Ai - Hoang

Process Engineer - PP

PP#3 Plant

1
 WHAT HAVE LEARNT

OJT HOW APPLY TO LSP

TRAINING

ACHIEVEMENT

2
 Technical description
Cyclone separator/ Condensing Recovery PR in
Dynamic separator Propylene purge stream

D3302
41.4 t/h
44 t/h 300 kg/h TO B/L
80 oC
Stop 41 oC
17 kg/cm2g D3301
Seal oil
E3308
Slurry 55 %wt 44 oC BRR

70 oC A3301 17 kg/cm2g
HV3001
42 kg/cm2g
R3202 Close LS 60 oC BRS
24 kg/cm2g 18 t/h
LBD 80% 35 oC
Divert D3301
F3201
T3301
CWR

LV3001
Close E3301
PK33001
CWS
E3307 E3308
5.6 t/h
93 oC
HV3002

1 HV3101 PWR

R3401 F3301

PWS
LC 3 kg/cm2g
LBD Level VH
LS P-3302

3320 kg/h
LC
80 oC
R3401
Increase pressure
for reflux & back
Vaporization & Scrubber: Separate polymer to Feed drum
superheat of C3= fines & heavier component

3
 Process Mass Quality
Equipment Controller
Parameter Balance Control
Flash Drum
TIC3001
Temperature 
D3301
Flash Drum

LIC3001 Level

Propylene

PIC3201 scrubber Top
pressure

Reflux 
FIC3201
flowrate
T-3301
Purge Gas
FIC3204
Flowrate  


FIC3205 T3301 to F3301

4
 Start

1. LBD is operational
Leak test, purge system
Service utilities

2. Replacement system
N2 PR
3. Pressurize system, Monitor level E3301

4. Start-up reflux pump, establish PR circulation PG PG

PR
5.Check conditions after start-up

End
5
1 Check condition before start-up:
Reactor feed system in operation
T3501 heating up
Warm-up LS steam
Service Utilities: FIC3204
D3302

• CWS to E3301: FIC3207.SP=250 t/h;

PV3201

• BR: FIC3208.SP=10t/h; TO B/L

• PW: FIC3208.SP=6 t/h; Temp: TIC5019.SP=100 oC

FV3204
D3301
FIC3209
Service oil seal : A3301, P3302A/B
PIC3201 BRR
FV3209

E3308
LBD FIC3201
BRS
FIC3207

CWR
TIC3001 LBD
FV3207
FO3203
FV3021 LIC3202
Seal HV3003 CWS
oil PK33001 T3301
E3301
PIC3001
A3301
HV3001 LIC3201

R3202 D3301
LS
HV2508B HV2503B PWR
PV3001 LIC3001
FIC2402 LBD FIC3208 LBD

F3201 PWS
FV2402 FV3208 FV3205
PIC3203
FIC3002 FIC3026
LBD
LV3001 FY P-3302
LS
PV3203
E307 E3308
TIC3201
FV3002 FIC3205

HV3002
R3401
1 T

R3401 F3301
LC

LC

6
 2 Replacement system
Introduction LS steam
• Line-up half of Jacket E3307: 3.5 Columns
• Open slowly PV3001, PIC3001.SP=0.5 kg/cm2g
Pressurize system
• Open slowly FV2402 introduction C3=, FIC2402. SP=4 t/h
Depressurize system PV3201
FIC3204
D3302

• Monitor pressure increase up to 5kg/cm2g

• Close FV2402, open FV3204 & bypass SV, low point
TO B/L
FV3204
D3301
drain for replacement FIC3209

• Repeat 3-4 times PIC3201 BRR

FV3209

E3308
LBD FIC3201
BRS
FIC3207

CWR
TIC3001 LBD
FV3207
FO3203
FV3021 LIC3202
Seal HV3003 CWS
oil PK33001 T3301
E3301
PIC3001
A3301
HV3001 LIC3201

R3202 D3301
LS
HV2508B HV2503B PWR
PV3001 LIC3001
FIC2402 LBD FIC3208 LBD

F3201 PWS
FV2402 FV3208 FV3205
PIC3203
FIC3002 FIC3026
LBD
LV3001 FY P-3302
LS
PV3203
E307 E3308
TIC3201
FV3002 FIC3205

HV3002
R3401
1 T

R3401 F3301
LC

LC

7
 3 Pressurize system, Monitor level E3301
Pressurize system
• Open slowly FV2402, SP=20 t/h
• Adjust PIC3001.SP, control D3301 Temp=80 oC
Monitor Level E3301
• Check pressure T3301 PIC3201.PV=14-15 k/g
• Observe level increase in E3301
D3302
FIC3204
PV3201

TO B/L
FV3204
D3301
FIC3209

PIC3201 BRR
FV3209

E3308
LBD FIC3201
BRS
FIC3207

CWR
TIC3001 LBD
FV3207
FO3203
FV3021 LIC3202
Seal HV3003 CWS
oil PK33001 T3301
E3301
PIC3001
A3301
HV3001 LIC3201

R3202 D3301
LS
HV2508B HV2503B PWR
PV3001 LIC3001
FIC2402 LBD FIC3208 LBD

F3201 PWS
FV2402 FV3208 FV3205
PIC3203
FIC3002 FIC3026
LBD
LV3001 FY P-3302
LS
PV3203
E307 E3308
TIC3201
FV3002 FIC3205

HV3002
R3401
1 T

R3401 F3301
LC

LC

8
 4 Start-up reflux pump, Monitor level T3301
establish PR circulation

Check lube oil, seal oil

Pump primed
Blocks FO3203 open; Block discharge : Open 30% D3302

PV3201.MV=30%;FV3201.MV=0%
FIC3204
PV3201

Level E3301, LIC3202.PV>30% TO B/L

Start pump P3302A/B

FV3204
D3301
FIC3209

Open FV3201, increase PV to 18.5 t/h switch to Auto

Monitor level T3301, LIC3021.SP=50% PIC3201
FV3209
BRR

Start A3301 E3308

LBD FIC3201
BRS
FIC3207

CWR
TIC3001 LBD
FV3207
FO3203
FV3021 LIC3202
Seal HV3003 CWS
oil PK33001 T3301
E3301
PIC3001
A3301
HV3001 LIC3201

R3202 D3301
LS
HV2508B HV2503B PWR
PV3001 LIC3001
FIC2402 LBD FIC3208 LBD

F3201 PWS
FV2402 FV3208 FV3205
PIC3203
FIC3002 FIC3026
LBD
LV3001 FY P-3302
LS
PV3203
E307 E3308
TIC3201
FV3002 FIC3205

HV3002
R3401
1 T

R3401 F3301
LC

LC

9
 5 Check conditions after start-up

Flushing line flowrate: FIC2402.SP=20 t/h

LS steam pressure to E3307: PIC3001.PV=0.2-0.8 k/g
Flash drum Temp: TIC3001.SP=80oC
Propylene Scrubber pressure: PIC3021.SP=15-16k/g
Reflux rate: FIC3021.SP=18.5t/h D3302
Level of E3301: LIC3202.SP=50% PV3201
FIC3204

Level of T3301: LIC3201.SP=50% TO B/L

Dynamic separator: Running, speed=1478 rpm FV3204

FIC3209
D3301

PIC3201 BRR
FV3209

E3308
LBD FIC3201
BRS
FIC3207

CWR
TIC3001 LBD
FV3207
FO3203
FV3021 LIC3202
Seal HV3003 CWS
oil PK33001 T3301
E3301
PIC3001
A3301
HV3001 LIC3201

R3202 D3301
LS
HV2508B HV2503B PWR
PV3001 LIC3001
FIC2402 LBD FIC3208 LBD

F3201 PWS
FV2402 FV3208 FV3205
PIC3203
FIC3002 FIC3026
LBD
LV3001 FY P-3302
LS
PV3203
E307 E3308
TIC3201
FV3002 FIC3205

HV3002
R3401
1 T

R3401 F3301
LC

LC

10
New Reboiler E-3303 (spare)
E-3303 Plugging

Plant S/D for Cleaning

Cleaning works
Maintenance
(Water jet; chemical
works
cleaning

12 hrs 24-72 hrs

11
Soft skills
Teamwork
Communication
Write report

Hard skills
Experience
Work instruction

12
THANK YOU

1
Start P-3302 Start A-3301 MV FlCA2402

FlCA2402

Pressure D-3301, T-3301

FlCA3001

Level T-3301

Level E-3301

15
 202 1.38
40 t/h 1.2 t/h Main inert gas :
17 % 2 17 % H2, C3
Off Gas B/L
1
91 t/h 41 t/h
259
8% 19 % Mass balance:
B/L 3 4
Feed drum Reactor HP section PR: 202+79-259=22 kg/h
H2 : 4.741-1.380-0.016-
51 t/h 22/42*2=2.3 kg/h
0.5 % H2 4.741
Max
Point J600
Grade J300 J900
No GP

H2 Conc LP section 0.016

1 0.612 2.36 6.828
Purge gas, % mol 79

H2 Conc 0.4 t/h

2 110 440 1250
PR Liq recycle, ppm 19 %
Steamer
3
H2 Conc
50 190 540
Off Gas B/L
PR Feed, ppm
Optimization
H2 Conc → Purge flowrate from
4 PR Feed (After Mix 330 1300 3100 E308, Dryer
H2) ppm

16
 Grade: F652
Slurry from R202
Temp Temp 60 oC
Press 42 kg/cm2g
Flow
143 Liq 44.55 t/h
Steam press: 0.2-0.8 k/g Solid 35 t/h
110 Slurry Conc 55 %
110 C3= and Powder to D301
Temp 70 oC
80 Press 18.5 kg/cm2g
Flow
Gas 44.55 t/h
46
Solid 35.00 t/h
Vaporization through valve
Heat of C3 Liq 360.58 Mcal/h
Total area= 80m2 Heat of PP 182.44 Mcal/h
Total 543 Mcal/h
Heat transfer: Q=UA∆T Duty Mass of vap 7.97 t/h
Heat Duty calculation Vap frac 0.10
Normal Operation: Start-up: Heat of E307
Heat duty: 3334 Mcal/h Heat duty: 2072 Mcal/h Heat of vap 2493.9 Mcal/h 75
U: Steam side & PR side: Boiling and Condensing Heat Gas C3 496.0 Mcal/h 15
heat transfer Heat of PP 343.9 Mcal/h 10
S/U heat transfer area: Total 3334 Mcal/h 100
To maintain steam pressure and Outlet Temp: LS steam 6.54 t/h
Heat transfer area=80*3334/2072=50 m2
Pressure rate: 3bar/min Pneumatic conveying
Pressurize system Pneumatic conveying
Hold-up volume SU N.Op
D301 12.1 m3 Particle diameter d 0.0021
T301 40.5 m3 Particle density ρ1 910
E301 11.0 m3 Gas density ρ2 34
63.6 m3 Viscosity m 0.000011
Temp 80 oC Gravity acc g 9.81
Increase rate 3 bar/min Powder mass rate Mp 1000 50000
MW 42 0.278 13.88888889
Flow 17 t/h Pipe dia D 0.154 0.15408
Hydraulic transport Alpha 5.0 4.984
Hydraulic transport Belta 4.81 4.81
Factor FL 1.3 Pi 3.142 3.141592654
Particle diameter d 0.004 Saltation velocity Usalt 7.42 14.54922684
Pipe diameter D 0.07792 Safety factor 1.2 1.2
Ar 6060472.066 Superficial Vel U 8.90 17.45907221
Solid-Liquid ratio S 2.24 Mass flow 20.3 39.82582447
Gravity acc g 9.81
Critical velocity Vc 1.82
Transport velocity 2.18
Flowrate Q 15239
Nor Operation 40950
Slurry velocity 5.86
 Check condition before start-up 4 Start-up Compressor
1
1. HP flash already start-up 1. Check Lube oil, seal, CWS for compressor
2. MO, LA preparation for make-up 2. Open Line T3301 to D3303, PIC3106= 5k/g
3. Leak test, purging check water dewpoint 3. PIC3101.SP=0.75 k/g; PV3503.SP=0.6 k/g
4. Service Utilities: LS, CWS 4. Open FV3201.MV=25% to pressurize system
5. Monitor pressure PIC3503= 0.6 k/g
PR Replacement 6. Start C3301 at Load= 0%
2 7. Check condition: Sound/noise, vibration,
lube oil
1. Open PIC3203, SP=0.3 k/g; TIC3201.SP=80oC 8. Increase load to 50%
2. Open FV3205.MV=25 % pressurize system to 9. Open LV3001 slowly 5-7%, Monitor pressure
3 k/g at F3301
3. Open PV3101 and Bypass PSV of KO drum to 10. Monitor PV3503 close
Replacement 11. When MV PV3503.MV<20%, increase load to
4. Repeat 3 times 100%
12. Increase MV LV3001 to 20%
13. Switch Blow back gas to PK3301
3 T3302 Circulation

5 Check conditions after start-up

1. Fill-up by MO/LA 50/50 %wt
2. Heating by circulation P3303 to reach 40 oC
3. Priming pump, check lube oil 1. Flowrate: FI3102=6-7 t/h
4. Start P3304. adjust flowrate =51 t/h 2. Blow back gas : PIC3106=5 k/g
3. P3304 Cir rate: 51 t/h
4. Pressure Suct C3301: 0.6 k/g

19