the construction work. As soon as erection is
advanced enough (equipment, piping and instrumentation) and when found convenient to both Owner and
Axens, Axens will send representative(s) to carry out the Equipment inspection (reactor, vessels, general
lay out). The sooner is the better since it will allow time for corrective work, if any.
6.1.2.1 Equipment Inspection
A) General
- Equipment inspection by Axens' representatives may be carried out in several phases.
- At the manufacturer's workshops.
- On site prior to the catalyst loading (Reactor) or prior to the mechanical completion (other
vessels).
- During and at the end of the catalyst loading.
- The workshop inspection is optional depending upon the complexity of the internals and the critical
nature of the items to be inspected.
- The site inspections prior to and during catalyst loading are mandatory, even if the workshop
inspection has been witnessed by Axens' representative and proved satisfactory.
B) Scope of Inspection
• The equipment to be inspected are as follows:
- Reactor
- Column
- Drums/Vessels
• Equipment is inspected for compliance with Axens' specifications and drawings, and Axens'
recommendations for construction, as expressed in Equipment datasheets. Axens' start-up advisor
will issue, if needed, a list of remedial works to be carried out.
• A typical, but not complete list of items to be checked is provided hereafter. The list needs to be
adapted according to the specific requirements of the unit as expressed in equipment datasheets:
- Vessel temperature and pressure rating

- Vessel metallurgy
- Vessel elevation
Page 35 of 118
- Vessel lining, internals

- Trays: number, type, spacing, levelness, liquid seal, weir height, valve number and type,
metallurgy, weep holes, supports
- Distributors: location, levelness, size and number of holes and chimneys, correct installation with
gaskets
- Quench devices: location, size and number of holes for quench pipe, size of quench box
- Ability to reinstall manways covers and associated elements after catalyst loading
- Nozzles
- Vortex breakers
- Demisters: size, materials, support
- Pressure instruments: location, range
- Thermowells: location and length
- Level instruments: location, level, range
- Fireproofing, insulation
- Presence of names plates
- Cleanness
C) Inspection Preparation Works
Here below is the description of the preparation work to be carried out by the Engineering Company or
Owner to allow access for Axens' representatives to the internals.
- Reactor Isolated by blinds, from any potentially dangerous source (flare,

fuel gas, hydrogen, N2, chemicals, HC...). Manways open and
breathable atmosphere to allow 1st inspection for reactor wall
state and a 2nd inspection after assembly of the internals
(without internal manways).
- Column, Drums and Vessels Isolated by blinds from any potentially dangerous source (flare,
fuel gas, hydrogen, N2, chemicals, HC...). Manways and vents
open, breathable atmosphere. Internals assembled.
Page 36 of 118
D) Vessels Internals Assembly and Inspection
It is advised to assemble the internals and have them inspected as early as possible, in order to perform
any adjustment without delaying the start-up planning. For the inspection of the various items listed
below, refer to the Reactor detail drawings, in equipment datasheet (Doc No: HS84218-52-PR-DS-0030-
0000).
Reactor (52-R-001)
- Install the outlet collector at the bottom of the Reactor. Check the size of the vee profile wire screen
(wire width and slots opening), its correct seal welding and the fastening of the various parts. Refer
to the relevant drawing.
- Put in place the closure cover and the glass fiber plug of the catalyst unloading nozzle and close the
nozzle. Refer to the relevant drawing.
- Install all thermowells as shown on the relevant drawing. Check their length. Fill the gap between
thermowell and reactor nozzle with glass fiber or ceramic fiber.
- Install the distributor tray, check its horizontality. Make sure of the tightness along the tray support
ring. Check the number, size and location of chimneys and holes. Refer to the relevant drawing.
- Check the feed diffuser: deflector plate opening size, pitch, fastening and levelling as per to the
relevant drawing. Perform a blank assembly on the Reactor top flange or top head.
Once this blank assembly has been carefully performed, all the internals will be left in the Reactor except
the distributor tray and the Reactor top flange / top head that are dismantled to prepare for the catalyst
loading.
6.1.2.2 Unit inspection
This inspection is the first task of Axens' team upon its arrival on site. It shall take place prior to the
mechanical completion of the unit.
A) PID check
Upon their arrival, the Axens team will carry out a check of the "as built" unit against the requirements
expressed by Axens. This check is primarily for construction conformity, piping, instruments and safety
Page 37 of 118
devices. Location of instruments, valves (including special shut off valves, tie-ins, etc.), whenever Axens
issued a special recommendation. Remedial work will be carried out, if necessary.
B) Operability check
This consists of an assessment of the possibility to carry out all the operations required for
commissioning, start-up and shutdown. It focuses mainly on access to instruments and valves (including
vents, drains), to manholes, to spectacle blinds, and to parts of equipment that need to be dismantled. The
presence of the required start-up and pressurization lines is checked as well as the impact of safety
devices on start-up operations.
C) Instrument check
This task is within the Engineering Company or Owner responsibilities. The following is only a reminder:
a) Prior to unit start-up, all instruments must have been checked with regard to:
• Proper tagging,
• Proper location in the process,
• Correctness of assembly,
• Operating range consistent with the operating conditions,
• Calibration,
• Flow orifice size, coefficients, orientation versus flow,
• Level instruments will be calibrated using the design liquid density,
• Instrument wiring integrity, polarity, grounding.
b) Alarm checking
Make sure that the released mechanism on the unit actuates the corresponding light or audible alarm in
the control room.
c) Valves
The control valves are removed during cleaning operations. They will be checked for cleanness of the
seats and free movement of the plug or ball.
Check the valves motion and their response to the controller signal.
Page 38 of 118
When all the single instruments have been individually checked, when all their addresses have been
verified in the DCS, then the loop checking can take place for each loop or group of control loops.
Each automatic action, either linked to the process or to equipment, shall also be individually tested.
d) Safety devices check
The process includes a number of specific safety devices which are implemented in the Emergency
Shutdown System (ESD). These devices are designed either to protect the unit against mis operation or to
fulfill safety actions.
The ESD is composed of independent systems which in the occurrence of pre-defined potentially harmful
events, initialize various actions such as:
- Valve(s) are set to their failure position (FC, FO or FL)
- Shutdown of equipment (pumps, compressors, electrical heater, etc.) to alleviate the risk.
Axens representative will ensure that as-built Cause & Effect Diagram conforms to Cause & Effect
Diagram as issued by Axens during Basic Process Design Package. Axens will NOT witness the Cause &
Effect Diagram field tests which remain under Detail Engineering Contractor and Owner responsibility.
6.1.3 Preliminary Operations
6.1.3.1 Definitions
The following definitions are used throughout this chapter:
• Pre-commissioning is the period during which non-operating checks and verifications that the
installation conforms to specifications, and drawings, are carried out. It includes the unit cleaning,
calibration of instruments, cold-alignment checks, testing of safety devices, etc. This phase leads to
the mechanical completion or ready for commissioning.
• Commissioning is the period during which the dynamic verification of the functioning of equipment,
the simulation of control loops and safety systems, and the operational tests are carried out.
Commissioning includes also a variety of activities such as cleaning and drying-out of piping systems,
tightness tests, loading of chemicals, desiccants and catalysts, running-in of pumps, turbines and
compressors and unit final inerting.
Page 39 of 118
These operations are conducted before feed introduction into the plant and end up at a point called ready
for start-up meaning that the plant is ready to be operated for the first time.
6.1.3.2 Axens' Involvement (Responsibilities)
Typically, Axens' start-up team arrives towards the end of the unit pre-commissioning. Sufficient time
must be allowed to the start-up team for the unit inspection prior to the mechanical completion of the unit.
Instructions related to the pre-commissioning activities shall be prepared by Engineering Company /

Owner with considering all the reported conditions in this document.
Regarding commissioning activities Axens' involvement is defined in the following paragraphs of this
chapter. In some instances, Axens is only a witness that the activity is carried out in accordance with the
state of the art and does not hamper the satisfactory execution of the forthcoming start-up operations. In
other instances, Axens either checks the results of tests or issues instructions that must be strictly
followed (special requirement, unit dry out, catalyst loading).
Both pre-commissioning and commissioning operations must be carried out in accordance with
equipment manufacturer's instructions and relevant standard codes and procedures.
Well planned and carefully executed pre-commissioning and commissioning activities generally result in
a quick and successful start-up.
6.1.3.3 Utility Systems Commissioning
Here is a non-restrictive list of these systems and the status under which they are expected to be before
start of commissioning.
• In service means the system is operational. Main header and supply lines are lined up. Each individual
user only is isolated either by block valves, if available, or blinds.
• Ready to use means the system (main header, individual supply lines) has been cleaned, dried if
required, leak and pressure tested and left under the appropriate atmosphere. The main header has been
subsequently shut off with block valves and blinds.
Instrument air : In service

Utility air: In service
Cooling water system: In service
Page 40 of 118
Individual user isolated, drain open

Nitrogen system: In service
Checked for oxygen content
Steam: In service
Drains and traps have been checked
Fire water: In service
Flare system: Ready to use
The flare main header of the unit is kept open to atmosphere and
isolated with blind from the flare collector at the battery limit
Hydrocarbon closed sewer: Ready to use
Electrical equipment: Ready to use
All wiring, junction boxes, breakers, switches have been checked for integrity, operability and
compliance with specifications. Electrical motors have been run in for 4 hours (disconnected from the
driven machine) if no mechanical objection arises.
6.1.3.4 Unit Commissioning
The following operations related to process unit equipment are to be completed in accordance with the
Owner's rules Codes, and the equipment manufacturers’ instructions and will be witnessed by Axens'
personnel:
• Hydrostatic test of piping.

• Equipment and piping cleaning.
• Rotating machine alignment.
• Pump running in.
6.1.3.5 Initial leak tests
Initial leak tests will be performed under Owner or Engineering Company responsibility and the general
instructions hereunder shall only be used as a reminder.
The initial leak tests can be performed using air (alternatively nitrogen if air is not available). The test
pressure will be at the air or nitrogen system pressure or at the unit (or section of unit) design pressure,
whichever is the lower. For equipment in low alloy steel, the test pressure shall remain below the quarter
of the design pressure of the equipment to avoid detrimental effect of temper embrittlement (refer to
Reactor Vendor Operating Manual. Doc No: HS84218-7500070523-00-C3B-0002-0001).
Page 41 of 118
The unit is isolated with blinds from adjacent sections containing hydrocarbons (liquid or gaseous), and
from utilities systems where pressure is lower than air (or nitrogen) pressure.
The pressure decrease must be checked on several pressure gauges and possibly checked on a pressure
recorder. Leaks must be carefully located and tightened. Their location must be recorded. The leak test is
satisfactory when the pressure decrease is lower than 0.05 kg/cm 2/hour over a period of 4
consecutive hours (at approximately constant temperature).
The air (nitrogen) used for leak tests should be purged out of the unit using low points drains to remove
free water, if any.
For the purpose of leak tests the unit will be divided into sections of approximately the same design
pressure. Air (nitrogen) will be injected at different locations depending on check valves locations.
Note: "Always", during initial leak test make sure, that all pumps/compressors are isolated with
vents/drains open to atmosphere to prevent accidental pressurization and as such possible seal
damage by effect of “reverse pressure”. Pumps and compressors are only to be leak tested when
seal systems are cleaned and properly commissioned by Vendor/Suppliers representatives and/or
Rotating Equipment specialists.
During the "Construction Phase», all seals and all rotating equipment must be carefully isolated,
must never be pressurized and should always be kept in a protective clean environment with
conservation oil in the seals, if lubricated by oil, or nitrogen in the seals operated by gas
(compressors).
6.1.3.6 Recommended Sections for Leak Tests
For the purpose of leak testing, Axens recommends to split the unit into several sections. All sections
have to be isolated from the other sections by blinds, or valves.
Low pressure section
- The Wash Water Drum, The Feed Surge Drum, The Waste Water Degassing Drum and its
associated piping (from the unit battery limit up to feed pumps suction). The Feed Pumps must be
isolated with blinds (suction and discharge).
High pressure sections
- The reaction section includes: Reactor, Recycle Drum, exchangers, Air coolers, coalescer and
associated piping. The Recycle Pumps must be isolated with blinds (suction and discharge).
Page 42 of 118
- The stabilization section includes: Stabilizer, Stabilizer Reflux Drum, exchangers, Air coolers. The
Reflux Pumps must be isolated with blinds (suction and discharge).
The Stabilization section shall be isolated from other sections by blinds or valves.
Catalyst Treatment Gas Electrical heater and associated piping are leak-tested separately.
6.1.4 Catalyst Loading
Refer to Attachment IV “CHEMICALS AND CATALYST SUMMARY–UNIT 52” (Doc No: HS84218-
52-PR-CC-0001-0000) for catalytic bed arrangements.
Dense catalyst loading is mandatory. The catalyst volumes given in the Attachment IV for the Reactors
are calculated for loading of the catalyst using the Axens’ high density loading technique. This
technique enables loading more catalyst, by weight, in a given volume, than by the normal sock loading
method.
A mobile loading kit is used for this operation, and consists of a rotary distributor assembly which is
introduced into the Reactor top flange access point.
The function of the rotary distributor is to sprinkle the catalyst evenly over the bed, allowing it to sit
uniformly on the surface. This more uniform distribution (less segregation of large beads towards the
periphery) reduces the risk of channelling. An added advantage of the high density loading method is that
it does not require the permanent presence of an operator inside the Reactor during loading operation.
Axens will provide, at Owner’s expenses, the service of its CATAPAC™ high density loading technique
and the technician to operate it (See Error! Reference source not found.)
6.1.4.1 Preliminary Checkings
• Check that the reactor is properly isolated and that the spectacle blinds in the nitrogen lines at the
reactors inlets are turned to the closed position. This verification should be recorded on the
commissioning/start-up blind list. This ensures that the loading teams do not risk the possibility of
asphyxiation by Nitrogen leaking to the reactor.
• Open the top manhole. Aerate and check that the atmosphere inside the reactor is suitable for entering
(21% O2). Respect the refinery vessel entry permit system at all times. Supply air hose connections to
reactor top as necessary.
Page 43 of 118
• Ensure that the catalysts and inert balls drums are gathered in a sheltered place, close to the reactor.
• Check the quality of the inert balls. If they are broken, they must be sorted out and fines removed.
• Check that all the internal parts to be installed during loading are available. Check their conformity to
the drawings and numbering done during preliminary assembling. If some gaskets remain in place
during catalyst loading protect them with adequate hard protections (plywood or aluminum).
• All the reactor internals are made of parts, which can be dismantled in order to allow passage through
the manhole. Their assembly must be checked beforehand.
• Ensure that all the necessary safety and personnel protection equipment is available (gloves, dust
masks, respirators, safety harness, etc.) as well as means of communication (walky-talkies).
• Before loading, the catalyst drums must be stored in a safe place and protected from rain.
6.1.4.2 Specific Recommendations
• To avoid catalyst attrition, do not roll drums of catalysts.
• Catalyst must be loaded carefully to minimize free fall. Maximum permissible free fall height is 1
meter. Do not walk directly on catalyst. Use wooden walking boards.
• In case of heavy rains stop loading. If prolonged rainy weather is forecast, provision for a
weatherproof cover must be made. If loading operations are not to continue for an extended period,
then the inlet flanges must be covered in a weather tight fashion whilst unattended.
• Working in a dusty catalyst atmosphere is not physically harmful, provided that dust masks are worn.
Make sure that no foreign material is left in the reactor (pieces of sleeve, walking boards, tools, etc.).
6.1.4.3 Special Loading Devices
The catalyst LD 485 is only delivered in steel drums.
The equipment includes:
- A stationary hopper to be built on site (See Error! Reference source not found.) The stationary
hopper is fitted with a slide valve (see Error! Reference source not found.). The hopper legs
should be long enough to allow access into the Reactor.
- Flexible sleeves (adequate length, 150 mm (6”) diameter minimum).
Page 44 of 118
- A shuttle hopper containing about 3-6 drums of catalyst (see Error! Reference source not
found.), fitted with a slide valve (see Error! Reference source not found.).
- A lifting device to lift the shuttle hopper from the ground level. This lifting device could be either a
crane or a system of winches (see Error! Reference source not found.).
- At ground level a temporary platform should be erected at the level of the truck used to transfer the
catalyst drums from storage facilities to the Reactor site (see Error! Reference source not
found.). The drums will be transferred from the truck to the platform, opened, and poured in the
shuttle hopper. Empty drums should be stored on site or immediately returned to storage facilities.
- On top of the Reactor a temporary platform should be installed (see Error! Reference source not
found. and Error! Reference source not found.), to allow the operation of the shuttle and
stationary hopper slide valve during loading.
- To protect catalyst from rain, temporary shelters should be installed on top of Reactor and ground
level platform.
- A vacuum cleaner should be available to eliminate dust and catalyst fines inside the Reactor.
- Tooling, lighting facilities, dust masks, respirators, safety harnesses, should be also prepared. It is
particularly recommended that personnel involved in handling and loading of the catalyst be
properly clothed, e.g. long-sleeved shirts, gloves and safety glasses.
- Bottles (1 liter) should be available to take samples of the catalyst during loading.
Page 45 of 118
Figure 6.2: Catalyst Handling–Loading with use of Hopper
Page 46 of 118
Figure 6.3: Stationary Hopper
Page 47 of 118
Figure 6.4: Filling up of the Shuttle Hopper at ground level
Page 48 of 118
Figure 6.5: Shuttle Hopper
Page 49 of 118
Figure 6.6: Catalyst Loading–Slide Valve
Page 50 of 118
Figure 6.7: CATAPAC™ – Utilities and equipment requirements
Page 51 of 118
Figure 6.8: CATAPACTM - Loading Hopper for CATAPACTM feeding

CATAPACTM on top flange - Under Air
Page 52 of 118
6.1.4.4 Loading Procedure
Check that the quality of the catalyst and the amount available are as specified (refer to section 6.6
“SPECIAL PROCEDURES”).
The following guideline assumes that the internals have been, first inspected in position, and then
partially dismantled to speed up the loading process.
Refer to the relevant loading diagram of the Reactor Attachment IV “CHEMICALS AND CATALYST
SUMMARY–UNIT 52” (Doc No: HS84218-52-PR-CC-0001-0000) for the various heights of catalyst
and inert balls, and to the detail drawings of the Reactor (equipment datasheet Doc No: HS84218-52-PR-
DS-0030-0000) for the installation of the internals. Inside the Reactor, measures will be taken from the
welding line. Manufacturer's vessels measurements are generally shown from tangent lines. Make the
necessary adjustment. Materialize the various levels with chalk marks on the Reactor wall. During
loading, the various levels of catalyst layers will be checked by measuring from the top manway.
Loading of catalyst in the Reactor (52-R-001)
- Check that the outlet collector is correctly installed.
- Ensure that catalyst draw-off pipe is flanged with plug and fiber plug fitted-in and totally filled
with inert balls (1/4”) before catalyst loading.
- Lift down the required volume of inert balls and build up the bottom layer of 3/4" inert balls,
carefully level the surface, then build up the volume of 1/4" inert balls layer and level the surface.
- Take care not to dislodge or bend the thermowells.
- Install the stationary hopper with CATAPAC™ device on top of the Reactor. This is the point at
which Axens technician will start the LD 485 dense loading procedure.
- During the catalyst loading, a sample will be taken in each drum in order to prepare an average
sample of the Reactor load. Two representative samples of 1 liter each are prepared, one for the
Owner and one for Axens.
- When the upper level of the catalyst bed is reached (up to the chalk mark on the reactor wall), build
the required layers of inert balls 1/4" and 3/4". Carefully level the surfaces.
- Install the Equiflow Hy-Mix trays. Check their horizontality and the sealing between the various
parts.
- Install the Reactor top flange with the Feed diffuser.
Page 53 of 118
- The loading is now complete. Ensure that no equipment left over from the loading operation (tools,
boards, lamps, and so on) remains in the Reactor.
Note: During the catalyst loading, 2 samples of 1 liter each will be taken in order to prepare a
composite sample of the reactor load (about every 2 meters of catalytic bed length). If possible, samples
should be taken from different batch numbers. Half of this sample will be for the Owner and half for
Axens.
Table 6.1: Sample Catalyst Loading Report Summary

REACTOR LOADING REPORT PLANT TYPE:
CLIENT & JOB NUMBER: LOCATION:
UNIT NUMBER:
REACTOR: DATE: SHEET OF
CATALYST TYPE:
Lot Drum Net Lot Drum Net Lot Drum Net
Drum Drum Drum
No: No: Wt. No: No: Wt. No: No: Wt.
1 18 35
2 19 36
3 20 37
4 21 38
5 22 39
6 23 40
7 24 41
8 25 42
9 26 43
10 27 44
11 28 45
12 29 46
13 30 47
14 31 48
15 32 49
16 33 50
17 34 51
TOTAL WEIGHT LOADED: LOADING SUPERVISOR NAME:
NUMBER OF DRUMS: SIGNATURE:
LOADING DENSITY:
6.1.4.5 Second leak test
After the catalyst loading completion, the tightness of the Reactor has to be checked again.
- Reactor, being isolated, is pressurized with air (alternatively nitrogen if air is not available) to
the maximum pressure compatible with the equipment.
Page 54 of 118
- The tightness is considered satisfactory when the pressure loss is less than 0.05 bar/hour during 4
consecutive hours at almost constant temperature.
- After the leak test the unit is purged with nitrogen until the oxygen content is 0.2 vol. % maximum.
This is achieved by successive pressurization/depressurization with nitrogen.
- If, for any reason, the leak test of the unit, as described in section 6.1.3.5 “Initial leak tests”, has not
been performed yet, proceed to an overall leak test of the unit, reactor included. After the leak test
reactor are isolated by blinds if start-up is not going to take place immediately and kept under a
nitrogen atmosphere, ready for catalyst activation.
6.1.4.6 Complete Inerting/Purging of Air
The purpose of this step is to reduce the O2 content in all the sections below 0.2% by volume prior to the
introduction of hydrogen or hydrocarbons.
Air can be eliminated by two methods:
1) Using the pressure cycling method with nitrogen:
By repeated filling and pressuring the system with nitrogen and then releasing the air enriched in
nitrogen to atmosphere until the oxygen content reaches the required minimum value. This method is
used in reaction section where humidity has adverse effect on equipment or catalyst. The vacuum
ejector installed in this section is used for decreasing the number of purging and nitrogen refilling
cycles.
2) Using steam in conjunction with sweet fuel gas or nitrogen:
By steam out and subsequent refilling the equipment with fuel gas. This method is general practice in
refinery operation on all equipment where humidity and steam cannot deteriorate the equipment or
catalyst. During steam out operation reaction section is isolated with blinds and filled with nitrogen. It
is recommended to start filling reaction section with nitrogen.
Page 55 of 118
6.2 START UP PROCEDURE
6.2.1 General
- It is recommended to use dry feed, in order to avoid free water occurring in the catalyst bed.
- The contaminants content of the start-up feed shall not exceed the allowable limits for the catalyst
(refer to section 2.7.5 "Catalyst Contaminants Summary Tables").
- The highly recommended procedure for start-up is to fill the unit with a C4 cut, essentially free of
unsaturated hydrocarbons (refer to section 6.2.4 “Start-up with a C4 cut essentially free of
unsaturated hydrocarbons”).
- An ideal composition of this start-up feed is a 100% butane feed.
- The purpose is to ensure a smooth start-up with a weakly reactive feed which is progressively
replaced in the Feed Surge Drum with reactive Raw C4 cut (high unsaturated hydrocarbons
content). Moreover, it provides a recycle flow which is used as a diluent of this reactive C4 feed.
- Should an essentially free of unsaturated hydrocarbons C4 cut not be available, a convenient hold-
up of Start-up feed shall be prepared in-situ by a progressive and smooth hydrogenation of the
reactive Raw C4 cut (refer to section 6.2.5 “Start-Up With a Reactive C4 Cut”).
Warning:
When the unit hold-up at start-up contains noticeable amounts of unsaturated hydrocarbons,
operators must keep in mind that it is hydrogen which actually controls the exothermic reaction.
Hence, hydrogen must be introduced at reduced throughput and increased very progressively. For
temperature control in the Main Reactor, the Main recycle flowrate must be set at its normal
operating value prior to hydrogen injection.
6.2.2 Status of the unit
- Tightness test and nitrogen purges have been completed (O2 lower than 0.2 vol. %).
- The unit is under a slight nitrogen pressure.
- Free water trapped has been drained at low points.
- All necessary utilities are in service: blinds on the headers have been removed and valves opened
on all users.
- All instrumentation has been checked and is in service.
- The emergency shutdown system has been tested.
Page 56 of 118
- The catalyst is reduced (Refer to section 6.6 “SPECIAL PROCEDURES”).
- The Reactor is isolated and kept under a slight nitrogen pressure.
- The estimated volume of inert feed for first start-up is: 395 m3.
- Note: The H2 Production Unit (PSA) and H2 from DHT Unit must run satisfactorily before feeding
Start-up feed to the unit.
Warning: Make sure, before introducing any raw C4 feed (containing unsaturated hydrocarbons) that the
hydrogen make-up is isolated by blind.
6.2.3 Chronology of start-up operations
The chronology of the various start-up tasks is shown on the attached schedule.
The durations shown are those required to perform the tasks. The time gap between two consecutive
operations has not been taken into consideration.
Figure 6.9: First Start-Up Schedule
Page 57 of 118
6.2.4 Start-up with a C4 cut essentially free of unsaturated hydrocarbons
6.2.4.1 Required specification of the Start-up Feed
A typical composition of the Start-up feed is:
- Olefins: 5 wt.% maximum
- Diolefins: 500 wtppm maximum
6.2.4.2 General
To minimize the sudden vaporization of C4 when filling-up, the Reaction section is first pressurized with
nitrogen. Pressurize at the maximum header pressure available or maximum pressure compatible with
equipment, whichever is lower.
6.2.4.3 Filling the Wash Water Drum and the Feed Surge Drum
Warning: During this operation, blind must be kept closed in the hydrogen make-up line.
- Handswitch selector 52-HS-0005 / 52-HS-0008 / 52-HS-0012 acting on:
- Hydrogen make-up flow control.
- Reactor (52-R-001) inlet pressure control.
is in start-up mode (refer to Attachment V “CONTROL NARRATIVE–UNIT 52” (Doc. No:

HS84218-52-PR-LN-0001-0000).
- Handswitch selector 52-HS-0009 acting on Reactor (52-R-001) inlet temperature control is in start-
up mode (refer to Attachment V “CONTROL NARRATIVE–UNIT 52” (Doc. No: HS84218-52-
PR-LN-0001-0000).
- Make sure the Reactor (52-R-001) is isolated and bypassed.
- Check that the block valves of 52-FCV-0023, in the unit product line, are closed.
- Switch the interlock system in the appropriate position for the emergency valves “HZV” and the
control valves to be operable. At start-up, it can happen that the detection of low level or low flow
prevents the operation of valves or the start-up of pumps. The related interlock has to be
temporarily inhibited until normal operating conditions are established.
- Check that the unit Raw C4 feed battery limit block valves and their bypasses are closed.
- Turn in open position the spectacle blind on start-up line at BL, open the block valve and start
filling the Wash Water Drum (52-V-001) and then the Feed Surge Drum (52-V-002) by slowly
opening the globe valve on start-up feed line.
Page 58 of 118
- The pressure in the Wash Water Drum and the Feed Surge Drum will rise to achieve the Start-up
C4 feed vapor partial pressure. Maintain the drum pressure at its normal value by venting the
excess nitrogen. Put in operation the Feed Surge Drum pressure controller 52-PIC-0005.
- Stop feeding the Feed Surge Drum when the level reaches about 60 %. Then ensure that ESD-0002
(Very high level in 52-V-002) and ESD-0003 (Very low level in 52-V-002) are commissioned.
- Check water settling in the boot of 52-V-002 and drain it, if necessary.
Prepare the Feed Pumps (52-P-002 A/B) for start-up by purging the nitrogen trapped in the casing, if
necessary.
6.2.4.4 Filling the Reaction section (Reactor by-passed) – closed loop circulation
The aims of the closed loop circulation in the Reaction section, Reactor bypassed are:
- To eliminate the free water which can remain in the lines and equipment (free water is a temporary
poison of the catalyst).
- To clean the lines before circulating through the Reactor (debris are collected in the pumps
strainers).
- To check the operation of all instrumentation involved in the closed loop.
Refer to Attachment XVIII “FILLING / CIRCULATING DIAGRAMS–UNIT 52”.
Once the Feed Surge Drum (52-V-002) reaches a sufficient level:
- Check that the Reaction section feed flow control valve (52-FCV-0004) is under manual mode.
Recycle flow control valve (52-FCV-0013), recycle temperature control valves (52-TCV-0008
A/B), hydrogen make-up control valve (52-FCV-0010) and Coalescer water level control valve
(52-XV-0011) should be closed.
- Open blinds and line-up the Start-Up Heater (52-EX-001) and its by-pass line, and the Reactor (52-
R-001) by-pass line.
- Pressurize the Recycle Drum (52-V-003) with nitrogen.
- Commission the pressure controller 52-PIC-0019 and 52-FCV-0018 venting control valve
(blanketing valve 52-PCV-0024 and related by-pass valve shall be kept closed). Normal operating
pressure will be used for set point (refer to section 6.3 “ROUTINE OPERATION”). This will allow
venting of the reaction section in case of pressure increase.
Page 59 of 118
- Using the reaction section feed control valve (52-FCV-0004) establish a circulation through the
Static Mixer (52-MX-001) the Start-Up Heater (52-EX-001) and its by-pass line, and the Recycle
Drum (52-V-003) via the Reactor by-pass line.
- Monitor the pressure increase at the Recycle Drum (52-V-003).
- Build-up a level in the Recycle Drum (52-V-003) up to 80%.
- Close the reaction section feed control valve (52-FCV-0004).
- During the following operations, the Feed Surge Drum, and the Recycle Drum levels shall be
checked carefully. Make-up with Start-up feed from battery limit if necessary.
- Start the Recycle Pump (52-P-003 A or B) for start-up. Vent the pumps casing if necessary.
- During the circulation, each pump (52-P-003 A or B) will run alternatively to check it operates
satisfactorily.
- Commission ESD-0007 and ESD-0008 (Very low level 1 and 2 in 52-V-003).
- Open 52-TCV-0008 A/B control valves and put the Recycle Air Cooler (52-EA-002) the Reactor
Off-Gas Air Condenser (52-EA-001) and the Reactor Off-Gas Trim Cooler (52-WX-001) in
operation.
- Commission Coalescer water level controller (52-LI-0011).
- Adjust the recycle flowrate at its normal operating value using the recycle flow controller (52-FIC-
0013).
- Commission ESD-0005 (52-R-001 protection–First level). Ensure ESD-0006 is commissioned (52-

R-001 protection/depressurization–Second level).
- Bring the Recycle Drum level back to 80%. Close the make-up of Start-up feed when the level is
achieved.
- Maintain the C4 cut circulation for one hour. Vent gases at high points. If any, drain free water at
all low points and in Recycle Drum water boot. Check Coalescer Package water level.
- Periodically clean the Recycle Pump strainers till they are found clean.
- Then keep the circulation in service.
- Take sample for analysis of recycle (52-SC.B-0006 around 52-TCV-0008 A).
Page 60 of 118
6.2.4.5 Filling the Stabilizer section
• 52-V-005 water level valve 52-XV-0028 needs to be closed.
• Check that the Stabilizer C4 product control valve (52-FCV-0023) and Stabilizer purge control
valve (52-PCV-0027) are closed, as well as their by-passes. The corresponding controllers should
be deactivated.
• Commission pressure controller 52-PIC-0027 and 52-PCV-0027. Normal operating pressure will
be used for set point (refer to section 6.3 “ROUTINE OPERATION”). This will allow venting of
the Stabilizer section in case of pressure increase.
• Open Stabilizer feed control valve (52-FCV-0017) and start filling Stabilizer bottoms. Make-up
with C4 cut via C4 start-up line if necessary, in order to maintain the level in Recycle Drum at 80
% at any time.
• When Stabilizer bottom is filled at 60%, close Stabilizer feed control valve (52-FCV-0017).
• Leave all isolation valves closed.
• Open blind on reflux drum filling line. Reflux Drum filling will be performed with material from
Recycle Drum (52-V-003) and pumped with Recycle Pumps (52-P-003 A/B).
• Open the globe valve and start filling the Stabilizer Reflux Drum (52-V-005). Check the Recycle
Drum liquid level and make-up with C4 feed, in order to maintain the level at 80 %.
• Let the level increase up to 80% in the Stabilizer Reflux Drum.
6.2.4.6 Filling the Reactor (52-R-001)
Before Reactor (52-R-001) filling, the depressurization valves 52-HZV-0034 and 52-HZV-0035 must
be lined-up to the Reactor outlet.
Initial status is as follows:
- Reactor is loaded with catalyst and leak tested; catalyst has been reduced and the Reactor is under
nitrogen pressure.
- Reactor is isolated (inlet and outlet) by block valves.
The procedure is the following:
- Catalyst treatment circuit (inlet/outlet) must be blinded.
- Line-up the filling circuit as per attached drawing "REACTOR FILLING-UP DIAGRAMS–UNIT
52" (Attachment XVII).
Page 61 of 118
- Crack open the by-pass valves of 52-PSV-0008 A/B located at the top of the Reactor. This allows
flaring the gas while filling up the Reactor.
- Open the block valve of filling line at the bottom of the Reactor.
- Crack open the globe valve and allow start-up feed to enter the Reactor. Proceed slowly in order
not to lift the catalyst bed (Estimated maximum filling rate is 245 m3/h). Reactor pressure should be
kept at least 0.2 or 0.3 bar below the normal operating pressure in order to avoid the risk of
overpressure during filling up.
- In order to compensate for the level decrease in the Recycle Drum, make-up with start-up feed
from battery limit.
- Open completely the globe valve of the 52-PSV-0008 A/B bypass on the top of the Reactor in order
to flare nitrogen to the Flare Header and complete the filling.
- When Reactor is full, the hissing of the gas through the globe valve stops and the line freezes (C4
flashing).
- Close the globe valve of the 52-PSV-0008 A/B bypass.
- Keep open the globe valve at the bottom filling line.
- Keep the Reactor in these conditions for at least 4 hours to soak the catalyst.
- After soaking of the catalyst, vent again to the wet flare to check that no vapor phase remains at the
top of the Reactor and close 52-PSV-0008 A/B bypass line.
- Open the block valves on the outlet line of the Reactor and close the filling valves.
6.2.4.7 Circulation through the Reactor (52-R-001)
- Open the block valves on the inlet line of the Reactor (52-R-001).
- Close slowly the block valves in the Reactor bypass line to force the circulation of Start-up feed
across the Reactor.
- Put in service the differential pressure indicator (52-PDI-0020) to monitor the Reactor pressure
drop.
Page 62 of 118
6.2.4.8 Start-up of the Stabilizer section
• Initiate low-pressure steam flow to the Stabilizer Reboiler (52-EX-002).
• After some temperature increase, pressure will build up in the Stabilizer and liquid level will
decrease. Keep bottoms liquid level at about 60% by using the Stabilizer feed control valve (52-
FCV-0017) if necessary.
• Allow enough time for all the system in the Stabilizer to heat up to the operating values (pressure
and temperature). As nitrogen is a non-condensable, slight Stabilizer purge will enhance
condenser performance later on.
• Put the Stabilizer Overhead Air Condenser (52-EA-003) in operation, establish the cooling water
circulation in the Stabilizer Overhead Trim Cooler (52-WX-002). Commission pressure control
valve, 52-PCV-0027, in automatic control mode. Check that the pressure controller works
properly.
• Start reflux pumps once overhead condensation is observed. Decant any free water.
• The Stabilizer is ready to operate. Keep it on stand-by: close its feed and maintain reboiling and
condensing.
6.2.4.9 Heating of the circulating Start-up feed
- Slightly close the Start-Up Heater (52-EX-001) bypass globe valve in order to heat a part of the
recycle.
- Fully bypass cold recycle by fully opening temperature control valve, 52-TCV-0008 B.
- Put the Start-Up Heater (52-EX-001) in operation and increase progressively the Reactor inlet
temperature to Start Of Run (SOR) Reactor inlet temperature.
- Often, for the first start-up with a fresh catalyst, the reaction starts at ambient temperature, and the
need to preheat the Reactor inlet stream is only to prevent free water from poisoning the catalyst
when the feed is saturated (refer to Section 6.3.3.2 "Reactor Inlet Temperature").
- Switch the Reactor inlet temperature control to automatic start-up mode (refer to Attachment V
“CONTROL NARRATIVE–UNIT 52” (Doc. No: HS84218-52-PR-LN-0001-0000)) and let the
temperature stabilize (at 55oC).
Page 63 of 118
- Wait until all thermocouples in the catalytic bed show the same temperature.
6.2.4.10 Hydrogen pressurization of the drums
- Check that the make-up hydrogen blanketing valves to The Feed Surge Drum, 52-V-002, (52-PCV-
0005A), to Recycle Drum, 52-V-003, (52-PCV-0024) and their bypasses are closed. Check also
that Hydrogen make-up valves to reaction section (52-FCV-0010) and their bypasses are closed.
- Prepare the hydrogen make-up circuit from the battery limit.
- Prior to inject hydrogen make-up gas, reliable analysis must be available and compliance with the
hydrogen gas specification must be checked.
- Inject make-up hydrogen through the bypass of 52-PCV-0005A located on the Feed Surge Drum
pressurization line and slowly raise the pressure up to the normal operating pressure. The use of the
bypass for this operation is recommended in order to avoid the control valve to open widely, should
the pressure of the drum be noticeably below the normal set point. The hydrogen gas may contain
some water. Check water settling in drum boot and drain, if necessary.
- Inject hydrogen through the bypass globe valve of the Reactor pressure control valve 52-PCV-0024
located on the Recycle Drum (52-V-003) pressurization line and slowly raise the pressure up to the
normal operating pressure of the drum. Check water settling in drum boot and drain, if necessary.
- Check that the differential temperature in the Reactor (reactor exotherm) due to reaction of the
dissolved hydrogen in the Reactor inlet stream does not exceed a few degrees, or decrease injection
rate of pressurization hydrogen to 52-V-003. This may be due to hydrogenation of unsaturated
compounds of start-up feed.
- Proceed step by step, until hydrogen breaks out from the Reactor and the pressure starts to increase
in 52-V-003.
- When conditions are stabilized, close the bypass of 52-PCV-0024 and put the Reactor inlet pressure
controller (52-PIC-0019, 52-PCV-0024 and 52-FCV-0018) in start-up mode at its normal operation
set point (refer to Attachment V “CONTROL NARRATIVE–UNIT 52” (Doc. No: HS84218-52-
PR-LN-0001-0000). In Start-up mode, 52-PIC-0019 is governing the supply of hydrogen
pressurization gas 52-V-003 and releasing as purge to Fuel Gas System.
Page 64 of 118
- Put the Feed Surge Drum (52-V-002) pressure controller (52-PIC-0005, 52-PCV-0005 A/B) in
automatic split-range mode at its normal operation set point.
- Continue recirculation for few hours. Then check the composition of the circulating C4. If it meets
the specifications of the Hydrogenated C4 cut product and if there is no more temperature
differential in the Reactor, it means the system is ready for a reactive feed introduction.
6.2.4.11 Raw C4 feed in
If the analysis, mainly the Raw C4 feed analysis, match closely with the design basis (refer to “Process
Basis of Design–Unit 52” (Doc No: HS84218-52-PR-BD-0001-0000)) then the make-up hydrogen
injection will be set in proportion to the normal operating feed flowrate.
Should the analysis of the Raw C4 feed during the start-up phase differ from the basis of design, then the
make-up hydrogen flowrate must be recalculated (refer to section 6.3.3 “Operating Parameters”).
- Check that the recycle flowrate is at 100% of the normal flowrate.
- Switch the handswitch selector 52-HS-0009 acting on Reactor inlet temperature in normal
operation mode. Fully bypass the Start-Up Heater (52-EX-001).
- Water line at BL; slowly open the globe valve on Demineralized Water line.
- Start the Wash Water Pump (52-P-001 A or B) for start-up. Vent the pumps casing if necessary.
satisfactorily.
- Check that the Demineralized Water feed flow control valve, 52-FCV-0001, is under manual mode.
Adjust the flowrate to 60 % of the normal operating flowrate. Level control valve (52-LCV-0001)
should be closed.
- Build-up a Water level in the Wash Water Drum (52-V-001) up to 30%.
- Commission Wash Water Drum level controller, 52-LIC-0001.
- Commission ESD-0001 (Very low level in 52-V-001).
- Open Level control valve (52-LCV-0001) and build-up a level in Waste Water Degassing Drum
(52-V-006) up to 60%.
Page 65 of 118
- Start the Waste Water Pump (52-P-005 A or B) for start-up. Vent the pumps casing if necessary.
satisfactorily.
- Commission Waste Water Degassing Drum level controller (52-LIC-0034).
- Continue demineralized water injection about 50 % of the demineralized water required for 60 % of
the Raw C4 feed (refer to the relevant material balance) with flow ratio (Demineralized Water /
Raw C4) controller 52-FY-0001 set in manual mode.
- Restart one of the Feed Pumps, 52-P-002 A or B, and start to feed the Reaction section, with flow
controller 52-FIC-0004 set in manual mode. Adjust the Reaction section feed to 60 % of the normal
operating flowrate.
- Turn in open position the spectacle blind on Demineralized Water line.
- When the level in the Feed Surge Drum (52-V-001) is stabilized at 60%, switch the level controller
(52-LIC-0006) in automatic mode resetting the Reactor feed flow controller (52-FIC-0004).
- When reactive feed enters the unit, the reactive C4 feed is diluted by the weakly reactive C4 in the
hold-up. Hence the hydrogen requirement is less than normal. Inject about 50 % of the hydrogen
required for 60 % of the Raw C4 feed (refer to the relevant material balance and to section 6.3.3.1
“Make-Up Hydrogen Flowrate”) with flow ratio (H2/ Raw C4) controller 52-FY-0008 set in manual
mode, 52-HS-0005 selector in start-up mode).
- Commission the Stabilizer product flow controller (52-FIC-0023) and open 52-FCV-0017.
- Crack open the block valves around 52-FCV-0023. The product is sent through off-spec line. Once
C4 product is on specification (measured by the product on-line analyser / sample point), it will be
sent to its normal destination.
- Monitor the temperature rise in the Reactor (52-R-001). If no temperature increase is noticed after
10 minutes, stop injecting hydrogen, stop the operating Feed Pump (52-P-002 A/B) and increase
the Reactor inlet temperature by 5oC.
- Check level increase in Recycle Drum.
Page 66 of 118
- Once the whole inventory of the Feed Surge Drum (52-V-001) has been displaced by the Raw C4
feed, increase the hydrogen flowrate. Proceed step by step, until hydrogen breaks out of the Reactor
and the vent valve (52-FCV-0018) starts to open at Reactor Off-Gas Separator Drum (52-V-004),
purging the hydrogen gas.
- Check by analysis the Reactor effluent product and adjust the operating parameters to meet 1 wt.%
of olefins.
- Stabilize the operating conditions, and then put in service the normal operation mode of Hydrogen
flow control and Reactor pressure control (52-HS-0008) in Reaction section.
- Increase the unit feed flowrate to 100% of the normal operating flowrate, in appropriate
increments.
- Monitor the olefins content of Reactor effluent (on-line analyzers / sample points) and adjust the
make-up hydrogen flowrate to meet the recommended figures.
6.2.5 Start-Up With a Reactive C4 Cut
6.2.5.1 Required specifications of the start-up reactive C4 cut
The reactive C4 cut must be within Raw C4 feed specifications defined in “Process Basis of Design–Unit
52” (Doc No: HS84218-52-PR-BD-0001-0000).
6.2.5.2 Chronology of operation
The chronology of the various tasks is similar to “Start-up with C4 cut essentially free of unsaturated
hydrocarbons (refer to section 6.2.3 “Chronology of start-up operations”) with the addition of the step
required by the hydrogenation of the start-up reactive C4 cut hold-up (about 1 day).
6.2.5.3 General
First proceed as described in the same paragraph of “Start-up with a C4 cut essentially free of unsaturated
hydrocarbons” (refer to section 6.2.4 “Start-up with a C4 cut essentially free of unsaturated
hydrocarbons”).
The filling-up of the Feed Surge Drum (52-V-002), the filling up of the Recycle Drum (52-V-003) the
closed loop circulation with the Reactor (52-R-001) by-passed, the filling-up of the stabilizer section, the
Page 67 of 118
filling-up of the Reactor, the circulation through the Reactor, the start-up of the stabilizer section and the
heating of the start-up feed, are performed as described in Sections 6.2.4.3 to 6.2.4.10 .
Then the circulating raw C4 feed has to be hydrogenated in order to prepare an unreactive inventory in the
unit before Raw C4 feed in.
6.2.5.4 Filling the Wash Water Drum and the Feed Surge Drum
Refer to section 6.2.4.3
The level in Feed surge drum (60%) is achieved through the unit feed line. The feed flow controller is
kept in manual.
6.2.5.5 Filling the Reaction section (Reactor by-passed) – closed loop circulation
6.2.5.6 Filling the Stabilizer section
6.2.5.7 Filling the Reactor (52-R-001)
6.2.5.8 Circulation through the Reactor (52-R-001)
6.2.5.9 Start-up of the Stabilizer section
6.2.5.10 Hydrogenation of the Raw C4 cut hold-up
- Prior to introducing hydrogen gas, reliable analyses of the Raw C4 cut and make-up hydrogen must
be available, and the upstream unit operation must be steady.
- Check that the Recycle Air Cooler (52-EA-002), the Reactor Off-Gas Air Condenser (52-EA-001),
and the Reactor Off-Gas Trim Cooler (52-WX-001) are ready for use.
- Prepare the make-up hydrogen circuit from the battery limit.
Page 68 of 118
- Check that the make-up hydrogen injection line to the reaction section is properly isolated (52-
FCV-0010 valve and bypass closed).
- Proceed as per paragraph 6.2.4.10 "Hydrogen pressurization of the drums" of section 6.2.4 "Start-
up with a C4 cut essentially free of unsaturated hydrocarbons", to pressurize the Feed Surge Drum
(52-V-002) and Recycle Drum (52-V-003) with hydrogen.
- If no reaction is noticed with dissolved hydrogen, at ambient temperature, use the Start-up Heater
(52-EX-001) to raise slowly (1oC steps) the Reactor inlet temperature up to the minimum
temperature (refer to section 6.3.1 "Summary of Operating Conditions). Refer to section 6.2.4.9
“Heating of the circulating Start-up feed”.
- Then, start intermittent injections of make-up hydrogen to the Reactor (52-R-001) through 52-
FCV-0010.
- As the reaction starts, temperature rises in the catalytic bed.
- Try to establish a very small continuous flow of hydrogen make-up gas, keeping the differential
temperature in the Reactor at about 20oC maximum (adjust make-up hydrogen injection as needed).
- As the Reactor outlet temperature increases, stop the steam supply to Start-up Heater and switch
the Reactor inlet temperature control to normal operation mode (bypass around Recycle Air Cooler
(52-EA-002)), Check that the Reactor inlet temperature controller works properly.
- Control carefully the temperature profile in the Reactor, and make sure that the differential
temperature remains lower than 20oC.
- Follow by laboratory analysis the progress of the hydrogenation of the C4 cut hold-up.
- The hydrogenation is completed when the composition of the C4 cut hold-up matches the Reactor
effluent specifications. The temperature difference through the catalytic bed decreases down to
zero.
When this is achieved:
- Stop the make-up hydrogen injection.
- Maintain the C4 liquid circulation and the Reactor inlet temperature.
Page 69 of 118
Note:
Sometimes, due to problems of analysis frequency, it is not possible to stop the hydrogenation before the
almost complete hydrogenation of the C4 cut hold-up. The completion of the hydrogenation is shown by
the temperature decreasing quickly at the bottom temperature indicator of the catalytic bed.
During hydrogenation phase, all the hydrogen injected is chemically consumed in the Reactor and the
inlet pressure at the Reactor remains steady. When the hydrogenation of unsaturated hydrocarbons is
nearly completed, hydrogen breaks out of the Reactor and the pressure at the Recycle Drum can increase
very quickly.
Hence, when the hydrogen starts to breakthrough, decrease the make-up hydrogen injection to the
Reaction section in order to decrease the gas purge downstream of Reactor Off-Gas Separator Drum (52-
V-004).
For the following steps here-below, refer to the procedure described in section 6.2.4 “Start-up with a C4
cut essentially free of unsaturated hydrocarbons”.
6.2.5.11 Heating of the circulating Start-up feed
6.2.5.12 Raw C4 feed in
Page 70 of 118
6.3 ROUTINE OPERATION
6.3.1 Summary of Operating Conditions
For the sake of easy reference throughout Operating Manual, a summary of the operating conditions is
given here-below. The parameters marked * can be set by operators and must be set as indicated in order
to meet the specifications. The other parameters are resulting ones and depend upon the conditions
(flowrate, feed quality...).
Table 6.2: Summary of operating conditions for Design Case
Design Case
Pressure (barg) SOR EOR
Wash Water Drum (52-V-001) 5.5
Feed Surge Drum (52-V-002) 4.5
Waste Water Degassing Drum (52-V-006) 0.3
Reactor (52-R-001)
Inlet* / Outlet 30.0 / 27.7 30.0 / 24.8
Pressure Difference 2.3 5.2
Recycle Drum (52-V-003) 27.1 24.2
Stabilizer (52-K-001)
Top* / Bottom 19.2 / 19.5
Stabilizer Reflux Drum (52-V-005) 18.6
Temperature (oC) SOR EOR
Wash Water Drum (52-V-001) 35
Feed Surge Drum (52-V-002) 35
Waste Water Degassing Drum (52-V-006) 35
Reactor (52-R-001)
Inlet* / Outlet 55 / 104 80 / 115
Temperature Difference 49 35
Recycle Drum (52-V-003) 104 114
Top* / Bottom 96 / 107 97 / 107
Feed 98 98
Stabilizer Reflux Drum (52-V-005) 40
Recycle flowrate (kg/h) SOR EOR
Recycle flowrate* 293 557
Page 71 of 118
Table 6.3: Summary of operating conditions for Check Case
Check Case
Pressure (barg) SOR EOR
Wash Water Drum (52-V-001) 5.5
Feed Surge Drum (52-V-002) 4.5
Waste Water Degassing Drum (52-V-006) 0.3
Reactor (52-R-001)
Inlet* / Outlet 30.0 / 28.3 30.0 / 27.5
Pressure Difference 1.7 2.5
Recycle Drum (52-V-003) 27.7 26.9
Top* / Bottom 19.2 / 19.5
Stabilizer Reflux Drum (52-V-005) 18.6
Temperature (oC) SOR EOR
Wash Water Drum (52-V-001) 35
Feed Surge Drum (52-V-002) 35
Waste Water Degassing Drum (52-V-006) 35
Reactor (52-R-001)
Inlet* / Outlet 60 / 90 80 / 108
Temperature Difference 30 28
Recycle Drum (52-V-003) 90 108
Top* / Bottom 95 / 108 96 / 108
Feed 88 102
Stabilizer Reflux Drum (52-V-005) 40
Recycle flowrate (kg/h) SOR EOR
Recycle flowrate* 293 558
6.3.2 SOR: Start of Run; EOR: End of Run Control Philosophy of the Process
6.3.2.1 Reaction Section Feed Flowrate
The unit feed is coming from upstream unit under flow control (outside of Unit–52 battery limit). The
demineralized water flow rate is controlled under flow ratio of the hydrocarbon flow rate. The flowrate to
Reaction section is under flow control reset by level of Feed Surge Drum (52-V-002). The flowrate to
stabilizer section is under flow control reset by level of Recycle Drum (52-V-003).
Page 72 of 118
6.3.2.2 Make-Up Hydrogen to Reaction Section
During the start-up, make-up hydrogen is supplied to the Reaction section under flow ratio control with
the unit feed flowrate. Assuming the unsaturated hydrocarbons content of the feed is steady, the make-up
hydrogen flowrate is slaved to the unit feed flowrate by a steady ratio. However, if the unsaturated
hydrocarbons content varies, adjustment of the ratio by the operator is required to meet the product
specifications.
During normal operation, make-up hydrogen is supplied to the Reaction section under pressure\flow
cascade control. Assuming the unsaturated hydrocarbons content of the feed is steady, the consumption of
make-up hydrogen will be constant and the pressure at Reactor inlet will be steady (vapor purge of
Reaction section under flow control). The make-up hydrogen flow controller is then slaved to the Reactor
inlet pressure by a steady set point. If the unsaturated hydrocarbons content gets higher, hydrogen
consumption will increase and the pressure in the reaction section will decrease. The set point of the
controller of the make-up hydrogen flow to Reaction section will be adjusted automatically by the
pressure controller at the Reactor inlet.
A handswitch (52-HS-0005 / 52-HS-0008) allows selecting the make-up hydrogen control mode either
under flow ratio control with the unit feed flowrate or under pressure\flow cascade control.
For safety reasons, never start or restart the unit in normal operation mode of the Reaction section.
6.3.2.3 Reaction Section Pressure
Reaction section pressure is set in order to ensure that the Reactor operates with the largest possible liquid
phase.
During the start-up, the Reactor (52-R-001) inlet operating pressure is maintained constant by a split
range control on the vapor purge of the Recycle Drum (52-V-003) and make-up hydrogen injected.
During normal operation, the pressure in Reaction section (inlet pressure of the Reactor) is controlled by
make-up hydrogen injection to the Reaction section. The Recycle Drum (52-V-003) vapour purge is
under flow control. This type of control ensures that the right amount of make-up hydrogen is supplied,
according to the unsaturated components content in the feed (refer to the previous section 6.3.2.2 "Make-
up Hydrogen to Reaction section") while ensuring a slight excess of hydrogen.
6.3.2.4 Reactor Inlet Temperature
During start-up, the required Reactor inlet temperature is obtained with the Start-up Heater (52-EX-001).
During the initial start-up, the use of 52-EX-001 is not always necessary as reactions can start at ambient
Page 73 of 118
temperature with a freshly reduced catalyst. But it is actually necessary for restart near End of Run
conditions.
During normal operation, the Reactor inlet temperature is obtained by adjusting, under temperature
control, the flow through the hot by-pass of the Recycle Air Cooler (52-EA-002).
A handswitch (52-HS-0009) allows selecting the temperature control mode from the Start-up Heater to
the Recycle.
6.3.2.5 Recycle Flowrate–Reactor Bed Temperatures
The temperatures in the catalytic bed are not directly controlled.
The liquid recycle is used as a diluent of the unit feed for the unsaturated content. It also absorbs the heat
released by the reactions. It limits the liquid vaporization in the Reactor and ensures that the Reactor
temperature increase will not exceed the expected amount.
The liquid recycle is under flow control; it has to be maximized at all times.
A safety device ensures automatic shutdown if the temperatures exceed the present limits. Refer to
Section 7.1 “EMERGENCY SHUTDOWN”
Table 6.4: Recycle Flowrate for each Operational Case
Operation Case Recycle flowrate (kg/hr)
Design Case 293 557
Check Case 293 557
Turndown Case 187 877
6.3.3 Operating Parameters
All the variables which can theoretically affect the process performances are not necessarily within the
reach of the operators.
The operating parameters are the process variables on which the operator can act in order to:
- Meet the required product specifications when the feed quality or quantity varies,
- Ensure a smooth and safe operation of the unit.
These operating parameters are adjusted to:
- Achieve the almost complete hydrogenation of diolefins (and acetylenics),
- Maximize the hydrogenation of olefins,

Page 74 of 118
- Ensure a long catalyst life.
The main operating parameters are:
- Make-up hydrogen flowrate,
- Reactor inlet temperature,
- Recycle flow.
6.3.3.1 Make-Up Hydrogen Flowrate
The make-up hydrogen flowrate required must meet the following criteria:
- Satisfy the chemical consumption for the hydrogenation of diolefins and olefins in the feed,
- Provide a slight excess of hydrogen above the stoichiometry for kinetics reasons, to meet the
required olefins specification in the product.
This flowrate to reaction section is set differently during start-up and normal operation.
During start-up, when the product quality is far from the target, the total amount of make-up hydrogen to
Main Reaction section is adjusted in ratio with the unit feed flowrate.
The hydrogen flowrate can be estimated in the following way when starting-up with a feed whose
composition differs from the design:
Available information:
– Feed composition (% mole) ............................... Laboratory analysis
– Feed molecular weight (MW) ............................ Laboratory analysis or from material
balances or 55 kg/kmol taken as
approximation
– Feed flow (kg/h) ................................................. Flowmeter indication
– % mole olefins wanted outlet of reactor ............. Calculated from material balances
Calculations:
– % olefins to be hydrogenated
A = % OL in feed - % OL wanted outlet reactor
– Feed in kmol/h
B = feed kg/h / MWT
– kmol/h olefins to be hydrogenated
C=AxB
– kmol/h diolefins in feed
Page 75 of 118
D = % diol x B
– kmol/h acetylenics in feed
E = % acetylenics x B
– Total of olefins equivalents
Diolefins and acetylenics are equivalent to 2 olefins in terms of double bonds and hydrogen
consumption
F = 2 x (D + E)
– kmol/h of olefins + olefin equivalents to be hydrogenated
G=C+F
– H2 kmol/h consumption considering 10% excess
H = 1.1 x G
– Hydrogen make-up in kg/h
(H x 2.03) / H2 purity
Finally, it is through the monitoring of the Reactor effluent analysis that the make-up hydrogen flowrate
is adjusted in conjunction with the Reactor inlet temperature.
During normal operation, when the unit operation is steady, the hydrogen flowrate to be injected to
Reaction section is adjusted through the set point of the flow controller, 52-FIC-0010, which will be reset
automatically by the pressure controller, 52-PIC-0019, at Reactor inlet.
6.3.3.2 Reactor Inlet Temperature
The minimum Reactors inlet temperature is the temperature required to initiate the hydrogenation
reactions. As long as the effluent specification is met, the lower the temperature, the better it is for the
catalyst cycle length.
If the unit feed, the make-up hydrogen, the cooling water (industrial water) and the climatic conditions are
as per the basis of design, the Start Of Run (SOR) temperature will be as indicated earlier in this section.
When the bypass of the Recycle air-cooler is fully closed (maximum cooling), the actual Reactor inlet
temperature may be lower (depending on the site conditions at start-up). As long as this Reactor inlet
temperature is enough to obtain on-specification product and does not result in any free water in the
Reactor, it can be substituted to the SOR inlet temperature.
It is reminded that free water is a catalyst temporary poison. Refer also to section 6.4.2 "Off-
Specifications Product". No water is normally present in the Raw C4 feed. To accommodate possible
presence of water in the hydrocarbon feed, the Feed Surge Drum (52-V-002) and Recycle Drum (52-V-
Page 76 of 118
003) are equipped with a boot to remove free water. Besides, Coalescer Package (52-PU-001) is removing
any free water at the cold temperature downstream of Recycle Air Cooler (52-EA-002) in order to avoid
water to build-up into the recycle loop. Reactor inlet temperature is normally set higher than temperature
associated with free water occurrence. Solubility curves with temperature for Raw and Hydrogenated C4
cut are shown in Error! Reference source not found..
The temperatures in the Reactor have to be carefully monitored in order to detect any abnormal
temperature profile or any hot spot. This behavior is generally the indication of a bad distribution and
channeling in the catalytic bed. Several temperature indicators are installed in the Reactor with alarms and
high temperature switches which actuate an emergency shutdown sequence (refer to section 7.1
“EMERGENCY SHUTDOWN”).
In order to compensate for the loss of catalyst activity and still maintain the product specification, the
Reactor inlet temperature is increased from the Start (SOR) to End of Run (EOR) figure during the
catalyst cycle duration (refer to section 6.3.1 "Summary of Operating Conditions").
The end of a cycle is reached when:
- The catalyst deactivation is such that it is no longer possible to meet the product specifications,
- The Reactor inlet or outlet temperature has reached the maximum allowed.
At the end of a cycle the catalyst must be regenerated. Sometimes regeneration does not completely
restore the catalyst activity and the time between two successive regenerations decreases. The catalyst life
ends when:
- The time between two regenerations is so short that regenerating becomes uneconomical,
- The catalyst regeneration does not sufficiently restore its activity and the product is off
specifications.
6.3.3.3 Recycle Flowrate
The make-up hydrogen flowrate being related to the unit feed flowrate, composition, and the specified
saturated content at the outlet of the Reactor, the recycle flowrate is then the only way to control the
temperature increase in the Reactor.
The recycle flowrate set point is stated in section 6.3.1 "Summary of Operating Conditions”.
Page 77 of 118
The recycle flow is adjusted by a flow controller and may be increased in normal operation if hot spots
appear in the catalytic bed.
Operators must be aware that changing the recycle flowrate affects the Reactor residence time.
- A recycle flowrate higher than the recommended value is not harmful as long as it does not result
in a significant increase of the saturated content in the Reactor effluent.
- A recycle flowrate lower than the recommended value is prohibited, as this will lead to a
reduced liquid fraction in the Reactor, higher temperatures than expected, possible channeling,
polymers formation and deposits.
6.3.3.4 Reaction Section Pressure
The pressure is rather a design figure than an operating parameter.
It must be maintained in accordance with figures mentioned in section 6.3.1 “Summary of Operating
Conditions” and controlled at the highest value compatible with the design of the Reactor and the make-
up hydrogen battery limit pressure (refer to section 6.3.2.3 “Reaction Section Pressure”).
Page 78 of 118
Figure 6.10: Solubility of water in Raw C4 Cut and Hydrogenated C4 Cut
Page 79 of 118
6.4 TROUBLESHOOTING
6.4.1 Troubleshooting situations
Troubleshooting consists of investigating and correcting the causes of unsatisfactory operations (typically
off-specifications product or unexpected operating conditions) before they deteriorate any further.
Troubleshooting actions must be undertaken when:
- The product is off-specifications,
- Temperature excursions in the Reactor are noticed,
- Reactor differential temperature increase due to a more reactive recycle than expected.
6.4.2 Off-Specifications Product
Typically, the following specifications are to be met:
- expected maximum olefins content,
- expected maximum diolefins content.
If this unsaturated compounds content is higher than the expected figures, operators must first check
whether the cause of malfunction is the Reactor.
On the Reactor effluent for which unsaturated content is substantially higher than expected figure,
operators must check the amount of make-up hydrogen to the related Reactor and increase it, as required.
If the above check proves that the make-up hydrogen flowrate is adequate for the feed quality, other
possible causes to be investigated are:
- Too low Reactor inlet temperature; This will be confirmed by low temperatures at the first
temperature indicators in the catalytic bed (refer to the curves below, Error! Reference source not
found.–graph A).
- Poor distribution in the Reactor; Operators must make sure that the recycle flowrate is at the
recommended figure, as well as the operating pressure.
- Catalyst contamination; This will be confirmed by low temperatures at the first temperature
indicator in the catalytic bed, even after increasing the Reactor inlet temperature (refer to the curves
below, Error! Reference source not found.–graph B).
Contamination by free water can occur as previously described (refer to section 6.3.3.2 "Reactor
Inlet Temperature"). If free water contamination is suspected, operators must make sure that the
Reactor inlet temperature is high enough.
Page 80 of 118
If water contamination is ruled out, check the other possible contaminants (refer to section 2.7.5 "Catalyst
Contaminants Summary Tables").
Figure 6.11: Reactor Temperature Profiles
6.4.3 Temperature Excursion
A steadily rising, then flat temperature profile in the Reactor is the sign of an efficient removal of the heat
of reaction.
A satisfactory operation of the Reactor, which operates essentially in liquid phase, requires a good
distribution of the liquid to ensure a uniform contact with the hydrogen on the catalyst. Besides, the more
intimate mix possible between the feed and the hydrogen is required in the liquid phase.
Page 81 of 118
Too low liquid flowrate in the Reactor induces an uneven liquid distribution i.e., "wet" areas where liquid
is largely predominant and "dry" areas where gas is predominant. This is channelling. In the "dry" areas
the heat of reaction cannot be removed effectively enough by the liquid vaporization. Temperature
excursions occur (hot spots). Hot spots favor polymers formation and reduce the catalyst activity.
The liquid recycle flowrate enables to avoid this occurrence, this is why the recycle flowrate must be
compulsorily maintained at the recommended value and must be checked first in case of temperature
excursion (check also the accuracy of the temperature indicators). Moreover, intimate mix is achieved by
the use of the static mixers after the hydrogen injection in the liquid feed.
Upon the occurrence of a hot spot (10°C temperature excursion) check the temperature indicators. If the
temperature excursion is confirmed, increase the recycle flowrate till the hot spot disappears.
6.4.4 High Temperature Increase in the Reactor
An increased temperature difference in the whole Reactor, if moderate and explainable is not as worrying
as a temperature excursion. Its main effect would be premature catalyst aging.
Higher than expected temperature difference can be due to an insufficient recycle flowrate. This could
happen if both the Raw C4 feed (or the unsaturated content) and the make-up hydrogen flowrate, though
in the right ratio, exceeded noticeably the design figure. The solution would be to reduce the unit feed
flowrate.
6.4.5 Reactive Recycle
When the unsaturated content in the liquid recycle is noticeably higher than normal operation (reactive
recycle), the dilution effect of the unit fresh feed by the recycle is reduced, and the temperature difference
in the Reactor increases.
This situation may occur after a unit shutdown:
- if the unit feed has been maintained too long after stopping the make-up hydrogen,
- if the level of the Recycle Drum (52-V-003) have been lost and a make-up of Raw C4 feed is
necessary.
In these cases, it is recommended to perform a batch hydrogenation of the hold-up as described in section
6.2.5.10 "Hydrogenation of the Raw C4 cut hold-up".
Page 82 of 118
6.5 SHUTDOWN PROCEDURE
6.5.1 Important recommendations for shutdown and restart
This procedure does not take into consideration the upstream and downstream units which are affected by
the Hydrogenation unit shutdown.
The shutdown sequences (either normal or emergency) must be executed in the following order:
Make-up hydrogen cut-off,
Raw C4 feed cut-off.
The reasons are:
- Shutting-off the hydrogen stops the reactions almost immediately (lack of one reactant). It is the
only way to actually stop the reactions.
- Shutting-off the Raw C4 feed does not stop the reactions immediately because of the liquid hold-up
in the Reaction section and the hydrogen injection still on. In addition, there would be no way to
remove the heat of reactions.
However, in the normal shutdown case, it is recommended to maintain a small flowrate of make-up
hydrogen to hydrogenate completely the unsaturated compounds in the reaction loop.
Warning: To avoid polymers deposits, never let C4 cut containing diolefins settles for some time, in
any section of the unit. The principle is to hydrogenate completely the diolefins during the
shutdown in order to get a stable material.
For the same reason, upon restart, never introduce hydrogen first, follow the start-up
sequence:
- Make sure that the specifications of the hold-up are the normal operating one.
- Inject the make-up hydrogen.
6.5.2 General (Normal Shutdown)
Normal shutdown applies to a shutdown planned in advance for preventive maintenance or to unexpected
events which are not of an emergency nature.
Before initiating any planned shutdown, review all records to determine what inspections and repair work
must be accomplished during the shutdown. Prepare a shutdown schedule, including plans for pre-
arranging feed and product inventories during turnaround time. Notify all services and other dependent
Page 83 of 118
operating units of the schedule so that all activities can be properly coordinated. Arrange for all required
parts, tools and services in advance, in particular adequate nitrogen for purging.
When shutting down, steps should be taken to prevent catalyst or equipment damage from expansion,
contraction, thermal shock or unusual pressure surges. Purge with care all vessels, using inert gas and
steam until all equipment is free of hydrocarbon liquids and gases. Purge thoroughly and check the
atmosphere in the vessels before entering or starting repairs. Rigorously observe all safety precautions.
The general procedure to be followed for a total shutdown is the following:
• Lower the capacity and if necessary the severity.

• Switch the product to off-spec. or raw storage.
• Shutdown the reaction section.
• Drain all hydrocarbons.
• Depressurize and purge.
After minimizing the hold-up inside equipment at the minimum allowed liquid level, by pumps
operation or by manual level control in pressure systems, the vents / HC liquids shall be sent to
flare / closed drain system by means of pressure or gravity. During maintenance, bleed valves
shall be open only after closing the main isolation valve .
Several shutdown cases are considered:
- Short duration shutdowns (i.e. less than 1 week).

- Short duration shutdowns with Reactor bypassed (i.e. less than 1 week).
- Long duration shutdowns (complete shutdown).
6.5.3 Short period shutdown (Reactor not by-passed)
This shutdown is typically less than 1 week to carry out minor repairs without opening any major
equipment.
Follow the following steps:
- Step-by-step, reduce the Raw C4 feed to 60% of the normal flowrate. Reduce simultaneously the
make-up hydrogen flowrate to keep the same hydrogen excess and reduce the recycle flowrate to
keep the same recycle / Raw C4 feed ratio.
Page 84 of 118
- Stop and isolate (locally) the Raw C4 feed to the unit. Maintain the recycle and check that the
recycle flowrate is at least 50% of the normal flowrate through the Reactor.
- Maintain a small flowrate of make-up hydrogen during 1 hour or more (until temperature
difference equals 0 across the Reactor) to be sure that the unsaturated content of the Reaction
section hold-up is not above the maximum permitted (typically 1 wt.% of olefins) using on-line
analyzer, cross-checked with laboratory analysis.
- Then stop and isolate (locally) the make-up hydrogen injection. Stop and isolate the purge gas flow.
- After stopping the unit fresh C4 feed injection, check that the Recycle Drums level/flow control
valves are closed. Isolate locally.
- Keep recycle in operation and the Reactor inlet temperature at its previous value. Use the Start-up
Heater (52-EX-001), for Reactor, if required.
- Operate the Stabilizer on total reflux.
- For a short duration shutdown the unit is kept in stand-by under these conditions.
If during the stand-by period, the unit pressure falls down, re-pressurize with make-up hydrogen via the
Recycle Drum. The only risk is to dissolve some hydrogen in the C4 cut. This should then be taken into
account when restarting the unit and introducing reactive Raw C4 feed again: start with a lower make-up
hydrogen flowrate than needed.
Warning: Remember that the liquid hold-up has to be hydrogenated in a first intention and that
the circulation must be maintained all the time.
6.5.4 Short period shutdown (Reactor by-passed)
This shutdown is typically less than 1 week to carry out special procedures on Reactor (52-R-001)
catalyst such as catalyst reactivation or catalyst regeneration.
It is possible to restart the unit with the liquid hold-up contained in the Recycle Drum. In that case, before
shutting down the unit, the liquid level in the Recycle Drum must be increased at least up to the HLL in
order to have enough liquid to refill the Reactor.
Page 85 of 118
- Once the level in the Recycle Drum is set at least to the HLL, step-by-step reduce the Raw C4 feed
to 60% of the normal flowrate. Reduce simultaneously the make-up hydrogen flowrate to keep the
same hydrogen excess and reduce the recycle flowrate to keep the same recycle / Unit feed ratio.
- Proceed as per procedure described in section 6.5.3 “Short period shutdown (Reactor not by-
passed)”.
- Open the valves on Reactor bypass line and close successively the Reactor (52-R-001) inlet and
outlet block valves. Close the spectacle blinds at the Reactor inlet and outlet. Proceed slowly.
- Once the Reactor is bypassed and well isolated, Reactor can be drained to Flare system. A slight
pressure of nitrogen is established during the draining phase to improve its efficiency.
- Do no strip the catalytic bed with cold nitrogen as this might lead to a decrease of temperatures in
the Reactor and at Reactor outlet. To avoid this phenomenon, proceed as for a catalyst reactivation
(described in section 6.6.4 “Reactivation of Catalyst LD 485”) with immediate high temperature
and high flowrate. Hydrocarbons will be removed during the reactivation. After reactivation, purge
with nitrogen, check that hydrocarbon content is 0.2 vol.% maximum and monitor the
temperatures.
- Keep recycle in operation.
- Operate the Stabilizer on total reflux.
If special procedures are carried out on the Reactor catalyst, resulting in the recovery of the catalyst
activity, it is not necessary to maintain the Reactor inlet temperature at its previous value (if higher than
SOR). In this case, the closed loop temperature can be decreased down to the SOR conditions by closing
the hot bypass of the Recycle Air Cooler.
For a short duration shutdown the unit is kept in stand-by under these conditions.
If, during the stand-by period, the unit pressure falls down, re-pressurize with hydrogen via the Recycle
Drum. The only risk is to dissolve some hydrogen in the C4 cut. This should then be taken into account
when restarting the unit and introducing reactive Raw C4 feed again: start with a lower make-up
hydrogen flowrate than needed.
Warning: Remember that the liquid hold-up has to be hydrogenated in a first intention, and the
circulation must be maintained all the time.
Page 86 of 118
6.5.5 Complete Shutdown
This shutdown is required for major repair of some equipment or some sections of the unit. The procedure
described above for short period shutdown (6.5.4 “Short period shutdown (Reactor by-passed)”) is
followed (except that the liquid level in the Recycle Drum is decreased to its minimum) and
completed with full cooling of equipment to ambient temperature. When required for entering the
equipment, the whole unit is drained and inerted.
After the normal shutdown as described above in 6.5.4 “Short period shutdown (Reactor by-passed)”:
- Stop and isolate the steam supply to the Start-up Heater (52-EX-001).
- Close the hot by-pass of the Recycle Air Cooler to have a maximum cooling of the recycle closed
loop.
- Close and isolate (locally) the make-up hydrogen injection to the Recycle Drum and Feed Surge
Drum.
- Stop the Recycle Pumps and the Feed Pumps.
- Drain the unit to the Flare system, depressurize, and purge with nitrogen until the hydrogen plus
hydrocarbons content is 0.2 % volume maximum. The completion of the full shutdown sequence
may be required for the whole unit or only for a selected number of pieces of equipment. This is
related to the cause of the shutdown.
- Stop the stabilizer section.
6.5.6 Unit Restart
6.5.6.1 After a short period shutdown (Reactor not by-passed)
For a scheduled shutdown, the Reactor inlet temperature is maintained; the unreactive recycle is
circulating in a closed loop after interruption of the make-up hydrogen injection. Level and pressure are
maintained.
- Restart by feeding the unit again with Raw C4 feed
- Follow with the make-up hydrogen injection step of the Start-Up procedure (refer to section
6.2.4.11 “Raw C4 feed in”).
Page 87 of 118
When re-starting the make-up hydrogen injection, be also aware that some hydrogen might be
dissolved in recycles from pressurization in the Recycle Drum.
6.5.6.2 After a short period shutdown (Reactor by-passed)
Proceed as per First start-up procedure, from step 6.2.4.6 (“Filling the Reactor (52-R-001)” ).
6.5.6.3 After an extended shutdown
The unit is supposed to have been drained, depressurized and put under nitrogen.
Restart as per complete section 6.2 “START UP PROCEDURE”. If the shutdown occurred for catalyst
change or catalyst activation has taken place a long time ago, a catalyst activation has to be performed,
first of all (refer to section 6.6.3 “Activation of Catalyst LD 485”).
6.6 SPECIAL PROCEDURES
6.6.1 Catalyst Supplier
Catalyst is manufactured by Axens in their facilities located at SALINDRES 30340 FRANCE.
Head office address:
Axens
89, boulevard Franklin Roosevelt
92500 RUEIL MALMAISON – FRANCE
Phone: 33 (0) 1 47.14.21.00 Fax: 33 (0) 1 47.14.25.00
6.6.2 Catalyst specifications
For specifications and Technical Data Sheets of products to be loaded in Reactor (catalyst, inert ceramic balls),
refer to Attachment IV “CHEMICALS AND CATALYST SUMMARY–UNIT 52” (Doc. No: HS84218-52-PR-
CC-0001-0000).
Table 6.5: Reactor Catalyst Specifications
Catalyst LD 485
Supplier Axens Catalyst & Adsorbents
Shape Sphere(1)
Nominal Particle Diameter 2 to 4 mm(1)
Loading Density 480 kg/m3 (Dense Loading)
Page 88 of 118
Catalyst LD 485
Catalyst Volume 76.0 m3 (2)
(1) See technical data sheet Attachment IV “CHEMICALS AND CATALYST SUMMARY–UNIT 52”
(Doc. No: HS84218-52-PR-CC-0001-0000).
(2) This volume corresponds to the vessel volume which shall be accurately filled-up.
This volume is the basis to evaluate the corresponding weight of catalyst, when using the loading density as indicated
in the attached technical data sheet.
This corresponding weight shall be confirmed at the time of the order.
• Packaging, handling and storage
The catalyst is delivered in steel cylindrical drums of 217 liters (net weight 90kg).
The catalyst is protected in a waterproof, polyethylene bag.
6.6.2.1 Handling recommendations
Drums must be handled with care to avoid catalyst breakage. The drums must not be rolled and must not
be allowed to fall.
Rain, snow, sand can damage the catalyst and its containers. Therefore, adequate shelter for the catalyst
during storage, transport and loading must be arranged.
Before loading operation, the catalyst loading equipment must be safely installed and checked ready for
operation. Reactors and internals must be previously inspected for dimension conformity and cleanliness.
During catalyst loading and unloading operations personnel must take the following precautions:
• Outside the reactors, wear a dust mask, protective clothing, goggles, gloves and a helmet.
• When inside the reactors for short periods, wear a safety harness. A second man must be in attendance
outside the vessel. Always, apply the Refineries Safety Rules.
As a general rule, no one is allowed to enter a vessel before the atmosphere has been proven suitable and
all vessel nozzles are blinded.
Page 89 of 118
In addition, personnel working in the reactor during the catalyst loading must wear an air mask covering
the entire face.
6.6.2.2 Storage recommendations
All catalyst, absorbents, and adsorbents are supplied in standard drums (fiber or steel) or plastic big bags and
following handling & storage conditions must be applied:
• The lids of all drums must be examined on receipt of the consignment and off-loading must be carried out
with care. Drums must not be rolled or dropped. Sacker truck methods or slings are most acceptable. If the
drums are badly damaged in transit, they may not be airtight giving the possibility of moisture ingress. Any
damaged drums must be discarded, and the contents transferred, if still in sound condition, to new airtight
containers.
• In no circumstance should drums or big bags be opened: seals must be kept intact.
• Drums & big bags must be stored preferably in a closed, ventilated and dry permanent building, to ensure
protection against humidity and corrosive wet atmosphere. They need to remain stored off the ground and
away from any risk of water or off-limit temperatures. Only pallets of drums can be stacked, up to 3 layers
max, using preferably the original wooden pallet as layer. Big bags must never be stacked, even using
interlayer pallets.
• Outside storage may also be used but both drums and big bags should be then isolated from the ground by
the use of its original pallet and should be protected against sun & rain direct exposure.
If the above conditions cannot be complied with, the storage of the catalyst, adsorbents, and absorbents is not
recommended. Catalyst drum lids should not be unfastened or removed during inspection, and drums should be
handled as little as possible.
See the characteristics of packaging in the technical and safety data sheets (refer to Attachment IV
“CHEMICALS AND CATALYST SUMMARY–UNIT 52”).
6.6.3 Activation of Catalyst LD 485
6.6.3.1 General
The metal of the catalyst loaded in the Reactor (52-R-001) is in the oxide form, which is inactive.
Consequently, it has to be reduced before start-up, with hydrogen to recover its active form. The
reduction reaction is the following:
PdO + H2  Pd + H2O
Palladium Palladium
Page 90 of 118
Oxide Metal
At the same time, the flow of dry activation gas through the catalyst allows the elimination of the water
contained in the catalyst. The activation gas can be either pure hydrogen, or a mixture of nitrogen and
hydrogen, or a mixture of fuel gas and hydrogen. Activation gas shall meet the 25% mol. minimum
content of hydrogen.
The same activation procedure is performed on the catalyst after regeneration.
6.6.3.2 Activation conditions
The activation conditions, with a hydrogen rich stream, are summarized in the following table depending
on the activation gas type taken into consideration:
Table 6.6: Catalyst Activation conditions
Activation
Gas Components H2 from PSA / H2 from CCR
H2 content 99.9 % / 92.2 %
Gas Flowrate (kg/h) 1357 / 3224
Temperature (oC) 100 (min. on all catalytic bed)
Duration at temperature 8 hours
Estimated duration 1 day
Effluent routed to Flare
6.6.3.3 Activation Procedure
The activation (reduction) procedure is:
- Isolate the Reactor (52-R-001) by blinds.
- Make sure the Reactor is depressurized and under nitrogen atmosphere. Check the oxygen content
in the Reactor (maximum 0.2 % volume).
- Line-up the activation circuit, the Catalyst Treatment Gas Electrical Heater (52-EH-001), the
Reactor (52-R-001) and the disposal line (the spent activation gas is sent to Flare).
Page 91 of 118
- Establish the flow of activation gas: With hydrogen flow control valve, 52-FCV-0025, is used for
the activation of the catalyst.
- Start the Catalyst Treatment Gas Electrical Heater (52-EH-001) and heat up the Reactor (52-R-
001) at 40°C/h up to 100oC minimum in the whole catalytic bed.
- As soon as the catalyst temperatures are above 100oC, it is a good policy to check dew point and
hydrogen content of the reactor effluent in order to follow the reduction reaction. Activation gas
shall meet the 25% hydrogen minimum content.
- Maintain all reactor temperatures indications above 100oC during 8 hours minimum. Check the
dew points at inlet and outlet of the Reactor to monitor the progress of the activation. If they are
nearly the same, the activation is completed.
- Cool down the catalyst at 50oC/h down to ambient in all parts of the catalyst.
- When the Reactor is cooled down, stop the activation gas flow. Close the valves and turn the
spectacle blinds in the activation lines.
- Remove the residual gas by successive pressurization and depressurization cycles with nitrogen.
- Check that all the activation circuit, lines, Heater and Reactor are well purged with nitrogen. The
hydrogen plus hydrocarbons content in the Reactor shall be lower than 0.2 vol.%.
- Isolate the Reactor, upstream and downstream of the catalyst treatment gas lines. Settle blind
flanges on the right position.
- Keep Reactor isolated by double valves and blind flange on the normal process lines (in and out).
Maintain a slight nitrogen pressure. The blind flanges will be removed when the unit is ready for
start-up.
- The Reactor is ready for the filling up.
Page 92 of 118
Temp. (deg.C)
8h @ 100 deg.C min.

25 vol. % H2 min.
100 deg.C
8h
ambient 40 deg.C/h 50 deg.C/h
Time (h)
Figure 6.12: Catalyst activation procedure
6.6.4 Reactivation of Catalyst LD 485
6.6.4.1 General
- The reactivation procedure is mainly used when the catalyst is deactivated by free water.
- Reactivation is hydrogen stripping at moderate temperature and the catalyst remains in the reduced
form.
6.6.4.2 Reactivation conditions
The conditions are the same as for activation except the temperature step, maintained at 150 oC during
minimum 8 hours.
The reactivation conditions, with hydrogen rich stream, are summarized in the following table depending
on the reactivation gas type taken into consideration:
Page 93 of 118
Table 6.7: Catalyst Reactivation conditions
Reactivation
H2 content 99.9 % / 92.2 %
Effluent routed to Flare(1)
(1) With suitable pressure to send the effluent to the Flare.
6.6.4.3 Reactivation procedure
The reactivation procedure is:
• In a first step the Reactor (52-R-001) is isolated by double block valves at inlet and outlet.
• The Reactor is drained to the appropriate drain system.
• The Reactor is depressurized to flare and purged with nitrogen.
• When liquid drainage is complete, line-up the catalyst treatment off-gas circuit to the flare and
isolate drainage circuit.
• The reactivation procedure is basically the same as the activation procedure.
• The reactivation is completed after 8 hours at the recommended temperature in the Reactor
(150oC minimum on the whole catalytic bed).
• The Reactor is then cooled down to ambient with the selected reactivation gas and purged with
nitrogen as for the activation procedure.
• Monitor reactivation by dew point measurements of the gas at inlet and outlet of the Reactor.
Page 94 of 118
Temp. (deg.C)
8h @ 150 deg.C min.

25 vol. % H2 min.
150 deg.C
8h
ambient 40 deg.C/h 50 deg.C/h
Time (h)
Figure 6.13: Catalyst Reactivation Procedure
6.6.5 Hot Hydrogen Stripping of catalyst LD 485
6.6.5.1 General
The Hot Hydrogen Stripping (HHS) procedure is mainly used when the catalyst is deactivated by soft
coke (i.e. low molecular weight oligomers) or sulfur.
HHS procedure is performed at higher temperature than reactivation procedure.
6.6.5.2 Hot Hydrogen Stripping Conditions
The conditions are the same as for reactivation except the temperature step, maintained at 400 oC during 8
hours. If external constraints limit the temperature during the procedure below 400 oC, the duration shall
be extended to 12 hours. If an inert gas (typically nitrogen) is used for heating and cooling phases, the
duration of the procedure shall also be extended to 12 hours.
The Hot Hydrogen Stripping conditions, with hydrogen rich stream, are summarized in the following
table depending on the HHS gas type taken into consideration:
Page 95 of 118
Table 6.8: Catalyst Hot Hydrogen Stripping conditions
Hot Hydrogen Stripping
H2 content 99.9 % / 92.2 %
Effluent routed to Flare(1)
(1) With suitable pressure to send the effluent to the Flare.
6.6.5.3 Hydrogen Hot Stripping Procedure
The Hot Hydrogen Stripping procedure is:
• In a first step, Reactor (52-R-001) is isolated by double block valves at inlet and outlet.
• The Reactor is drained to the appropriate drain system.
• The Reactor is depressurized to flare and purged with nitrogen.
• When liquid drainage is complete, line-up the catalyst treatment off-gas circuit to the flare and isolate
drainage circuit.
• The Hot Hydrogen Stripping procedure is basically the same as the reactivation procedure.
• Heat up the Reactor (52-R-001) at 80oC/h up to the recommended temperature (400oC) in the whole
catalytic bed.
• The Hot Hydrogen Stripping is completed after 8 hours minimum at the recommended temperature.
Care must be taken no to have a temperature gradient greater than 150oC across the Reactor.
• Cool down the catalyst at 80oC/h down to ambient in all part of the catalyst.
• The Reactor is purged with nitrogen as for the reactivation.
Page 96 of 118
Temp. deg.C)
8h @ 400 deg.C min.

25 vol. % H2 min.
400 deg.C
8h 80 deg.C/h
ambient 80 deg.C/h
Time (h)
Figure 6.14: Catalyst Hot Hydrogen Stripping procedure
6.6.6 Catalyst Unloading
Catalysts may be unloaded for various reasons:
- The catalyst is used (no longer regenerable) and to be disposed of;
- The catalyst is unloaded for an ex-situ regeneration;
- The catalyst is still active but must be dumped for the inspection of the Reactor.
The catalysts are unloaded either under nitrogen atmosphere or be oxidized before unloading under air.
6.6.6.1 Unloading under nitrogen for ex-situ regeneration
Ex-situ regeneration can allow saving time if a spare load of catalyst is available. In this case, catalyst
coated with coke and/or polymers is withdrawn and care must be taken to avoid its oxidation in the
ambient air. The catalyst must be stripped from hydrocarbons and unloaded under a nitrogen atmosphere.
Proceed as per the reactivation procedure (refer to section 6.6.4):
• Inerting with nitrogen is required prior to unloading.
• Make sure the catalyst bed is uniformly below 50oC.
• Make sure that the (H2 + HC) content in the Reactor is lower than 0.2 vol.%.
Page 97 of 118
• Since the catalyst is still in a metal form, it has to be unloaded through the catalyst unloading nozzle
under a continuous sweep of cold nitrogen.
• The collecting drums can also be swept with a gentle stream of cold nitrogen to limit catalyst self-
heating.
If no one is required to enter the Reactor, it will be left under nitrogen pressure. Otherwise, in case of
Reactor inspection for instance, a man equipped with an adequate breathing apparatus must enter to clean
the Reactor from the remaining catalysts prior to aerating. The usual safety measures must be
implemented when this operation takes place (refer to section 6.6.6.2 “Unloading for Reactor
inspection”).
6.6.6.2 Unloading for Reactor inspection
For Reactor inspection, since the catalyst is still active, one must proceed first, prior to unloading:
• Either to a full regeneration if the catalyst is dumped in an ambient atmosphere with no special
precaution against its oxidation outside.
• Or to a stripping and cooling procedure (refer to section 6.6.6.1 "Unloading under nitrogen for ex-
situ regeneration” The unloading must be carried out with due safety caution because of the catalyst
activity.
A man equipped with an adequate breathing apparatus must enter to clean the Reactor from the remaining
catalyst prior to aerating. The usual safety measures, including safety harnesses and a man in attendance
with a spare breathing equipment, must be implemented when this operation takes place.
Then the Reactor is aerated and inspected.
Page 98 of 118
7 EMERGENCIES
7.1 EMERGENCY SHUTDOWN
7.1.1 General
This unit is equipped with certain emergency shutdown controls which will automatically place the unit in
a non-hazardous status should a major failure occur. The actions of the emergency shutdowns are aimed
at protecting (a) the personnel and (b) the catalyst and equipment from heavy coking or serious damage.
Personnel and equipment protection also results from the following:
• Personnel having a thorough knowledge of the safe operating and shutdown procedures.
• A compliance with the safety rules in plant construction i.e. safety distances, adequate orientation, etc.
• The installation of adequate fire and gas detection devices and fire fighting equipment.
• Thorough operator safety awareness and procedures training.
The role of the process licensor is to provide safe operating and shutdown procedures based on his
knowledge of the chemical reactions involved, the unit design and past experience.
Concerning the catalyst preservation, operators must avoid:
• An excessive catalyst temperature increase which can change the structure of the alumina (higher than
700oC). To avoid damaging the catalyst structure, bulk temperature must never exceed 500oC. Note
that the design temperature of the reactor (under design pressure) is much lower.
• The presence of hydrocarbons without a sufficient hydrogen quantity which would result in a rapid
deposit and the possible agglomeration of catalyst particles.
The following sections cover most situations operators may have to face according to Axens' operating
experience. All operating personnel must study and fully understand the steps to be taken in such
situations prior to the unit start-up.
Many of these situations are handled by automatic shutdown trips. These trips must always be
operational, by-passing must be kept to a minimum e.g. during start-up, transient periods only. Refer to
Attachment VI “CAUSE & EFFECT DIAGRAMS–UNIT 52” (Doc. No: HS84218-52-PR-CE-0001-
0000).
Page 99 of 118
The following procedures include all the actions to be taken by the operator assuming no action by the
automatic devices.
Some of the following situations may happen in an emergency shutdown. If the right and prompt action is
taken, an orderly normal shutdown is possible.
7.1.2 Reactor Temperature–Alarms, Manual Actions
Before the actuation of the automatic shutdown ESD-0005, the following alarm trips are actuated.
• Initiating events:
High temperature alarm (TAH) is set at Reactor inlet temperature +10oC.
- High temperature at the inlet of Reactor (52-R-001) 52-TAH-0008.
High temperature alarms (TAHs) are set at Reactor catalytic bed / outlet temperature +10oC.
- High temperature in the catalytic bed of the Main Reactor 52-TAH-0011 to 52-TAH-0025
- High temperature in the Main Reactor effluent line 52-TAH-0026
High temperature alarm (TAH) is set at C4 Recycle Air Cooler outlet temperature +5oC (52-TAH-0007).
• Operator’s actions:
- Reduction of the hydrogen make-up flowrate to the Reactor (52-FIC-0010), which ultimately
may go till no flow (or cut-off of the total hydrogen make-up, 52-HZV-0031 and HZV-0032).
- Increase the recycle flowrate to the Reactor (52-FIC-0013).
- Check temperature control loop.
- Check Recycle cooling systems (Air-cooling).
- Check Start-up Heater (52-EX-001) is properly isolated and shut-off.
7.1.3 Reactor Temperature–First Level (Automatic Actions Through ESD-0005)
Note: Actions described below must be overridden (by hand-switch 52-HS-0004) during catalyst gas
treatment (activation, reactivation, hot hydrogen stripping).
Page 100 of 118

- Hand switches 52-HS-0006 (consol panel in control room) (or 2oo3 local at safe location).
- High temperature switches/alarms set at Reactor catalytic bed / outlet temperature +20 oC,
detected by (2 out of 3 voting system):
52-TAHH-0027 A1/A2/A3 to 52-TAHH-0040 A1/A2/A3 level 1 for the Reactor (in the
catalytic bed)
52-TAHH-0041 A1/A2/A3 level 1 for the reactor effluent line.
- Low flow switches set on recycle at 90000 kg/h, detected by (2 out of 3 voting system):
52-FALL-0014 A/B/C
• Automatic actions:
- Cut-off feed to Reaction section (Feed Pumps discharge) (52-XZV-0010).
- Stop the total hydrogen make-up to the unit (closes 52-HZV-0031 and HZV-0032 and opens
52-HZV-0033 (bleed line) for venting to flare) to stop the reactions.
- Maximize the recycle flowrate to the Reactor to cool it down. Fully open the recycle flow
control valve, 52-FCV-0013.
- Maximize Reactor cooling through recycle cooling. Fully open control valve 52-TCV-0008A
and fully close hot bypass control valve 52-TCV-0008B.
- Cut-off steam to the Start-up Heater (52-EX-001).
• Possible causes:
- Higher diolefins content in the unit feed.
- Low recycle flowrate to the Reactor.
- Channeling in the Reactor.
- Low pressure in the Reactor leading to more vaporization in the Reactor.
Page 101 of 118

- Temperature control loop failure.
- Fire in the unit.
• Additional actions:
- Investigate the cause and correct the default.
- Let the Reactor cool down.
- Make sure that no hot spot remains and when all temperatures are under control again, after
resetting the on/off valves, start the unit considering the liquid hold-up is reactive.
- Watch the Reactor temperatures.
- As soon as the flow can be resumed, check the catalyst bed temperatures, then resume the Raw
C4 feed to reaction section and restart the hydrogen injection.
7.1.4 Reactor Temperature–Second Level (Automatic Actions Through ESD-0006)
Note: Actions described below must be overridden (by hand-switch 52-HS-0004) during catalyst gas
treatment (activation, reactivation, hot hydrogen stripping).
- Hand switches 52-HS-0007 (consol panel in control room) (and 2oo3 local at safe location).
- Very high temperature switches/alarms set at Main Reactor catalytic bed / outlet temperature
+40oC, detected by (2 out of 3 voting system):
52-TAHH-0027 B1/B2/B3 to 52-TAHH-0040 B1/B2/B3 level 2 for the Reactor (in the
catalytic bed)
52-TAHH-0041 B1/B2/B3 level 2 for the reactor effluent line.
• Automatic actions:
- Isolate the Reactor:
Cut-off the Reactor inlet (52-HZV-0014)
Page 102 of 118

Cut-off the Reactor effluent (52-HZV-0015)
- Depressurize the Reactor to the flare:
Open the depressurization valves (52-HZV-0034 and 52-HZV-0035)
- Stop Recycle Pumps (52-P-003 A/B).
- Cut-off feed to Reaction section (Feed Pumps discharge) (52-XZV-0010).
- Cut-off steam to Start-Up Heater (52-EX-001).
- Stop the total hydrogen make-up to the unit (closes 52-HZV-0031 and HZV-0032 and opens
52-HZV-0033 (bleed line) for venting to flare) to stop the reactions.
• Possible causes:
- Temperature runaway due to an excess of hydrogen.

- Major leak in the unit.
- Fire in the unit.
• Additional actions:
It all depends on the reason leading to the decision of depressurizing the Reactor and on the situation after
depressurization.
7.1.5 Emergency Shutdown Situations
Automatic emergency shutdowns can be carried out through the various interlocks described below.
However, operators must carefully analyze the initiating events and their possible causes in order to
prevent, whenever possible, the emergency shutdown.
Emergency shutdown initiation is always preceded by alarms which generally give time to carry out
corrective actions.
Operators must be thoroughly familiar with these safety shutdowns and able to perform the emergency
systems step by step, should the emergency system fail.
For the right understanding of what follows, operators must refer to the sections afterwards.
Page 103 of 118

7.2 PROCESS FLOW FAILURES
7.2.1 Lack of Make-Up Hydrogen
There are no automatic actions linked to a lack of make-up hydrogen.
However, a loss of hydrogen can be expected as a result of misoperation in the upstream DHT Unit. To be
safe in case of sudden hydrogen recovery:
- Put the make-up hydrogen injection in flow ratio control mode.
- Reduce the unit feed flowrate in proper proportion to the hydrogen availability.
- If hydrogen is completely unavailable, shut-off the unit feed to the Reaction section and open the
line to LPG Storage Tank (unit bypass). Close the product line at battery limit.
- If the shutdown is expected to be of short duration, keep the recycle going. Monitor the Reactor
inlet temperature and outlet temperature increase.
When the make-up hydrogen is restored, proceed with a progressive hydrogenation of the unit hold-up
prior to reintroducing the Raw C4 feed (refer to section 6.2 “START UP PROCEDURE”).
If the make-up hydrogen cannot be restored very quickly, proceed to a complete normal shutdown.
Warning:
Do not feed the unit with no or insufficient make-up hydrogen. This would result in an accumulation of
reactive liquid in the Recycle Drum, having a reduced diluent ability. When the hydrogen is restored,
check the Recycle Drum hold-up, and if necessary, proceed with a progressive hydrogenation of the hold-
up prior to reintroducing the Raw C4 feed.
7.2.2 Lack of Unit Feed
A lack of feedstock (C4 feed) can be anticipated from the conditions in upstream unit and from the level
of the Feed Surge Drum (52-V-002).
- As a first step, reduce the hydrogen in proper proportion to the unit feed availability. If the feed is
not available at all, make sure the Pressure–Hydrogen flow control (PC-FC) closes the hydrogen
flow control valve.
Page 104 of 118

- If the shutdown is expected to be of short duration, keep the recycle going and maintain the Reactor
inlet temperature.
- Disconnect the Pressure–Hydrogen flow controller in the Reaction section (PC-FC) and inject a
small flowrate of make-up hydrogen to the Reaction section, to hydrogenate the liquid hold-up of
the unit.
- Stop the make-up hydrogen injection. Shut the block valves on hydrogen lines.
- Make sure the PCV on both Feed and Reaction sections are closed.
- If the feed cannot be restored very quickly, proceed to a normal shutdown.
7.3 EQUIPMENT FAILURE
7.3.1 Recycle Pumps Failure
In case of failure of Recycle Pumps, 52-P-003 A/B:
- The very low recycle flow switches in Reaction section actuates auto-start of the spare Recycle
Pump, and then ESD-0005 after a 20 second delay.
- Make sure that the auto-start of the spare Recycle Pump and ESD-0005 operate properly. If not,
carry out the actions in manual mode.
- Maintain the pressure in the Reaction section by closing the 52-FCV-0018 on the Reactor Off-gas
purge line.
- Monitor the Reactor bed temperatures. If Reactor temperatures run out of control a partial
depressurization can be used to cool down.
Note: The on/off and control valves on hydrogen injection lines must be isolated by block valves.
7.4 UTILITY FAILURES
7.4.1 Electrical Power Failure
All pumps driven by electrical motor will stop.
- Feed to the unit is cut off. Close the feed valves and block valves.
Page 105 of 118

- Recycle are cut off.
- Hydrogen make-up to the Reactor is cut off. Close the hydrogen make-up valves and block valves.
- Maintain the pressure by closing the 52-FCV-0018 on the Reactor Off-gas purge line.
- Watch the temperature difference in the Reactor.
In case of temperature increase:
- To avoid the use of the emergency depressurization, depressurize progressively to the flare. The
resulting vaporisation will cool the Reactor down.
- If Reactor temperature runs out of control, the emergency depressurization shall be used.
As soon as possible, start the recycle through the Reactor.
7.4.2 Fire or Major Leak
In case of a fire of some magnitude, the recommended actions are:
- Close the hydrogen supply valves.
- Direct the Raw C4 feed to LPG Storage Tank (close the feed flow control valve to Reactor and
open valve to LPG Storage Tank).
If the fire is kept under control:
- whenever possible, let the recycle flowrate run,
- isolate steam to Start-Up Heater,
- close the Recycle Cooler by-pass for a maximum cooling of the Reactor.
If the fire cannot be controlled, or in case of a major leak on a vessel, or if the temperatures in the
Reactors keep increasing:
- consider activating the quick depressurizations (switches 52-HS-0007 A/B for 52-R-001 / 52-HS-
0011 A/B for 52-V-003).
Page 106 of 118

7.4.3 Cooling Water Failure
This failure will affect the Reactor Off-Gas Trim Cooler (52-WX-001), the Stabilizer overhead Trim
Cooler (52-WX-002), and Product Trim Cooler (52-WX-003) and possibly the pumps (cooling water to
bearings).
- It leads to a loss of temperature and pressure control and possibly also the shutdown of the recycle
pumps (high temperature on pump bearings).
- If there is a sufficient inertia in the cooling water system, proceed to a normal shutdown but
hydrogen must be shut-off immediately. While cooling down the Reactor, the pump bearing
temperature of the recycle pumps must be carefully watched and the pump stopped as soon as the
bearing temperatures are too high.
- Closely monitor the Reactor temperature.
- Loss of product quality.
7.4.4 Steam Failure
A lack of steam in start-up heater may not initiate hydrogenation reaction.
A lack of steam in stabilizer reboiler leads to lack of good stripping in Stabilizer (52-K-001).
If the situation cannot be restored rapidly, start the normal shutdown procedure.
7.4.5 Instrument Air Failure
The loss of instrument air pressure is generally slow and there is time to proceed to a normal shutdown. In
case of instrument failure:
- The control valves take their safe position according to the fail open or fail close specification as
reminded hereunder:
- Pressures are maintained (all the PCVs close), except the PCV on condensate recovery
system,
- Reactor Off-gas purge control valves are closed,
- Levels are maintained (all the LCVs and XVs close),
Page 107 of 118

- C4 feed and hydrogen are shut-off,
- C4 product valve is shut-off,
- Recycle control valves are open, Recycle Cooler hot bypass valve 52-TCV-0008B is
fully closed and 52-TCV-0008A is fully open, in order to cool the Reactor down,
- Heating steam to Start-Up Heater is shut-off,
- Equipment protection valves (minimum-flow) open.
• All HZVs are provided with air reserves, which can maintain air up to 3 valve/actuator strokes. After
3 strokes, the status of following emergency safety valves (HZV) are closed (FC):
- 52-HV-0003: C4 feed inlet.
- 52-HZV-0004: Wash Water Drum (52-V-001) outlet.
- 52-HZV-0028: Demineralized Water to Static Mixer (52-MX-002).
- 52-HZV-0009: Feed Surge Drum (52-V-002) outlet.
- 52-HZV-0006: Feed Surge Drum degassing line.
- 52-HZV-0001: Feed Surge Drum (52-V-002) water outlet.
- 52-XZV-0010: Feed Pumps discharge to Reaction section.
- 52-HZV-0031 and 52-HZV-0032: Make-up hydrogen inlet.
- 52-XZV-0012: Steam to the Start-Up Heater (52-EX-001).
- 52-HZV-0014 & 52-HZV-0015: Reactor (52-R-001) inlet/outlet.
- 52-XZV-0018: Hydrogen Make-Up to Recycle Drum (52-V-003).
- 52-HZV-0016: Reactor Off-Gas Separator Drum Vapor to B.L.
- 52-HZV-0019: Recycle Drum (52-V-003) outlet.
- 52-HZV-0029: Recycle Drum (52-V-003) water outlet.
Page 108 of 118

- 52-HZV-0021: Reactor Off-Gas Separator Drum (52-V-004) water outlet.
- 52-HZV-0022: Reactor Off-Gas Separator Drum (52-V-004) outlet.
- 52-HZV-0030: Reaction section effluent to Stabilizer section.
- 52-HZV-0023: Steam to the Stabilizer Reboiler (52-EX-002).
- 52-HZV-0027: Stabilizer Reflux Drum (52-V-005) outlet.
- 52-HZV-0024: Stabilizer Reflux Drum (52-V-005) water outlet.
- 52-HZV-0025: Hydrogenated product to battery limit.
- 52-HZV-0026: Stabilizer Reflux Drum (52-V-005) vapour to B.L.
- 52-XZV-9001: Flare KO Drum (52-V-930) liquid outlet.
• The status of following emergency safety valves (HZV) is opened (FO):
- 52-XZV-0002: C4 feed to LPG Storage Tank.
- 52-HZV-0007: Depressurization of Feed Surge Drum (52-V-002).
- 52-HZV-0033: Make-up hydrogen bleed line.
- 52-HZV-0034 and 52-HZV-0035: Depressurization of Reactor (52-R-001).
- 52-HZV-0020: Depressurization of Recycle Drum (52-V-003).
- 52-HZV-0017: Depressurization of Stabilizer (52-K-001).
Note:
The HZV and control valves on the hydrogen injection lines to both reaction sections shall be isolated by
block valves on site.
The depressurization valves of Hydrogenation Reactor, Feed Surge Drum, Stabilizer, and Recycle Drum
are provided with air reserves, in order to prevent any undesirable depressurization.
Page 109 of 118

8 HAZARDS
8.1 FACILITIES HAZARDS REQUIRING SPECIAL PRECUATIONS
8.1.1 Various hazardous and toxic substances are present in this process
These substances are contained in the different streams and chemical products discussed in 2.6.2 “Process
Chemicals”
Detailed data regarding the hazard and toxicity of these compounds can be found in the following
documents:
• OSHA Regulated Hazardous Substances published by the Occupational Safety and Health
Organization - US Department of Labor.
• « Fiches toxicologiques » published by:
Institut National de Recherche et de Sécurité

30, rue Olivier Noyer 75680 PARIS CEDEX
The unit owner is advised to request the relevant data sheets from the above organizations. These sheets
are regularly updated by these organizations.
Concerning catalysts and additives supplied under a trade mark, the relevant updated Material Safety Data
Sheets must be required from the manufacturer.
The European Directive instructs all companies supplying products, to provide product Safety Data
Sheets in a controlled manner.
In order to comply with this obligation, Axens has installed on the internet network an access to Axens'
Safety Data Sheets, with a record of customer names and e-mail addresses. This mechanism enables the
automatic dispatch of safety data sheets revisions related to each customer's needs.
Consequently, we invite you to connect to the site "www.quickfds.com" to discover the procedure to
record your name and e-mail address and to obtain access to the Safety Data Sheets that meet your
needs.
Page 110 of 118

9 SUMMARY OF MAJOR EQUIPMENT
9.1 LINE LIST
For Line list refer to Attachment XIII “LINE LIST” (Doc No: HS84218-00-PIP-LIST-0002-0000).
9.2 EQUIPMENT LIST
For Equipment list refer to Attachment XIV “EQUIPMENT LIST” (Doc No: HS84218-00-PEN-EQ-
0001-0000–Unit 52).
9.3 INSTRUMENT LIST
For Instrument list refer to Attachment XV “INSTRUMENT INDEX–UNIT 52 C4H” (Doc No:
HS84218-52-INS-ILT-0002-0000).
9.4 EQUIPMENT BLIND LIST
For Equipment Blinds and positions refer to Unit 52–C4 Hydrogenation P&IDs (Doc. No: HS84218-52-
PR-PID-0000-0001 to HS84218-52-PR-PID-0000-0200).
Page 111 of 118

10 PACKAGE EQUIPMENT DESCRIPTION
10.1 COALESCER PACKAGE
C4 Hydrogenation unit includes one Coalescer Package (52-PU-001) in order to remove any free water in
recycle fluid to prevent the catalyst poisoning.
For Details of Coalescer Package refer to Coalescer Package (52-PU-001) Process Datasheet (Doc. No:
HS84218-52-PR-DS-0031-0000).
For operating manual of Coalescer Package (52-PU-001) refer to Attachment XVI “OPERATING AND
MAINTENANCE INSTRUCTIONS–COALESCER PACKAGE (52-PU-001)” (Doc. No: HS84218-
7500072904-52-C3B-0001-0001).
Page 112 of 118

11 PLANT SAFETY
All operating personnel must fully understand the principles of safe plant control and correct operating
procedures, as detailed in this manual.
All the existing Safety procedures of HAOR shall be applied to the C4 Hydrogenation Unit. The
emergency shutdown system, and relief valves must be carefully checked before the unit is started.
11.1 MEASURES TO AVOID CORROSION
Corrosion during normal operation is usually quite small, except the lines and equipment in demineralized
water service, if the plant is properly heated and insulated. Severe corrosion may take place when the
plant is shut down and out of service for a long period of time, unless the plant is properly purged and
dried by inert gas.
If the plant is to be down for a long period (more than one week), plant should be drained and kept under
a dry nitrogen atmosphere with a small bleed of nitrogen.
11.2 MEASURES TO AVOID FIRE
11.2.1 Prevention against Explosion and Fires
The unit area should be cleaned of all unnecessary construction material, which might burn, and the
area around the unit should be cleared adequately to provide complete safety of movement by operating
and fire fighting personnel.
All fire fighting and gas protection facilities within the unit should be available for immediate use.
During the first start up and normal operation, periodic tests with a portable gas detector should be carried
out to detect any presence of a mixture of air and hydrocarbon gases, or any other inflammable gas. The
area should be covered at scheduled intervals and, if a dangerous amount of gas is found, steps must be
done at once to determine the source and eliminate it.
Welding in the plant causes an increased danger of fires. Welding is not allowed to be started before a
written permit has been obtained from the Unit Supervisors. This permit should specify all preparatory
work necessary, dependent upon the location of the work.
11.2.2 Precautionary measures to avoid Hydrocarbon burning
Hydrocarbon burns exothermically with oxygen; uncontrollable Hydrocarbon fire can destroy the catalyst,
damage vessels, and pipework either for the resulting high temperatures or for the corrosive atmosphere
Page 113 of 118
due to the formation of CO2 or CO during the combustion. Therefore, care must be taken to limit its
contact with oxygen.
During the plant start-up, Plant shall be purged with nitrogen to control that CO and O2 are contained in
the following safe limits.
O2 0.4 % by volume maximum (0.2 % by volume maximum in reaction section)
CO 0.4 % by volume maximum
11.2.3 Extinguishing Hydrocarbon Fires
In case of Hydrocarbon fire in plant, water is used to snuff the fire. This operation will/shall be done with
automatic water sprays provided on each fire potential equipment and Monitors, Hydrant and hose system
at a safe location from the source of fire.
Water shall not be used on electrical equipment because the water will conduct electricity and may
aggravate the difficulty or result in the electrocution of personnel. Dry powder extinguishers may be used
safely on electrical fires.
11.2.4 Fire Protection
All operating personnel must be aware of the possible areas susceptible to fire and of the fire fighting
procedures. In the event of a fire, operators must comply with the existing Emergency Procedures.
In order to minimize the risk of fires, all hydrocarbon spillage must be removed as soon as they occur.
While fighting a fire the fireman should ware suitable breathing apparatus and stand on the windward side
of the fire.
11.3 MEASURES TO AVOID LEAKS
The leak test shall verify the tightness of flanged connections, manholes and hand holes, which have been
opened during the previous precommissioning operations. Flanged connections shall be tested by means
of a soapy solution. Operating equipment should be checked frequently for signs of leakage.
11.4 MEASURES TO AVOID EXPLOSION
During the first start up and normal operation, periodic tests with an explosivity meter should be carried
out to detect any flammable gas leaks.
Page 114 of 118

11.5 MEASURES TO AVOID CATALYST DAMAGE
The Hydrogenation catalyst shall be protected from contaminants listed in section 2.7.4 “Catalyst
Contaminants”, specially from free water, exist in recycle flow, which is temporary poison for catalyst
and from Silicon, lead, and chlorides which are permanent poisons for catalyst.
Precautions against catalyst damage while handling/loading/unloading the catalyst is detailed in section
6.6 “SPECIAL PROCEDURES”.
11.6 SAFE SAMPLING
Only authorized personnel who have been properly instructed shall draw samples from unit. Protective
gloves and goggles or face shields must be worn during the sample withdrawn.
Adequately sized sample containers should be used to avoid overflowing or splashing of personnel. Never
fill sample containers to the rim, since expansion of the liquid later may burst them.
While taking samples from hot stream/equipment, precautions must be taken. Operators must check
temperature gauges at the downstream of sample cooler to make sure stream had been cooled enough to
withdrawn sample safely. Samples should be drawn off very slowly and cautiously to give enough time
for stream cooling in sample cooler.
For sample analyzing methods refer to Attachment XXI “IFP ANALYTICAL METHODS”.
For sampling test method refer to Attachment XXV “Sampling Schedule and Specific Laboratory
Equipment” (doc no. HS84218-00-PR-PL-0002-0000).
11.7 GENERAL PRECAUTIONS
As general rule, considering the presence of several units handling H2S in the refinery, all operators shall
be provided with emergency escape masks.
Page 115 of 118

12 ATTACHMENTS
• Attachment I
HEAT AND MATERIAL BALANCE–UNIT 52 (Doc. No: HS84218-52-PR-HM-0001-0000).
• Attachment II
PROCESS FLOW DIAGRAMS–UNIT 52 (Doc. No: HS84218-52-PR-PF-0001-0000).
• Attachment III
BLOCK FLOW DIAGRAM–UNIT 52 (Doc. No: HS84218-52-PR-BF-0001-0000).
• Attachment IV
CHEMICALS AND CATALYST SUMMARY–UNIT 52 (Doc. No: HS84218-52-PR-CC-0001-

0000).
• Attachment V
CONTROL NARRATIVE–UNIT 52 (Doc. No: HS84218-52-PR-LN-0001-0000).
• Attachment VI
CAUSE & EFFECT DIAGRAMS–UNIT 52 (Doc. No: HS84218-52-PR-CE-0001-0000).
• Attachment VII
DCS POINT CONFIGURATION DATABASE–UNIT 52 (Doc. No: HS84218-52-INS-ILT-

0004-0000).
• Attachment VIII
ESD & FGS POINT CONFIGURATION DATABASE–UNIT 52 (Doc. No: HS84218-52-INS-

ILT-0005-0000).
• Attachment IX
HAZARDOUS AREA CLASSIFICATION LAYOUT–UNIT 52 (Doc. No: HS84218-52-PSE-

HAD-9001-0000).
Page 116 of 118

• Attachment X
MATERIAL SELECTION DIAGRAMS–UNIT 52 (Doc. No. HS84218-52-MT-MS-0001-0000).
• Attachment XI
INSTRUMENT INDEX FOR FIRE AND GAS DETECTION SYSTEM–UNIT 52 C4H (Doc
No: HS84218-52-INS-ILT-0003-0000).
• Attachment XII
FIRE AND GAS DETECTION LOCATION LAYOUT–UNIT 52 C4H (Doc No: HS84218-52-
INS-ILD-0004-0000 & HS84218-52-INS-ILD-0005-0000).
• Attachment XIII
LINE LIST (Doc No: HS84218-00-PIP-LIST-0002-0000).
• Attachment XIV
EQUIPMENT LIST (Doc No: HS84218-00-PEN-EQ-0001-0000).
• Attachment XV
INSTRUMENT INDEX–UNIT 52 C4H (Doc No: HS84218-52-INS-ILT-0002-0000).
• Attachment XVI
OPERATING AND MAINTENANCE INSTRUCTIONS–COALESCER PACKAGE (52-PU-

001) (Doc. No: HS84218-7500072904-52-C3B-0001-0001).
• Attachment XVII
REACTOR FILLING-UP DIAGRAMS–UNIT 52.
• Attachment XVIII
FILLING / CIRCULATING DIAGRAMS–UNIT 52.
Page 117 of 118

• Attachment XIX
ANALYTICAL CONTROL.
• Attachment XX
PRELIMINARY PERFORMANCE TEST PROCEDURE.
• Attachment XXI
IFP ANALYTICAL METHODS.
• Attachment XXII
ONE LINE DIAGRAM SUBSTATION.
• Attachment XXIII
FIRE FIGHTING AND SAFETY EQUIPMENT LAYOUT–UNIT 52.
• Attachment XXIV
:
UTILITIES CONSUMPTION LIST (doc. no. HS84218-52-PR-UB-0001-0000).
• Attachment XXV
:
SAMPLING SCHEDULE AND SPECIFIC LABORATORY EQUIPMENT (doc no. HS84218-
00-PR-PL-0002-0000).
• Attachment XXVI
EMISSIONS AND EFFLUENT SUMMARY (Doc. no. HS84218-52-PR-EB-0001-0000).
Page 118 of 118

Unit 52 Operating Manual

Uploaded by

Copyright:

Available Formats

You might also like

Unit 52 Operating Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Unit 52 Operating Manual

Uploaded by

Copyright:

Available Formats

SOCAR HAOR MODERNIZATION AND RECONSTRUCTION PROJECT

BAKU- AZERBAIJAN REPUBLIC

OPERATING MANUAL – UNIT 52

PROJECT : SOCAR HAOR MODERNIZATION AND

9 SUMMARY OF MAJOR EQUIPMENT ................................................................................. 111

Table 1.1: Inlet Feed Composition to C4 Hydrogenation unit 7

Figure 1.1: Block flow diagram 11

Figure 6.7: CATAPAC™ – Utilities and equipment requirements 51

The changes referred to IP Register change are identified by <1IP> indication

1.1.1 Purpose of the Document

1.2 PURPOSE OF THE FACILITY

1.3 PROCESS OVERVIEW

The C4 Hydrogenation unit consist of:

Saturation reactions involved in reactor are:

1.4 FEED CHARACTERISTICS.

1.4.1 C4 Cut Composition

Table 1.1: Inlet Feed Composition to C4 Hydrogenation unit

FCC unit (Design Case) MTBE unit (Check Case)

Propylene 0.24 0.17

Propane 0.68 1.12

Butene-1 13.8 17.23

Butene-2 (cis+trans) 26.2 32.67

Isobutylene 17.72 0.30

Butadiene 0.32 0.39

i-Butane 24.32 29.83

n-Butane 15.0 18.14

Isopentane 1.74 0.14

Total 100.00 100.00

1.4.2 Unit Capacity

1.4.3 Turndown Case FeedStock

Unit Design Case Check Case

Sulphur ppmwt 10 max 10 max

1 ppmw max 1 ppmw max

DME ppmwt – 1000 max

Methanol ppmwt – 25 max

MTBE ppmwt – 25 max

Free water - Nil

H2S+COS wppm < 0.1

NH3 + Amines wppm <1

Tertiary Butyl Catechol (TBC) wppm < 50

Acetonitrile wppm < 10

NMP wppm < 10

DMF wppm < 10

C8+ and oligomers wppm < 100

Methanol and other alcohol wppm < 50

Organic Chlorides - Nil

Caustic wtppm < 0.1

1.4.5 Hydrogen Make-Up

Table 1.4: Hydrogen Make Up Composition

Composition Value (mol%=vol%)

1.4.6 Hydrogen for Start-Up

Table 1.5: Start-up Hydrogen Specification

Gas components H2 from PSA / H2 from CCR

H2 content mol % 99.9 / 92.2

Gas Flowrate (kg/h) kg/h 1357 / 3224

1.4.7 C4 Feed for Start-Up

► Olefins: 5 wt.% maximum

► Diolefins: 500 wt ppm maximum

1.4.8 Wash Water