NHT Isom Draft

OPERATING MANUAL FOR
ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Doc No. Draft

Rev. A
Page 1 of 221
OPERATING MANUAL
OF
ISOMERISATION UNIT
(UNIT NO.73)
VISAKH REFINERY CLEAN FUELS PROJECT
HINDUSTAN PETROLEUM CORPORATION LIMITED

VISAKH REFINERY
A
Rev No.
Date
Issued for comments

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

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Doc No. Draft

Rev. A
Page 2 of 221
This operating manual for Isomerization Unit of HPCL, VISAKH has been prepared by M/s
Engineers India Limited for M/s Hindustan Petroleum Corporation Limited.
This manual contains process description and operating guidelines for the unit and
is based on documents supplied by the Process Licensor (Axens). Hence the manual
must be reviewed /approved by the licensor before the start-up /operation of the
unit.
Operating procedures & conditions given in this manual are indicative. These should be
treated as general guide only for routine start-up and operation of the unit. The actual
operating parameters and procedures may require minor modifications/changes from those
contained in this manual as more experience is gained in operation of the Plant.
For detailed specifications and operating procedures of specific equipment, corresponding
Vendor's operating manuals/instructions need to be referred to.

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Doc No. Draft

Rev. A
Page 3 of 221
Table of Contents
SECTION-1...................................................................................................................................................6
INTRODUCTION........................................................................................................................................6
1.1
INTRODUCTION............................................................................................................................6
SECTION-2...................................................................................................................................................8
DESIGN BASIS............................................................................................................................................8
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
INTRODUCTION............................................................................................................................8
UNIT CAPACITY............................................................................................................................8
ON-STREAM FACTOR..................................................................................................................8
TURNDOWN CAPABILITY..........................................................................................................8
FEED................................................................................................................................................8
PRODUCTS...................................................................................................................................11
BATTERY LIMIT CONDITIONS.................................................................................................17
UTILITY CONDITION.................................................................................................................17
SECTION-3.................................................................................................................................................21
CHEMISTRY OF THE PROCESS...........................................................................................................21
3.1
3.2
3.3
3.4
INTRODUCTION..........................................................................................................................21
ISOMER REACTIONS.................................................................................................................21
ISOMAR CATALYST....................................................................................................................25
CATALYST CONTAMINANTS....................................................................................................27
SECTION-4.................................................................................................................................................30
PROCESS DESCRIPTION.......................................................................................................................30
4.1
4.2
4.3
4.4
4.5
ISOMERIZATION UNIT PROCESS SYSTEM:..........................................................................30

PROCESS DESCRIPTION............................................................................................................34
CHLORIDE INJECTION FACILITIES........................................................................................41
UTILITY SYSTEM........................................................................................................................41
WASTE EFFLUENT FROM ISOMERIZATION SECTION........................................................45
SECTION 5..............................................................................................................................................47
PRE-COMMISSIONING PROCEDURE................................................................................................47
5.1
5.2
5.3
5.4
5.5
GENERAL.....................................................................................................................................47
PRE-COMMISSIONING ACTIVITIES........................................................................................47
INSPECTION / CHECKING.........................................................................................................47
PREPARATION FOR PRE-COMMISSIONING..........................................................................49
PRE-COMMISSIONING OPERATION.......................................................................................50
SECTION 6..............................................................................................................................................60
COMMISSIONING PROCEDURE.........................................................................................................60
6.1
6.2
FIRST START UP..........................................................................................................................60

STATUS OF THE UNIT................................................................................................................60

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
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CHRONOLOGY............................................................................................................................60
COMPLETE INERTISING............................................................................................................61
HYDROCARBON CIRCULATION AND INITIAL DRY DOWN..............................................63
HYDROGEN SWEEP...................................................................................................................64
OIL CIRCULATION, AND STABILIZER / DEISOHEXANIZER / LPG RECOVERY
SECTION START-UP....................................................................................................................66
REACTION CIRCUIT OIL-IN......................................................................................................71
ACIDIZING AND FINAL DRY-DOWN.......................................................................................75
HYDROGENATION AND ISOMERISATION CATALYST LOADING UNDER N2............81
HYDROGENATION REACTION SECTION START-UP......................................................81
ISOMERIZATION REACTION SECTION START-UP..........................................................84
ISOMERIZATION UNIT LINE-OUT AT DESIGN CAPACITY............................................87
LPG RECOVERY SECTION LINE-OUT................................................................................88
UNIT RESTART.......................................................................................................................89
SECTION 7...............................................................................................................................................90
NORMAL OPERATING PROCEDURES...............................................................................................90
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
INTRODUCTION..........................................................................................................................90
CONTROL PHILOSOPHY...........................................................................................................90
OPERATING PARAMETERS.......................................................................................................93
OPERATING PARAMETER.........................................................................................................95
SET POINTS OF ALARMS AND TRIPS...................................................................................122
EQUIPMENT LIST.....................................................................................................................127
LIST OF INSTRUMENTS..........................................................................................................136
PRESSURE SAFETY VALVES..................................................................................................143
ANALYZERS...............................................................................................................................145
SECTION - 8.............................................................................................................................................147
SHUTDOWN PROCEDURES................................................................................................................147
8.1
8.2
8.3
8.4
8.5
8.6
8.7
GENERAL...................................................................................................................................147
NORMAL SHUTDOWN PROCEDURE....................................................................................147
SHORT DURATION SHUTDOWNS..........................................................................................148
LONG DURATION SHUTDOWNS...........................................................................................149
SHUTDOWN FOR CATALYST REPLACEMENT...................................................................151
EMERGENCY SHUTDOWN PROCEDURE............................................................................152
AUTOMATIC SHUTDOWNS....................................................................................................159
SECTION-9...............................................................................................................................................163
PROCESS VARIABLE............................................................................................................................163
9.1
9.2
BENZENE SATURATION..........................................................................................................163
ISOMERIZATION.......................................................................................................................164
SECTION-10.............................................................................................................................................170
TROUBLE SHOOTING..........................................................................................................................170
10.1
10.2
10.3
10.4
10.5
WATER BREAKTHROUGH FROM THE DRYERS............................................................170

SULPHUR BREAKTHROUGH: SULPHUR STRIPPING PROCEDURE..........................172
LOSS OF C2CL4 INJECTION.................................................................................................173
CHLORIDE BREAKTHROUGH...........................................................................................174
PREVENTIVE MAINTENANCE:.........................................................................................174

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
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SECTION -11............................................................................................................................................175
SPECIAL PROCEDURES/INSTRUCTION/INFORMATION...........................................................175
11.1
11.2
11.3
11.4
11.5
CATALYSTS LOADING UNDER N2....................................................................................175

SPENT CATALYST UNLOADING.......................................................................................183
SPECIFICATIONS OF CATALYSTS.....................................................................................184
CHEMICALS DURING NORMAL OPERATION................................................................187
CHEMICALS DURING TRANSIENT OPEARTION...........................................................188
SECTION-12.............................................................................................................................................189
UTILITY CONSUMPTION SUMMARY..............................................................................................189
12.1
INTERMITTENT CONSUMPTIONS FOR ISOMERIZATION SECTION.........................189
SECTION-13.............................................................................................................................................191
SAMPLING PROCEDURE AND LABORATORY ANALYSIS REQUIREMENT..........................191
13.1
13.2
13.3
GENERAL..............................................................................................................................191
SAMPLING PROCEDURE....................................................................................................191
LABORATORY TEST METHOD AND SCHEDULE...........................................................194
SECTION -14............................................................................................................................................198
SAFETY PROCEDURE..........................................................................................................................198
14.1
14.2
14.3
14.4
14.5
14.6
14.7
14.8
INTRODUCTION...................................................................................................................198
SAFETY OF PERSONNEL....................................................................................................198
WORK PERMIT PROCEDURE.............................................................................................199
PREPARATION OF EQUIPMENT FOR MAINTENANCE.................................................201
PREPARATION FOR VESSEL ENTRY................................................................................203
HAZARDOUS CHEMICAL HANDLING.............................................................................209
FIRE FIGHTING SYSTEM....................................................................................................218
USE OF LIFE SAVING DEVICE...........................................................................................219
SECTION -15............................................................................................................................................221
GENERAL OPERATING INSTRUCTIONS FOR EQUIPMENT.....................................................221
15.1
15.2
15.3
15.4
15.5
GENERAL..............................................................................................................................221
CENTRIFUGAL PUMPS.......................................................................................................221
POSITIVE DISPLACEMENT PUMPS..................................................................................224
CENTRIFUGAL COMPRESSOR..........................................................................................226
HEAT EXCHANGERS...........................................................................................................229

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
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Rev. A
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SECTION-1
INTRODUCTION
1.1
INTRODUCTION
Isomerization is the conversion of low octane straight chain compounds to their higher
octane branched isomers. The purpose of this process is to saturate benzene and to
isomerise normal paraffins to improve the research and motor octane number of the light
naphtha feed (predominantly C5/C6) before blending into the gasoline pool. The light
naphtha fraction is typically high in normal isomer content resulting in a low octane
number (typically < 68). The isomerization process converts an equilibrium proportion
of these low octane normal isomers into their higher octane branched isomers.
This process developed and licensed by Axens consists of three fixed bed adiabatic
reactors, with benzene saturation carried out in the first reactor, and C 5/C6 isomerization
reactions completed in the following two reactors. The isomerization reactions are
carried over a fixed chlorinated platinum catalyst bed in a hydrogen environment.
Operating conditions are not severe as reflected by moderate operating pressure, low
temperature, low hydrogen partial pressure and high catalyst space velocity. These
operating conditions promote the isomerization reaction, minimize hydrocracking and
minimize equipment capital costs.
The feedstock of the Isomerization unit is light hydrotreated naphtha coming from
Naphtha Hydrotreating Unit. Naphtha is mixed with hydrogen. A small amount of
chlorinating agent is continuously injected in to the isomerization catalyst. The mixture
enters in first stage reactor where isomerization reaction occurs. The effluent is cooled
before entering the second stage reactor. Remaining isomerization reaction occurs in
third stage reactor. The effluent is then routed to stabilizer to reduce C4 rate in the
isomerization reactor effluent. The stabilizer overhead is partially cooled and vapor
phase is routed to LPG recovery section while liquid is used as reflux. Stabilizer bottom
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VRCFP, HPCL VISAKH
Rev. A
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is routed to deisohexaniser where low octane C6- n paraffin and methyl pentane is
recycled to the reactor circuit in order to obtain a high octane product.

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
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SECTION-2
DESIGN BASIS
2.1
INTRODUCTION
The isomer unit is required to produce an Isomerate product which is suitable for gasoline
pool.
Important content of design basis is given below.
2.2
UNIT CAPACITY
Isomar Unit is designed for a capacity of 228641 T/yr.

2.3
ON-STREAM FACTOR
The facility is designed for 8000 operating hours per year.

2.4
TURNDOWN CAPABILITY
The facility is capable of operating at 50 percent of design feed capacity, while

maintaining the designated product specification.
2.5
FEED
The feedstock of the Isomerization unit is light hydrotreated naphtha coming from
Naphtha Hydrotreating Unit.
Three different feeds were considered for the design of the unit NIT CASE, AM CASE
(Arabian Mixed) and BH CASE (Bombay High).

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
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Rev. A
Page 9 of 221
2.5.1. Light Hydrotreated Naphtha

NIT case
AM case
BH case
Molecular weight
83.5
81.1
81.3
Sp Gravity @ 15C
0.689
0.6647
0.711
Composition, wt%
IBUTANE
NBUTANE
IPENTANE
NPENTANE
22DMB
23DMB
3METHYLPENTANE
NHEXANE
CYCLOPENTANE
METHYLCYCLOPENTANE
BENZENE
CYCLOHEXANE
NHEPTANE
METHYLCYCLOHEXAN
Iso C7
TOLUENE
0.00
0.00
8.48
9.51
0.44
1.41
7.98
27.09
1.15
19.51
4.24
0.72
1.67
8.41
0.01
0.00
0.23
10.89
24.07
0.30
9.28
9.93
25.19
1.39
4.26
1.63
2.79
9.13
0.46
0.00
0.45
0.01
0.24
11.41
12.32
0.52
6.83
5.36
11.98
1.62
7.78
16.51
15.39
9.81
0.20
0.00
0.03
C8
0.14
0.00
0.00
100
100
Total
100
Impurities:
The Isomerization catalyst is an activated chloride, alumina based catalyst with a
platinum promoter. It is highly sensitive to impurities in the feedstock, in particular
water or other oxygenated compounds. Feed to this unit is hydrotreated and both feed
and make-up hydrogen are passed through dryers to remove any traces of water. Some
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ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 10 of 221
impurities are considered to be irreversible poisons such as water and nitrogen

compounds. Others are reversible such as sulfur.
It is critically important that the operating performances of both upstream hydrotreater
and dryers are such that the impurity levels in the isomerization reactor feed do not
exceed the levels shown hereafter. Discussions regarding feed poisons and their effects
will be presented in the Operating Instructions Section.
MAXIMUM ALLOWABLE IMPURITY LEVELS
IN THE FEED
Total Sulphur
0.5 ppm wt max. (1)
Total Nitrogen compounds
0.1 ppm wt max. (1)
Water + Oxygenates
0.1 ppm wt max. (1)
Metals
5 ppb wt max.
Chloride
1 ppm wt max. (1)
Olefins
1% wt max.
Arsenic
1 ppb wt max.
(1) At the outlet of the feed dryer.
2.5.2. Hydrogen
Hydrogen make-up to this unit is needed for isomerization unit for benzene
hydrogenation to cyclohexane and in order to satisfy the hydrogen partial pressure
requirement for the naphtha hydrotreatment and for the isomerization reactions.
Hydrogen is supplied from a new CCR unit. A gas compressor is required to satisfy the
process requirements of the different users.
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ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Components
Rev. A
Page 11 of 221
(Mole %)
Origin
CCR Unit
H2
93.0
C1
2.3
C2
2.2
C3
1.7
iC4
0.3
nC4
0.3
C5+
0.2
Impurities:
H2S
HCl
CO
COS
CO + CO2
H2O
Olefins
N2 compounds
Hydrogen quality
5 ppm vol max

0.5 ppm vol max
6-10 ppm vol
1 ppm vol max
25 ppm vol max
50 vol ppm
10 ppm wt max
1 wt ppm max
MAXIMUM ALLOWABLE CONTAMINANT LEVELS
FOR HYDROGEN TO ISOMERIZATION UNIT
Total Sulphur
Total Nitrogen compounds
Water
CO + CO2
Olefins
Chloride
1.0 ppm wt max.

1.0 ppm wt max.
0.5 ppm wt max.(1)
10 ppm wt max.(1)
10 ppm wt max.
5 ppm wt max
(1) At the outlet of the hydrogen dryers.
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ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
2.6
Rev. A
Page 12 of 221
PRODUCTS
There are four products. The primary product is light Isomerate i.e. deisohexaniser
distillate. The secondary product is heavy Isomerate, i.e. deisohexaniser bottom. The
third product Fuel gas comes from LPG separator drum. The fourth product is LPG
stream produced isomerization stabilizer overhead.
Light Isomerate product
The light isomerate product estimated flowrates and product characteristics are
presented hereafter:
SOR
Isomerate Product flowrate, kg/h
Sp. Gravity @15C
Estimated RON
Estimated MON
Estimated Yield, wt % (1)
Estimated RVP, kg/cm2 abs
Composition, wt %
PROPANE
IBUTANE
NBUTANE
IPENTANE
NPENTANE
22DMB
23DMB
2METHYLPENTANE
3METHYLPENTANE
NHEXANE
CYCLOPENTANE
METHYCYCLOPENTANE
BENZENE
CYCLOHEXANE
NHEPATANE
NIT CASE
17859
0.6456
88.9
88.2
65.7
13.56
AM CASE
21203
0.6414
89.4
88.3
78
14.9
BH CASE
11961
0.6391
88.5
86.7
44
16.7
0.01
1.4
0.53
25.56
8.28
39.02
7.25
13.73
2.51
0.11
1.55
0.05
0
0
0
0.02
1.02
0.43
35.38
10.82
41.32
3.6
5.22
0.71
0.02
1.45
0.01
0
0
0
0.01
0.71
0.39
43.53
16.47
34.01
0.75
0.71
0.07
0
3.35
0
0
0
0
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ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
SOR
METHYLCYCLOHEXANE
11DIMET-CYCLOHEXANE
Total
Yield
LightIsomerate
Freshfeed
NIT CASE
0
0
100
EOR
Sp. Gravity @15C
Estimated RON
Estimated MON
Estimated Yield, wt% (1)
Composition, wt %
PROPANE
IBUTANE
NBUTANE
IPENTANE
NPENTANE
22DMB
23DMB
2METHYLPENTANE
3METHYLPENTANE
NHEXANE
CYCLOPENTANE
METHYCYCLOPENTANE
BENZENE
CYCLOHEXANE
NHEPATANE
METHYLCYCLOHEXANE
11DIMET-CYCLOHEXAN
Total
(1)
Yield
LightIsomerate
Freshfeed
Page 13 of 221
AM CASE
0
0
100
BH CASE
0
0
100
NIT CASE
AM CASE
BH CASE
18377
0.6448
89.0
88.2
64.3
22292
12575
0.6401
89.4
88.3
78
0.6366
88.5
86.4
44
13.98
15.80
17.3
0.02
1.66
0.44
26.8
8.76
39.05
6.87
1.54
2.16
0.09
1.58
0.03
0
0
0
0
0
100
0.03
1.93
0.66
35.76
10.99
40.11
3.45
4.95
0.67
0.02
1.43
0
0
0
0
0
0
100
0.02
1.65
0.69
47.24
17
29.41
0.33
0.31
0.03
0
3.32
0
0
0
0
0
0
100
flowrate (kg / h)
flowrate (kg / h)
Rev. A
* 100
flowrate ( kg / h)
flowrate (kg / h)
* 100
Heavy Isomerate Product
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
SOR
Sp. Gravity @15C
Composition, wt %
IBUTANE
NBUTANE
IPENTANE
NPENTANE
22DMB
23DMB
2METHYLPENTANE
3METHYLPENTANE
NHEXANE
CYCLOPENTANE
METHYCYCLOPENTANE
BENZENE
CYCLOHEXANE
NHEPATANE
METHYLCYCLOHEXANE
11DIMET-CYCLOHEXAN
Total
Yield
HeavyIsomerate
Freshfeed
EOR
Sp. Gravity @15C
Composition, wt %
IBUTANE
NBUTANE
IPENTANE
NPENTANE
22DMB
23DMB
2METHYLPENTANE
3METHYLPENTANE
Page 14 of 221
NIT CASE
7148
0.7562
26.3
3.31
AM CASE
3791
0.7243
13.9
4.3
BH CASE
13788
0.7402
50.7
4.4
0.28
0.1
0.08
0.01
0
0.02
0.1
0.3
1.63
0
7.61
0
31.63
18.02
23.24
16.97
100
0.34
0.23
0.84
0.07
0.02
0.31
1.7
3.75
16.6
0
8.05
0
21.1
23.52
12.27
11.21
100
0.08
0.1
0.94
0.09
0.03
0.62
2.72
4.32
8.56
0
22.18
0
33.84
11.7
7.56
7.27
100
flowrate ( kg / h)
flowrate (kg / h)
Rev. A
*100 ]
NIT CASE
AM CASE
BH CASE
7669
0.7542
26.8
3.58
3857
14239
0.7252
13.5
4.1
0.7408
49.8
4.2
0.23
0.15
1.43
0.12
0.02
0.02
0.1
0.29
0.35
0.2
0.49
0.04
0.02
0.31
1.77
3.9
0.08
0.08
0.67
0.06
0.04
0.61
2.72
4.37
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
NHEXANE
CYCLOPENTANE
METHYCYCLOPENTANE
BENZENE
CYCLOHEXANE
NHEPATANE
METHYLCYCLOHEXANE
11DIMET-CYCLOHEXAN
Total
1.52
0
6.26
0
27.23
17.61
26.9
18.11
100
Rev. A
Page 15 of 221
17.43
0
7.34
0
17.88
21.85
15.014
13.41
100
8.62
0
21.48
0
28.79
11.33
11.63
9.52
100
LPG Product
LPG is recovered at LPG stripper 73-C-04 draw-off. Estimated flowrates and

compositions are presented hereafter.
SOR
NIT Case
AM case
BH case
LPG normal flowrate kg/h

Composition, wt%
H2
C1
C2
C3
iC4
nC4
C5+
Total
2427
2320
1930
0
0.03
0.76
28.53
65.33
5.11
0.24
100.00
0.01
0.58
32.72
59.75
6.68
0.24
0
100.00
0.02
0.95
27.68
61.38
9.72
0.25
0
100.00
Specific gravity @15C
0.5448
0.5432
0.5456
Yield estimated, wt % (1)
8.9
8.5
7.1
EOR
NIT Case
AM case
BH Case
LPG normal flowrate kg/h

Composition, wt%
H2
C1
C2
C3
iC4
nC4
iC5
Total
Specific gravity @15C
Yield estimated, wt % (1)
2794
2566
2283
0
0.02
0.68
27.31
65.71
6.03
0.25
100
0.5459
9.8
0
0.01
0.59
33
60.38
5.77
0.25
100
0.5429
9.0
0
0.02
0.95
27.46
62.69
8.63
0.24
100
0.5455
8.0
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Yield
(1)
Note:
LPG
flowrate ( kg / h)
NHDT Feed
flowrate ( kg / h)
Rev. A
Page 16 of 221
* 100
LPG flowrates described here above take into account the LPG stream
coming from reforming unit.
Fuel gas
Fuel gas is recovered at caustic scrubber 73-V-11. Estimated flowrates and compositions
are presented hereafter:
SOR
Off gas normal flowrate
(kg/h)
Composition, mol %
H2
C1
C2
C3
iC4
nC4
C5+
H2O
Total
Molecular Weight
EOR
Off gas normal flowrate
(kg/h)
Composition, mol %
H2
C1
C2
C3
iC4
nC4
C5+
H2O
Total
Molecular Weight
NIT Case
AM Case
BH Case
285
261
590
83.49
6.89
5.22
3.37
0.3
0.03
0.7
0
100
6.7
86.33
5.14
3.88
3.43
0.27
0.07
0.88
0
100
6.2
69.06
11.39
9.78
7.43
0.78
0.08
1.48
0
100
11.2
NIT Case
AM Case
BH Case
312
292
647
82.9
6.97
5.31
3.65
0.32
0.05
0.8
0
100
6.9
85.46
5.27
3.95
4.03
0.33
0.06
0.9
0
100
6.5
68.19
11.49
9.76
8.03
0.98
0.07
1.48
0
100
11.6
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ISOMERISATION UNIT,
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2.7
Rev. A
Page 17 of 221
BATTERY LIMIT CONDITIONS

Temperature
Pressure
Kg/cm2 g
Feedstock :
o
Light Naphta feed
40
7.0
H2 make-up
40
22.0
H2 for start-up
45
20.0
10% caustic soda
40
3.0
Products :
2.8
LPG
40
16.0
Light Isomerate
40
7.0
Heavy Isomerate
40
7.0
Sweet Fuel gas
40
4.5
Spent caustic soda
45
6.0
UTILITY CONDITION
UTILITY CONDITION AT UNIT BATTERY LIMIT
(All battery limit pressures are measured at grade)
Sr. No.
Minimum (for
Parameter
thermal design)
Normal
Maximum
Mech.
Design
HIGH PRESSURE STEAM

2
Pressure, Kg/cm g
33
35
38
40
Temperature, oC
340
360
380
400
MEDIUM PRESSURE STEAM

Pressure, Kg/cm2g
Temperature, oC
10
11
12.5
Satd
250
280
300
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ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Sr. No.
Minimum (for
Parameter
thermal design)
Rev. A
Page 18 of 221
Normal
Maximum
Mech.
Design
LOW PRESSURE STEAM

2
Pressure, Kg/cm g
2.5
3.0
4.0
5.5
Temperature, oC
Satd
150
170
190
STEAM CONDENSATE
Pressure, Kg/cm2g
--
5.5
--
10
Temperature, oC
--
100
--
185
COOLING WATER SUPPLY

Pressure, Kg/cm2g
--
5.3
--
7.6
Temperature, oC
--
33
--
65
COOLING WATER RETURN

Pressure, Kg/cm2g
--
3.5
--
7.6
Temperature, oC
--
44
--
65
BOILER FEED WATER ( VHP )

Pressure, Kg/cm2g
47
50
--
71
Temperature, oC
120
120
--
120
BOILER FEED WATER ( MP )

Pressure, Kg/cm2g
Temperature, oC
17.5
20.5
--
29
120
120
--
120
DEMINERALIZED WATER
Pressure, Kg/cm2g
--
3.0
--
9.0
Temperature, oC
--
Ambient
--
65
10
PLANT AIR
Pressure, Kg/cm2g
3.0
4.0
5.0
9.0
Temperature, oC
--
Ambient
--
65
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ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Sr. No.
Minimum (for
Parameter
thermal design)
11
Normal
Rev. A
Page 19 of 221
Maximum
Mech.
Design
INSTRUMENT AIR
2
Pressure, Kg/cm g
4.0
5.0
6.0
9.0
Temperature, oC
--
Ambient
--
65
12
NITROGEN
2
Pressure, Kg/cm g
5.0
6.0
7.0
10.5
Temperature, oC
--
Ambient
--
65
13
FUEL OIL SUPPLY

Pressure, Kg/cm2g
Temperature, oC
14
11
17
100
130
170
200
FUEL OIL RETURN

Pressure, Kg/cm2g
2.5
--
--
--
Temperature, oC
--
--
--
--
15
FUEL GAS
Pressure, Kg/cm2g
2.5
3.0
3.5
9.0
Temperature,
30
40-50
60
100
16
FLARE HEADER
Super imposed
back pressure at
B/L(kg/cm2g)
Built up
back pr.
(kg/cm2g)
Total
back
pressure at PSV
--
0.1
--
--
--
1.5
--
--
--
1.7
--
--
outlet(kg/cm2g)
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 20 of 221
SECTION-3
CHEMISTRY OF THE PROCESS
3.1
INTRODUCTION
The main purpose of this process is to saturate benzene and to isomerise normal
paraffins to improve the research and motor octane number of the light naphtha feed
(predominantly C5/C6) before blending into gasoline pool. The light naphtha fraction is
typically high in normal isomer content resulting in a low octane number
(typically<68).The isomerization process converts an equilibrium proportion of these
low octane normal isomers into their higher octane branched isomers. In addition the
LPG recovery section allows separating light products (H2, C1, C2) from C3+ either from
isomerization or reformer stabiliser column.
This process consists of three fixed bed adiabatic reactors, with benzene saturation
carried out in the first reactor, and C 5/C6 isomerization reactions completed in the
following two reactors. The isomerization reactions are carried over a fixed chlorinated
catalyst bed in a hydrogen environment. Operating conditions are not severe as reflected
by moderate operating pressure, low temperature, low hydrogen partial pressure and
high catalyst space velocity. These operating conditions promote the isomerization
reaction, minimize hydrocracking and minimize equipment capital costs.
General process variables will be presented and discussed first and process performance
will then be discussed with respect to these variables. Finally, the Isomar kinetic model
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Rev. A
Page 21 of 221
will be discussed. This model helps to define the operation of the unit and provides
insight into monitoring and adjusting plant operation.
3.2
ISOMER REACTIONS
The isomerization reactions are carried out in two steps:
1st step: Hydrogenation of benzene.
2nd step: Isomerization of normal paraffins
3.2.1
Hydrogenation of benzene:
This reaction is highly exothermic and occurs in a separate reactor, namely the
Benzene Saturation Reactor. This allows carrying out the isomerization reactions
separately at lower temperatures in the downstream isomerization reactors.
C6H6 + 3H2 C6H12
3.2.2
Isomerization:
Isomerization is the conversion or rearrangement of the structure of a compound

to its more branched, higher octane structure. These rearrangements are depicted
by the following formula:
CH3
CH3 - CH2 - CH2 - CH2 - CH3
n-pentane
(RON = 62)
CH3 - CH - CH2 - CH3

isopentane
(RON = 93)
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VRCFP, HPCL VISAKH
Rev. A
Page 22 of 221
CH3 - CH - CH2 - CH2 - CH3
CH3 - CH2 - CH2 - CH2 - CH2 - CH3
CH3
n-hexane
(RON = 30)
2 methylpentane
(RON = 74 )
CH3 - CH2 - CH - CH2 - CH3

CH3
3 methylpentane
(RON = 75 )
CH3
CH3 - C - CH2 - CH3

CH3
2,2 dimethylbutane
(RON = 92)
CH3
CH3 - CH - CH - CH3
CH3
2,3 dimethylbutane
(RON = 104)
These reactions, as shown, are reversible and the final distribution of the isomers is
based on the equilibrium composition which is dictated by the reactor process conditions
and kinetics.
In addition to the isomerization reactions, there are other side reactions taking place as
well, and some of them are not desirable.
3.2.3
Naphthene Ring Opening :
The three naphthene, which are typically, present in an isomerization feed are
cyclopentane (CP), methyl cyclopentane (MCP) and cyclohexane (CH). These
naphthenic rings break and hydrogenate to form paraffins. Ring opening reactions
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Rev. A
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increase with increasing temperature and again are governed by equilibrium

compositions at the reactor process conditions. At typical isomerization reactor
conditions the conversion of naphthene rings to paraffins will be approximately
20-30 percent.
+ H2
C5 H12
C5H10
(cyclopentane)
+ H2
C6 H14
C6H12
(cyclohexane)
CH3
+ H2
C6 H14
C6H12
(methyl cyclopentane)
Naphthenic or cyclic components tend to inhibit the isomerization reactions and are
therefore undesirable in large quantities. The cyclic components are absorbed on the
catalyst and reduce the active sites available for paraffin isomerization. They also
consume hydrogen, produce exothermic heat which is undesirable from the
isomerization equilibrium standpoint. However undesirable as they are, they are a
natural fraction of C5/C6 cut naphtha and are difficult to eliminate without also
eliminating other desirable components.

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
3.2.4
Doc No. Draft

Rev. A
Page 24 of 221
Hydrocracking
Operating at the low severity reactor conditions, very little C5/C6 hydrocracking occurs
in the isomerization reactors. C7 paraffins however hydrocrack readily to produce C3 and
C4 components. Much of the hydrocracking occurs in the first reactor which typically
operates at a higher temperature. Hydrocracking reactions consume hydrogen, and hence
it is recommended to restrict the C7+ content of the isomerization feedstock.
C7 H16 + H2
3.3
C3 H8 + C4 H10
ISOMAR CATALYST
There are several reaction mechanism theories presented based on the type of catalyst
used, i.e. whether it is a dual functional catalyst consisting of a metal and a support or if
its acidity is enhanced by a halogen. Whatever the type of catalyst used the intermediate
step is the same i.e., the formation of a carbonium -ion.
Isomerization on dual-function catalysts in a hydrogen atmosphere is generally
described by the following reaction scheme:
Pt
CH3 - CH2 - CH2 - CH2 - CH3
CH3 - CH2 - CH2 - CH = CH2 + H2
The metallic function of the catalyst, in this case platinum, catalyses the formation of an
olefin intermediate by dehydrogenation of the paraffin. The olefins are then converted
into carbonium ions by the addition of a proton during adsorption onto the acidic surface
of the catalyst.
+H+
CH3 - CH2 - CH2 - CH = CH2
CH3 - CH2 - CH2 - CH - CH3
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Rev. A
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Skeletal rearrangement then occurs:

C
CH3 - CH2 - CH2 - CH - CH3
CH3 - CH2 - C - CH3
The rearranged carbonium ion is then desorbed as an iso-olefin which is then

hydrogenated by the catalyst metallic function to the iso-paraffin:
C
CH3 - CH2 - C - CH3
CH3 - CH2 - C = CH2 + H
C
Pt
CH3 - CH2 - C = CH2 + H2
CH3 - CH2 - CH - CH3
Dual-functional hydro-isomerization catalysts which operate at very low temperature

have stronger acid sites than those which require higher temperatures. In this case, the
theory postulates that the carbonium ion is formed by direct hydride ion abstraction from
the paraffin by the acid function of the catalyst.

CH3 - CH2 - CH2 - CH2 - CH3 + H A
CH3 - CH - CH2 - CH2 - CH3 + H2 + A
After rearrangement, isopentane is formed and the chain is propagated by the generation
of a new acid site.
CH3
CH3 - C - CH2 - CH3 + A
CH3
+ H2

CH3 - CH - CH2 - CH3 + H A
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Another principal theory of initiation and propagation is that based on the Friedel-Crafts
theory. Friedel-Crafts isomerization is believed to require the presence of traces of
olefins or alkyl halides as carbonium ion initiators with the reaction thereafter
proceeding through chain propagation. The initiator ion, which needs to be present only
in small amounts, may be formed by the addition of HCl to an olefin which is present as
an impurity in the paraffin or is formed by paraffin hydrocracking.
RCH = CH2 + HCl
R CH CH3 + Cl
The initiator then forms a carbonium ion with the paraffin to be isomerized.
R CH CH3 + CH3 - CH2 - CH2 - CH2 - CH3
R CH2 CH3 + CH3 - CH - CH2 - CH2 - CH3
After skeletal rearrangement, isopentane is formed and the chain is propagated by the
generation of a new normal carbonium ion.
C
CH3-C-CH2-CH3 + CH3-CH2-CH2-CH2-CH3 CH3-CH-CH2-CH3 + CH3-CH-CH2-CH2-CH3
3.4
CATALYST CONTAMINANTS
The contaminants and poisons for this catalyst are mainly sulfur, mercury and free water.
Table below shows the maximum allowable limit of impurities for feed and hydrogen
make-up gas.
The isomerization unit feed is dried and hydrotreated prior to contact with the
isomerization catalyst IS-614 A. These operations eliminate or reduce to an acceptable
level the contaminants naturally present in the feedstocks. However, it is possible that
upstream unit upsets or misoperation could lead to a contaminant breakthrough. The
following discusses their impact on the process.
a) Sulfur:
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Rev. A
Page 27 of 221
The presence of sulfur in the feed or make-up hydrogen will immediately decrease the
activity of the catalyst. Sulfur reacts with the platinum to form platinum sulfide, and this
reduces the metallic function of the catalyst affecting the hydrogen transfer mechanism.
This decrease in activity is temporary and recovery is normally rapid once the sulfur has
been removed. However, an increase in reactor temperature and a higher make-up
hydrogen rate will assist in purging the sulfur from the catalyst more rapidly. While
sulfur is present in the feed, an increase in temperature may help to partially compensate
for the reduced catalyst activity.
b) Water / Oxygenates:
The deactivation which results from water or other oxygenates breakthrough is
permanent. The oxygenated compounds react chemically with the active chloride on the
catalyst, which is chemically bound into the alumina structure during manufacture. The
water, once it reacts with the catalyst is chemically bound as hydroxyl to the alumina
and the chloride is removed as HCl. Approximately one kilogram of oxygen in any form
will deactivate 100 kg of catalyst. If breakthrough occurs, the catalyst deactivation will
occur in a piston-like fashion moving down the first catalyst bed. In addition to the loss
of product quality, a clear sign is the lack of reactor T in the top portion of bed and this
inactivity slowly moving down the bed. Once the catalyst is deactivated, it must be
removed for platinum recovery and replaced with fresh catalyst.
c) Nitrogen Compounds:
This refers to organic nitrogen or ammonia, not to molecular nitrogen N 2. Nitrogen
compounds react to form ammonia which in turn reacts with the chloride in the catalyst
or the HCl to form ammonium chloride salt. This leads to a permanent deactivation of
the catalyst by a coating of the catalyst active sites, loss of chloride and possibly
inactivity due to maldistribution from salt deposits.
d) Fluoride Compounds:
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Rev. A
Page 28 of 221
This is also a permanent catalyst poison caused by the fluoride bonding to catalyst active
sites affecting the catalyst acidity. Again one kilogram of fluoride will deactivate
100 kilograms of catalyst.
Maximum Allowable Contaminant Levels in
a) Hydrogen Make-up :
Contaminants
Total Sulfur
Water
CO + CO2
Olefins
Chloride
Total Nitrogen
(1) At hydrogen dryer outlet
(by wt)
1 ppm wt. Max.
0.5 ppm wt. Max. (1)
10 ppm wt. Max.
10 mol wt max.
5 ppm wt. Max.
1 wt ppm max.
Maximum Allowable Contaminant Levels in

b) Light Naphtha Feed:
Contaminants
Total Sulfur
Water + oxygenates
Metals
Olefins
Chloride
Arsenic
Total Nitrogen
(1) At the outlet of the feed dryer
(by wt)
0.5 ppm max (1)
0.1 ppm max. (1)
5 wt ppb max.
1% wt max
1 ppm wt max
1 ppb wt max
0.1 ppm max (1)
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SECTION-4
PROCESS DESCRIPTION
4.1
ISOMERIZATION UNIT PROCESS SYSTEM:
Isomerization of the light hydrotreated naphtha is carried out in a series of two fixed bed
reactors. As benzene content in feed is high and benzene hydrogenation reaction is
highly exothermic, benzene hydrogenation takes places in a separate fixed bed reactor,
installed upstream of the two isomerization reactors. In order to limit the temperature
increase across the hydrogenation reactor, part of the effluent is cooled and recycled to
dilute the reactor.
Isomerization is the conversion of hydrocarbons to their isomers, which have the same
molecular formula but a different arrangement of molecules. The C 5 /C6 Isomerization
Section specifically converts the normal C5 / C6 paraffins to their isomers, i.e. to a higher
octane branched arrangement, over a proprietary platinum catalyst in the presence of
hydrogen. The conversion per pass of the normal paraffins to their isomers is determined
by the reaction equilibrium at the reactor operating conditions. The low octane methylpentanes and the unconverted n-hexane are recycled back to the isomerization reactors
to achieve the objective to produce light isomerate stream with an estimated minimum
octane no. of 88.5 in order to meet gasoline pool constraints.
A stabilizer column is used for removing light ends from the reactor effluent. Stabilizer
bottom is routed to deisohexaniser column via chloride guard bed.
A Deisohexaniser tower is used for recovering stabilized isomerate product and
recycling the low octane methyl-pentanes and the unconverted n-hexane to the reactor.
The Deisohexaniser distillate goes as light isomerate to MS Pool via storage and
bottoms streams is pumped to LPG recovery section, where it is used as lean oil makeup.
The stabilizer reflux drum off gas contains LPG, hydrogen and chloride which is sent to
the LPG recovery unit. The chloride is removed by scrubbing with caustic soda in
Caustic Scrubber.

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Doc No. Draft

Rev. A
Page 30 of 221
The unit consists of the following sections:

- Dryer Section
- Hydrogenation Section
- Isomerisation Section
- Stabilizer Section
- Deisohexaniser
- Scrubber Section
- LPG Recovery Section
- Dryer Regeneration
- Chloride Injection Facility
Chemical reactions in Isomerization Section
There are principally two fundamental reactions occurring:-
Benzene hydrogenation
Isomerization
The first reaction is highly exothermic. In order to monitor the isomerization

temperature, the benzene hydrogenation takes place in the hydrogenation reactor 73-R01.
The second reaction is the isomerization reaction itself and it occurs in the two last
reactors 73-R-01 & 73-R-02.
Benzene hydrogenation:
Benzene and hydrogen react to form cyclohexane.
C6H6 + 3H2 C6H12
This reaction takes place in the superior part of the first reactor 73-R-01. Benzene
hydrogenation is an exothermic reaction (16660 kcal/kmole of consumed hydrogen).
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VRCFP, HPCL VISAKH
Rev. A
Page 31 of 221
Isomerization
Isomerization is the conversion of hydrocarbons to their isomers, which have the same
molecular formula but a different arrangement of molecules. C 5 /C6 Isomerization
section specifically converts normal C5 / C6 paraffins to their isomers, i.e. to a higher
octane branched arrangement, over a proprietary platinum catalyst in presence of
hydrogen. The conversion of normal paraffins to their isomers is determined by the
reaction equilibrium at reactor operating conditions.
The term isomer refers to compound which have the same molecular formula but
different structural formula or a different arrangement of molecules. In general any
compounds that are linear or straight chain are termed normals, if they are in a
different arrangement, i.e. branched, they are termed isomers.
Examples:
n-pentane C5 H12:
Pentane has five carbon atoms. When in a straight chain as shown, this is called normal
pentane or n-pentane. The Research Octane Number (RON) of n-pentane is 62.
i-pentane C5 H12:
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
H
H
H
H
Rev. A
Page 32 of 221
This is isopentane, one of the isomers of n-pentane; it has the same molecular formula
but a different arrangement or structure. Isopentane or i-pentane has a Research Octane
Number (RON) of approximately 93.
Isomerization is simply the conversion of compounds to their isomer, i.e., to a higher
octane branched arrangement.
Similarly with hexane:
n-hexane C6 H14:
H
H
Hexane has six carbon atoms. When in a straight chain as shown, this is called normal
hexane or n-hexane. The Research Octane Number (RON) of n-hexane is 30.
i-hexane C6 H14:
H
H
H
H
H
H
H
H

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Doc No. Draft

Rev. A
Page 33 of 221
This is isohexane, one of the isomers of n-hexane; again it has the same molecular
formula but a different arrangement or structure. This is called 2,2 Dimethylbutane
(2,2,DMB) and has a Research Octane Number (RON) of approximately 92.
Not all n-pentane and n-hexane will convert to their isomer but a certain percentage or
equilibrium amount will exist at given operating conditions. This is then the measure of
the performance of an Isomerization unit, i.e. the percentage of the isomer in the reactor
effluent.
The conversion of n-pentane to isopentane and n-hexane to 2,2,DMB are only two of the
many reactions occurring simultaneously in the Isomerization process. These reactions
take place in the 73-R-02 and 73-R-03 reactors.
4.2
PROCESS DESCRIPTION
4.2.1. Dryer section

The hydrotreated naphtha is fed to the feed surge drum
73-V-01. Then it is pumped by
pumps 73-P-01 A/B under flow control to the two feed dryers 73-DR-01 A/B in series.
The feed dryers protect the isomerization catalyst from irreversible damage with water,
which is extremely poisonous to the reactor catalyst.
The make-up hydrogen gas from CCR unit also needs to be dried for the same reason.
Hydrogen from the CCR unit goes through make-up H 2 K.O. drum 73-V-02. It is
compressed to the desired pressure level by compressors 73-K-01 A/B and cooled in
exchanger 73-E-01 A/B (one spare cooler is required due to frequent maintenance on
cooling water side). A part of the cooled gas is sent to the Prime G+: HDS section and
SHU section (unit 75). Hydrogen to Isomerization section is sent to dryers 73-DR-02
A/B in series, under flow control; excess hydrogen is routed to the flow control valve on
H2 compressor recycle (73-K-01 A/B). Set point of flow controller is reset by flow
controller on the feed to the isomerization reactor. Remaining dried hydrogen is mixed
with dried Naphtha under flow control and sent to the benzene hydrogenation section.
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Set point of this flow controller is adjusted manually, according to the benzene
composition of the feed, as indicated by on line analyzer.
Remark: Isomerization section cannot be fed directly by hydrotreated naphtha from a
storage tank.
4.2.2. Hydrogenation Section
The combined two phase feed from the dryer section is preheated in Deisohexanizer
recycle/ Reactors feed exchanger 73-E-02 and in first stage reactor feed/effluent
exchanger 73-E-03. It is mixed with the diluent recycle from hydrogenation reactor and
further heated by HP Steam, if required, in hydrogenation reactor feed heater 73-E-04 to
the reaction temperature.
Feed enters the hydrogenation reactor 73-R-01, where benzene is hydrogenated to
cyclohexane. The hydrogenation reaction is highly exothermic.
The reactor effluent is routed to hydrogenation reactor flash drum 73-V-04. Operating
pressure leads to an almost liquid phase at the hydrogenation reactor effluent.
Thermodynamic model heat and material balances define reactor outlet as fully liquid,
but some vapor phase could be present.
The pressure of vessel 73-V-04 is controlled by split range controller, with an injection
of dry hydrogen to pressurize the drum and a vent line routed to the stabilizer.
A major part of the liquid from 73-V-04 is pumped via recycle pumps hydrogenation
reactor recycle pumps 73-P-03A/B under flow control and used as feed diluent. The
other part is pumped, under flow control; by isomerization reactor feed pumps 73-P-04
A/B to first stage isomerization reactor
73-R-02.
In case of high benzene content in feed, a part of diluent is cooled in reactor recycle air
cooler 73-A-01, while remaining goes through the air cooler by-pass line, in order to
allow the control of the isomerization reactor inlet temperature (and consequently of the
hydrogenation reactor). An additional pitch fan control is used for higher temperature
rise in benzene saturation reactor.

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Doc No. Draft

Rev. A
Page 35 of 221
In case of low benzene content in feed, the temperature is controlled via HP steam of the
73-E-04 (air cooler is not required and is fully bypassed).
Diluent recycle is the key factor to control the temperature of the hydrogenation reactor.
Indeed, the rate of diluent recycle controls the reactor temperature gradient, while the
level of cooling on the diluent recycle controls the reactor inlet temperature.
The rate of diluent recycle must be adjusted by operator in order not to exceed 35C of
exothermicity in the hydrogenation reactor.
4.2.3. Isomerization Section
The isomerization reactors feed from flash drum is fed under flow control and mixed
with hydrogen under ratio flow control.
A small amount of chloriding agent is continuously injected into isomerization reactor
feed, by pump 73-P-02 A/B, in order to maintain the chloride balance on the
isomerization catalyst. This is a make-up for catalyst chloride, which is lost in reactor
effluent.
The mixture is routed to a static mixer 73-M-01 (homogenous mixing) before entering
the first stage isomerization reactor 73-R-02, where isomerization reactions occur. These
reactions are slightly exothermic. The reactor effluent, that leaves the first isomerization
reactor, has to be cooled before entering the second stage isomerization reactor 73-R-03.
Temperature of the second isomerization reactor inlet is controlled by first stage
isomerization reactor feed / effluent exchanger 73-E-03 bypass. In 73-R-03, remaining
isomerization reactions occur.
Both 1st and 2nd stage isomerization reactors are mixed phase, down-flow reactors, with a
single catalyst bed. The isomerization reactors are designed to operate in the lead/tail
position or in a single reactor configuration.
The reactor circuit inlet pressure is controlled using a back pressure controller located on
the reactor effluent stream, routed to the stabilizer 73-C-01. The temperature profile in
each of the reactors is monitored with multiple temperature indicators located across the
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catalyst bed. The differential temperature between adjacent thermocouples is a measure

of the extent of reaction, while also indicating the reactive zone of the catalyst bed.
The effluent is then routed to the stabilizer 73-C-01 under pressure control.
4.2.4. Stabilizer Section
The raw isomerate is received in the stabilizer column
73-C-01 under pressure control.
The purpose of the stabilizer is to reduce C 4- rate in the isomerization reactor effluent.
LPG, H2 and HCl are stripped and sent to LPG recovery section. The Stabilizer
operating pressure is optimized to strip out the C 4 components from the reactor effluent,
while minimizing the C5 hydrocarbon vent losses and reducing the C4 content of the
Isomerate product.
The stabilizer overhead is partially cooled in stabilizer air condenser 73-A-02. It is
collected in the stabilizer reflux drum 73-V-05 where the vapor phase is routed under
pressure control to the scrubber while the liquid is pumped by pump 73-P-05 A/B under
flow control with level reset to the stabilizer as reflux.
Stabilizer bottoms are reboiled with high pressure steam in exchanger 73-E-05. Reboiler
duty is under temperature control at the sensitive tray of the column. The temperature
control is cascaded with the flow control on low pressure condensate.
Stabilizers bottom is routed to deisohexaniser column
73-C-02 under flow control
cascaded with the level control on the column bottom, via a chloride guard bed 73-V-06.
This guard bed prevents any chloride component in the deisohexaniser section during
upset.
4.2.5. Deisohexaniser
Deisohexaniser (called DIH) 73-C-02 is fed with stabilizer bottom which preheat the
DIH pump around through DIH feed/recycle exchanger 73-E-07. Deisohexaniser
recovers stabilized isomerate product and recycles low octane methyl-pentanes and nhexane to the reactors. This is done via the DIH recycle drum 73-V-07, which is fed on
level control. Recycle is pumped, by pump 73-P-07 A/B as a recycle to the reactor
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VRCFP, HPCL VISAKH
Rev. A
Page 37 of 221
section after being cooled successively in the deisohexaniser recycle/reactor feed

exchanger 73-E-02 and recycle trim cooler 73-E-08.
Remaining liquid from 73-P-07 A/B is fully vaporized by heat exchange with DIH feed
in 73-E-07, and is recycled to the DIH column, in order to reduce the heat load required
for reboiling of the column.
Overhead vapor of the column is totally condensed through deisohexaniser air condenser
73-A-03 and is routed to the deisohexaniser reflux drum 73-V-08. Reflux is pumped by
deisohexaniser reflux pump 73-P-06 A/B under flow control. Isomerate product is
pumped, under flow control reset by 73-V-08 level control, by pumps 73-P-09 A/B and
is further cooled in sea water cooler 73-E-09 and routed to storage.
The Deisohexaniser reflux drum pressure is controlled by split range pressure controller
at column overhead.
Deisohexaniser bottom is reboiled by medium pressure steam in exchanger 73-E-10.
Steam flow controller to the reboiler is reset by temperature control at the sensitive tray
of the column.
The bottom stream is concentrated in C7+ and C6 Naphthenes. It is pumped by
Deisohexaniser bottoms pumps 73-P-08 A/B to the LPG recovery section, where it is
used as lean oil make-up. The lean oil is under flow control cascaded by the column
level control.
4.2.6. LPG Recovery Section
The purpose of this section is to optimize LPG recovery from the stabilizer off gas, by
using of DIH bottom stream as lean oil.
The dry off gas is mixed with the recycle gas from LPG stripper reflux drum 73-V-12.
This stream is contacted with cold lean oil from LPG separator drum 73-V-11. The two
phase stream is further cooled LPG refrigeration system 73-E-13B exchanger and fed to
the LPG separator drum, in which gas phase and liquid phase are separated. The gas
phase is send to a packed zone, located in upper section of drum, for counter current
contacting with the cold lean oil, in order to maximize LPG recovery.
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Off gas from this section is sent, under pressure control, to Fuel Gas.
The rich oil containing the absorbed LPG is pump from the cold separator drum through
73-P-14 A/B, underflow control cascaded with level control of separator drum 73-V-11,
to stripper 73-C-04. The stripper feed is preheated through heat exchangers 73-E-14 and
73-E-15, in order to optimize the recovery.
LPG stripper reboiler with HP steam as in 73-E-17 allows recovering the LPG product
which is produced as side stream liquid draw-off below pasteurization zone. Draw off is
cooled in LPG trim cooler 73-E-18 A/B and pumped by LPG product pumps 73-P-16
A/B to the battery limit. The LPG product is on flow control cascade by column top
temperature control.
Stripper overhead is partially condensed in LPG stripper condenser 73-E-19 A/B. The
stripper off gas is recycled and mixed with the dry scrubber off gas. The stripper
overhead is under pressure control.
The stripper bottoms stream is routed, under flow control cascade with the level control,
to feed/bottom heat exchangers of LPG stripper via 73-P-15 A/B. then lean oil is
combined with DIH bottom stream. The mixture is cooled down through LPG stripper
feed/bottom exchanger 73-E-15 and through water cooler 73-E-16 A/B. Part of this
stream is sent to export via storage. The other part is fresh lean oil (to be cooled down
before absorption of LPG) and is recycled to packed zone of the LPG separator drum.
Reboiler duty is under temperature control at the sensitivity tray of column.
In case LPG recovery is in shut down, facility is provided to by-pass completely this
section and route scrubber off gas directly to Fuel gas or to flare.
4.2.7. Scrubber Section
As the gas from stabilizer overhead contains HCl, it must be caustic treated and water
washed before released to LPG recovery section. Off gas enters the bottom of the caustic
scrubber 73-C-03 through hold-up and is first caustic washed, in a first packed bed.
Then off gas, saturated by caustic, is water washed in second packed bed before being
routed to scrubber off gas dryer. Caustic weight fraction varies from 10% wt to 2% wt as
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it reacts with HCl to produce NaCl. The caustic is re-circulated by 73-P-11 A/B and is
maintained at the 55 oC through the caustic recycle heater 73-E-12, in order to keep the
caustic a few degrees warmer than the feed gas to avoid potential foaming problems due
to any hydrocarbon condensation.
Both the scrubber section are packed with raschig rings. The caustic inventory
requirement is stored in the tower bottom section and feed gas is bubbled through this
caustic inventory. A portion of the circulating caustic is sprayed on to the column walls
below the caustic wash packed section to avoid any wet hydrogen chloride corrosion in
this part of the scrubber.
When the concentration of circulating caustic has been decreased to about 2% wt, the
caustic inventory is drained through pump 73-P-11 A/B discharge and tower bottom is
filled up with 10% wt fresh caustic. Spent caustic is sent to the spent caustic system.
Fresh 10% wt is made up through pumps 73-P-10 A/B.
The gas leaving the caustic wash section is washed with water in the top packed section,
to remove any entrained caustic. Water is collected in the chimney tray below the water
wash packed section, and is circulated using the pumps 73-P-13 A/B. water loss to the
vent gas leaving the scrubber is made-up periodically by fresh de-mineralized water
addition (via pump 73-P-12 A/B and de-mineralized water drum 73-V-10), and once
every several days the water inventory is drained and replaced.
4.2.8. Dryers regeneration:
Naphtha feed, H2 make up and scrubber off gas flow through their respective dryers in
series. Molecular sieve becomes saturated after a certain period of time. Then they need
regeneration. The on line moisture analyzer is used to monitor the moisture content of
the streams leaving each dryer.
The feed dryers (73-DR-01 A/B), the Hydrogen dryers(73-DR-02 A/B) and the scrubber
off gas dryers are regenerated using vaporized deisohexaniser distillate product (from
73-P-09 A/B) as regenerant medium to remove down-flow the water trapped by the
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VRCFP, HPCL VISAKH
Rev. A
Page 40 of 221
molecular sieves. The concerned dryer is isolated from the other one which is still in
service.
This regenerant is completely vaporized by high pressure steam in dryers regenerant
vaporizer 73-E-20. Liquid level in the vaporizer is monitored closely to avoid liquid
carryover to dryers regeneration superheater 73-F-01 (electrical heater). The steam to the
vaporizer is under flow control and is cascaded to the level control of the vaporizer.
After passing through the dryers, the regenerant stream is cooled down by dryers
regenerant air condenser 73-A-04 and further by dryers regeneration trim cooler 73-E21. This stream is routed via dryers regenerant degasser 73-V-13 to isomerate storage.
The Regenerant Degasser is a liquid flooded drum, releasing the effluent regenerant
liquid on pressure control for mixing with the isomerate product. Any light components
which accumulate in the Regenerant Degasser are purged to flare as required through a
liquid level controller, which maintains a low liquid level at the very top of the drum.
Free water collected at the bottom of the Regenerant Degasser is periodically drained to
oily water sewer.
4.3
CHLORIDE INJECTION FACILITIES
Tetra-chloro-ethylene, C2Cl4 is the recommended chloriding agent which is injected

continuously from the chloride agent injection drum (73-V-03) to the Isomerization
reactors by pumps 73-P-02 A/B. This injection corresponds to the make-up for the
amount of chloride loss from the chlorinated platinum catalyst. C2Cl4 is fully converted
to HCl at reactor normal operating conditions. Hence chloride lost in the reactor effluent
is HCl form, which is finally converted into NaCl in the caustic scrubber.
4.4
UTILITY SYSTEM
The utility system consists of HP steam, MP steam, LP Steam, Condensate, Service Water,
Cooling Water, Bearing Cooling Water, Instrument Air, Plant Air, Nitrogen, Fuel Gas, etc.
Closed Blow Down (CBD), Flare is also provided within the unit.
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Rev. A
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4.4.1. HP Steam System

An 8 High pressure steam header has been provided for ISOM unit.
HP steam is distributed to the following equipment of the ISOM unit.
-
Hydrogenation reactor feed heater 73-E-04
Stabilizer reboiler 73-E-05
LPG stripper reboiler 73-E-17
Dryer regenerant vaporiser 73-E-20
4.4.2. MP Steam System

A 10 header supplies MP steam to the ISOM unit.
Use of MP steam in ISOM unit is mainly as follows:
-
Deisohexaniser reboiler 73-E-10
Start-up ejector 73-J-01
4.4.3.
LP Steam System
A 4 header supplies LP steam to the ISOM unit. Mainly use of LP steam in ISOM unit is
as follows:
-
Utility hose station
Feed Surge drum 73-V-01
Chloriding agent injection drum 73-V-03
Compressor 73-K-01 A/B
DIH Recycle drum 73-V-07
Deisohexaniser 73-C-02
Refrigeration package 73-LC-01
LPG stripper 73-C-04
LPG stripper reflux drum 73-V-12

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
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4.4.4. Cooling Water System

The cooling water requirement for cooling purpose in the ISOM unit is met through sea
cooling water system. A 20 cooling water supply header supplies water to ISOM unit.
Cooling water from the supply header is taken to the following equipment in ISOM unit.
-
Compressor 73-K-01 A/B
LPG trim coolers 73-E-18 A/B
Make up H2 trim cooler 73-E-01 A/B
Lean oil trim coolers 73-E-16 A/B
To sample points
To analysers
Isomerate trim coolers 73-E-09 A/B
Recycle trim coolers 73-E-08 A/B
Stabilizer trim cooler 73-E-06 A/B
Dryers regeneration trim cooler 73-E-21 A/B
The return water is collected from all the equipments through cooling water return header
and sent to B/L.
Cooling water regularly PH, Chlorine, turbidity and conductivity to be monitored regularly.
In this PH and chlorine are most important parameters. Due to this, chances of exchanger
shell or tube damage increases.
4.4.5. Bearing Cooling Water System
Bearing cooling water is required for pump and compressor cooling purpose. A 4 bearing
cooling water supply header supplies water to ISOM unit. Bearing Cooling water from the
supply header is taken to the pumps and compressors.
The return bearing cooling water is collected in a 4 return header and sent to B/L.

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
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4.4.6. Service Water System

The 3 common service water header supplies service water to the ISOM unit. The service
water header supplies water to various hose stations and chloriding agent injection pump
73-P-02 A/B, to prevent any spillage, in the units. Service water is required mainly for
cleaning and washing.
4.4.7. Instrument Air System
A 2 Instrument Air header supplies IA to ISOM unit. Apart from instrument air tapping
instrument air is supplied to the following facilities.
-
Hydrogen Compressor 73-K-01 A/B
Refrigeration package 73-LC-01
Instrument air Dew point (-400 C) is to be monitored regularly. If moisture is more then it
will create problems in control valves (mainly scaling).
4.4.8. Plant Air System
A 3 plant air header supplies plant air to the ISOM unit. Plant air is required for the hose
stations, Anhydrous HCL bottle, Refrigeration package etc.
4.4.9. Nitrogen
A 3 header supplies N2 to the ISOM unit. N2 is used for various purposes in equipment,
line etc. for inertisation, blanketing, purging etc. In addition to that following permanent
connections are provided for N2 in the ISOM unit.
-
Hydrogen make up compressor (73-K-01 A/B)
Isomerisation feed surge drum (73-V-01)
Close Blow Down system (73-V-16)
Stabiliser bottom chloride guard bed(73-V-06)
Deisohexaniser reflux drum (73-V-08)
Stabiliser (73-C-01)
Stabiliser reflux drum( 73-V-05)
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Hydrogenation reactor flush drum (73-V-04)
Isomerization reactors (73-R-02 / 03)
Hydrogenation reactor (73-R-01)
LPG separator drum (73-V-11)
LPG stripper (73-C-04)
ISOM feed dryers (73-DR-01 A/B)
ISOM hydrogen dryers (73-DR-02 A/B)
Scrubber offgas dryer (73-DR-03 A/B)
Dryer regenerant vaporizer (73-E-20)
Anhydrous HCL bottle etc.
Rev. A
Page 44 of 221
Nitrogen purity is to be maintained by controlling oxygen ppm (<0.5). If nitrogen purity is

less then chances of damaging catalyst increases.
4.4.10. Fuel Gas System
FG supply header is of 2 size. Fuel Gas is mainly used for flare header purging and
maintaining the pressure of feed surge drum 73-V-01.
4.4.11. Flare System
Relief line from safety valves, Dry gas seal system of the compressor, Purge gases etc. are
collected in the common 28 common flare header.
4.4.12. Closed Blow-Down System
Drains from various equipments are collected in two nos of Closed Blow-down headers (4
size each) and combined to form 6 header leaving the battery limit.

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
4.5
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WASTE EFFLUENT FROM ISOMERIZATION SECTION
4.5.1. Spent Caustic from Scrubber section:

Spent caustic is one of the effluents leaving the unit, and it is sent to the ETP unit. The
spent caustic is removed from the bottom of the Caustic Scrubber 73-C-03 on an
intermediate basis of estimated at 7 days.
Quantity, Tons/week
Temperature, oC
Water
23
45-50
87.3
Also, a small amount of spent water that is purged periodically from the scrubber water
wash section is combined with the spent caustic. This purge water contains entrained
caustic and dissolved light hydrocarbons.
4.5.2. Oily water:
Normally there is no sour water effluent leaving this unit, as the hydrocarbons and the
hydrogen feed streams contain only traces of water. However the maximum effluent
discharge from Regenerant Degasser is approximately 16 Kg/hr based on the maximum
effluent water content specified for the hydrocarbon feed, H 2 make-up and scrubber off
gas streams.
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SECTION 5
PRE-COMMISSIONING PROCEDURE
5.1
GENERAL
As the new unit nears completion, there is a large amount of preparatory work, which
should be performed by the operating crew. A planned check of the unit will not only set
the foundation of a smooth start-up, but will also provide a firm basis for acquainting
operators with the equipment. Start-up is a critical period and the operator must know
exactly the operation of all equipments.
Some of the pre-commissioning works can be carried out simultaneously along with
construction. But, care in the organisation of this work is necessary so that it will not
interfere with construction work. It is most important to plan schedule and record with
checklists and test schedules all the preliminary operation and to co-ordinate the
construction programme.
5.2
PRE-COMMISSIONING ACTIVITIES
The material in this section gives general guidelines for preparing a unit for start-up.
Some sections need to be expanded to give specific directions (water flushing procedure,
inertising procedure for example); this shall be prepared by commissioning personnel
prior to start of the pre-commissioning/start-up.

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
5.3
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INSPECTION / CHECKING
Sections of the unit should be checked out as soon as the contractor completes work in
those areas. Immediately following inspection of those areas, punch lists which indicate
the deviations from the design specifications should be written and distributed to the
contractor. In this manner mistakes in construction can be found and corrected early.
Inspection of the plant can be basically divided into the following areas:
-
Vessels including reactor
Piping
Heaters
Exchangers
Pumps
Compressors
Instrumentation
Catalyst/Chemical Inventory
Inspection of vessel, column, heaters etc.

Inspection of the interior of the vessels, columns, heaters and other equipments not
normally accessible during operation should be made to ensure that they are complete,
clean and correctly installed. Tray assemblies in columns should be checked with reference
to the engineering drawings to detect any defect in assembly or construction and to ensure
cleanliness. Packings, if any, are to be done after internal inspection and flushing. The
vessels are to be checked with reference to engineering drawings. The demisters are to be
fitted after internal cleaning and water washing.
In heaters, the burner assemblies should be checked for easy operation of air registers,
contour of the burner throat, debris material etc. The heater coils supports to be checked for
proper installation.
a) Piping and Accessories
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Piping and accessories will be checked against drawings and specifications. Piping support
and hangers will be inspected to ensure that all anchorages are firm. Valves will be checked
for proper packing and mounting direction and accessibility for operation and maintenance.
Spring supports, if any, to be checked for the cold setting and later for hot settings while
plant is in operation. Check for completion of welding work, especially on small bore
piping and socket weld valves.
b) Instruments
All instrument tapings for pressure, level and flow should be clear and thermo wells should
not foul with the internals. These should be checked prior to box up of the equipment.
Instruments will be checked, starting from the controller and proceeding logically through
the control loop. Cascade control system will be checked from the impulse point of
primary loop. Operating crew should check proper mounting of control valves. Control
valves responses should be checked for controller outputs. The shutdown systems of the
equipments should be checked by simulating the various conditions in the control circuits.
c) Relief Valves
Relief valves will be set in the shop and mounted before the system pressure test. Block
valves ahead and after relief valves will be checked for lock open or lock close position as
per P&ID. Relief valves will be checked against specifications.
d) Rotary Equipment
All rotary equipment such as pumps, compressors, turbines etc. are to be checked for
bearings, internals and free movement. The auxiliaries, control systems on this equipment
should be thoroughly inspected.
e) Drainage System
Check the OWS and blow down system against drawings. Check for free flow.
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
5.4
Rev. A
Page 49 of 221
PREPARATION FOR PRE-COMMISSIONING

-
Check the unit for completion of mechanical work against P&ID.
Check list points are liquidated. Any pending point should not affect precommissioning operation.
Remove all construction debris lying around in the unit and clean up the area.
Install blinds as per master blind list.
Safety valves should be kept blinded during flushing and re-installed afterwards.
These should be shop tested and set at the stipulated values.
Ensure that underground sewerage system is in working condition. Clear

plugging, if any. Check by flushing with water.
Check that communication between units, control room, offsites and utilities are
complete and in working condition.
Ensure that the required lube oil, grease and other consumable are available in
the unit.
5.5
PRE-COMMISSIONING OPERATION
Prior to the commissioning of the plant there are several pre-commissioning operations
that must be conducted to prepare the plant for the actual start-up; these are:
1.
Commissioning of utilities
2.
Final inspection of vessels
3.
Flushing
4.
Functional test of rotating equipment
5.
Service and calibrate instruments
6.
Vessel Loading
7.
Tightness test
8.
Purge and gas blanketing
9.
Dry out of Reactor section
10.
Reactor catalyst loading

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Doc No. Draft

Rev. A
Page 50 of 221
It is important that these operations be carried out as thoroughly as possible to help

achieve a smooth and trouble-free start-up and later steady normal operation. A
discussion detailing the major items to monitor in each of these operations follows.
The above outline may be expanded somewhat as follows:
5.5.1.
Commissioning of Utilities
The various utility lines should be tested and placed into service as soon as the
construction schedule allows.
Pressure tests should be carried out on all steam
condensate, air, fuel gas, flare, and nitrogen lines as is done on all process lines.
A.
Steam Network
Network shall be blown through completely from battery limit with a strong steam flow in
order to clean the lines. The following steps are recommended:
-
Check network, all equipment will be disconnected to avoid entry of flushed

material.
Drain all the low points. If necessary open steam trap inlet flanges.
Open slowly battery limit valve and let the temperature rise in the header, slowly
and steadily.
Check support of fixed points and expansion loops.
When line is hot, blow it through completely with a strong steam flow.
Close battery limit valve and prepare another network. When the blowing is
satisfactory, reconnect all equipment and remount steam traps. Recharge header
as above.
To gauge the effectiveness of the steam blowing (and the amount of scale left in
the lines), target plates should be installed at the blow down points. The lines
should be repeatedly blown down until virtually unmarked target plates are
obtained. Condensate lines should be continually checked and traps removed
and cleaned if plugged.
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Note: The following precautions to be taken while blowing / commissioning steam header:
-
To drain the low points of the lines before and during heating period in order to
avoid water accumulation, this causes hammering.
To open drain / vent during cooling period to prevent vacuum formation
To isolate the instruments, remove orifice plates and control valves; to re-install
the orifice plates and control valves after blowing is over.
B.
Cooling Water and Service Water:
Network shall be cleaned from battery limit with a strong water flow. All equipment will
be disconnected at the inlet and reconnected when lines are cleaned. Control valves and
orifice plates will be removed and re-installed, after the lines become clean. When system
has been flushed, charge the lines to the operating pressure.
The following precautions to be taken:
-
To open vents at high points in order to expel air from equipment and piping
To open the battery limit valve, slowly and steadily.
C.
Instrument and Plant Air:
Network shall be blown through completely from battery limit with strong flow of air in
order to clean and dry the lines. All joints and connections shall be checked for tightness
with soap solution. Header and branch lines will be blown through with a high flow rate of
air. During all tests, the instruments and control valve shall be carefully isolated from the
system.
D.
Fuel Gas Networks:
Networks shall be blown through from battery limit with a strong air flow in order to clean
the lines. During the operations, orifice plates and control valves shall be removed.
5.5.2.
Final Inspection of Vessels
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All vessels should be inspected before final closing and any loose scale, dirt, etc., should
be removed. Any line coming directly off of the bottom of a dirty vessel should be
removed.
It is very important that the internals of the hydrotreating reactor be inspected very
carefully.
The hydrotreating reactor internals should be checked for holes and/or
damage and repaired as required. The catalyst support basket and unloading sleeve
should be checked to ensure correct fit in the nozzles.
The separator should be checked carefully to be sure the cement lining is installed well
and that the mesh blanket is securely fastened to the support ring. There should be no
gaps in the mesh blanket.
5.5.3.
Flushing
After pressure test has been completed on any vessel with its connected piping,
receivers, exchangers, etc., required blanks are pulled and water is circulated for the
purpose of removing any dirt, scale, etc. Much of the dirt is picked up in the pump
screens where it is taken from the system by removing and cleaning the screen.
All possible lines and pumps should be used during the washing procedure for complete
cleanout of the system. Of course, no water circulation should be carried out in the gas
sections of the unit. Temporary water connections should be provided at convenient
locations in the system for carrying out water flushing.
The following points should be remembered during water flushing.
-
Low point drains and high point vents should be purged.
All instrument connection should be isolated, orifice plates removed,

control valves isolated and by-passed. In case there is no bypass, remove control
valve and flush the line. The valve will be installed after clean water starts
coming out and further flushing may be continued.
If there is any heat exchanger in the line, flushing should be done up

to and around the exchanger using by-pass line. It should be ensured that dirty
water from initial flushing does not get into the exchanger. Wherever by-passes
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Rev. A
Page 53 of 221
are not available, the flanged joints at the inlet of heat exchanger should be first
opened and the line flushed till clear water starts coming out. Then reconnect
flange and flush through the exchanger.
-
At each opening of the flanged joints, a thin metallic sheet should be

inserted to prevent dirty water from entering the equipment or piping.
The flow of water should preferably be from top to bottom for

flushing of heat exchanger coolers. The bottom flange of the equipment should
be opened to permit proper flushing.
The flushing should be carried out with maximum possible flow of

water till clear water starts coming out.
Vertical lines which are long and rather big (say over 100 mm dia)
should preferably be flushed from top to bottom. This will ensure better flushing.
Filling the lines and releasing from bottom is also helpful. The rundown lines
can also be flushed conveniently from the unit to the respective tanks.
It should be ensured in all flushing operation that design pressure of

lines and equipment are never exceeded. After flushing of lines and equipment,
water should be thoroughly drained from all low points. Lines and equipment
containing pockets of water should not be left idle for a long time; it is preferable
to dry these lines and equipment with air after water flushing.
Where low chloride test water is required to prevent the potential of chloride stress
corrosion cracking of austenitic stainless steel, it is especially important that all water
from low points is removed by being purged with nitrogen. Otherwise, as the remaining
water evaporates, the chloride concentration that started at lower concentration will
concentrate to levels that can (and will) crack or cause pitting of the austenitic stainless
steel. If pitting occurs, it may be discovered during a final equipment inspection (for
example, at the bottom of a fractionation column), allowing time for repairs. On the
other hand, if stress corrosion cracking occurs it will probably not be discovered until

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Doc No. Draft

Rev. A
Page 54 of 221
the equipment temperature is increased for the first time, causing a delay in the start up
schedule.
5.5.4.
Functional Test of Rotating Equipment
All rotary equipment (including dosing pumps) will undergo functional test to check their
performance.
i) Motors
Each motor should be checked and started to ensure that it has the correct direction of
rotation. The motor speed should be checked with tachometer to ensure that RPM is
correct. The manufacturers lubrication schedule should be used to ensure that all
lubrication points have been serviced. After a short run each bearing should be felt to
ensure that it is free and not overheated.
ii) Pumps
Prior to unit start up, all centrifugal pumps should be thoroughly checked and run in
properly (after pressure testing and water flushing) as indicated in the following outline:
The pumps will be started and operated according to the manufacturers instructions.
CAUTION: Many high head pumps are not designed to pump water. To do so can
result in damage to the pump internals. Check the vendors specifications before
attempting to run in pumps with water.
iii) Compressors / Other Special Equipments
In the case of rotating equipment, such as the recycle gas compressor, net gas
compressor the separator pumps, and other special equipment, vendor representatives
(motor vendor also in some cases) normally directs rotation and alignment checkout and
all other activities required to prepare the equipment for service. Rotating equipment
specialists and operations representatives should monitor and participate in this activity
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 55 of 221
for verification purposes, as well as for the opportunity to learn valuable information
about
the
equipment.
However
the
following
measures
before
compressor
commissioning is suggested.
The compressors will be started and operated according to the manufacturers
instructions. Vendor representative should present for start-up of compressor.
5.5.5.
Service and Calibrate Instruments
Normally, instrument lead lines will be tested hydrostatically up to block valves when
the balance of the unit is tested. Hydrostatic test pressure will not be made on
instruments which normally handle gas and no pressure-measuring element should be
subjected to test pressures above its range. Also, never pull a vacuum on a pressure
instrument or gauge unless it is specifically designed for it.
All instrument air piping should be tested at 7kg/cm2g (100 psig), with compressed air.
Soap solution should be used on all joints to check for leakage. Care should be taken to
ensure that this high air pressure is not put on any instruments or control valve
diaphragms. Likewise, when pressure testing of the unit is done, care must be taken that
the fuel gas pressure balance valves are blinded off to keep high pressure off the
diaphragm. Before starting up, all instruments should be serviced and calibrated. This
includes carefully measuring all orifice plate bores with a micrometer. The following
guidelines may be adopted for checking and calibration of all instruments.
i) Orifice Plates
Before each orifice plate is installed the orifice taps should be blown clear. The orifice
plate should be callipered to check, if the correct size orifice plate is installed. The plate
should then be installed after checking for the correct direction.
ii) Differential pressure Transmitters and Receivers
Ordinarily these should be calibrated locally against a manometer. The calibration
should be checked at the receiver, which may be board or locally mounted, recorder or
indicator.
iii) Pressure Transmitters and Receivers

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Doc No. Draft

Rev. A
Page 56 of 221
These should be checked in place. The calibration of the receiver should be checked at
the same time.
iv) Alarms
All alarms, auto start and cut off systems should be checked by simulating the
conditions.
5.5.6.
Vessel Loading
All vessels can be loaded except the reactor catalyst due to its extreme sensitivity to
moisture and air. In the design, the vessels to be loaded are:-
Feed Dryers
Hydrogen Dryers
Scrubber off-gas dryers
Reactor (support material)
Caustic scrubber (Raschig Ring)
Chloride guard bed (stabiliser bottom)
Before loading ensure that the vessels are clean and dry. They have previously been
pressure tested and water washed, ensure there are no water pockets in the piping loops
(not critical for the scrubber). Brush and vacuum the inside of the vessel if necessary and
ensure they are completely isolated and flanges or manways are open, top and bottom.
The inside must be thoroughly vented with air.
5.5.7.
Tightness Test
The initial leak tests are to be performed according to the unit owner and engineering
contractor normal practices. These tests can be carried out using air or nitrogen
depending upon local facilities. As these utility pressures are much lower than the unit
design pressure, the test pressure should be the maximum available from either of these
facilities. The unit must be totally isolated from the fuel gas and flare headers and from
any adjacent units or sections which may contain hydrocarbons and also from other
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 57 of 221
utility systems where the design pressure is lower. This includes sewers which should
have already been tightened during previous start-up preparations.
Install a minimum of two pressure gauges in each section to monitor the unit pressure.
Pressure each section up to the air or nitrogen maximum operating pressure. Survey the
unit for leaks and carefully tighten. Their location should be recorded for further checks.
Continue this exercise, tightening each leakage point until the pressure loss in that
section is less than 0.05 kg/cm2/hour for four hours.
When the leak test is considered satisfactory for all sections, depressurize at all the low
points.
For the leak tests purpose, the following division into sections is recommended.
i) Dryers Section Including Regeneration Facilities :
Feed surge drum 73-V-01
Feed Dryers 73-DR-01 A/B
H2 Dryers 73-DR-02 A/B
H2 make-up cooler 73-E-01
H2 make-up K.O. Drum 73-V-02
Regenerant Vaporizer 73-E-20
Scrubber offgas dryers 73-DR-03
Dryers Regeneration Superheater 73-F-01
Dryers Regenerant Air Condenser 73-A-04
Dryers Regenerant Trim Condenser 73-E-21
Dryers Regenerant Degasser 73-V-13
Deisohexaniser recycle/reactor feed exchanger (tube side) 73-E-02
ii) Reactor Section :
Hydrogenation Reactor 73-R-01
Isomerization Reactors 73-R-02 & 73-R-03
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 58 of 221
Feed/effluent exchangers 73-E-03 A/B

Deisohexaniser recycle/reactor feed exchanger(shell side) 73-E-02
Hydrogenation reactor feed heater (shell side) 73-E-04
iii) Stabilizer Section:
Stabilizer 73-C-01
Stabilizer Air Condenser 73-A-02
Stabilizer Trim condensers 73-E-06 A/B
Stabilizer Reflux Drum 73-V-05
Stabilizer Reboiler 73-E-05
Stabilizer bottom chloride guard bed 73-V-06
Deisohexaniser feed/recycle exchanger (tube side) 73-E-07
iv) Deisohexaniser Section:
Deisohexaniser 73-C-02
Deisohexaniser Air Condenser 73-A-02
Deisohexaniser Reflux Drum 73-V-08
Deisohexaniser Reboiler 73-E-10
Deisohexaniser Recycle Drum 73-V-10
Deisohexaniser Feed/Recycle exchanger (shell side) 73-E-07
Off-spec Isomerate Trim Cooler 73-E-11
Isomerate Trim Coolers 73-E-09
v) Scrubber section:
Scrubber 73-C-03
Caustic Recycle Heater 73-E-12
vi) LPG recovery Section:
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 59 of 221
LPG refrigeration system (tube side) 73-E-13

LPG separator drum 73-V-11
Separator drum bottom/Lean oil exchanger 73-E-14
LPG stripper Feed/bottom exchanger 73-E-15
Lean oil Trim Cooler (shell side) 73-E-16
LPG stripper 73-C-04
LPG stripper Condenser 73-E-19
LPG stripper Reflux Drum 73-V-12
LPG stripper Reboiler 73-E-17
LPG Trim Cooler 73-E-18
SECTION 6
COMMISSIONING PROCEDURE
6.1
FIRST START UP
The following text describes the first start up of the new built unit. Any subsequent start
up of the same unit may or may not include all of the following steps depending upon
the status of the unit after shutdown.
6.2
STATUS OF THE UNIT
The unit prior to its first start up is as follows:

-
Each section has been thoroughly drained free of water and lines have been blown
with air to remove ant pocket.
All adsorbent have been loaded in the dryers.
Pall and Raschig rings have been loaded, respectively, into the top of the LPG
separator drum and scrubber packed section.
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
The bottom inert balls have been loaded into the reactor.
The chloride guard bed has been loaded
Each section has been satisfactorily leak tested.
The unit has not been inerted but is isolated with blinds:-
Rev. A
Page 60 of 221
On the feed and product lines

On the flare and fuel gas headers
On the sewer lines and utilities except cooling water, nitrogen and steam
ejector
On pressure relief valves to flare
On spent caustic and caustic make-up facilities
6.3
CHRONOLOGY
The first start up sequence is as follows:

-
Complete inerting of
the dryer section, reactor section and regeneration section
the stabilizer, deisohexaniser, LPG recovery section
Hydrogen sweep
Oil circulation and stabilizer / deisohexaniser / LPG recovery section start-up.
Reactor oil in
Acidizing and final dry-out
Hydrogenation / Isomerization catalyst loading
Isomerisation unit start-up
Lining out the isomerisation unit at design conditions
LPG recovery start-up
Lining out LPG recovery section at design conditions
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
6.4
Rev. A
Page 61 of 221
COMPLETE INERTISING
The purpose is to reduce the O 2 content in all of the sections below 0.2 volume % prior
to hydrogen or hydrocarbons introduction.
Evacuation using steam ejector followed by vacuum breaking with nitrogen is preferable
for the unit section where water is not desirable, like the dryer and reaction sections. The
inertising
of
these
sections
could
also
be
carried
out
with
repeated
pressurization/depressurization cycles using nitrogen. For the rest of the unit where
water is not a problem, the steam out procedure could be used.
Dryers, Dryers Regeneration Facilities and Reaction Sections
The inertising is assumed to be performed by evacuation using the start-up ejector. Steps
to be followed:
-
Test the ejector to make sure that it is operational.
Ensure the entire system is open, i.e., all pathways between pieces of equipment are
clear. Pumps should be isolated.
Isolate the instruments not suitable for vacuum service.
Install a minimum of two vacuum or compound gauges to monitor the vacuum level.
Locate as far as possible from the ejector.
Pull a vacuum down to 0.2 bar absolute.
Hold the vacuum for one hour to check for leaks, the pressure must not rise more
than 0.07 bar per hour.
Break the vacuum by N2 pressurizing.
Pressure up the unit to 1.0 bar with nitrogen.
Depressurize through all low points, dead legs, vents, etc.
Repeat until the oxygen content is less than 0.2% by volume. Check the system at
several points during depressurizing.
Leave a residual nitrogen pressure of 0.1 bar g. Typically the required O 2 content is
achieved with 3 cycles of pressurizing / evacuating.
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 62 of 221
Stabilizer, Deisohexaniser and LPG recovery Sections

These sections can be inerted with nitrogen or steam, as during the start-up any water
will be removed during oil circulation.
The chloride guard beds should be isolated and by-passed. Their inertising is
independently realized with nitrogen.
If inertising is performed with LP steam, the following brief procedure applies:
-
Open high point vents and low point drains on the vessels to be steam purged.
Start introducing steam into the bottom of all the columns using the steam-out
connection and steam out the reboiler and reflux drums separately. It may be
necessary to make-up additional steam connections to properly purge some
piping which may be dead ended.
Thoroughly purge all equipments and associated piping, venting at all high
points and draining at all the low points.
Continue steaming for one hour minimum after steam appears at all the vents.
Remove the blinds on the :

safety valves to flare
flare header, fuel gas header
products to battery limits
Remaining blinds on utilities, sewers and caustic facilities.
When steam purging is complete, start to close all the vents and drains.
Immediately start to introduce fuel gas or hydrogen to prevent the possibility of a
vacuum forming as the steam condenses.
Cut back the steam flow until it is stopped. As the fuel gas or hydrogen is
admitted, the system will cool down and the condensate can be drained off.
Pressure this section up to 1 bar g with either fuel gas or hydrogen. Check for
any leaks at flanges and gasketed points.
This section is now ready to be charged with naphtha.
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
6.5
Rev. A
Page 63 of 221
HYDROCARBON CIRCULATION AND INITIAL DRY DOWN
Before loading catalyst into the reactor, it is necessary to dry the piping and equipment
to remove any traces of water which might have remained from construction and
pressure testing. The unit is now considered oxygen free and leak tested. The following
procedure introduces hydrogen and then hydrocarbon circulation at design operating
pressure in order to begin dry out. During this period it will be necessary to change the
flow pattern through the reactors and associated piping to ensure that all lines are used.
In addition any dead lags such as control valve bypass should have flow established
through them for a short time and all instrument lead lines must be adequately purged.
This is to ensure that no water pockets remain in the system. These flow patterns are
repeated during the subsequent acidizing steps. Initially line up the isomerization
reactors for series flow operation. Then every six hours after hydrocarbon circulation
has been established switch the flow pattern as
a)
Reactor 73-R-02 single operation.
b)
Reactor 73-R-03 single operation.
c)
Reactor 73-R-02 to Reactor 73-R-03 series operation.
d)
Reactor 73-R-03 to Reactor 73-R-02 series operation.
6.6
HYDROGEN SWEEP
This step involves introducing hydrogen to the reaction section and pressuring up to
operating pressure.
-
The hydrogen comes from the hydrogen unit. Check the hydrogen availability and
quality.
With the Feed Dryers isolated and the distillation section blocked off from the
reaction section, line up the circuit before introducing hydrogen.
The LPG recovery section is isolated.
Introduce hydrogen through the hydrogen dryers in series at a filling rate which will
not upset the other hydrogen users.
Pressurize the reaction section up to operating pressure.

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Doc No. Draft

Rev. A
Page 64 of 221
Survey the unit for leaks and in particular the locations which were leaking during
the initial leak test.
With the reactors holding at operating pressure, slowly open the H2 pressurization
line (to the stabilizer reflux drum) and pressurize the stabilizer column up to normal
operating pressure.
Check that LPG recovery section is isolated.
Crack open the bypass on the stabilizer overheads pressure control valve PV-2001
and pressure up the scrubber to design operating pressure. This must be carried out
very carefully so as not to bump or dislodge the packed sections. The DIH section is
not included in this system.
Using LPG dedicated H2 pressurization line, pressurize the LPG stripper and the
LPG separator drum up to operating pressure
Add sufficient hydrogen to the reaction section to maintain operating pressure and
close the H2 pressurization line.
Set in service the pressure controllers on the stabilizer feed and overhead, the
scrubber, LPG stripper and the LPG separator drum. Route any excess gas first to
flare, then to fuel gas.
Survey the unit for leaks. Set the hydrogen make-up flow at 40% of design rate.
Switch the flow pattern around the dryers and ensure all possible dead legs are
adequately purged.
Hydrogen sweep:a) Reaction section :H2 from CCR
73-V-02
Start up line
(4-P-73-1606)
73-K-01 A/B
73-R-01
73-DR-02A/B
73-E-04 / E-03 / E-02

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
73-M-01
73-R-02
73-E-03
Doc No. Draft

Rev. A
Page 65 of 221
73-R-03
b) Stabiliser Section :Start up line

73-DR-02 A/B
73-V-05
(2-P-73-1514)
73-E-06 A/B
73-A-02
73-PV-2001
73-C-01
73-C-04
6.7
OIL CIRCULATION, AND STABILIZER / DEISOHEXANIZER / LPG

RECOVERY SECTION START-UP
This sequence allows the C5 / C6 feed introduction in the system through the Feed
Dryers, to the Stabilizer, the Deisohexaniser and the LPG recovery section by utilizing
the start-up line by-passing the Feed dryers and the reactors and the other one only bypassing the reactors.
The dryers regeneration circuit is also flushed with oil and the oil is finally routed to
storage through the product lines. This performs a thorough flushing of foreign material
from the equipment and liquid lines.
-
Check the C5/C6 feed availability and quality. It must be on-spec with regard to
contaminant content.
Check that the Feed Dryers are blocked off from the reaction section.
Check that the C5/C6 feed is by-passing the Feed Dryers. Line call start-up line
should be used.
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 66 of 221
Before establishing the complete loop it is necessary to draw off the C 5/C6 to off-spec
storage to remove the equipment oil coating and not to contaminate the dryers molecular
sieves. A period of 8 hours is necessary before closing the loop. During this step, the
chloride guard bed will be by passed.
-
Establish a level in the stabilizer bottoms 73-C-01.
When the level in the stabilizer reaches 40%, route the bottoms to the
Deisohexaniser 73-C-02. The chloride guard bed 73-V-06 is still by-passed.
Commission the Deisohexaniser air condenser 73-A-03A-H and then the reboiler 73E-10. Remove in a first step, route the isomerate product to off-spec storage (sidedraw control valve LV-2101 closed). In a second step, after all the equipment are
cleaned, commission the side-draw, and begin recycling the side-draw and keep
removing the isomerate to the off-spec storage. Set the pressure controller at the
deisohexaniser overhead.
After the 8 hour period, the complete loop including dryers can be established.
-
Slowly fill each Feed Dryers separately using the globe valves and venting the
nitrogen to flare through the pressure safety valves bypass. Dryers filling and
nitrogen displacement is to be monitored through the level glasses on the PSV
bypasses.
Once both dryers are full, the start-up line by passing the dryers is closed and the oil
circulation is continued to the stabilizer through the reactor bypass line.
Commission the stabilizer overheads air condenser.
As the level appears in the stabilizer, commission the reboiler.
Slowly bring the stabilizer up to operating temperature. As the level appears in the
reflux drum 73-V-05 start the reflux pumps 73-P-05A/B and reflux back to the
column.
Adjust the flow on the reactors by-pass line to reach a circulation rate of 60% of
design throughput.
Once the circulation is steady, line up the regeneration circuit to by-pass the dryers.

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Doc No. Draft

Rev. A
Page 67 of 221
Crack open the flow controller on the regeneration loop and flush the loop free of
foreign material, back to rundown to storage.
Adjust the flow to design rate, hold for 4 hours and then stop the circulation through
the regeneration loop. Close the by-pass line and re-establish the flow through the
dryers.
Calibrate the moisture analyzers on the feed and hydrogen dryers. Commission them
to monitor dryer performance.
During the circulation, switch the flow pattern around the dryers and ensure all
possible dead legs are adequately purged.
Oil Circulation and stabilizer / Deisohexaniser start-up

Treated Naphtha from
NHDT
73-V-01
73-P-01 A/B
6-P-73-1105
Start-up line
4-P-73-1321
Chloride Guard
Bed bypass
(4-P-73-1902)
73-C-01
8-P-73-1908
73-E-07
73-C-02
commission 73-E-10
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 68 of 221
73-A-03
(LV-2101 close)
1st step: -
73-P-08/B
Off-spec isomerate
to storage for min. 8 hrs.
Start-up line
3-P-73-2212
73-E-11
Note: - Feed dryers blocked off from the reaction section:

NOTE: Enclosed start up circuits will be detailed by process licensor during Precommissioning/Commissioning and shall be submitted accordingly by the licensor.
2nd Step:73-C-02
8-P-73-2206
73-V-07
4-P-73-1615)
73-E-08 A/B
73-E-02
73-P-07A/B
4-P-73-2101
73-V-01
After 8 hours: (Feed Dryers taken on line)
6-P-73-1105
From 73-V-01
73-DR-01 A/B
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 69 of 221
6-P-73-1303
73-C-01
(through reactor
bypass line
4-P-73-1513
Reflux
Commission 73-E-05 & A02
reboiler & condenser
after level appears
73-P-05 A/B
73-V-05
73-C-02
through
73-C-01 overhead
73-E-07
73-V-06
Similar to previous circulation

Note: Enclosed start up circuits will be detailed by process licensor during Precommissioning/Commissioning and shall be submitted accordingly by the licensor.
LPG recovery section Start-up
Section status
-
Leak test has been performed
Raschig rings are installed on top of the scrubber and pall rings in the LPG separator
drum.
Absorbent is loaded in the scrubber off-gas dryer.
All utilities are available including chilling package
Section is isolated as follows
Off gas from caustic scrubber : UV 2501 + block valves closed
Lean gas from LPG separator drum to fuel gas : PV 2801 + block valves closed
LPG : FV 3301 + block valves closed
Lean oil inlet from deisohexaniser bottoms : FV 2202 + block valves closed
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 70 of 221
Heavy product outlet : PV 2802 + block valves closed
LPG stripper bottom : FV 2803 close
LPG stripper reflux drum : PV 3001
Procedure
-
Line-up the internal circuit between 73-V-11 (LPG separator drum) and 73-C-04
(LPG stripper).
Slowly introduce heavy product from DIH bottom through FV-2202 at 73-P-08
discharge to 73-V11 upto 100 % at LG-2802 (LPG separator drum).
Start the pump 73-P-04 and through FV 2801 introduce liquid to 73-C-04 (LPG
stripper)
Commission VHP steam to 73-E-17 (LPG stripper reboiler) and bring 73-C-04 at
total reflux conditions. Make-up heavy product to 73-V-11 and restart 73-P-14 as
necessary to maintain LPG stripper levels.
Commission the PIC-2801 at the LPG separator drum overhead. When PIC has
reached normal operating pressure set point, open UV 2501.
Most of the rich off gas is still routed to fuel gas.
Very slowly start to romp down PV 2501 (valve to close in approximately 20 mins)
When PV 2501 is fully closed, then close UV 2503
Commission chilling medium to 73-E-13 A/B
Start recycling heavy product through FV 2804 , then restart 73-P-14 A/B
PV 3001 (LPG stripper reflux drum), in auto mode, will start to open , to maintain
73-C-04 pressure, recycling the lean off gas to separator.
When level reaches 50% at draw off tray level gauge (LG 2907), start 73-P-16 A/B
on minimum flow line, and then open FV 3301. The LPG product is ent to the off
spec storage during 8 hours.
Commission PV 2802 and route LPG stripper bottoms to storage.

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
6.8
Doc No. Draft

Rev. A
Page 71 of 221
REACTION CIRCUIT OIL-IN
Status
Hydrogen is flowing at 40 % of design capacity through the H 2 dryers 73-DR-02 A/B
and the reaction circuit at operating pressure, through the stabilizer 73-C-01, the
deisohexaniser 73-C-02, to the scrubber 73-C-03, the LPG recovery section, and out to
fuel gas.
C5/C6 feed is flowing through the Feed Dryers 73-DR-01 A/B bypassing the reactor
section to the stabilizer.
The Stabilizer, the Deisohexaniser and the LPG recovery section are operating under
total reflux at 60% capacity.
The dryer regeneration loop has been flushed and is full of liquid naphtha.
The pressure controllers of:
-
stabilizer feed and overhead
deisohexaniser overhead
scrubber overhead
LPG separator drum overhead
LPG stripper overhead
are in service at their respective operating set-points

The caustic and water washes are not in service.
The isomerization reactors 73-R-02, 73-R-03 are loaded with bottom inert balls only and
are lined up for series flow.
-
Establish normal hydrogen make-up flow.
Commission the reactor feed heater 73-E-04 and slowly raise the hydrogenation
reactor inlet temperature to 110 C at 40 C/h. Place the reactor inlet temperature
controller in cascade service.
Survey the unit for leaks.
With all conditions steady, crack open the globe valve on the C5/C6 feed to allow
10% of the naphtha to flow through the reactors.
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 72 of 221
Continue increasing the flow in 10% increments, maintaining system pressure,

closing the by-pass valve until all of the 60% design flow is flowing through the
reactors.
Slowly increase the hydrogenation reactor inlet temperature to 160C at 20C/hr.

Test the reactor inter-coolers temperature control and alarms. Set in auto mode the
isomerization reactors TIC at 160C.
The liquid flowing through the reaction section will remove the oil film on the vessel
inside walls and internals placed there after sandblasting. This oil will contaminate
the dryer adsorbent if regeneration is taking place.
During this period, it is also recommended that the deisohexaniser side-draw product
is not used to avoid contaminating the dryer adsorbent. The oil will flow out the
deisohexaniser bottoms and be routed to off-spec storage. The stabilizer chloride
guard bed is by-passed for the same reasons.
Dryer regeneration and/or cooling should be completed and discontinued before
reactor oil-in. Regeneration of either dryer must not take place until 8 hours after
reactor oil in,
8 hours after the reactor oil in, open the side-draw control valve, and increase slowly
the recycle flowrate to the reactors.
During the hydrogen and hydrocarbons circulation, it will be necessary to switch the
flows through the different reactors circuits as discussed previously. It is imperative
that all piping sections are exposed to this dry out step. Also, line-up sulfur
stripping line.
Continue drying until the water content is below 10 ppm at the reaction section
outlet. The water content in the heavy product to storage must also be lower than 10
ppm.
Regenerate the dryers (feed and hydrogen and) on a regular basis.
Commission the chloride absorber on stabilizer bottoms only when water content is
below 10 ppm.
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 73 of 221
Note 1: During this step all efforts should be made to get all moisture analyzers working
properly and most specially those down stream reactors, which will be used during
acidizing.
Note 2: The moisture analyzer installed downstream the reactor, which will be used
during acidizing should have its sampling system equipped with separator liquid / gas.
The liquid sample only will be send to the moisture analyzer cell.
The analyzer measure repeatability should be checked carefully at this stage as the
acidizing step follow-up will rely only on the good operation of this analyzer.
Reactor Circuit oil in:Naphtha
73-V-01
73-P-01 A/B
73-DR-01 A/B
73-E-02
73-E-03
73-E-04 (commission & rise

temp.upto 110C at
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 74 of 221
40C/h)
73-R-01 (at very slow rate,
10% of naphtha
should flow through
reactor)
73-R-02
73-E-03
Start-up line
4-P-73-1606
73-R-03
(through
8-P-73-1804)
73-C-01
73-V-06 bypass
(4-P-73-1902)
Off-spec
Isomerate
to storage
73-P-08 A/B
73-C-02
73-E-07
6.9
ACIDIZING AND FINAL DRY-DOWN
As previously mentioned iron oxide on contact with HCl will liberate H 2O which is an
irreversible poison to the isomerization catalyst. In this step, the final dry down occurs
and anhydrous HCl is added to remove all traces of iron oxide in isomerization section
and LPG recovery section. These steps could take up to 3-4 weeks to satisfactorily
complete depending upon the equipment conditions, the sandblasting efficiency and the
previous initial dry down steps. The unit chemical cleaning during pre-commissioning
can significantly reduce the length of the dry out period.
Preparation:
-
Make-up an inventory of 10% caustic solution in the scrubber bottom.
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ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 75 of 221
Remove the blind on the spent caustic to safe disposal.
Establish the water wash in the scrubber top section. Adjust the globe valve to
achieve design circulation.
Establish the caustic circulation. Adjust the globe valves on the top and bottom
inlets to achieve design injection rates.
Ph of the circulating water to be kept below 9/10
Drain any liquid water which may have been accumulated in the stabilizer reflux
drum. During the acidizing period with HCl, it will be necessary to check and
drain these points on a frequent basis as highly acidic liquid could be present.
Connect up the anhydrous HCl. The HCl cylinder should be mounted on an

accurate scale to determine and control the injection rate.
Block in the reactor effluent moisture sample point to the dryer moisture
analyzer as the highly acidic effluent could damage the analyzer cells. After HCl
has been injected it is necessary to wait for at least one hour before reconnecting
the analyzer.
Swing the blinds on the HCl injection facilities.
Perform a leak test on the injection piping and the pressure controller.
LPG section and DIH shall be isolated.
Acidizing Step :
With hydrogen flow at design rate, C 5 / C6 feed at 60% of design, and the unit steady
with the reactors inlet temperature set at 160C.All hydrogenation reactor, recycle
section equipments, isomerization reactors and equipments are including in this
acidizing step.
Through out the HCl injection period, monitor the caustic strength in the scrubber
bottoms. Replenish as necessary. Do not allow NaOH concentrate decrease below 3%
wt. Check HCl content in the scrubber off gas with dragger tubes (HCl-1ppm vol)
1st Step:-
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ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 76 of 221
Inject 5 kg of HCl into the hydrogen line going to hydrogenation reactor (1st
hydrogen make up line) at a steady rate over a 5 minute period.
Note: the first injection should take into account the volume of the injection line
(the quantity injected to be adjusted).
-
Wait for one hour or until the reactor effluent sample pot vapour contains less
than 10 ppm HCl.
Reconnect the moisture analyzer and obtain a reading on the sample pot liquid,
then disconnect. Record the moisture level, HCl addition and sample time (see
typical injection table data report attached).
Continue HCl injecting in the same manner until the moisture level peaks start to
decline. During this period continue draining all low points, purging instrument
lead lines, flushing bypasses around control valves and switching the reactors
flow pattern.
Continue HCl injection until no further response is noted by the moisture

analyzer.
Check that the moisture analyzer is operating correctly and that the readings are
correct.
Add another 10 kg of HCl over a 10 minute period. When the HCl content has
decreased below 10 ppm, recheck the moisture content. If a response is noted
return to regular injections of 5 kg of HCl over a 5 minute period. If no response
is noted, discontinue HCl injection.
H2S stripping line and the superheater are lined up and acidified (160C at the
superheater). Crack closed the isolation block valve at the hydrogenation reactor
inlet.
Continue unit circulation until the moisture content is 1 ppm at the reactor outlet.
2nd Step:-
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ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 77 of 221
Swing the HCl line injection into the hydrogen line going to the isomerisation
section (2nd hydrogen make up line)
Inject 5 kg of HCl at steady rate over a 5 minute period.
Repeat same operation as 1st (regular HCl injections) until the moisture content is
1 ppm at the reactor outlet.
Remark : in case of vaporisation of all dissolved HCl in the separator drum, an

additional HCl injection point is foreseen at the separator outlet.
3rd Step:-
Reduce the first isomerisation reactor inlet temperature to 100C over a one hour
period.
When the reactors have cooled to 100C, slowly open the reaction section bypass
and route the naphtha around the reactors to the stabilizer.
Reduce the steam flow to the Reactor Feed Heater until closed.
The naphtha feed flow to the stabilizer can be stopped at this stage.
Shut-off steam to the reboiler and shutdown the reflux pump.
Reduce the stabilizer bottoms level to 30% and block in the stabilizer on standby
mode until ready for restart. The deisohexaniser and LPG recovery section
remain in standby mode.
The stabilizer off gases are sent to the scrubber.
Shutdown the caustic circulation and water wash pumps.
Maintain stabilizer, LPG recovery section and scrubber pressure with hydrogen.
Continue H2 make-up at design flowrate to cool and to sweep the reactor circuit
of liquid hydrocarbons to the stabilizer.
Switch the reactor flow pattern to sweep out all liquid hydrocarbons.
Cool the reactor circuit to 40C then shut-off the H2 make-up but maintain
pressure in the reaction section, stabilizer, LPG recovery section and scrubber by
switching normal hydrogen make-up line to dedicated start-up line.
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ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 78 of 221
Block in and blind reactors.
Depressurize and purge each reactor with nitrogen. Use only nitrogen containing
less than 1 ppm of water. If necessary route this nitrogen through a regenerated
H2 Dryer which has been properly purged.
Pressure and depressurize with nitrogen until the hydrocarbon content is less
than 0.2 vol%.
Maintain a slightly positive nitrogen pressure of 0.5 kg/cm2 g.
The hydrogenation and isomerization reactors are now ready for loading.
ACIDIZING INJECTION TABLE DATA REPORT 1

N
Date
Time
Cylinder
Weight
Weight
HCl
Total
Number
Before
after
Injected
HCl
injection
injection
Kg/h.
injected
1
2
3
4
5
6

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
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Rev. A
Page 79 of 221
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
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ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 80 of 221
ACIDIZING INJECTION TABLE DATA REPORT 2

No.
Moisture
Reactors
Reactor A
Reactor B
Inlet T
Inlet T
Value
Base line
Arrangement
Wt ppm
wt ppm
AB BA
Scrubber
NaOH
Water
% wt
Ph
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
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ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
6.10
Rev. A
Page 81 of 221
HYDROGENATION AND ISOMERISATION CATALYST LOADING

UNDER N2
Please refer section 11.1 for the detail procedure for catalyst loading of hydrogenation
and isomerization reactors.
6.11
-
HYDROGENATION REACTION SECTION START-UP
Check the dryers operation, the moisture analyzer on the tail dryer must be reading
under 0.1 ppm wt H2O.
Depressurize the hydrogenation reactor full of hydrogen and pressurize with

nitrogen. Use only nitrogen containing less than 1 ppm of water. If necessary route
this nitrogen through a regenerated make-up gas dryer which has been properly
purged.
For start-up, feed will be introduced cold into the hydrogenation reactor 73-R-01. If
possible, it is recommended that this naphtha be as low as possible in benzene
content until the three reactors are up and running.
Line-up the feed dryers and the hydrogenation reactor.
Establish a level in the hydrogenation reactor flash drum.
When the level in the hydrogenation reactor separator drum reaches 40%, start the
hydrogenation reactor recycle pumps 73-P-03 A/B. Establish a close loop from the
flash drum to the hydrogenation reactor passing through the recycle air cooler
73-A-01A/B/C/D and its by-pass.
Stop the feed when the recycle is at design flowrate. Maintain the flowrate in the
recycle loop.
Once a steady operation is reached, commission the reactor feed heater 73-E-04 and
slowly increase the hydrogenation reactor inlet temperature to 105C at a rate of
10C per hour.
Using the 1st hydrogen make-up line going to the DIH recycle / reactor feed
exchanger 73-E-02, inject hydrogen in batch operation. There will be an immediate

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Doc No. Draft

Rev. A
Page 82 of 221
exothermic reaction; this phenomenon will be short in duration, the magnitude of the
temperature increase will depend very much on the feed quality. Under no
circumstance the hydrogenation reactor should be above 200C. If it occurs, follow
the emergency procedure for high reactor temperature.
-
Slowly pressurize with hydrogen the hydrogenation reactor flash drum.
Repeat the hydrogen batch injection until there is no benzene in the recycle loop and
no temperature increase in the hydrogenation reactor.
Start the isomerization reactor feed pump 73-P-04 A/B and line-up the
hydrogenation reaction section to the stabilizer 73-C-01, the isomerization reaction
section is still bypassed.
With the stabilizer in normal operation, route the feed to the isomerization feed surge
drum 73-V-01. Close the loop from the feed surge drum 73-V-01, through the dryers
73-DR-01 A/B and the hydrogenation reaction section to the stabilizer 73-C-01 and
the chloride guard bed 73-V-06.
Pressurize with hydrogen at design flowrate the isomerization section using the 2 nd
hydrogen make-up line.
Adjust the feed dryers inlet at 50% of design flowrate using fresh naphtha make-up.
Adjust the hydrogen at the hydrogenation reactor inlet at 50% of the design flowrate.
If necessary, rundown the excess of stabilizer product to off-spec storage.
When there is no benzene in the recycle loop and no temperature increase in the
hydrogenation reactor 73-R-01, reduce the feed heater temperature down to 75C.
Check the quality of the hydrogenation reactor outlet.
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ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 83 of 221
Hydrogenation reaction section start-up:H2 through 8-P-73-1503
6-P-73-1303
73-V-01
Hydro treated naphtha

6-P-73-1105
73-DR-01A/B
73-E-02
73-E-03
4-P-73-1322
73-E-04
73-A-01
73-V-08
73-P-03A/B
73-R-01
73-V-04
73-P-06A/B
6-P-73-1705
73-C-01
73-C-02
73-P-08A/B
73-P-04A/B
73-V-06
3-P-73-2212
Off-spec isomerate through 73-E-11
3-P-73-3306 / 3310
(through 73-E-11)
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
6.12
-
Rev. A
Page 84 of 221
ISOMERIZATION REACTION SECTION START-UP
On start up feed will be introduced into the benzene saturation reactor at a minimum
of 75% (FT-1101) of reactor design feed rate. Remark: reactor feed rate includes
recycle + unit fresh feed. 75% of the reactor design feed rate, corresponds to 50% of
unit design fresh feed (FT-1104). The reactors should never be operated less than
75% of design feed rate (FT-1101) and no part of reactor should be above 65 oC
The 2nd isomerization reactor (73-R-03) in lag position is bypassed.
Gently open the valve at the isomerization section inlet (downstream the static
mixer) and in the same time slowly choke the globe valve on the isomerization
reactors bypass line. Inject feed of isomerization reactor in about 5 minute.
Survey the possible pressure surge to stabilizer 73-C-01 and scrubber 73-C-03.
The temperature rise, although rapid, should not be a problem if the initial reactor
temperature is less than 65C.
Adjust the flowrate at the hydrogenation reaction section inlet at 50% of design
flowrate with fresh naphtha feed in the feed surge drum.
Once a steady operation is reached, commission the reactor feed heater and slowly
increase the isomerization reactor inlet temperature to 130C at a rate of 10C per
hour, while monitoring the exotherm and catalyst bed temperatures.
When the temperature reaches 105C in the isomerization reactor, start C2Cl4
injection at 400 ppm wt based C5/C6 feed rate to the reactors.
Monitor the chloride in the stabilizer off-gas. When the first isomerization reactor
stops consuming chloride, reduce the C2Cl4 injection to 150 ppm.
Check the stabilizer bottoms quality, adjust the reactor temperature to achieve the
optimum product quality when operating on one reactor at 75% of design feed rate
(FT-1101). Slowly increase the fresh naphtha feed rate and decrease (and finally
close) the recycle from isomerate product (start-up line).
Switch to isomerate rundown storage if desirable.
Commission the scrubber off-gas H2 analyzer. Check the H2/HC ratio to be sure of
the procedure.
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ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 85 of 221
Allow the operation to stabilize, adjust conditions where necessary, ensure all
instrumentation is working and in the proper range. The first isomerization reactor
should operate alone for at least two days in steady state operation before the second
isomerization reactor is brought on-line.
Isomerisation reaction section start-up

Feed
73-DR-01A/B
73-R-01
73-V-04
73-P-04A/B
6-P-73-1706
73-R-02
Offgas to scrubber
73-E-03
8-P-73-1805
73-C-01
73-C-02
73-P-08A/B
73-V-08
73-V-06
Heavy isomerate to storage

73-P-09A/B
Off-spec isomerate to
storage (4-P-73-3307)
Isomerate to storage
(4-P-73-3308)
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 86 of 221
Series Flow Operation:

When the second stage isomerization reactor is ready to be brought on-line, check the
reactor pressure versus the system pressure to ensure there is no significant differential.
If there is a pressure differential, depending on the magnitude, the Axens start-up
representative will advise on the best method to equilibrate the pressures before bringing
the second reactor on line. Naphtha feed rate should be at least 75% (FT 1101) of design
prior to this step.
-
Reduce the first isomerization reactor outlet temperature to 110C and establish flow
through the Cold Feed / Effluent Exchanger (73-E-03) to cool the second reactor
inlet temperature as much as possible.
Open the second reactor inlet and outlet block valves (inlet first) very slowly as to
maintain always flow to the stabilizer while filling the reactor.
Establish flow through the second reactor by closing very slowly the single reactor
bypass line. The TIC should be on manual with all of the first reactor effluent
passing through the tube side of the Cold Feed / Effluent Exchanger.
Increase the C2Cl4 injection back to 400 ppm to compensate for the chloride
consumption in the second reactor.
Again monitor the stabilizer off-gas and reduce the chloride injection once the
consumption levels off.
As before, there will be an increase of temperature in the second reactor, but this will
not be dramatic
Allow the operation to stabilize. As the second reactor is brought on-line, there could
be some flow perturbation to the stabilizer.
Commission the second reactor inlet temperature controller and slowly increase the
second reactor inlet temperature to 115C at 10C/hour.
Adjust all operating conditions for optimum operation.

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
6.13
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Rev. A
Page 87 of 221
ISOMERIZATION UNIT LINE-OUT AT DESIGN CAPACITY
Status
-
The unit is operating at 75% of reactor (FT 1101) design capacity (is equivalent to
50% unit design fresh feed) at design hydrogen make-up.
Inlet temperatures to reactors have been adjusted for optimum isomerate quality.
The Stabilizer 73-C-01 and the Deisohexaniser 73-C-02 are operating at design
reflux rates and the scrubber 73-C-03 is in operation with both water wash and
caustic circulation at design rates. Isomerate product is routed to rundown product
storage and scrubber off-gas to fuel gas.
The dryer analyzers are in operation and the dryers have been recently regenerated.
The stabilizer off-gases are sent to the scrubber (UV 2501 closed, UV 2503 open)
and LPG recovery section is bypassed.
Procedure:
-
Slowly increase the C5/C6 isomerization unit feed rate to design in increments of
10% per hour. Monitor the catalyst bed temperatures for higher than normal
exotherms. Allow the unit to stabilize after each change.
Record all operating data at each 10% increment, i.e., flows, temperatures,
conversion levels out of each reactor.
At design capacity and steady temperatures, sample the isomerate product for
analysis.
Adjust temperatures as necessary to improve the conversion ratios of the isomers.

The first reactor temperature should be adjusted to maximize isomerization in the
first reactor, and the second reactor temperature adjusted to take the advantage of the
higher equilibrium isomer content at lower temperatures. A sample point is located at
the first reactor outlet to allow an analysis of the conversion in the first reactor.
Check the scrubber off-gas H2 analyzer to ensure that H2/HC ratio is above 0.06.
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VRCFP, HPCL VISAKH
Rev. A
Page 88 of 221
Adjust the temperature and reflux on the stabilizer to meet the product RVP
requirements and to minimize the loss of C5+ in the overheads. Also, the stabilizer
should completely strip-out the HCl from the reactor effluent.
6.14
LPG RECOVERY SECTION LINE-OUT
The LPG recovery section operation is very sensitive to any upset in reflux or reboiling
duty at the LPG stripper, in which case chloride content in LPG product will not be
acceptable. For this reason, the gas feed to the LPG recovery section is only permitted
when LPG recovery has been lined up on lean oil side, LPG stripper being on total
reflux and lean oil at design flowrate.
For any upset in the stabilizer or in the LPG recovery section (loss of reboiler or reflux),
LPG recovery section will be bypassed on off-gas side (UV 2501 closed UV 2503
open).
The Isomerization unit is operating at design capacity. The stabilizer off-gases are sent to
the scrubber.
The LPG recovery section is isolated on isomerization off gas side (UV 2501 closed
UV 2503 open).
-
Line-up the LPG recovery section on the lean oil side only, i.e. UV 2501 closed
UV 2503 open.
Slowly increase the lean oil up to 60% of the design flowrate.
Commission LPG refrigeration system, LPG separator drum and LPG stripper.
LPG product is routed to isomerate off-spec product.
Only when the design flowrate of lean oil is reached and LPG stripper operates at
design conditions (design reboiler duty and design reflux- PIC 2801 at design set
point), isomerization off gas feed to LPG recovery section is permitted. Open UV
2501, slowly ramp down PV 2501 (valve to close in approximately in20 minutes).
When PV 2501 is fully closed, then close UV 2503.
Check the LPG separator off-gas H2 analyser to ensure that H2/HC ratio is above
0.06

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
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Rev. A
Page 89 of 221
PC 2501 to be reset (PC 2501 and PV 2501 to remain in control mode in normal
operation of the unit.
6.15
UNIT RESTART
Any unit restart procedure derives from the first start-up procedure. The unit status after
the shutdown will dictate the point during restart where the general start-up procedure
can be resumed.
For example during the unit life, there will be instances when the lead isomerization
reactor will need to be taken out of service for catalyst replacement with other reactor
remaining in service. Restart procedure at this situation begins at the point for series
flow operation in the initial start-up procedure. Except in this case this reactor will be
under a low pressure nitrogen atmosphere.
As the freshly loaded catalyst will be cold, the reactor can be re-pressurized using the inservice reactor feed through the bypass globe valve. As soon as the freshly loaded
reactor is up to operating pressure follow the series flow start-up procedure to align this
reactor in the tail position of the flow configuration.
A precautionary note for any restart or commission of the second reactor:
Maximize hydrogen make-up, set the naphtha feed at 75% of design and maximize
reactor temperature. Introduce the naphtha feed quickly to the fresh catalyst and
carefully monitor the catalyst bed temperature.
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ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 90 of 221
SECTION 7
NORMAL OPERATING PROCEDURES
7.1
INTRODUCTION
After the unit has been started up and lined out, the focus shifts to reaching and
maintaining a state of optimum operation. This state of optimum operation can be
achieved by establishing a few general operating rules and being aware of potential
problems which can occur. First, a means of judging performance must be defined.
Secondly, a list of operating variables is established. Using these operating variables, an
approach to operating the Isomar unit is outlined with respect to the performance
indicators.
This procedure establishes a logical method for operating the plant,
increasing yields and ensuring longer catalyst cycles.

7.2
CONTROL PHILOSOPHY
The control philosophy for the C5 / C6 cut isomerization unit is simple and conventional.
Refer to P & IDS.
Reaction Section:
-
The set point of hydrogen make-up going to the hydrogenation reactor is adjusted by
the operator according to the amount of benzene in the feed (on line analyzer).
Hydrogen make-up gas going to the isomerization section is under flow ratio control
with the total liquid feed to the reactors.
First isomerization reactor inlet temperature is controlled by steam flow to the

Reactor Feed Heater and by split range on the recycle air cooler and its by-pass.
Second isomerization reactor inlet temperature is controlled through a by-pass of the

First stage reactor Feed / Effluent Exchanger.
The reactor section pressure is controlled directly by a back-pressure controller on

the stabilizer feed.
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ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 91 of 221
Hydrogen / HC Mole Ratio

Measured by hydrogen analysis in the scrubber off-gas, this ratio must be maintained
close to 0.06. If there is a problem maintaining this ratio, reduce the feed rate
accordingly.
Stabilizer
-
Stabilizer bottom is supplied to the Deisohexaniser on flow-control reset by level

control of the stabilizer tower.
Reboiling is under steam condensate flow control reset by a sensitive tray

temperature.
Pressure is controlled by a pressure controller on the stabilizer off gas.
Reflux is under flow control reset by the Stabilizer Reflux Drum level.
Deisohexaniser
-
Feed from the stabilizer bottoms is supplied on flow control reset by the stabilizer
bottoms level.
Reflux to the Deisohexaniser is on flow control.
Distillate product is withdrawn on flow control reset by level control of the reflux
drum.
Side-draw is on level control of the Deisohexaniser Recycle Drum.
Side-draw pump around is on flow control.
Reboiling is under flow control reset by a sensitive tray temperature.
Column pressure is controlled by a split range controller.
Deisohexaniser bottom is supplied to the LPG recovery section on flow-control reset

by level control.
LPG recovery section

-
Pressure of the LPG separator drum is controlled by a pressure controller on the

overhead gas.
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ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 92 of 221
LPG separator drum bottom is routed to the LPG stripper on flow-control reset by
level control.
Lean oil is on flow control.
LPG stripper pressure is controlled by a pressure controller on the overhead gas.
Reboiling is under flow control reset by sensitive tray temperature.
LPG stripper bottom is routed to the storage on flow-control reset by level control.
Side-draw is under flow control reset by sensitive tray temperature.
LPG side stripper bottom is fed to storage on flow control reset by level control.
LPG stripper reflux is on flow control reset by level control.
Neutralization
-
The scrubbed off gas is withdrawn under pressure control.
Temperature control of the caustic circulation is achieved through the Caustic

Recycle Heater.
Dryers
-
The dryers will be in series flow for the feed, the make-up H 2 services. Once the
moisture content in the lead dryer effluent, reaches 1 ppm wt, it must be taken out of
service for regeneration.
The regeneration flow is flow controlled into the regeneration loop.
A pressure controller maintains a backpressure in the loop prior to re-blending with

the isomerate product after the pressure control valve.
A Degasser is required in the loop to purge off gas leakage from the dryers and to
separate water from the regenerant. Gas purging is under level control of the
Degasser which is maintained almost full of liquid.
The regeneration temperature is controlled by electrical power of the Regenerant

Superheater.

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
7.3
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Rev. A
Page 93 of 221
OPERATING PARAMETERS
The process variables which according to the thermodynamics and kinetics have an
impact on the reactions of the isomerization process are listed below. This chapter
covers briefly these variables but does not present the variables from an operator
standpoint i.e. which variables can the operator actually adjust to improve or restore the
unit performance.
7.3.1
Temperature
As stated, the inlet temperature to the reactors is the most direct variable the operator
has available to control product quality. Typically during start-up when the unit is lined
out at design capacity and the stabilizer bottom product is on-spec. there are only a few
instances when the operator needs to adjust the reactor inlet temperature.
a) Coke accumulates on the catalyst surface:
During the cycle, coke will build up on the catalyst surface within the pores; reduce the
reaction surface and consequently the activity. An adjustment will be required on the
reactor inlet temperature to compensate for this activity loss. The difference between
start of run and end of run inlet temperatures could be as much as 30C. This change is
very gradual over typically a 2-3 year period.
b)
Feed quality changes:
If the feed quality changes i.e. there are higher levels of benzene or C 7+ in the feed, then
the operator must decrease the reactor inlet temperature to offset the increase in
exothermic heat.
c)
For major changes in feed rate:
As catalyst activity is higher with the lower space velocity, and then the reactor inlet
temperature at 60% capacity should be different from that at 100% capacity. Typically
the temperature may be only a 5-8C difference. The operator can lower the reactor inlet
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 94 of 221
temperature at lower space velocity to control hydrocracking and preserve catalyst cycle
length.
7.3.2
Hydrogen make-up rate:
The design hydrogen to hydrocarbon ratio for this unit is 0.06 moles of hydrogen at the
reactor outlet per mole of naphtha feed. Operating below this ratio will increase coke
deposits or lead to a maldistribution of the flow in the reactors. Operating above this
ratio will preserve the cycle length but will not enhance the isomerization reactions by a
measurable degree. It is left to the operator discretion to reduce hydrogen make-up rate
as the naphtha feed rate is reduced to maintain a 0.06 ratio. This is mostly dependent on
the high pressure hydrogen and fuel gas balances.
7.3.3
a)
-
Stabilizer / Scrubber / Deisohexaniser section operation:

Stabilizer
Check the isomerate for HCl content. Periodic testing of the isomerate for chloride is
necessary to ensure no chloride is exiting with the isomerate. Upsets in stabilizer
operation will impact in chloride content in stabilizer bottom and shall be
recorded. Corresponding chloride will be absorbed on the chloride guard bed.
Record of the upset will enable the operator to predict the life length of the
chloride bed. As isomerate is used to regenerate the dryers, it must be free of HCl.
Otherwise damage to the molecular sieve will occur.
Adjust the temperatures and reflux on the stabilizer to meet RVP requirements and to
minimize C5+ in the overheads.
b)
-
Scrubber
Check the scrubber operation for caustic losses and caustic strength in the circulating
caustic wash. The stabilizer off-gases are first scrubbed with 10% caustic solution
then water washed before routing to fuel gas. Check the exiting gas for HCl content
and caustic entrainment.

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Doc No. Draft

Rev. A
Page 95 of 221
The caustic inventory is replaced once the concentration drops to 2 to 3 wt. %, and
the caustic concentration should not be allowed to fall below 2 wt %. The circulating
caustic temperature should be maintained a few degrees above the off gas inlet
temperature in order to avoid condensation which can cause foaming and operating
problems in the scrubber.
c)
-
Deisohexaniser:
Deisohexaniser fractionates the isomerate product from the reactor recycle liquid,
and the octane number of the isomerate product is dependant on recycling the low
octane C6 components to the reactor.
The recycle liquid also serves as a diluent for controlling the exotherm in the
benzene saturation reactor, especially when processing benzene rich feed streams
only.
The recycle liquid in addition helps in diluting the C7+ components in the total
reactor feed to avoid excessive cracking of these heavy components in the
isomerization reactors.
d)
7.4
LPG Recovery section

Practically this section operates independently with feed from isomerisation unit.
OPERATING PARAMETER
Operating conditions are given in the table below.

ISOM UNIT PROCESS SYSTEM
Description
FEED SECTION
Feed to Dryers
Feed to Dryers
73-P-01A/B discharge
Feed to Dryers
Feed to surge drum
Feed to surge drum
Tag no.
Unit
Value
FI-1101
FIC-1101
FIC-1102
FT-1103
FI-1104
TI-1101
M3/hr
M3/hr
M3/hr
M3/hr
M3/hr
o
C
82.1
82.1
29.0
82.1
44.5
40
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 96 of 221
Description
Tag no.
Unit
Feed surge drum boot

Feed surge drum
Feed surge drum
Feed surge drum boot
Feed surge drum
Feed surge drum
Feed surge drum
Feed surge drum
Feed to surge drum
Feed surge drum
73-P-01A discharge
LI-1101
LI-1102
LI-1103
LT-1104
LG-1105
LG-1106
PIC-1101
PT-1101
PT-1102
PI-1103
PI-1104
PI-1105
MM
MM
MM
MM
MM
MM
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Value
MIN
300
600
600
300
600
300
4.0
4.0
28.3
5.0
4.0
28.3
PI-1106
Kg/cm2 G
28.3
Kg/cm2 G
5.0
Kg/cm2 G
5.0
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
41.8
41.8
5.0
6.0
2
NOR
73-P-01B discharge
CHLORIDE INJECTION SECTION

N2 to chloride
PI-1201
injection drum
Chloride injection
PI-1202
drum
73-P-02A discharge
PI-1205
73-P-02B discharge
PI-1204
Drum pump discharge
PI-1209
N2 to drum
PI-1207
Dry naphtha to
FO-1201
73-V-03
M3/HR
17.6
(min)
10.6
(max)
35.8
(min)
(max)
FO-1202
LIT/HR
FEED DRYER SECTION

73-DR-01A bottom
73-DR-01A top
73-DR-01B top
Dryer bottom
PI-1301A
PI-1302A
PI-1302B
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
24.6
23.6
23.6
evacuation line to static
PI-1303
Kg/cm2 G
ATM to FV
PI-1301B
TI-1301A
Kg/cm2 G
C
mixer
73-DR-01B bottom
Treated naphtha to
MAX
900
2000
2000
900
2000
900
24.6
40
DCS
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Description
dryer 73-DR-01A
Treated naphtha to
Tag no.
TI-1301B
Unit
C
C
C
dryer 73-DR-01B
HYDROGEN MAKE-UP COMPRESSOR
H2 to compressor
PI-1401
Kg/cm2 G
73-K-01A/B
H2 make up from CCR
PI-1409
Kg/cm2 G
73-K-01 A discharge
PI-1404
Kg/cm2 G
73-K-01 B discharge
PI-1408
Kg/cm2 G
H2 to unit 74
PI-1406
Kg/cm2 G
73-K-01A suction
PI-1403
Kg/cm2 G
73-K-01B suction
PI-1407
Kg/cm2 G
H2 to unit 74
FQI-401
NM3/HR
H2 to dryers
FI-1402
NM3/HR
( S stripping line)
Rev. A
Page 97 of 221
143-310
40
143-310
Value
Dryer regeneration
DCS
Dryer regeneration
21.9
7917
22.0
39.9
39.9
39.0
21.8
21.8
1333 (min)
1000 max
3475
H2 make up to KOD
FI-1403
NM3/HR
H2 from CCR to KOD

Make up compressor
TI-1401
(min)
40
TI-1404
93
TI-1407
93
40
C
C
MM
MM
44 max
44 max
300
300
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
39.4
39.4
38.4
38.4
22.9
Kg/cm2 G
ATM/ FV
A discharge
Make up compressor
B discharge
H2 to unit 74 &
TI-1404
dryers
CWR from 73-E-01A
TI-1405
CWR from 73-E-01B
TI-1406
H2 make up KOD
LI-1401A
H2 make up KOD
LT-402
HYDROGEN DRYER SECTION
73-DR-02A inlet
PI-1501A
73-DR-02B inlet
PI-1501B
73-DR-02A outlet
PI-1502A
73-DR-02B outlet
PI-1502B
Dry H2 to 73-E-02
PT-1503
Evacuation line to
PI-1504
static mixer
11698
1050
1050
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Description
Tag no.
Rev. A
Page 98 of 221
Unit
Value
PI-1505
Kg/cm2 G
39.4
73-DR-02A inlet
TI-1501A
40
73-DR-02B inlet
TI-1501B
40
73-DR-02A outlet
TI-1502A
40
73-DR-02B outlet
TI-1502B
40
Hydrogen from dryers

H2 to 73-M-01
Depressurization Line
FIC-1501
FIC-1504
FO-1505
NM3/HR
NM3/HR
NM3/HR
Hydrogen to flare
NOR
4436
---
MIN
259
MAX
5381
HYDROGENATION SECTION
PI-1601
PI-1602
Kg/cm2 G
Kg/cm2 G
21.6
19.6
PI-1603
Kg/cm2 G
21.6
PI-1605
Kg/cm2 G
21.6
PI-1606
Kg/cm2 G
19.6
PI-1607
Kg/cm2 G
29.0
PI-1609
Kg/cm2 G
8.6
73-E-02 to
PI-1610
Kg/cm2 G
7.9
73-E-08
73-E-03 shell side outlet
Reactor effluent from
PI-1611
Kg/cm2 G
22.4
73-E-03
73-E-02 outlet
Dry feed from
PI-1612
Kg/cm2 G
32.5
PI-1613
Kg/cm2 G
23.3
PI-1614
Kg/cm2 G
23.8
PI-1615
PI-1616
Kg/cm2 G
Kg/cm2 G
21.6
16.1
Feed inlet to 73-R-01

73-R-01 outlet
Feed inlet to
Hydrogenation reactor
Feed inlet to
outlet
HP steam to
73-E-04
DIH recycle to 73-E-02
DIH recycle from
73-
DR-01/02 A/B
Reactor feed inlet
73-R-01 outlet

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Description
Evacuation line to
73-J-01
Hydrogenation
reactor
01/02 A/B
73-E-04 temperature
control
Hydrogenation
reactor
outlet
73-E-03
DIH recycle to
73-E-
02
DIH recycle from 73-E02
73-R-01
73-R-01
73-R-01
73-R-01
73-R-01
73-R-01
73-R-01
73-R-01
73-R-01
73-R-01
Reactor effluent to
73-E-03
Steam to 73-E-04
Rev. A
Page 99 of 221
Tag no.
Unit
Value
PI-1608
Kg/cm2 G
ATM/ FV
PDI/PDAH-
diff. Pressure
Dry feed from 73-DR-
Doc No. Draft
Kg/cm2 G
PDAH = 2.0
TI-1601
40.0
TI-1602
TI-1603
C
C
60
108
TIC-1604
168
TI-1605
176
TI-1606
145
TI-1607
105
TI-1608
60
TI-1609
TI-1610
TI-1611
TI-1612
TI-1613
TI-1614
TI-1615
TI-1616
TI-1617
TI-1618
C
C
C
C
C
C
C
C
C
C
176 max
176 max
176 max
176 max
176 max
176 max
176 max
176 max
176 max
176 max
TI-1619
182
FIC-1601
KG/HR
3870
1603
HYDROGENATION REACTOR SEPARATOR DRUM SECTION

Controller in H2
PIC-1701
Kg/cm2 G
19
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Description
pressurization line of
73-V-04
73-V-04
depressurized
line to flare
73-P-04A/B discharge to
Rev. A
Page 100 of 221
Tag no.
Unit
PKIC-1702
Kg/cm2 G
--
PT-1702
Kg/cm2 G
40.1
PT-1703
PI-1709
PI-1705
PI-1706
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
28.1
19.2
28.1
28.1
PI-1707
Kg/cm2 G
40.1
PI-1708
Kg/cm2 G
40.1
PI-1704
Kg/cm2 G
19.2
PI-1710
Kg/cm2 G
40.1
TIC-1702
TI-1703
FIC-1701
FIC-1702
FT-1703
FT-1704
FI-1705
C
C
M3/HR
M3/HR
M3/HR
M3/HR
105.4
265.1
105.4
265.1
137-176
137-176
70.1
117
70.1
117
NM3/HR
6200
NM3/HR
6200
M3/HR
265.1
FO-1707
M3/HR
70
FO-1708
M3/HR
LI-1701
MM
400
2250
LI-1702
MM
400
2250
static mixer
73-V-04
73-P-03 A discharge
73-P-03 B discharge
73-P-04 A discharge
to static mixer
73-P-04 B discharge
to static mixer
73-P-04A/B suction
73-P-04A/B discharge to
ISOM reactor bypass
73-A-01 downstream
73-P-04A/B suction
73-V-04 purge gas out
73-V-04 H2
pressurization
73-P-03 A/B minimum
flow circulation
flush drum 73-V-04
flush drum 73-V-04
CASE I
FI-1705
CASE II
FO-1706
Value
117
121.2
318.1
121.2
318.1
318.1
121.2

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Description
Tag no.
Unit
Doc No. Draft

Rev. A
Page 101 of 221
Value
LG-1703A
MM
400
2250
LG-1703B
flush drum 73-V-04
ISOM REACTION SECTION
Isomerate from reactor
PT/PIC-
MM
400
2250
flush drum 73-V-04

to stabilizer
Reactor feed inlet to 73R-02
1801
PI-1802
73-R-02
73-R-03
73-R-02
73-R-03 inlet
Isomerate from 73-R03
Isomerate from 73-R-
35
Kg/cm2 G
33
PI-1804
Kg/cm2 G
32
PI-1805
Kg/cm2 G
30
PI-1806
Kg/cm2 G
35
PI-1807
Kg/cm2 G
33
PI-1808
Kg/cm2 G
32
PI-1809
Kg/cm2 G
30
PI-1810
Kg/cm2 G
30
Kg/cm2 G
Software, PAHH=2
Kg/cm2 G
Software, PAHH=2
Kg/cm2 G
35
PI-1815
Kg/cm2 G
33
PI-1816
TIC-1801
Kg/cm2 G
C
32
125-145
PDI/PAHH-
R-02
Diff pressure across 73-
1812
PDI/PAHH-
R-03
1813
PI-1814
Kg/cm2 G
30
PI-1803
03
73-R-02
Kg/cm2 G
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 102 of 221
Description
Tag no.
Unit
73-E-03
73-R-02
73-R-02
73-R-02
73-R-02
73-R-02
73-R-02
73-R-02
73-R-02
73-R-02
73-R-02
73-R-02
73-R-02
73-R-02
73-R-02 effluent
73-R-03
73-R-03
73-R-03
73-R-03
73-R-03
73-R-03
73-R-03
73-R-03
73-R-03
73-R-03
73-R-03
73-R-03
73-R-03
73-R-03 effluent
TI-1802
TI-1803
TI-1804
TI-1805
TI-1806
TI-1807
TI-1808
TI-1809
TI-1810
TI-1811
TI-1812
TI-1813
TI-1814
TI-1815
TI-1816
TI-1817
TI-1818
TI-1819
TI-1820
TI-1821
TI-1822
TI-1823
TI-1824
TI-1825
TI-1826
TI-1827
TI-1828
TI-1829
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
130-182
130-182
130-182
130-182
130-182
130-182
130-182
130-182
130-182
130-182
130-182
130-182
130-182
130-153
125-153
125-153
125-153
125-153
125-153
125-153
125-153
125-153
125-153
125-153
125-153
125-153
125-153
130-153
TI-1831
148-182
FI-1801A
M3/Hr
PIC-1901
Kg/cm2 G
73-R-02
MP steam inlet to
ejector
ISOM stabilizer section
Stabilizer OVHD vapor
Value
--
--
--
14.8
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Description
Stabilizer OVHD
Stabilizer OVHD
Stabilizer OVHD
73-C-01 bottom
Diff press across
Tag no.
PT-1902
PT-1903
PT-1904
PI-1905
PDI/PDAH-
chloride guard bed

VHP steam to
73-E-05
Feed inlet to 73-C-01
73-C-01 top
73-C-01 bottom
Chloride guard bed inlet
73-E-05 inlet
Feed inlet to 73-C-01
73-C-01 top
73-C-01
73-C-01 top
73-C-01
73-C-01 inlet
73-E-05 outlet to 73-C01
73-E-05 inlet shell side
Chloride guard bed inlet
Rev. A
Page 103 of 221
Unit
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Value
14.8
14.8
14.8
15.1
Kg/cm2 G
PDAH=0.4
PI-1914
Kg/cm2 G
32.1
PI-1915
PI-1910
PI-1911
PI-1912
PI-1914
TI-1901
TI-1902
TI-1903
TI-1904
TIC-1905
TI-1906
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
C
C
C
C
C
C
15.2
14.8
15.1
15.1
32.1
127-145
74-84
170-181
90
138
127-145
TI-1907
170-181
TI-1908
TI-1909
C
C
169-179
170-181
MIN
3026
MAX
7860
49.5
118
1906
FIC-1901
KG/HR
NOR
7140
FIC-1902
M3/HR
107.4
LIC-1901
MM
650
4150
LIC-1902
MM
**
**
LI-1903
73-C-01
73-V-19
LG-1904
73-C-01
LG-1905
ISOM STABILISER OVHD
MM
650
4150
MM
MM
**
650
**
4150
VHP steam to 73-E-05

73-C-01 outlet to 73-C02
Stabilizer
73-C-01
Condensate pot 73-V19
Stabilizer
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Description
73-V-05
Reflux to
73-C-01
73-V-05
73-P-05A discharge
73-P-05B discharge
73-P-05A suction
73-P-05B suction
OVHD vapor inlet to
73-E-06
OVHD vapor inlet to
73-V-05
OVHD vapor inlet to
73-V-05
Cooling water return
from 73-E-06A
from 73-E-06B
Offgas line from 73-V05
73-P-05A/B min flow
circ line
Page 104 of 221
Tag no.
PI-2001
Unit
Kg/cm2 G
Value
14.3
PT-2002
Kg/cm2 G
19.4
PI-2003
PI-2004
PI-2005
PI-2007
PI-2006
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
14.3
19.4
19.4
14.7
14.7
TIC-2001
65
TI-2002
43-49
TI-2003
43-49
TI-2005
44 max
TI-2004
44 max
FIC-2001
M3/HR
41.8
19.7
50.1
FI-2002
NM3/ HR
2232
971
2456
FO-2003
M3/HR
Stabilizer reflux drum

LIC-2001
MM
LI-2002
MM
LG-2003
MM
ISOM DIH RECYCLE DRUM SECTION
73-E-07 shell side inlet
PI-2101
Kg/cm2 G
PI-2102
Kg/cm2 G
73-E-07 tube side inlet
PI-2103
Kg/cm2 G
73-E-07 tube side outlet
PI-2104
Kg/cm2 G
DIH recycle drum top
PI-2105
Kg/cm2 G
73-P-07B discharge
PI-2106
Kg/cm2 G
73-P-07A discharge
PI-2107
Kg/cm2 G
DIH recycle to 73-VPI-2108
Kg/cm2 G
Rev. A
14
150
150
150
1550
1550
1550
4.6
2.2
11.7
11.0
2.0
9.6
9.6
6.6
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Description
Rev. A
Page 105 of 221
Tag no.
Unit
01
73-P-07A suction
73-P-07B suction
73-E-07 shell side inlet
73-E-07 tube side outlet
DIH recycle to 73-V-01
Cooling water outlet
PI-2109
PI-2110
TI-2101
TI-2102
TI-2103
TI-2104
TI-2105
Kg/cm2 G
Kg/cm2 G
C
C
C
C
C
2.2
2.2
105
123
168
127
40
from
TI-2106
44 max
TI-2107
44 max
FIC-2101
M3/HR
39.3
18.3
47.1
FIC-2102
M3/HR
**
30
97.9
FIC-2103
M3/HR
38
17.5
45.6
FI-2104
M3/HR
38
17.5
45.6
300
300
4300
4300
73-E-08A
Cooling water outlet
from 73-E-08A
73-P-07 discharge to
73-C-02
DIH recycle to 73-V01
DIH recycle from 73-E-
08A/B to storage
73-V-07
LIC-2101
MM
73-V-07
LG-2102
MM
ISOM DEISOHEXANISER SECTION:
PT/PIC73-C-02 top
Kg/cm2 G
2201
Deisohexaniser
PT/PAHHKg/cm2 G
overhead
2202
Deisohexaniser
PT/PAHHKg/cm2 G
overhead
2203
Deisohexaniser
PT/PAHHKg/cm2 G
overhead
2204
73-C-02 top tray
PI-2205
Kg/cm2 G
73-C-02 bottom
PI-2206
Kg/cm2 G
73-P-08A suction
PI-2213
Kg/cm2 G
73-P-08B suction
PI-2214
Kg/cm2 G
Value
1.7
1.7 PAHH=2.6
1.7 PAHH=2.2
1.7 PAHH=2.2
1.7
2.3
2.3
2.3
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Description
73-P-08A discharge
73-P-08B discharge
MP steam to 73-E-10
73-C-02
Above tray 35
73-C-02 top
Tag no.
PI-2212
PI-2216
PI-2208
PI-2209
PI-2210
PI-2211
PDT/PDAH
C-02
73-C-02 above feed tray
73-C-02 feed from
-2207
PI-2215
73-E-07
73-C-02, above feed
tray
73-C-02
73-C-02 above tray 37
73-C-02
73-C-02
73-C-02
Deisohexaniser
overhead
73-C-02
103-E-2008 shell side
inlet
73-P-08 A/B suction
73-E-08 shell outlet
Reflux to 73-C-02
73-P-08 A/B discharge
MP steam to 73-E-08
73-P-08 discharge
73-P-08 minimum flow
Page 106 of 221
Unit
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Value
21.1
21.1
8.3
2.3
2.0
1.7
Kg/cm2 G
PDAH=0.5
Kg/cm2 G
1.9
TI-2201
96
TI-2202
95
TI-2203
TI-2204
TI-2205
TI-2206
TI-2207
C
C
C
C
C
78
78
105
124
124
TI-2208
78
TIC-2209
124
TI-2210
122-136
TI-2211
TI-2212
C
C
FIC-2201
FIC-2202
FIC-2203
FI-2204
M3/HR
M3/HR
KG/HR
M3/HR
NOR
146.7
22.1
12500
22.1
122-137
120-137
MIN
68
3.0
5229
3.0
FO-2205
M3/HR
7.5
line
73-C-02 bottom
LIC-2202
MM
73-C-02 bottom
LG-2203
MM
ISOM DEISOHEXANISER OVHD SECTION
From 73-C-02 to
PDT/PDICKg/cm2 G
Rev. A
MAX
176.1
24.3
13920
24.3
3.0
24.3
300
300
1700
1700
1.7, PDIC=0.5
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Description
73-V-08
73-V-08
73-P-06 discharge
73-P-06 A discharge
73-P-06 B discharge
73-P-09 B discharge
73-P-09 A discharge
OVHD vapor from 73C-02 to 73-V-08 (AFC
2003 downstream)
Deisohexaniser reflux
drum 73-V-08
73-P-06 A suction
73-P-06 B suction
73-P-09 A suction
73-P-09 B suction
OVHD vapor from 73C-02 to 73-V-08 (AFC
2003 downstream)
to 73-E-09
73-P-06A/B minimum
Tag no.
2301
PI-2302
PT/PALL-
Page 107 of 221
Unit
Value
Kg/cm2 G
1.2
Kg/cm2 G
10
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
10
10
15.8
15.8
PI-2308
Kg/cm2 G
1.3
PI-2309
Kg/cm2 G
1.2
PI-2310
PI-2311
PI-2312
PI-2313
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
1.3
1.3
1.3
1.3
55
2303
PI-2304
PI-2305
PI-2306
PI-2307
TIC/ TI2301
FIC-2301
M3/HR
37.1
10.0
40.8
FIC-2302
M3/HR
36.1
10
39.7
53
6.7
**
300
300
1600
1600
FO-2303
M3/HR
flow
73-V-08
LIC-2301
MM
73-V-08
LG-2302
MM
ISOM SCRUBBER DM WATER PUMPS SECTION
73-P-13A suction
PI-2401
Kg/cm2 G
73-P-13B suction
PI-2402
Kg/cm2 G
73-P-12A discharge
PI-2403
Kg/cm2 G
73-P-12B discharge
PI-2404
Kg/cm2 G
73-P-13A discharge
PI-2405
Kg/cm2 G
73-P-13B discharge
PI-2406
Kg/cm2 G
PI-2407
Kg/cm2 G
to 73-C-03
Rev. A
14.5
14.5
15.5
15.5
17.0
17.0
17.0
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Description
73-V-10 drum level
Page 108 of 221
Tag no.
Unit
Value
LG-2401
MM
300
ISOM SCRUBBER SECTION

Off gas to fuel gas
PIC-2501
header
73-C-03
PI-2502
73-C-03 top
PI-2503
73-C-03
PI-2504
73-C-03
PI-2505
73-P-11A suction
PI-2506
73-P-11A discharge
PI-2507
PI-2508
73-P-11B suction
PI-2509
73-P-11B discharge
PI-2510
LP steam to 73-E-12
PI-2511
Off gas to fuel gas
PI-2512
header
73-C-03 overhead vapor
PI-2513
Differential pressure of
PDI-2514
73-C-03
TIC-2501
73-C-03 overhead
TI-2502
Off gas from 73-V-05 to
TI-2503
73-C-03
73-E-12 shell inlet
TI-2504
Off gas to fuel gas
TI-2505
header
Condensate from 73FIC-2501
E-12
DM water to 73-C-03
FI-2502
Off gas to fuel gas
FI-2503
header
Off gas to 73-DR-03
FI-2504
A/B
73-E-12 shell outlet to
FI-2505
73-C-03
Rev. A
Kg/cm2 G
12.5
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
12.7
12.6
12.8
12.9
13.9
18.7
18.7
13.7
18.7
1.8
Kg/cm2 G
4.6
Kg/cm2 G
12.6
Kg/cm2 G
PDAH=0.9
C
C
3350
55
43-49
o
o
43-49
45-55
43-49
C
C
C
Kg/HR
193
100
1143
M3/HR
19.9
**
24.0
NM3/HR
2550
980
2476
NM3/HR
2250
980
2476
M3/HR
19.9
15.0
36.0
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Description
73-E-12 shell outlet to
Tag no.
Unit
FI-2506
M3/HR
73-C-03
73-C-03 chimney tray
LI-2501
MM
73-C-03 bottom
LI-2502
MM
73-C-03 bottom
LG-2503
MM
LG-2504
SCRUBBER OFF GAS DRYER SECTION
Off gas to 73-DR-03 A
PI-2601A
Kg/cm2 G
Off gas to 73-DR-03 B
PI-2601B
Kg/cm2 G
Off gas from
PI-2602A
Kg/cm2 G
73-DR-03A
Off gas from
PI-2602B
Kg/cm2 G
73-DR-03B
PI-2603A
Kg/cm2 G
PI-2603B
Kg/cm2 G
o
TI-2601A
C
o
TI-2601B
C
Off gas from
o
TI-2602A
C
73-DR-03A
Off gas from
o
TI-2602B
C
73-DR-03B
LPG REFREGERATION SECTION
Off gas to 73-E-13B
PI-2701
Kg/cm2 G
Rich oil + gas to
TIC-2701
C
73-V-11
Lean oil from 73-E-14
TI-2702
C
Lean oil to 73-V-11
TIC-2703
C
Off gas to 73-E-13B
TIC-2704
C
Lean oil to 73-V-11
TI-2706
C
Off gas to 73-E-13B
TI-2707
C
LPG SEPARATOR DRUM SECTION
LPG separator drum 73PIC-2801
Kg/cm2 G
V-11 overhead
Heavy isomerate to
PIC-2802
Kg/cm2 G
Rev. A
Page 109 of 221
Value
10
15
100
600
600
100
36
1500
5950
5950
1500
12.6
12.6
11.6
11.6
12.6
12.6
43-49
43-49
43-49
43-49
11.6
5
16
5
40
5
40
11 PAH=12
PAL=10.2
16.0
storage 73-E-16 A/B

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Description
shell outlet
73-V-11 differential
Tag no.
PDI/PDAH-
Unit
Doc No. Draft

Rev. A
Page 110 of 221
Value
Kg/cm2 G
PDAH=0.1
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
11
11.1
11.0
PI-2807
Kg/cm2 G
4.5
PI-2808
PI-2809
PI-2810
PI-2811
PI-2812
PI-2813
PI-2814
PI-2815
PI-2816
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
11.2
11.2
20.5
20.5
16.8
15.7
17.0
16.2
16.0
storage 73-E-16 A/B
PI-2817
Kg/cm2 G
6.1
shell outlet
73-E-14 tube inlet
73-E-14 tube outlet
73-V-11 OVHD
73-E-14 shell inlet
73-E-15 tube inlet
73-E-15 tube outlet
73-E-14 tube inlet
Oil + gas to 73-V-11
Off gas to fuel gas
PI-2818
PI-2819
TI-2801
TI-2802
TI-2803
TI-2804
TI-2805
TI-2806
TI-2807
TI-2808
Kg/cm2 G
Kg/cm2 G
C
C
C
C
C
C
C
C
14
12.4
15.0
5.0
15.7
124.0
95.0
40.0
40.0
5.0
TI-2809
24.0
TI-2810
5.0
TI-2811
40.0
pressure
73-V-11 overhead
73-V-11
73-V-11 top
73-V-11 overhead to
fuel gas header
73-P-14 A suction
73-P-14 B suction
73-P-14 A discharge
73-P-14 B discharge
73-E-14 shell inlet
73-E-15 tube inlet
73-E-15 tube outlet
73-E-16 A/B shell outlet
Heavy isomerate to
header
73-V-11 bottom to 73P-14 A/B suction
Heavy Isomerate to
storage
2803
PI-2804
PI-2805
PI-2806
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Description
73-E-14 tube outlet
from 73-E-16 B
Rev. A
Page 111 of 221
Tag no.
TI-2812
Unit
C
Value
16.0
TI-2813
44 max
44 max
from 73-E-16 A
73-P-14A/B min flow
TI-2814
FIC-2801
M3/hr
10.6
3.8
11.7
line
Off gas from 73-V-11
LPG separator drum
FIC-2802
M3/hr
**
8.0
11.7
FIC-2803
FI-2804
FI-2805
FI-2806
M3/hr
M3/hr
M3/hr
NM3/hr
6.2
4.4
19.8
1250
1.95
1.4
2.7
477
6.8
4.8
21.8
1374
LIC-2801
MM
Low=300 Max=2400
MM
Low=300 Max=2400
Kg/cm2 G
13.4
Kg/cm2 G
PDAH=0.5
Kg/cm2 G
13.9
Kg/cm2 G
13.4
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
C
13.8
13.9
21.1
21.1
14.1
14.5
14.1
19.1
19.1
12.8
12.8
13.4
32.0
63.0
73-V-11
LPG separator drum
LG-2802
73-V-11
LPG STRIPPER SECTION
LPG stripper OVHD
PIC-2901
73-C-04 differential
PDI/PDAHpressure
73-C-04 bottom
73-C-04 OVHD
LPG stripper feed
73-C-04 bottom
73-P-15 A discharge
73-P-15 B discharge
73-P-15 B suction
73-P-18 A/B shell inlet
73-P-15 A suction
73-P-16A discharge
73-P-16B discharge
73-P-16A suction
73-P-16B suction
73-C-04 top
73-P-18 A/B shell inlet
2902
PI-2903
PT/PAHH
2904/05/06
PI-2907
PI-2908
PI-2909
PI-2910
PI-2911
PI-2912
PI-2913
PI-2914
PI-2915
PI-2916
PI-2917
PI-2918
PI-2919
TI-2901
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Description
LPG stripper feed
73-C-04 OVHD
73-P-18 A/B shell outlet
73-C-04 above 25th tray
73-C-04 below 28th tray
73-E-17 shell inlet
73-E-18A tube outlet
73-E-18A shell inlet
LPG stripper feed
Stripper overhead
73-P-16A/B suction
73-E-18B tube outlet
Rev. A
Page 112 of 221
Tag no.
TI-2902
TI-2903
TI-2904
TIC-2905
TI-2906
TI-2907
TI-2908
TI-2909
TIC-2910
TI-2911
TI-2912
TI-2913
TI-2914
TI-2915
TI-2916
TI-2917
TI-2918
TI-2919
Unit
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
FIC-2901
M3/hr
11.1
3.8
13.3
FIC-2902
M3/hr
4.5
**
6.8
FIC-2903
M3/hr
1.5
0.5
1.70
FIC-2904
M3/hr
4.5
1.9
6.0
LPG stripper bottom
LIC-2901
MM
MIN=300 MAX=1500
73-C-04 side draw line
LT-2902
MM
MIN=150 MAX=1900
LIC-2904
MM
MIN=100 MAX=1000
LPG stripper bottom
LG-2906
MM
MIN=300 MAX=1500
Kg/cm2 G
13.0
to 73-C-04
Condensate line from
73-V-21
73-P-16A/B minimum
circulation line
LPG STRIPPER OVHD SECTION

73-V-12 inlet
PI-3001
Value
98.0
56.0
40.0
98.0
98.0
98.0
98.0
212.0
98.0
98.0
208.0
212.0
44 max
63.0
98.0
56.0
40.0
44 max
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Description
LPG stripper reflux
drum 73-V-12
73-P-17B suction
Off gas from 73-V-12
73-P-17A suction
73-P-17B discharge
73-P-17A discharge
73-V-12 inlet
Offgas from 73-V-12
73-V-12 off gases
73-P-17A/B minimum
Page 113 of 221
Tag no.
Unit
PI-3002
Kg/cm2 G
13.0
PI-3003
PI-3004
PT/PALL-
Kg/cm2 G
Kg/cm2 G
13.0
13.0
Kg/cm2 G
18.5
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
C
C
C
C
NM3/HR
399
13.0
18.5
18.5
40.0
40.0
44 max
44 max
129
440
M3/hr
4.5
4.4
**
3005
PI-3006
PI-3007
PI-3008
TI-3001
TI-3002
TI-3003
TI-3004
FI-3001
FO-3002
flow circulation
73-V-12
LIC-3001
MM
73-V-12
LG-3002
MM
ISOM DRYERS REGENERATION SECTION
PI-3101
Kg/cm2 G
Regenerant to 73-FPI-3102
Kg/cm2 G
01
Hot vapor to 73-A-04
TI-3101
C
73-F-01 outlet
TI-3102
C
Hydrogen to 73-F-01
TI-3103
C
73-F-01 outlet
TIC-3104
C
Light isomerate to
TI-3108
C
73-E-20
FIC-3101
Kg/Hr
HC feed to 73-E-20
FIC-3102
M3/Hr
(case-1)
HC feed to 73-E-20
FIC-3102
M3/HR
(case-II)
N2 to 73-E-20
FI-3103
NM3/ HR
Dryer regenerant
LT-3101
MM
Rev. A
Value
Low=150,High=600
Low=150,High=600
32.0
10.5
143-310
143-310
143-153
143-310
40.0
6061
782
6667
15.0
5.0
16.5
15.0
5.0
16.5
240
--

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Description
vaporizer 73-E-20
Dryer regenerant
vaporizer 73-E-20
Dryer regenerant
vaporizer 73-E-20
Light isomerate to
Rev. A
Page 114 of 221
Tag no.
Unit
LIC-3102
MM
--
LG-3103
MM
--
PIC-3201
Kg/cm2 G
8.2
Kg/cm2 G
Kg/cm2 G
Kg/cm2 G
C
C
C
C
C
MM
MM
MM
MM
8.7
8.4
8.2
65.0
40.0
290.0
44 max
44 max
MIN=2450 MAX=4000
MIN=300 MAX=800
MIN=300 MAX=800
MIN=2450 MAX=4000
Kg/cm2 G
16.7
Kg/cm2 G
7.1
Kg/cm2 G
7.1
44 max
40.0
137.0
40.0
40.0
C
C
40.0
40.0
storage
73-E-21A/B shell inlet
PI-3202
73-E-21A/B shell outlet
PI-3203
73-V-13
PI-3204
73-E-21A/B shell inlet
TI-3201
73-E-21A/B shell outlet
TI-3202
Hot vapor to 73-A-04
TI-3203
TI-3204
TI-3205
73-V-13
LIC-3201
73-V-13
LI-3202
73-V-13
LG-3203
73-V-13
LG-3204
PRODUCT COOLING SECTION
LPG product to storage
PI-3301
PI-3302
slop
Light isomerate to
PI-3303
storage
73-E-11 tube outlet
TI-3301
Light isomerate to
TI-3302
storage
73-E-11 shell inlet
TI-3303
Off spec isomerate to
TI-3304
storage
Light isomerate to
TI-3305
storage at B/L
LPG to storage
TI-3306
Off spec isomerate to
TI-3307
Doc No. Draft
Value
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Description
storage at B/L
LPG to storage
LPG to off spec LPG
storage
Light isomerate to
storage
slop
7.5
Tag no.
Unit
TI-3308
TI-3309
FIC-3301
C
C
M3/hr
FO-3302
Rev. A
Page 115 of 221
Value
5.4
44 max
44 max
1.9
6.0
M3/hr
5.4
1.9
6.0
FI-3303
M3/hr
36.1
10.0
39.7
FI-3304
M3/hr
22.1
3.0
24.3
SET POINTS OF ALARMS AND TRIPS

Tag no.
Description
Unit
Setting
PAH-1101
73-V-01
Kg/cm2 G
5.0
PAL-1101
73-V-01
Kg/cm2 G
3.7
PALL-1102
73-P-01 discharge
Kg/cm2 G
27.4
FAH-1101
73-P-01 discharge
M3/HR
94.4
FAL-1101
73-P-01 discharge
M /HR
55.7
FAL-1104
Feed to
73-V-01
M3/HR
19.5
FAH-1104
Feed to
73-V-01
M3/HR
53.4
73-V-01 boot
MM
450
LAH/LAL-1201
73-V-03
MM
1600/500
PAH/PAL-1201
73-V-03
Kg/cm2 G
7.0 / 4.7
TAH-1402
H2 make up comp
discharge
103
TAH-1403
H2 make up comp
discharge
50
LAH/LAL-1401
73-V-02
MM
700 / 400
LAHH-1402
73-V-02
MM
1050
PALL-1503
Dry H2 to 73-E-02
Kg/cm2 G
21.7
H2 from dryers
73-DR-02A/B
NM3/HR
5381 / 259
LAL-1104
FAH/FAL-1501

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Tag no.
PAL-1603
Doc No. Draft

Rev. A
Page 116 of 221
Description
Unit
Setting
Feed inlet to 103-R2001
Kg/cm2 G
20.8
PAL-1604
Feed to
73-V-04
Kg/cm2 G
18.8
TAH/TAL-1604
Feed to
73-R-01
Set Point +5 Set Point

-5
TAH-1605
Feed to
73-V-04
Set Point +10
TAH-1609 to 1618
73-R-01
Set Point +5
TAHH-1609 to 1618
73-R-01
Set Point +10
73-V-04 system
pressure
Kg/cm2 G
20.0 / 18.2
PALL-1702
73-P-04 discharge
Kg/cm2 G
38.6
PALL-1703
73-P-03 discharge
Kg/cm2 G
26.6
TAH/TAL-1701
Recycle to
hydrogenation
reactor
Set Point +5 Set Point

-5
TAH-1702
Recycle to
hydrogenation
reactor
Set Point +10
FAH/FAL-1701
73-P-04 discharge
M3/HR
121.1 / 70.1
LAH/LAL-1701
73-V-04
MM
2000 / 650
LAH/LAL-1702
73-V-04
MM
2000 / 650
PAH/PAL-1801
Isomerate to 73-C01
Kg/cm2 G
31.0 / 29.2
PAHH-1815
Feed inlet to 73-R02
Kg/cm2 G
**
PAHH-1812
Diff press across

73-R-02
Kg/cm2 G
2.0
PAHH-1813
Diff press across

73-R-03
Kg/cm2 G
2.0
73-R-03 inlet
Set Point +10 Set

Point -5
PAH/PAL-1701
TAH/TAL-1801

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Tag no.
Doc No. Draft

Rev. A
Page 117 of 221
Description
Unit
Setting
73-R-02
Set Point +10
73-R-03 outlet
Set Point +10
73-R-03
Set Point +10
TAH-1829
73-R-03 outlet
Set Point +10
TAH-1831
Reactor effluent
from 73-R-02
Set Point +10
PAH/PAL-1901
73-C-01 overhead
Kg/cm2 G
15.8 / 14.0
PAHH-1902
73-C-01 overhead
Kg/cm2 G
16.3
PAHH-1903
73-C-01 overhead
Kg/cm2 G
16.3
PAHH-1904
73-C-01 overhead
Kg/cm2 G
16.3
FAH-1901
Condensate from
103-D-2019
Kg/hr
78060
LAH/LAL-1901
Stabilizer
MM
3800 / 1900
LAH/LAL-1902
Condensate
pot( 73-V-19)
MM
** / **
Stabilizer (73-C-01)
MM
3800/1900/650
73-V-05
Kg/cm2 G
15.3 / 13.5
PALL-2002
73-P-05 discharge
Kg/cm2 G
17.9
TAH/TAL-2001
OVHD vapor inlet

to 73-E-06 A/B
Set Point +10 Set

Point -5
TAH/TAL-2002
OVHD vapor inlet

to 73-V-05
Set Point +10 Set

Point -5
FAH-2002
Off gas from 73-V05
NM3/HR
**
LAH/LAL-2001
Stabilizer reflux
drum 73-V-05
MM
950 / 350
LAHH/LAH/LAL2002
Stabilizer reflux
drum 73-V-05
MM
1550/950/350
TAH-1802 to 1814
TAH-1815
TAH-1816 to TAH1828
LAH/LAL/ LALL1903
PAH/PAL-2001

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Tag no.
Doc No. Draft

Rev. A
Page 118 of 221
Description
Unit
Setting
TAH-2105
DIH recycle to 73V-01
50
FAH/FAL-2101
73-E-07 inlet line
M3/HR
47.1 / 18.3
73-P-07 min
circulation line
M3/HR
30.0
LAH/LAL-2101
DIH recycle drum

(73-V-07)
MM
3800 / 800
PAH/PAL-2201
73-C-02 top
Kg/cm2 G
2.2 / 1.3
PAHH-2202
73-C-02 OVHD
Kg/cm2 G
2.6
PAHH-2203
73-C-02 OVHD
Kg/cm2 G
2.2
PAHH-2204
73-C-02 OVHD
Kg/cm2 G
2.2
TAH-2208
73-C-02 OVHD
Set Point +10
FAL-2201
73-P-06A/B
discharge
M3/HR
68.0
FAH/FAL-2202
73-P-08A/B
discharge
M3/HR
24.3 / 3.0
73-E-10 steam inlet
KG/HR
13920
LAH/LAL-2201
73-V-20
MM
**
LAH/LAL-2202
DIH column (73-C02)
MM
1550 / 450
73-P-06 discharge
Kg/cm2 G
7.5
TAH/TAL-2301
73-V-08 inlet
Set Point +10 Set

Point -5
FAH/FAL-2301
73-P-09A/B
discharge
40.8 / 10.0
LAH/LAL-2301
DIH reflux drum
MM
1450 / 500
PALL-2407
73-P-13 discharge
Kg/cm2 G
15.5
PAH-2501
73-C-03 OVHD
Kg/cm2 G
13.5
PALL-2508
73-E-12 shell inlet
Kg/cm2 G
17.2
TAH/TAL-2501
Set Point +10 Set

Point -5
FAL-2102
FAH-2203
PALL-2303

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Tag no.
Doc No. Draft

Rev. A
Page 119 of 221
Description
Unit
Setting
73-C-03 chimney
tray
MM
1500 / 100
FAL-2502
Water inlet to 73-C03
M3/hr
19.0
FAH -2504
Off gas to dryer
NM3/hr
2476.0
FAL-2505
Caustic circulation
M3/Hr
19.0
TAH-2701
73-E-13B tube
outlet
Set Point +2
TAH-2703
73-E-13A tube inlet
Set Point +2
PAH/PAL-2801
Offgas to fuel gas

header
Kg/cm2 G
12.0 / 10.2
TAH-2801
Offgas to fuel gas

header
Set Point +10
TAH-2806
73-E-16 A/B shell

outlet
Set Point +5
FAH/FAL-2801
73-P-14A/B
discharge
M3/Hr
11.6 / 3.8
FAH/FAL-2804
73-E-15 tube inlet
M3/Hr
6.8 / 2.0
LAH/LAL-2801
73-V-11
MM
2150 / 550
PAH/PAL-2901
73-C-04 overhead
Kg/cm2 G
14.4 / **
PAHH-2904/05/06
73-C-04 overhead
Kg/cm2 G
14.9
TAH/TAL-2902
Feed to LPG
stripper
Set Point +10 Set

Point -5
TAH/TAL-2903
73-C-04 overhead
Set Point +10 Set

Point -5
TAH/TAL-2905
73-C-04
Set Point +10 Set

Point -5
TAH/TAL-2906
73-C-04
Set Point +10 Set

Point -5
TAH/TAL-2907
73-C-04
Set Point +10 Set

Point -5
LAH/LAL-2502

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Tag no.
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Rev. A
Page 120 of 221
Description
Unit
Setting
TAH/TAL-2910
73-C-04
Set Point +10 Set

Point -5
TAH/TAL-2912
73-E-17 shell inlet
Set Point +10 Set

Point -5
M3/Hr
4.5
FAL-2902
73-P-15A/B
discharge
LAH/LAL-2901
73-C-04
MM
1350 / 450
PAH/PAL-3004
Off gas to 73-E13B
Kg/cm2 G
14.0 / 12.2
73-P-17A/B
discharge
Kg/cm2 G
17.0
TAH/TAL-3001
Overhead vapor to
73-V-12
Set Point +10 Set

Point -5
FAH/FAL-3001
Off gas to 73-E13B
NM3/hr
440 / 129
LAH/LAL-3001
73-V-12
MM
500 / 250
TAH/TAL-3104
73-F-01 outlet
320 / 305
VHP steam to 73-E20
Kg/HR
6667.0
PAH/PAL-3201
Light isomerate to
storage
Kg/cm2 G
9.2 / 7.9
TAH-3201
73-E-21A/B shell
inlet
Set Point +10
TAH-3202
73-E-21A/B shell
outlet
Set Point +10
LAL-3201
73-V-13
MM
2550
LAH-3202
73-V-13
MM
750
PALL-3005
FAH-3101
FAH/FAL-3301
7.6
LPG to storage
M /Hr
6.0 / 1.9
EQUIPMENT LIST
PUMPS

ISOMERISATION UNIT,
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Design
Item No.
Item Description
Capacity
(m/hr)
Doc No. Draft

Rev. A
Page 121 of 221
Design
Discharge
Pressure
(Kg/cmg)
Diff.
Head
(m)
AROMATIC
73-P-01 A/B
73-P-02 A/B
73-P-03 A/B
HYDROGENATION
PUMP
CHLORIDING AGENT
INJECTION PUMP
HYDROGENATION
REACTOR RECYCLE
94.4
37.0
373.9
10.6 lit/hr
46.0
255.8
318.2
33.0
174.3
121.2
78.0
406.3
50.2
23.5
95.4
176.1
14.0
129.5
97.9
15.0
127.2
24.3
28.0
290.0
40.8
22.0
239.8
30.9
21.0
159.1
36.0
23.0
46.3
100 lph
17.5
154.2
PUMP
ISOMERIZATION
73-P-04 A/B
73-P-05 A/B
73-P-06 A/B
73-P-07 A/B
73-P-08 A/B
73-P-09 A/B
73-P-10 A/B
73-P-11 A/B
73-P-12 A/B
REACTOR FEED
PUMP
STABILIZER REFLUX
PUMP
DEISOHEXANIZER
REFLUX PUMP
DEISOHEXANIZER
RECYCLE PUMP
DEISOHEXANIZER
BOTTOM PUMP
ISOMERATE
STORAGE PUMP
CAUSTIC PUMP
CAUSTIC
CIRCULATION PUMP
DEMINIERALISED
WATER PUMP
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Design
Item No.
Item Description
Capacity
(m/hr)
73-P-13 A/B
73-P-14 A/B
73-P-15 A/B
73-P-16 A/B
73-P-17 A/B
WATER CIRCULATION
PUMP
SEPARATOR DRUM
BOTTOM PUMP
LPG STRIPPER
BOTTOM PUMP
LPG PRODUCT PUMP
LPG STRIPPER
REFLUX PUMP
Rev. A
Page 122 of 221
Design
Discharge
Pressure
(Kg/cmg)
Diff.
Head
(m)
24.0
21.0
25.0
11.7
27.0
138.9
6.82
28.0
130.4
6.0
25.0
122.8
13.3
23.0
107.7
VESSELS
Internal
Tag No.
Item Description
Diameter
(mm)
TL-TL
(mm)
Design
Design
Temp
Pressure
Kg/cmg
ISOMERISATION
73-V-01
73-V-02
73-V-03
FEED SURGE
DRUM
HYDROGEN
MAKE UP KOD
CHLORIDING
AGENT
2500
6500
80
6.0+FV
600
1800
80
26.0+FV
1100
3300
80
10.5
2800
7300
210
21.0
1900
5600
INJECTION DRUM
HYDROGENATIO
73-V-04
73-V-05
N REACTOR
FLASH DRUM
STABILIZER
REFLUX DRUM
80
(-)25
17.0
Doc No. Draft

ISOMERISATION UNIT,
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Internal
Tag No.
Item Description
Diameter
(mm)
TL-TL
(mm)
Rev. A
Page 123 of 221
Design
Design
Temp
Pressure
Kg/cmg
STABILIZER
73-V-06
73-V-07
73-V-08
BOTTOM
CHLORIDE
GUARD BED
DIH RECYCLE
DRUM
DIH REFLUX
DRUM
3120
2500
195
18.0
1850
5350
120
5.0
2100
6100
80
4.0+FV
Full of
73-V-09
73-V-10
73-V-11
73-V-12
73-V-13
CAUSTIC DRUM
DM WATER DRUM
LPG SEPARATOR
DRUM
LPG STRIPPER
REFLUX DRUM
DRYERS
REGENERANT
3400
3700
1200
450(TOP)9
4000
50(BOTTO
14800
M)
80
Liquid +
80
250MM WC
3.5
80
(-25)
80
15.5
900
2600
2550
850
310
12.5+FV
1900
5700
180
16.0
450
3100
400
40.0+FV
450
3200
400
40.0+FV
450
3000
300
12.5+FV
(-40)
15.5
DEGASSER
CLOSED
73-V-16
73-V-18
73-V-19
73-V-20
BLOWDOWN
DRUM
CONDENSATE
POT
CONDENSATE
POT
CONDENSATE
POT
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Internal
Tag No.
Item Description
Diameter
(mm)
73-V-21
CONDENSATE
POT
450
TL-TL
(mm)
2900
Rev. A
Page 124 of 221
Design
Design
Temp
Pressure
Kg/cmg
400
40+FV
COLUMNS
Tag No.
Internal
Item Description
Diameter
(mm)
1400/ 2100/
73-C-01
STABILIZER
3000
(top/mid/bot
Height
(mm)
31150
Design
Design
Temp.
Pressure
(C)
(Kg/cm2g)
195
(-25)
17.5
tom)
73-C-02
DEISOHEXANISE
R
3400
45350
155
5+FV
18850
80
16.0
27300
230
16.0
1300/
73-C-03
73-C-04
CAUSTIC
2400
SCRUBBER
(top/
LPG stripper
bottom)
650/ 1200
(top/bottom)
DRYER
Tag No.
Item
Description
73-DR-01
FEED
A/B
DRYERS
Internal
Diameter
(mm)
1800
Height
(mm)
6850
Design
Design
Temp.
Pressure
(C)
80 /
(Kg/cm2g)
325
37.0+FV
(REGEN)
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Tag No.
Internal
Item
Diameter
Description
73-DR-02
HYDROGEN
A/B
DRYERS
73-DR-03
(mm)
Height
(mm)
900
9250
Page 125 of 221
Design
Design
Temp.
Pressure
(C)
135 /
(Kg/cm2g)
325
46.0+FV
(REGEN)
80 /
SCRUBBER
OFFGAS
A/B
Rev. A
1100
10150
DRYER
325
15.0
(REGEN)
COMPRESSOR
Tag No.
Item
Description
73-K-01
H2 MAKE UP
A/B
COMPRESSOR
Design
Capacity
(NM3/HR)
14038
DELTA
P Design Press
(Kg/cm2g)
(Kg/cm2g)
18.1
46.0
Design
Temp
(C)
135
REACTOR
Tag No.
Internal
Item Description
Diameter
(mm)
73-R-01
HYDROGENATIO
N REACTOR
Height
Design
(mm)
Temp. (C)
Design
Pressure
(Kg/cm2g)
210
1450
4650
325
24+FV
(regen)
1st STAGE
73-R-02
ISOMERIZATION
1400
21510
210
41+FV
1400
21510
210
41+FV
REACTOR
2nd STAGE
73-R-03
ISOMERIZATION
REACTOR
Doc No. Draft

ISOMERISATION UNIT,
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Rev. A
Page 126 of 221
HEAT EXCHANGER (AIR COOLED)

Tag No.
Item Description
Design Duty
(Mkcal/HR)
Design
Press.
(Kg/cm2g)
Design
Temp(C)
HYDROGENATI
ON REACTOR
73-A-01
RECYCLE AIR
73-A-02 A/B
73-A-03 A-H
73-A-04 A/B
COOLER
STABILIZER AIR
CONDENSER
DIH AIR
CONDENSER
DRYERS
REGENERANT
AIR
1.52
25+FV
210
1.47
17
9.87
4.0+FV
95
1.96
12.5+FV
325
105/
(-25)
CONDENSER
HEAT EXCHANGER
Tag No.
Item Description
73-E-01
H2 MAKE UP
A/B
COOLER
DIH RECYCLE/
73-E-02
REACTOR FEED
Design Press
Design Temp
Shell/Tube
Shell/Tube
(Kg/cm2g)
(C)
2*0.28
46.0/36.5
150/65
0.65
37.0/29.0
135/120
1.56
31/40
135/210
Design Duty
(Mkcal/HR)
EXCHANGER
FIRST REACTOR
73-E-03
FEED/ EFFLUENT
EXCHANGER
Doc No. Draft

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Tag No.
Item Description
Rev. A
Page 127 of 221
Design Press
Design Temp
Shell/Tube
Shell/Tube
(Kg/cm2g)
(C)
4.89
31/40+FV
210/400
3.32
40+FV /31.0
400/195
2*0.54
17.0/13.5
Design Duty
(Mkcal/HR)
HYDROGENATIO
73-E-04
73-E-05
73-E-06
A/B
73-E-07
N REACTOR
FEED HEATER
STABILIZER
REBOILER
STABILIZER
TRIM OOLER
DIH FEED/
73-E-08
RECYCLE
DIH TRIM
A/B
73-E-09
COOLER
ISOMERATE
A/B
TRIM COOLERS
73-E-10
DIH REBOILER
2.02
14.0+FV/
18.0+FV
80(-25)/
65
140/195
2*0.16
15.0/11.5
120/65
2*0.114
22.0/17.0
80/65
6.66
12.5+FV/
10+FV
300/155
OFF SPEC
73-E-11
ISOMERATE
0.638
28.0/21.5
155/65
0.50
23.0/17.7
80/190
0.022/0.41
20.0/15.5
0.04
19.0/17.5
TRIM COOLER
CAUSTIC
73-E-12
73-E-13
A/B
73-E-14
RECYCLE
HEATER
LPG
REFRIGERATION
SYSTEM
SEPARATOR
DRUM
BOTTOM/LEAN
-45,65/80/
-45,65/80, -40
80,(-25)/
100
OIL
Doc No. Draft

ISOMERISATION UNIT,
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Tag No.
Item Description
Rev. A
Page 128 of 221
Design Press
Design Temp
Shell/Tube
Shell/Tube
(Kg/cm2g)
(C)
0.41
22.0/28.0
120/185
2*0.26
28.0/22.0
185/65
Design Duty
(Mkcal/HR)
LPG STRIPPER
73-E-15
FEED/BOTTOM
73-E-16
EXCHANGER
LEAN OIL TRIM
A/B
73-E-17
COOLER
LPG STRIPPER
73-E-18
REBOILER
LPG TRIM
A/B
73-E-19
COOLERS
LPG STRIPPER
A/B
CONDENSER
DRYERS
73-E-20
REGENERANT
73-E-21
A/B
7.7
40.0+FV/
0.55
31.0
2*0.022
17/13.5
2*0.252
15.5/12.0
31.0+FV/
1.10
40.0+FV
VAPORIZER
DRYERS
REGENERATION
2*0.078
12.5+FV/ 10
400/230
80,-25/
65
80,-40/
65
195/400
310/65
TRIM COOLER
LIST OF INSTRUMENTS
In this section control valves, pressure safety valves, analyzers etc are listed.
Information regarding indicators & controllers (temperature, pressure, flow and level
instrument) are already given in previous section.
Control Valves:
Sr. No.
1
2
3
4
Tag No.
73-FV-1101
73-FV-1102
73-LV-1101
73-PV-1101A
Description/Location
MCF of 73-P-01 A/B
Sour water from 73-V-01
Nitrogen blanketing of 73-V-01

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Sr. No.
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
Tag No.
73-PV-1101B
73-PCV-1201
73-PV-1401
73-FV-1501
73-FV-1502
73-FV-1601
73-LV-1602
73-TV-1603A
73-TV-1603B
73-FV-1701
73-FV-1702
73-PV-1701A
73-PV-1701B
73-PV-1702
73-TV-1701A
73-TV-1701B
73-TV-1801A
73-TV-1801B
73-FV-1901
73-PV-1901
73-PV-1901B
73-FV-2001
73-PV-2001
73-PV-2002
73-FV-2101
73-FV-2102
73-FV-2103
73-FV-2201
73-FV-2202
73-FV-2203
73-FV-2205
73-FV-1902
73-LV-2101
73-FV-2302
73-PV-2201A
73-PV-2201B
73-PDV-2301
73-FV-2302
73-PV-2201A
73-PV-2201B
Doc No. Draft

Rev. A
Page 129 of 221
73-V-01 flare
Nitrogen to 73-V-03
Hydrogen (73-K-01 A/B spillback line)
Hydrogen from dryer 73-DR-02A/B
Hydrogen from dryer 73-DR-02A/B
Steam inlet to 73-E-04
Condensate from 73-E-04
73-E-03 shell side flow bypass line
73-E-03 shell side inlet flow line
Isomerization feed from 73-P-04A/B
Reactor recycle (73-P-03 A/B discharge)
73-V-04 Hydrogen pressurization
73-V-04 purge gas
73-V-04 offgas to flare
73-A-01 bypass line
73-A-01 bypass line
Reactor effluent to 73-R-03
Reactor effluent 73-E-03 bypass
VHP condensate from 73-E-05
Reactor effluent from 73-R-03
Depressurization line
73-C-01 reflux
73-V-05 off gases to 73-C-03
Depressurization line to 73-C-03
DIH pump around 73-P-07 A/B
73-P-07A/B minimum circulation flow
DIH recycle from 103-E-08
DIH reflux (73-P-06A/B )
DIH bottom (73-P-08A/B discharge)
73-E-10 outlet condensate
73-P-08A/B minimum flow circulation
DIH feed from 73-E-07
DIH recycle to 73-V-07
73-P-09A/B minimum flow circulation
Liquid 73-A-03 outlet
73-V-08 flare line
73-V-08 Vapor equalizing line
73-P-09 A/B minimum flow circulation
Liquid 73-A-03 outlet
73-V-08 flare line

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Sr. No.
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
Tag No.
73-FV-2501
73-PV-2501
73-FV-2801
73-FV-2802
73-FV-2803
73-FV-2804
73-PV-2801
73-PV-2802
73-FV-2901
73-FV-2902
73-FV-2903
73-FV-29004
73-PV-3001
73-FV-3101
73-FV-3102
73-FV-3102
73-LV-3201
73-PV-3201
73-FV-3301
73-FV-3302
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
73-UV-1101
73-UV-1102
73-UV-1201
73-KV-1301A
73-KV-1301B
73-KV-1302A
73-KV-1302B
73-KV-1303A
73-KV-1303B
73-KV-1304A
73-KV-1304B
73-KV-1305
73-KV-1306
73-KV-1307
73-KV-1308
73-KV-1309A
73-KV-1309B
73-KV-1310A
73-KV-1310B
Doc No. Draft

Rev. A
Page 130 of 221
LP condensate from 73-E-12
73-C-03 off gases to fuel gas header
Fluid to 73-E-15
73-E-14 tube inlet liquid
Off gases from 73-V-11
Isomerate from 73-E-16A/B to storage
LPG stripper reflux
Condensate from 73-E-17
73-V-12 off gases
Steam to 73-E-20
Isomerate to 73-E-20 (Case-1)
Naphtha to 73-E-20 (Case-2)
Residual Vapor from 73-V-13
Light isomerate to storage
LPG from 73-P-16 A/B
On/Off valves
73-P-01A/B suction line
Sour water from 73-V-01
73-P-02 A/B discharge line
73-DR-01A regeneration line
73-DR-01B regeneration line
73-DR-01A inlet
73-DR-01B inlet
73-DR-01A inlet
73-DR-01B inlet
73-DR-01A/B regeneration line
73-DR-01A/B inlet (regeneration line)
73-DR-01A/B outlet (regeneration line)
73-DR-01A/B inlet (Regeneration line)
73-DR-01A inlet
73-DR-01B inlet
73-DR-01A inlet
73-DR-01B inlet

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Sr. No.
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
Tag No.
73-KV-1311A
73-KV-1311B
73-KV-1312A
73-KV-1312B
73-KV-1313A
73-KV-1313B
73-KV-1314A
73-KV-1314B
73-KV-1315A
73-KV-1315B
73-UV-1401
73-UV-1402
73-UV-1501
73-UV-1502
73-UV-1503
73-UV-1504
73-KV-1501A
73-KV-1501B
73-KV-1502A
73-KV-1502B
73-KV-1503A
73-KV-1503B
73-KV-1504A
73-KV-1504B
73-KV-1505A
73-KV-1505B
73-KV-1506A
73-KV-1506B
73-KV-1507A
73-KV-1507B
73-KV-1508A
73-KV-1508B
73-KV-1509A
73-KV-1509B
73-KV-1510A
73-KV-1510B
73-KV-1511A
73-KV-1511B
73-KV-1512A
73-KV-1512B
Doc No. Draft

Rev. A
Page 131 of 221
73-DR-01A outlet line
73-DR-01B outlet line
73-DR-01A (Regeneration line)
73-DR-01B (Regeneration line)
73-DR-01A (Regeneration line)
73-DR-01B (Regeneration line)
73-DR-01A outlet line (single reactor)
73-DR-01B outlet line (single reactor)
73-DR-01A outlet (analyzer loop line)
73-DR-01B outlet(analyzer loop line)
73-K-01A/B suction line
73-K-01A/B discharge line
73-DR-02A/B outlet line
Dry naphtha to 73-E-02
73-DR-01A/B inlet line
73-DR-02A/B inlet line flare
73-DR-02A (regeneration line)
73-DR-02B (regeneration line)
73-DR-02A outlet (single reactor)
73-DR-02B outlet (single reactor)
73-DR-02A inlet (regeneration)
73-DR-02B inlet (regeneration)
73-DR-02A inlet (tail period)
73-DR-02B inlet (tail period)
73-DR-02A outlet (single)
73-DR-02B outlet (single)
73-DR-02A inlet
73-DR-02B inlet
73-DR-02A/B outlet (analyzer lop)
73-DR-02A/B outlet (analyzer lop)

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Sr. No.
60
61
62
63
Tag No.
73-UV-1601
73-UV-1701
73-UV-1702
73-UV-1703
73-UV-1704
64
73-UV-1705
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
73-UV-1706
73-UV-1801
73-UV-1901
73-UV-1902
73-UV-2001
73-UV-2101
73-UV-2201
73-UV-2202
73-UV-2301
73-UV-2501
73-UV-2502
73-UV-2503
73-KV-2601A
73-KV-2601B
73-KV-2602A
73-KV-2602B
73-KV-2603A
73-KV-2603B
73-KV-2604A
73-KV-2604B
73-KV-2605A
73-KV-2605B
73-KV-2606A
73-KV-2606B
73-KV-2607A
73-KV-2607B
73-KV-2608A
73-KV-2608B
73-KV-2609A
73-KV-2609B
73-KV-2610A
73-KV-2610B
73-KV-2611A
Doc No. Draft

Rev. A
Page 132 of 221
73-E-04 steam inlet line
73-V-04 hydrogen pressurization line
73-V-04 purge gas
73-P-03 a/B discharge
73-P-04A/B discharge line
73-P-04A/B discharge line isomerization, reactor
bypass
73-P-04 & 73-P-04 suction line
H2 inlet line to 73-M-01
73-C-01 bottom outlet
73-P-05 A/B suction line
DIH recycle from 73-E-08 A/B
73-C-02 bottom outlet
73-P-06 & 09A/B suction line
73-C-03 gases to 73-DR-03 A/B
73-C-03 off gases to flare
73-C-03 off gases to fuel gas header
73-DR-03A inlet
73-DR-03B inlet
73-DR-03A outlet (single)
73-DR-03B outlet (single)
73-DR-03A inlet
73-DR-03B inlet
73-DR-03A/B outlet (analyzer loop)
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Sr. No.
98
99
100
101
7.8
Sr.
No.
1
Tag No.
73-KV-2611B
73-KV-2612A
73-KV-2612B
73-UV-2901
Page 133 of 221
73-DR-03A/B outlet (analyzer loop)
PRESSURE SAFETY VALVES

Tag No.
73-PSV-1101 A/B
73-PSV-1202 A/B
73-PSV-1202 A/B
73-PSV-1301 A/B
5
6
7
8
9
10
11
12
73-PSV-1401
73-PSV-1402/1403
73-PSV-1404/1405
73-PSV-1501A
73-PSV-1501B
73-PSV-1601
73-PSV-1602
73-PSV-1603
73-PSV-1701A /
13
Rev. A
1701B
14
73-PSV-1703/1704
15
16
17
18
19
73-PSV-1801
73-PSV-1802
73-PSV-1901
73-PSV-1902
73-PSV-2001 A/B
Description/Loc
Set Pressure
ation
(Kg/cm2g)
73-V-01
6.0
Chloride agent
injection drum
Chloride injection
pump
73-DR-01 A/B
outlet
73-V-02
73-K-01A/B
Sea cooling water
73-DR-02 A
73-DR-02 B
DIH recycle
73-V-18
73-R-01
73-V-04
73-P-04 A/B
discharge
73-R-02 inlet
73-R-03
73-V-19
Stabilizer bottom
73-V-05
Base of selection
Blocked liquid
discharge, Fire case
On hold
On hold
36.5
Fire case
26.0
46.0
7.6
46.0
46.0
15.0
40.0
24.0
Fire case
Operational failure
Thermal expansion
Fire case
Fire case
Tube rupture
Fire case
Fire case
Operational failure,
21.0
Fire case
21.0
Blocked outlet
39.8
39.8
40.0
21.0
17.0
Fire case
Fire case
Fire case
Fire case
Fire case, Reflux,
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Sr.
No.
Tag No.
Rev. A
Page 134 of 221
Description/Loc
Set Pressure
ation
(Kg/cm2g)
Base of selection
cooling water, air
cooler, electrical,
20
21
22
73-PSV-2002 A/B
73-PSV-2101 A/B
73-PSV-2201
A/B/C
73-E-06 A/B
73-E-08 A/B
7.6
7.6
73-C-02
4.0
failure case
Thermal relief
Thermal Expansion
Fire case, Reflux,
cooling water, air
cooler, electrical,
23
24
25
73-PSV-2202
73-PSV-2301
73-PSV-2401/2402
73-V-20
73-V-08
73-P-12 A/B
12.5
4.0
17.5
failure case
Fire case
Fire case
Blocked discharge
Fire case,
26
73-PSV-2501 A/B
73-C-03
15.0
Operational failure,
27
73-PSV-2502
5.5
Blocked outlet
Tube rupture
28
73-PSV-2503 A/B
73-E-12
Spent caustic to
17.5
Blocked condition
29
73-PSV-2601 A
15.0
Fire case
30
73-PSV-2601 B
15.0
Fire case
31
73-PSV-2701
7.6
Thermal expansion
32
73-PSV-2801 A/B
73-V-11
15.0
33
73-PSV-2803/2804
73-E-16 A/B
7.6
34
73-PSV-2901 A/B
73-C-04
15.5
35
73-PSV-2902 A/B
73-V-21
40.0
ETP
73-DR-03 A
outlet
73-DR-03 A
outlet
73-E-13 B shell
outlet
Fire case, Blocked

outlet,
Thermal expansion
Fire case/CW, reflux,
feed cutoff, power
failure, blocked
outlet
Fire case
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Sr.
Tag No.
Set Pressure
(Kg/cm2g)
7.6
7.6
18.0 (hold)
73-PSV-2903/2904
73-PSV-3001/3002
ation
73.-E-18 A/B
73-E-19 A/B
38
73-PSV-3101
73-F-01 outlet
39
73-PSV-3102/3103
73-E-20
12.5
40
41
42
42
73-PSV-3201 A/B
73-PSV-3203/3204
73-PSV-3301
73-PSV-3302/3303
73-V-13
73-E-21 A
73-E-11
73-E-09 A/B
12.5
7.6
7.6
7.6
Sr.
No.
1
2
3
4
5
Page 135 of 221
Description/Loc
No.
36
37
7.9
Rev. A
Base of selection
Thermal relief
Thermal expansion
Blocked outlet, fire
case, thermal
expansion
Fire case, blocked
outlet
Fire case
Thermal relief
Thermal relief
Thermal relief
ANALYZERS
Tag No.
Type
Location/Service
73-AE-1101
73-AE-1301 A/B
73-AE-1501 A/B
73-AE-1901
73-AE-2601
Benzene
Moisture
Moisture
Moisture
Moisture
On isom feed line to 73-DR-01 A/B

73-DR-01A/B outlet
73-DR-02 A/B outlet
Across 73-PV-1901
73-DR-03 A/B outlet

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Doc No. Draft

Rev. A
Page 136 of 221
SECTION - 8
SHUTDOWN PROCEDURES
8.1
GENERAL
While shutting down the unit due to maintenance or emergency, care must be taken not to
admit air into the system until all hydrocarbon vapours have been removed. Operators
should be thoroughly familiar with shutdown procedures and understand the reasons for
each work. Good judgement must be exercised as no written procedure can completely
cover all details or problems that can arise in an emergency. Judgement is more likely to be
exact if prior thought and planning have been made.
In this section the activities related to the normal as well as emergency shutdown
procedures have been briefly outlined.

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
8.2
Doc No. Draft

Rev. A
Page 137 of 221
NORMAL SHUTDOWN PROCEDURE
Normal shutdown applies to a shutdown planned in advance for preventive maintenance

or to unexpected events which are not an emergency.
Before initiating any planned shutdown, review all records to determine what
inspections and repair works that 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 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 or vacuum surges. Purge
with care all vessels, using steam for those that are not subject to condensation damage
and inert gas for the critical vessels until all equipment is hydrocarbon liquid and gas
free. Avoid a vacuum formation which could cause vessel collapse if insufficient inert
gas is admitted after flow ceases or as liquids are removed. Ventilate 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:
-
To lower the severity
To lower the capacity
To switch the product to off-spec. or raw naphtha storage
To shutdown the reaction section
To drain all hydrocarbons
To depressurize and purge.
Several shutdown cases are considered:

i)
Short duration shutdowns (i.e. less than 24 hours)
ii)
Long duration shutdowns for major repairs, equipment entry etc
iii)
Partial shutdowns for catalyst replacement.
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
8.3
Rev. A
Page 138 of 221
SHORT DURATION SHUTDOWNS
These shutdowns are typically less than 24 hours to make minor repairs without opening
any major equipment.
It is recommended to begin a shutdown after a dryer has completed a regeneration cycle
so as to have sufficient dryer cycle capacity on restart.
-
Increase the make-up hydrogen flow to design
Reduce the reactors inlet temperatures to 100C at a rate of 20C/hour. If necessary,

switch the stabilizer bottom and LPG product to off-spec storage.
When the reactors beds temperatures have stabilized, decrease slowly the naphtha
feed rate to 50% of design fresh feed (correspond to 75% of the reactor design feed
rate FT 1101). Reduce the feed rate by steps of 10% per 30 minutes. It is important
to wait until the reactors temperatures have stabilized to avoid any increase in
reactors severity.
As this is a short shut down, leave the Deisohexaniser in service.
Reduce the reactors inlet temperatures to 90C over a one hour period and allow the
beds to cool. When isomerization reactors temperatures reach 105C approximately,
stop the chloride injection. Maintain these conditions for one hour (i.e. at 90C) to
sweep chloride from the feed circuit upstream of the reactors.
Open the reactors bypass to bypass the C5/C6 feed directly to the stabilizer and close
the reactor feed valve. Cut the feed out as quickly as possible to minimize the low
liquid flow period over the catalyst.
Continue sweeping the reactors with make-up hydrogen at design rate. Reduce the
reactors inlet temperatures at 20C/hour until the reactor feed heater is shutdown.
When reactors have cooled below 60C, stop the hydrogen flow.
Reduce the stabilizer temperature but as this is a short duration shutdown, leave the
stabilizer in operation at a low reflux rate.
Maintain pressure in the reaction section, stabilizer and LPG stripper. If necessary
use the hydrogen make-up through the start-up line.
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 139 of 221
The unit is now considered to be on standby with C5/C6 feed bypassing the reactors, the
Deisohexaniser fed at 75% capacity with distillate and bottoms routed to off-spec
storage, the stabilizer on a low rate total reflux. The unit is under normal pressure with
hydrogen make-up as required. The reactors have cooled to below 60C.
8.4
LONG DURATION SHUTDOWNS
These are considered to be shutdowns for major repairs and for equipment entry or
inspection. Proceed as per the steps for a short duration shutdown, followed by the
additional steps summarized below:
-
Stop fresh C5/C6 Feed.
Close the reactor recycle liquid from the Deisohexaniser. Shut down gradually the
Deisohexaniser Reboiler and Reflux pumps.
By pass the LPG recovery section, the off gas from the stabilizer overhead are sent
to the scrubber. Provide hydrogen from dryers by the start-up line to maintain the
pressure. Stop rundown the heavy product to the storage.
Stabilizer circuit is also shutdown gradually. If the stabilizer needs to be opened for
inspection, a purge of make-up hydrogen should be sent to the tower to strip any HCl
in the overheads. This can be stopped after there is no measurable HCl in the gas
sample.
Stop the LPG recovery section.
Block in and isolate the reactors.
With the unit still under pressure drain all the major vessels, first to storage then to
slop.
Depressurize all sections to fuel gas first if desired then to flare. Avoid
depressurizing the stabilizer below the scrubber pressure as there is a risk of caustic
entrained gas backing up into the stabilizer.
Depressurize all the reactors to flare through the hydrocarbon drain lines.
Depressurize the LPG recovery section if required.
Shutdown both the caustic and water washes in the scrubber.
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 140 of 221
Shutdown all air coolers and water coolers.
When the unit is considered totally depressurized and all the utilities e.g. water,
steam have been drained and isolated from their respective equipment, the reactors
can be blocked.
Isolate the stabilizer section from the reaction section.
Isolate with blinds the feed lines, hydrogen make-up, product lines and fuel gas
headers. Isolate all PSV's lines to flare and instruments not suitable for vacuum
service.
Remove one of the blinds from the reactors to the ejector and pull a vacuum in the
reaction and dryer sections (the dryers can be evacuated separately if desired) down
to 0.2 bar abs.
Break with dry nitrogen and pressure up 1.0 bar g.
Depressurize through all low points, dead legs, vents etc
Repeat the evacuation breaking with nitrogen steps until the hydrocarbon level has
decreased below 0.5 vol. %.
Note the porous catalyst and adsorbent will require time to displace the
hydrocarbons inside the pores. Proceed with caution around the reactors and dryers
by allowing one hour before pulling the sample for testing.
Leave a residual nitrogen pressure of 0.5 bar g.
Purge scrubber with steam and if desired leave in it a positive nitrogen pressure.
Purging the stabilizer and all items in LPG recovery section with steam is prohibited
(except for the initial start-up) as chloride traces in presence with water are
excessively corrosive.
As a safety precaution block and blind reactors from the reaction circuit.
Depending upon the extent and reason for shutdown the various pieces of equipment can
be isolated and air purged for entry.
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
8.5
Rev. A
Page 141 of 221
SHUTDOWN FOR CATALYST REPLACEMENT
For replacing the catalyst in any one of the isomerization reactors, it is recommended
that the unit be shutdown using only the short duration shutdown procedure. This would
enable immediate restarting of the unit with one isomerization reactor. The other
isomerization reactor, where the catalyst requires to be replaced, is isolated and purged
with N2 to flare using the hydrocarbon drain connections, prior to the beginning of
catalyst unloading operations.
Caution
For the benzene hydrogenation catalyst replacement, if the benzene hydrogenation
reactor bypass is used while isomerization reactors are still in operation, special
precaution shall be taken. This bypass should only be used for a limited time.
During that period monitoring of benzene (on line analyzer + frequent sampling) in
the fresh feed shall be closely followed. No unit feed with a benzene content higher
than 2.5 wt % is permitted.
8.6
EMERGENCY SHUTDOWN PROCEDURE
8.6.1. 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 responsible for protecting the personnel, the
catalyst and equipment from heavy coking or irreparable damage.
Personnel and equipment protection also results from:
-
Personnel having a satisfactory 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.
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 142 of 221
Adequate operator safety awareness and procedures training.
The following special considerations are highlighted for operator awareness of the
isomerization process.
-
The unit contains benzene and tetrachloroethylene which are known health hazards.
The unit contains HCl downstream of the first isomerization reactor inlet. The
concentration is particularly high in the stabilizer overhead and in the LPG separator
drum. For this reason, operator shall bypass LPG recovery section, for any upstream
upsets, such as loss of H2, loss of feed, upset in stabilizer operation.
The reactions are highly exothermic, mostly due to the benzene saturation and the
C7+ components hydrocracking. If the levels of these components in the feedstock
increase significantly, the hydrogenation reactor temperature could raise beyond a
controllable range.
A reactor temperature excursion could occur if the flow of liquid through a hot
reactor is too low or if the reactor temperatures are too high. Reactor feed rate should
not decrease below 75% of design capacity (FT 1101).
During an emergency situation in the stabilizer section, the stabilizer must not
depressurize below the pressure of the scrubber. There is a check valve in the
stabilizer overheads gas line to the scrubber and a static height to overcome but
despite this water and caustic could back up into the stabilizer causing a potential
corrosion problem.
In the event a reactor temperature excursion occurs and the reactor temperatures
increase above 190C, the reactors must be depressurized to avoid excessive
hydrocracking reactions and to prevent mechanical damage. If for some reason the
reactors cannot be depressurized through the stabilizer, only as a last resort should
they be depressurized to the flare through the hydrocracking drain lines. It is
recommended to block the reactors in prior to depressurizing and to start a cold
nitrogen purge if necessary. Depressurization is started once the LPG recovery

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Doc No. Draft

Rev. A
Page 143 of 221
section has been bypassed on off gas side (bypass is activated by I-101 emergency
shut down interlock).
Concerning the catalyst preservation, operators must avoid:

-
An excessive catalyst grain temperature which can change the structure of the
alumina (> 700C). To avoid damaging the catalyst structure, bulk temperature must
never exceed 500C. Note that the reactor design temperature (under design
pressure) is much lower.
The hydrocarbons presence without a sufficient hydrogen quantity which would lead
to a rapid coke deposit and the possible agglomeration of catalyst particles.
The following sections cover most of the emergencies that may have to face by the
operator. All operating personnel must study and fully understand the steps to be taken
in such situations prior to the unit start-up.
Some of these situations are handled by automatic shutdown trips. These trips must
always be operational, bypassing must be kept to a minimum e.g. during start-up,
transient periods etc
The following procedures include all the actions to be undertaken by the operator
assuming no action by the automatic shutdown devices.
8.6.2.
Loss of Feed
Loss of feed to the isomerization reactors is an emergency situation. When feed flow
stops, the feed in the reactor circuit will pass slowly through the reactors swept by the
low flow of make-up gas. For a sudden decrease in feed flow, the temperature controller
on the inlet will not act fast enough and the unit pressure will decrease causing the back
pressure controller to close. The net effect is high severity in the reactors, over
conversion and soaring reactor bed temperatures.
Actions:
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 144 of 221
Cut steam immediately from the reactor feed heater and close the bypass around
feed/effluent exchanger. Bypass LPG recovery section on off gas side.
Increase the make-up hydrogen flow to maximum (2nd hydrogen make up line).
Stop the isomerization feed pumps at hydrogenation reactor flash drum.
Slowly depressurize the reaction section to stabilizer (via control valve PV 1901).
Depressurize at a rate which allows stable pressure control of the stabilizer.
Stop the C2Cl4 injection when the lead reactor temperature reaches 105C.
Monitor the reactor bed temperatures. If the hydrogenation reactor temperature is

below 190C and stable, continue cooling with make-up gas and cool down to 65C.
If the reactor bed temperatures are still climbing, cut the hydrogen make-up, block in
the reactors and depressurize to flare through the stabilizer and the Scrubber. Purge
with dry nitrogen.
8.6.3. Loss of Make-up Hydrogen

When make-up hydrogen flow is lost, reactor pressure will decrease immediately, no
hydrogen will be available for hydrogenation or isomerization reactions. A
hydrocracking increase may occur, possibly causing a temperature excursion and a coke
deposits increase.
Actions:
-
Cut steam immediately from the reactor feed heater.
Cut the feed to unit.
Increase ti maximum the recycle flowrate in the recycle air cooler. Close the recycle
air cooler bypass line. Start all fans at the air cooler.
Bypass LPG recovery section on off gas side.
Stop C2Cl4 injection when the isomerization lead reactor reaches 105C.
Stop the isomerization reactor pump at the hydrogenation reactor flash drum.
Slowly depressurize the hydrogenation reactor via the associated flash drum.
Slowly depressurize the reaction section to the Stabilizer to keep the back pressure
control valve open and cold feed flowing through the reactors.
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 145 of 221
Reduce the stabilizer pressure as necessary to maintain pressure control on the

column and flow of bottom to Deisohexaniser column.
If the reactor temperatures cannot be controlled and increase above 190C during
this procedure, interlock I-101 must be activated (emergency shut down).
8.6.4. High Reactor Temperature

High isomerization reactor temperature could be the result of a high content of C 7+ in the
feed or high catalyst severity due to low feed rates or poor temperature control of the
reactor inlet feeds. In order to avoid a reactor temperature excursion:
-
Avoid liquid feed rates less than 75% of design (FT 1101)
Avoid larger than design quantities of benzene or C7+ in the feed. It is also important
to be aware of changes in these contents due to crude changes or variations in the
upstream units.
Avoid overheating the reactor charge.
Actions
-
Increase the recycle flowrate to maximum.
Cut steam immediately to the reactor feed heater.
Increase to maximum the recycle flow rate in the recycle air cooler. Close the recycle
air cooler bypass line. Start all fans at air cooler.
Maximum hydrogen make-up flow in the isomerization reaction section (2 nd

hydrogen make up line)
Stop C2Cl4 injection when the isomerization reactor reaches 105C.
Hold the reactor inlet temperatures at 100C if conditions are stable.
Modify the fractionation towers upstream of the unit to restore the design quantities
of benzene and C7+ in the feed.
Or check out the controllers to determine the cause of the poor control.
When the faults have been corrected, increase the reactor temperatures slowly back
to normal operating point.
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 146 of 221
If any of the reactor temperatures exceeds 190C, cut the liquid feed and make-up
hydrogen. Activate I-102 / 103, emergency shut-down interlock in order to
depressurize the reaction section.
If the reactor temperature excursion is due to low liquid feed rate and this cannot be
corrected quickly, cut out the remaining feed and follow the procedures for loss of feed.
8.6.5.
Steam Failure
If steam is lost in the unit, the Reactor Feed Heater, the Reboilers of the stabilizer, the
Deisohexaniser and the LPG stripper, the Caustic Recycle Heater and the Regenerant
Vaporizer will shut down.
Critical equipment is the reboiler of the stabilizer as unstabilized product containing HCl
could be sent through the downstream equipment to tankage, making the storage
equipment susceptible to corrosion.
Actions:
-
Bypass the LPG recovery section on off gas side. The stabilizer off-gases are sent to
fuel gas via scrubber.
Increase the hydrogen make-up flow to maximum rate in the isomerization reaction
section (2nd hydrogen make up line)
Stop the C2Cl4 injection.
When the reactors cool down to 100C, cut C 5/C6 fresh feed to 50% of design rate by
steps of 10%.
When 50% is reached, open the reactor bypass line and quickly remove the
remaining C5/C6 feed from the reactors.
Continue the reactors cooling with hydrogen make-up gas, while maintaining
pressure profile in the reaction section and stabilization section.
Cut the C5/C6 feed circulation and maintain the recycle flow rate around the
hydrogenation reactor.
If at any time temperature begins to increase rapidly in any one of the reactors, begin
depressurizing through the stabilizer and scrubber.

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Stop the heavy product rundown as soon as possible.
8.6.6. Cooling Water Failure

This refers to cooling water failure or air cooler failure. If the recycle of the C 5/C6 feed
fails, the dryers will be operating at a higher temperature significantly reducing the
dryers water retention capability. Any water breakthrough would be detrimental to the
isomerization catalyst.
Loss of cooling around the Deisohexaniser, stabilizer and LPG stripper will cause an
over pressuring of the column leading to possible relief through the PSV. There is also
the risk of sending hot isomerate or LPG product to tankage causing a fire hazard.
If cooling water or air cooling fails for an extended period of time, shutdown the unit
using the following procedure:
-
Cut steam immediately from the Reactor Feed Heater.
Bypass the LPG recovery section on off gas side. The stabilizer off-gases are sent to
the scrubber.
Increase hydrogen make-up to maximum rate to the isomerization reactors.
Increase to maximum the recycle flow rate in the recycle air cooler. Close the recycle
air cooler bypass line. Start all fans at air cooler.
When the isomerization lead reactor reaches 105C, cut the C2Cl4 injection.
Reduce steam to deisohexaniser reboiler, stabilizer reboiler and LPG stripper

Reboiler, but maintain the pressures.
Follow the procedure as above for steam failure.
8.6.7. Power Failure

If a power failure occurs, all electrically driven equipment i.e. pumps; air coolers and
compressors (make-up hydrogen) will stop.
This is a severe condition as loss of flow through the reactors where exothermic
reactions occur will lead to a temperature runaway situation.

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Actions:
-
Immediately bypass LPG recovery on off gas side and simultaneously begin
depressurizing the reactors to flare (through the stabilizer and scrubber for the
isomerization section.
When the pressure is low begin purging with cold dry nitrogen to cool the reaction
beds and displace the hydrocarbons.
Shut off steam to the Reactor Feed Heater, the Reboilers of stabilizer, deisohexaniser
and LPG stripper.
8.6.8. Instrument Failure: Air or Power

It is too early to prepare a procedure on this type of failure without knowledge of the
system back-up and level of redundancy, etc, preferred by the unit owner. This section
will be fully defined during the detailed engineering stage based on the strategies
developed for other emergency situations.
8.6.9. Major Leak or Fire:
The following is only an overview of the steps to be taken during the discovery of a
major leak resulting in a fire. The following steps are from a process view mainly aimed
at avoiding runaway reactions and protecting the equipment and catalyst.
Incase of fire, depressurization of the reactors shall be actuated as per API 521
3.19. As the safety valves at the reactors have set pressure corresponding to
supercritical conditions, protection against fire exposure by safety valves is not
sufficient. It is mandatory to depressurize the corresponding vessels whenever a
fire is detected.
Actions:
-
Shut off both C5/C6 feed and hydrogen make-up to the unit and block in the product
lines.

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Shut off steam to the Reactor Feed Heater, Stabilizer Reboiler, deisohexaniser
reboiler and LPG stripper reboiler.
Immediately bypass LPG recovery on off gas side and simultaneously begin
depressurizing the reactors to flare, through the stabilizer and scrubber.
If it is possible, isolate the problem area and block in the reactors and purge with
nitrogen to flare.
The objectives of the following steps which should be developed by the

client/engineering contractor are to drain hydrocarbons from all the vessels, purge
the unit with inert gas in particular the reactors if they cannot be accessed. Leaving
the reactors with hydrocarbon inside and no flow will eventually lead to a
temperature excursion and mechanical failure, so all effort must be made to purge
these vessels.
8.7
AUTOMATIC SHUTDOWNS
There are several automatic shutdown process interlocks in the design of this unit to
protect the catalyst and the equipment during an incident or failure. Refer to the Process
Design Book for the shutdown and safety interlocks description and the P&ID'S.
8.7.1. Hydrogenation reaction section

If the naphtha feed flow rate to the hydrogenation reaction section or if the recycle flow
rate reduce the feed rate at the inlet of the reactor to 70% of design rate (or less), the low
flow switch will automatically stop:
-
naphtha feed,
hydrogen,
steam of the hydrogenation reactor feed heater,
stop the feed to the isomerization section,
open the block valve of the recycle air cooler,

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close the bypass of the recycle air cooler.
This protects the catalyst from very low space velocity and potential hydrocracking
leading to a temperature runaway.
In case of high high temperature in the hydrogenation reactor, the same procedure is
followed.
8.7.2. Isomerization reaction section
If the naphtha feed flowrate to the isomerization reaction section reduces to 70% of
design rate (or less), the low flow switch will automatically stop the feed to the section.
If no problem is observed on the hydrogenation reaction section, the feed will bypass the
two reactors to the stabilizer.
This protects the catalyst from very low space velocity and potential hydrocracking
leading to a temperature runaway.
8.7.3.
Stabilizer Reflux Drum High Liquid Level
The PSV protecting the stabilizer circuit is located on top of the Stabilizer Reflux Drum
discharging to the Caustic Scrubber. The release of hydrocarbon liquid to the caustic
scrubber causes foaming in the scrubber, and hence an HLL switch is added to the
Stabilizer Reflux Drum to shut down the unit.
8.7.4.
Regenerant Superheater Shutdown
Activated by the following:

-
a high liquid level in the Regenerant Vaporizer,
a high coil skin temperature in the electrical Superheater,
low regenerant feed flow.
8.7.5. Emergency Shutdown Hand Switch

This is not an automatic shutdown but a board mounted hand switch to be used at the
discretion of the operator. Should an emergency situation occur such as a temperature
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runaway in the reactors or warning of a potential slug of water in the feed, the operator
can activate this switch which will:
-
Shut off the fresh feed to the hydrogenation reactor.
Shut off the recycle feed to the reactor.
Stop the chloride injection pump.
Shut off the hydrogen make-up.
Shut off the isomerate to storage.
Reroute scrubber off-gas to flare.
Bypass LPG recovery section.
Depressurize at a controlled rate the reaction section to the stabilizer.
Depressurize at a controlled rate the stabilizer to the scrubber.
At no time should reactor be allowed to set with liquid hydrocarbon inside and no
flow. Under these conditions with no flow across, the thermocouples temperature
measurement would be false and the temperature runaway could be occurring with
no indication. Once depressurized reactor should be swept to remove any liquid
hydrocarbon using cold hydrogen make-up or nitrogen.
8.7.6. LPG Recovery section bypass hand switch

The operator, for a particular emergency situation, could decide to activate the hand
switch which will permit the bypass of the LPG recovery section on off gas side (UV
2501 closed and UV 2503 open).
It may occur during chloride breakthrough, water breakthrough, loss of make-up
hydrogen, high reactor temperature, steam failure, cooling failure, power failure and
major leak or fire.

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SECTION-9
PROCESS VARIABLE
Process variables that affect the isomerization process are discussed below.
9.1
BENZENE SATURATION
There are six process variables which have an effect on the reactor performance:
- Reactor temperature.
- Reactor pressure

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- Hydrogen make-up flow

- Liquid diluents recycle
- Space velocity.
- Feed composition
9.1.1
Reactor Temperature:
The high activity of the catalyst allows operation at moderate reactor inlet temperatures
(100 to 140C). Typical heat of reaction for the benzene hydrogenation reaction is
50,000 kcal/kmol.
9.1.2
Reactor Pressure:
A moderate pressure is sufficient to obtain the benzene hydrogenation. The pressure

recommended in the heat balance leads to an almost liquid phase at the reactor outlet.
9.1.3
Hydrogen make-up flow
Hydrogen in small excess (5 mole%) is mixed with dry feed under flow control.
Operator will adjust hydrogen flow set point according to amount of benzene measured
by on-line analyzer.
9.1.4
Liquid diluents recycle
The exothermicity in the reactor is linked to the benzene content in the feed. With 7.5%
wt of benzene, the reactor delta T is estimated to be about 75-80oC. The control of
exotherm in then reactor, in smooth and safe conditions, is realised with the recycled
hydrogenation reactor effluent, used as inert diluents recycle. The heat and material
balances show the recommended recycle flow for the maximum benzene content in the
reactor feed to maintain an acceptable delta T in the reactor. Temperature gradient
should always be limited to 30oC.

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Space Velocity:
Liquid Hourly Space Velocity (LHSV) is defined as the ratio of the hourly flowrate of
liquid feed in m3 to the volume of catalyst in m3, i.e.
LHSV
9.1.6
Hourly feed rate @15C ( m 3 / h)

Total catalyst volume( m 3 )
Feed Composition:
Feed composition is an indirect variable, a variable the operator reacts to, rather than
adjusts for performance control. If the benzene content of the feedstock varies , the
operator will have to:
-
Adjust the hydrogen makeup to ensure excess of 5% vol.
Modify the recycle flowrate in order to have an acceptable gradient of temperature in the
hydrogenation reactor (no more than 30 oC elevation
9.2
ISOMERIZATION
There are six primary process variables which have a direct effect on the reactors
performances:
- Reactor temperature.
- Space velocity.
- Hydrogen / hydrocarbon ratio.
- Feed composition.
- Reactor outlet pressure
- Chloride Injection.
9.2.1
Reactor Temperature:
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The high activity of the catalyst allows operating at moderate temperature (125-165 oC).
The inlet temperature to the reactors is the most direct variable the operator has
available to control product quality. Higher temperatures enhance catalyst activity and
approach to equilibrium, but it decreases the equilibrium amount of isomer in the reactor
effluent. Higher temperatures also increase hydrocracking reactions, and consequently
the coke deposits on the catalyst. An optimum temperature is determined which balances
the potential slight exotherm, the approach to equilibrium and the equilibrium level to
maximize the performance of the isomerization reactor. This optimum temperature
varies with feedstock variations, catalyst activity levels and space velocities without
forgetting that it must be adequate with the benzene saturation constraints.
9.2.2
Space Velocity:
Weight Hourly Space Velocity (WHSV) is defined as the ratio of the hourly flowrate of
liquid feed in kg/h to the weight of catalyst, i.e.
WHSV =
Hourly feed rate (kg/h)

total catalyst weight (kg)
This parameter is fixed by the feed rate.

The quantity of catalyst being a constant, the space velocity can only be changed by
varying the liquid feed rate.
Decreasing the feed rate decreases the space velocity. At constant temperature this
increases activity and therefore the approach to equilibrium. The operator can therefore
reduce the reactor inlet temperature while maintaining catalyst optimum performance.
9.2.3
Hydrogen to Hydrocarbon Ratio:
This ratio is defined as the number of moles of hydrogen at the reactor outlet per mole of
C5+ liquid feed passing over the catalyst. The design ratio for this unit is 0.06, to supply
sufficient hydrogen at the active sites for the isomerization reactions to proceed and to
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saturate the benzene. Also, it avoids carbon deposition on the catalyst with sufficient
hydrogen to saturate the hydrocracked components.
This ratio must at all times remain above 0.06. The operator should check this regularly
and pay particular attention during feed changes and end of life conditions in the
reformer. If necessary, reduce the reactor feed rate to maintain the ratio.
Hydrogen makeup is under ratio flow control according to the amount of the feed
coming from separator drum and going to the isomerization section.
9.2.4
Feed Composition:
Feed composition is an indirect variable, a variable the operator reacts to rather than
adjusts for performance control. As the feedstock compositions changes from processing
different crudes, the operator must make the necessary temperature adjustments to
maintain unit performance.
For example, when the cyclic content is high in the feed, the first stage isom reactor inlet
temperature is increased to increase the weight average bed temperature. This increases
ring opening in the first reactor and reduces the inhibition effect the cyclics have on the
isomerization reactions in the second stage reactor.
9.2.5
Reactor outlet pressure :
At the outlet of the second reactor, pressure shall be above the minimum of 30 kg/cm2
9.2.6
Chloride Injection:
The chlorinated platinum catalyst loses a small amount of chloride continuously to the
reactor effluent, and this is made-up by the continuous injection of a chloride agent to
the isomerization reactors. Tetrachloroethylene (C2Cl4) not stabilized is the
recommended Chloriding agent. The isomerization reactors should not be operated
for more than six hours without chloride injection, as the isomerization reactions
slow down significantly with chloride deficiency.

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Figure 1
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MOLE % ISOPENTANE/ISO + n-PENTANE
ISOPENTANE/ISO + NORMAL PENTANE EQUILIBRIUM PLOT

100
80
60
40
20
0
100
150
200
250
300
TEMPERATURE C
Figure 2
iC5/C5 Paraffin equilibrium ratio
85
83
81
IC5/C5P
79
77
75
73
71
69
67
65
60
80
100
120
140
160
180
200
TEMPERATURE C
Vapor phase equilibrium

Liquid phase equilibrium
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Figure 3
C6 Fraction equilibrium Plot
100
MCP/MCP + CH
80
60
2-MP+3MP/ C6 PARAFFINS
40
n-HEXANE/ C6 PARAFFINS
2,2 DMB/ C6 PARAFFINS
20
2,3 DMB/ C6 PARAFFINS
0
100
200
150
250
300
TEMPERATURE C
Figure 4
22 DMB/C6P
2.2 DMB / C6 equilibrium ratio

52
50
48
46
44
42
40
38
36
34
32
30
28
26
24
22
60
80
100
120
140
160
180
200
TEMPERATURE C
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SECTION-10
TROUBLE SHOOTING
The main concern for the isomerization unit operation is water breakthrough through a
malfunction of the dryers or major water upset in the upstream hydrotreater.
Two other concerns are:
-
Sulfur poisoning which is reversible and poor de-nitrification in the upstream units
leading to chloride stripping off the catalyst.
Chloride breakthrough in isomerate/LPG products.
The operator must be knowledgeable and experienced enough to make the proper
corrective actions immediately and to know if he should cut feed to the unit before any
catalyst activity loss occurs. The ultimate safe rule is to cut feed from the unit if a
breakthrough is suspected and follow carefully the necessary procedures for total unit
shutdown. Remember this unit produces a gasoline component for blending; it does not
produce any feedstock for other units and can therefore be shutdown with relatively little
disruption to the other refinery operations. The upset seriousness and the contaminant
breakthrough level will dictate the necessary course of action to take.
In this chapter we will highlight some of the potential problems which the operator may
have to face.
10.1
WATER BREAKTHROUGH FROM THE DRYERS
a. Feed and Hydrogen dryer

If water breaks through a dryer, as indicated by the moisture analyzers, immediate action
must be taken. Water entry into the reaction circuit will cause irreversible catalyst
damage as well as creating a highly corrosive environment.
Generally the dryers are taken off line and regenerated on a regular basis or when 1ppm
water content is registered in the lead dryer outlet analyzer. These analyzers are critical
to the performance and the unit condition and should be well maintained and calibrated
on a regular basis.

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A sudden irregular indication of water breakthrough in the lead dryer analyzer indicates
either a malfunction of the analyzer or water upset upstream.
Operator action is to immediately cut out the feed indicating the high-water content i.e.
C5/C6 feed, make-up hydrogen.
After this, the corresponding emergency procedure for shutdown and purging can be
followed.
After the unit has been secured, the dryers which experienced the water breakthrough
should be regenerated and the dryer checked for water removal capability. The feed, the
make-up gas should be tested for moisture content and the source of the problem
corrected.
Then only a unit restart should be considered.
Remark: Water breakthrough from other sources
Chloride is not corrosive with dry hydrocarbons, but becomes very corrosive when
traces of water are present.
Stabilizer and equipment in LPG recovery section are made of carbon steel as reactor
effluent is water free.
However water ingress may occur with a leaking (cooling water exchanger or steam
reboiler). If water is detected in a stabilizer or LPG recovery section stream, unit shall be
shut down, for exchanger maintenance, in order to avoid extensive chloride corrosion.
b. Off-Gas Dryer
Water breakthrough will lead to purging of 73-E-13 (ice / LPG hydrates formation) and
ultimately to LPG recovery section bypass and shutdown. Incase of water breakthrough
Immediate action must be taken.
Also note that performance of the dryers is poor when process fluid temperature exceeds
50 oC. Therefore stabilizer overhead temperature and scrubber operating temperature
shall be closely monitored, in order to have a stable off-gas temperature at dryer inlet.
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10.2
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SULPHUR BREAKTHROUGH: SULPHUR STRIPPING PROCEDURE
If there is a disoperation in the upstream units leading to an increase in the level of

sulfur in the C5/C6 feed, then the isomerization unit must be immediately shutdown.
Sulfur breakthrough into the benzene saturation reactor and isomerization reactors is
indicated by a loss of benzene saturation and isomerization activity. If this occurs, the
temperature differential will shift down the benzene saturation reactor and possibly
across to the next reactor. H2S will also be detectable in the stabilizer off-gas.
If this occurs, discontinue naphtha feed to the unit immediately. It is possible after sulfur
poisoning to regain activity by stripping with hot hydrogen make-up gas. Good recovery
can be achieved, but complete recovery should not be expected.
The following outlines the sulfur stripping procedure when the lead isomerization
reactor has been sulfur poisoned:
-
With light naphtha feed discontinued, maximize hydrogen make-up gas through the
reactors.
For this operation, use hydrogen compressor bypass line. Hydrogen is routed via
hydrogen drier through normal circuit, with additional heating in the superheater.
Check that the blinds and block valves are lined out properly to use the electric super
heater. Hydrogen leaves the unit through the stabilizer and the caustic scrubber (LPG
recovery section must be bypassed).
Increase the inlet temperature to about 260C, at 50C/hr rate based on the heater
limitations and mechanical design of the other equipment.
Inject chloride into the first isomerization reactor inlet at a rate equivalent to
injecting 100 ppm chloride on a design throughput basis.
Monitor the H2S content in the stabilizer off-gas. The H 2S content will peak perhaps
as high as 1000 mol ppm depending upon the sulfur amount on the catalyst.
Maintain the stripping operation for 24 hours or until the H2S content has decreased
to a low stable level.
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At this point the stripping operation is considered complete. Stop the chloride
injection, shutdown the reactor feed heater and the superheater and cool the reactor
catalyst beds to 65C.
Follow the normal start-up procedures.
10.3
LOSS OF C2CL4 INJECTION
If C2Cl4 injection is lost, chloride will be stripped from the isomerization catalyst
resulting in an isomerization activity loss.
If chloride is lost for only a few hours, the catalyst activity can be regained by resuming
chloride injection at a higher rate (400ppm) until HCl in the Stabilizer off gas reaches
about 2000ppm.
If the chloride injection is lost for more than six hours, the ability for the catalyst to
regain activity is reduced leading to irreversible damage of the catalyst.
If chloride is lost the following actions should be taken:
-
Reduce reactor inlet temperatures to 110C.
If it appears that the chloride injection will not be available for more than six hours,
prepare the unit for shutdown.
Reduce net naphtha feedrate to 50% of design capacity.
When chloride becomes available, maintain the low severity conditions (110C inlet
temperature) inject into the reactor feed at 400 ppm wt until the stabilizer off-gas
chloride content increases back to 2000ppm.
C2Cl4 injection rate: C2Cl4(Kg/h.) = Reactor feed flow (T/h.) /1000
Caution:
When a new load of C2Cl4 is required check that the purchase order indicates C2Cl4
unstabilized or catalytic grade. The stabilized C2Cl4 will not decompose in the reactors
and will end up with product in the Stabilizer leading to some problems with the
isomerate used to dryers regeneration.
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10.4
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CHLORIDE BREAKTHROUGH
Isomerate, heavy product and LPG product are regularly checked for HCl content.
Periodic testing is necessary to ensure no chloride exiting with the isomerate and LPG
product. As isomerate is used to regenerate the dryers, it must be free of HCl not to
damage the molecular sieves.
The isomerate unit and the LPG recovery section are very sensitive to any upset in
reflux or reboiling duty at the stabilizer and at the LPG stripper. Any upset will impact in
chloride content in isomerate, LPG product and heavy product shall be recorded.
Corresponding chloride will be absorbed on the chloride guard beds and the record of
the upset will enable the operator to predict the life length oh the chloride beds.
For any upset in the stabilizer or in the LPG recovery section (loss of reboiler or reflux),
the LPG recovery section will be bypassed on, off gas side. The stabilizer off gases are
sent to the scrubber and routed to fuel gas header. The lean oil still circulates in the LPG
recovery section.
10.5
PREVENTIVE MAINTENANCE:
To ensure a more trouble free operation of the isomerization unit, the mechanical unit
integrity should be adequately monitored and the equipment including instrumentation
inspected on a periodic basis. Items of particular importance are:
-
The automatic valves around the naphtha feed, hydrogen make-up dryers. These
should be periodically checked for leakage.
Spare automatic valves shall be provided in warehouse.
The C2Cl4 injection pumps should be periodically checked for leakage and switched
to the standby.
The water removal capability of the dryers should be monitored. Consider absorbent
replacement after 500 cycles.
The moisture analyzers should be checked frequently for response and accuracy.
Monitoring of the chloride absorbers life length.
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SECTION -11
SPECIAL PROCEDURES/INSTRUCTION/INFORMATION
11.1
CATALYSTS LOADING UNDER N2
General:
The following procedure describes in detail the loading steps of catalyst. As the reaction
section has undergone a special drying procedure, care must be taken to ensure that no
air or moisture enters the reactors during the catalyst loading period. It is recommended
that the reactors be loaded using Axens' dense loading apparatus "CATAPAC".
The benzene hydrogenation catalyst LD-412 R and the isomerization catalyst IS-614 A
manufactured by Axens are shipped in sealed drums (120 kg for LD-412 R and 130 kg
for IS-614 A) that have a special protective lining (see Figure 5).
The catalyst is contained in a heavy plastic bag with an unloading neck. This bag is
inside another heat-sealed plastic bag. Care should be taken in the drums handling so as
not to break or puncture the plastic bags.
Before, during and after catalyst loading the catalyst must be protected from moisture at
all times.
Any contact with water or air will result in permanent deactivation of the catalyst.
The empty drums and bags should be kept to return the spent catalyst for platinum
recovery.
Preparation:
Prior to the loading, preliminary checking:
-
The LD-412 R and the IS-614 A catalysts for loading, are stored by sealed plastic
bags in drums.
The inert balls for top of the catalyst bed, it is recommended that these balls be oven
dried and stored in sealed plastic bags in drums similar to the catalyst.
The CATAPAC dense loader device (see Figures 7, 8, 9 and 10).
Special unloading lids with quick release retainer rings (4 required fitted at ground
level - see Figure 5).
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Sufficient dry nitrogen (less than 1 ppm wt H2O). If not available provide temporary
piping to route nitrogen through the hydrogen dryers.
Provide emergency nitrogen storage in case of refinery nitrogen failure.
Make available several nitrogen flexible hoses. They must be specified for nitrogen
service, must be new and perfectly dry.
One telescopic crane capable of lifting a drum 3 m above the reactor upper flange
(see Figure 6).
One standing hopper (see Figure 9).
One forklift to handle the drum pallets.
Tarpaulins should be available in case of rain or interruption during loading.
One structure (scaffolding) disposed on the top of the reactor adapted to receive the
drums and to fill them into the reactor through the special device (see Figure 7).
One safety harness, portable oxygen analyzer, air packs and dust masks.
The oxygen analyzer will be used when reactors are open for catalyst loading to
make sure that no air is entering.
Catalyst Loading Procedure

The following instructions must be strictly followed throughout the entire catalyst
loading for the 3 reactors. It is imperative that no air or moisture enters the reactors or
comes in contact with the catalyst at any time.
-
Connect the nitrogen flexible hoses from nitrogen header to drain point at reactor
bottom and to inlet pressure gauge tapping at reactor inlet line.
Start a small purge of nitrogen into the reactor bottom and out the reactor inlet PI
connection.
Unbolt and remove the reactor inlet elbow and top head. As the reactor is opened,
tightly cover the open flanges with plastic until the bottom inert balls entry.
To install the dense loading device (CATAPAC) on the top distributor of the reactor,
attach the nitrogen connection and then attach the loading sock from the stationary
pipe above.
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Set down on the top man hole the stationary steel cover, the standing hopper and
pipe catalyst loading.
At the same time, care must be taken to ensure that the sock penetrates in the center
of CATAPAC device. Look it through the little hole drilled on the steel cover
(figure 7).
Then load, drum by drum the required quantity of catalyst.
After the catalyst has been loaded install the top bed inert alumina balls layer
Note: At no time should a person enter a reactor having a nitrogen purge on it without
full instruction and experience with a fresh air mask, safety harness, safety clothes and
life line.
-
Cover the manway again with plastic. Remove all the loading devices off the top
platform.
Install the inlet distributor tray, reactor cover and inlet removable elbow as quickly
as possible after the loading is complete.
Continue the nitrogen purge at the bottom of the reactor out through the inlet PI.
Check that the purge out through the PI is oxygen free.
Pressure the reactor back up to 0.5 bar g. Check for flange leaks.
Record all loading data, number of catalyst drums, inert balls, etc
Repeat loading procedure for the second then third reactor.

Note: The opening, loading and closing procedure of the reactors should be a
continuous operation without break. During this operation a positive nitrogen
pressure should be maintained in the reactor at all times.

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Figure 5
Preparation of the Drums

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Figure 6
DRUM LIFTING CATALYST DENSE LOADING

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Figure 7
Catalyst Handling with Catapac

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Figure 8
Catalyst DENSE LOADING (part 1)

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Figure 9
Catalyst DENSE LOADING (part 2)

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11.2
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SPENT CATALYST UNLOADING
When the catalyst is at end of life, it will be necessary to unload it. Spent catalyst can be
dumped from the reactors without previous coke combustion. This procedure must be
carried out with extreme caution under a nitrogen blanket at all times. The same
precautions used to keep air and moisture away from fresh catalyst must be used when
unloading spent catalyst. Specifically, the spent catalyst from isomerization reactors
contains a large chloride amount (3 to 4 %) and any moisture will make the material
very corrosive.
The reactor to be unloaded has to be depressurized, isolated with blinds, evacuated and
swept with cold dry nitrogen to a hydrocarbon level of less than 0.5 vol %. The reactor
is kept under a positive nitrogen pressure of 0.1 bar g with a nitrogen bleed entering at
the reactor bottom and exiting through the inlet PI.
-
Close the nitrogen vent through the top PI and remove the blind flange on the
catalyst withdrawal nozzle.
Attach the catalyst unloading sock. The bottom end of this sock must have a solid
metal section in order to clamp the catalyst bag.
The spent catalyst can be loaded into the original catalyst drums and liners to protect
against corrosion during shipment.
Place an empty drum on a scale, then put the inner plastic bag with the unloading
neck inside the outer heavy plastic bag. Purge the inner bag with nitrogen.
Clamp the plastic unloading neck of the inner bag over the end of the unloading
sock.
Partially detach the unloading spout, crimp the sock to stop any catalyst flow and
quickly remove the catalyst draw-off cover, reattaching the unloading spout.
Uncrimp the loading sock and load into the drums. The first material will be inert
material followed by catalyst. If possible segregate the first few drums of inert
material for screening.
The catalyst is dropped in the original catalyst drums.
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Load catalyst into each drum. Wire clamp the plastic unloading neck in two places
then wire clamp the outer heavy plastic bag.
Close the drum tightly, record the weight and label the drum.
A small amount of spent catalyst and inert material will be left in the bottom of the
reactor. This must be removed manually with a person inside the reactor to sweep
the catalyst toward the withdrawal spout.
All the precautions previously listed for personnel entry during catalyst loading and
inspection should be followed here.
With the reactor empty, an inspection can be carried out on the internals, and then
prepared for immediately catalyst reloading.
Catalyst spillage should be minimized using the above procedure.
However the concrete pad at the base of the reactors should be swept clean prior to
unloading. Any spillage during unloading can then be swept and placed in one of the
drums.
The catalyst can then be shipped for platinum recovery including any catalyst
retrieved from screening of the initial drums of inert balls.
11.3
SPECIFICATIONS OF CATALYSTS
a) Benzene saturation catalyst:

73-R-01
Supplier
LD-412 R (1)(2)
Axens
Shape
Grey cylindrical extrudates
Nominal Particle Diameter
1.2 mm
Catalyst volume, m3
4.6 m3 (3)
Catalyst Cycle Length (estimated)
3 years (4)
Catalyst Life (estimated)

10 years
(1)Ready to use form
(2)Reduced and activated platinum on high purity alumina
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(3)Dense catalyst loading method

(4)Ex-situ regeneration / reduction required at the end of cycle
The 73-R-01 was designed to have provision for future loading. Total future catalyst
amount will be 5.06m3
b) Isomerization catalyst:
73-R-02 & 73-R-03
IS 614 A (1)
Supplier
Axens
Shape
Cylindrical extrudates
Nominal Particle Diameter
1.6 mm
3
Catalyst volume, m
56.22 m3 (28.11x2) (2) (4)
Catalyst Cycle
First reactor : 4 years (3)
Length(estimated)
Second reactor : 4 years (3)
Catalyst Life(estimated)
10 years
(1)Reduced and activated platinum on high purity alumina
(2)Dense catalyst loading method
(3)Ex-situ regeneration / reduction required at the end of cycle
(4)Total requirement for both reactors
The 73-R-02/03 were designed to have provision in the reactor for a future loading.
Total future catalyst amount will be 61.46m3 (30.73*2)
c) Dryers Adsorbents
Manufacturer
AXENS
Type
Molecular Sieve4A
Volume, m3 (1) (2)
37.56 m3
Estimated cycle length
30 hours (per bed)
Life period
3 years (estimated)
Notes: - (1) Total requirement for: 73-DR-01 A/B, 73-DR-02A/B, 73-DR-03A/B.
Manufacturer will advise on contingency to consider for this material.
(2) Sock catalyst loading method.
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Manufacturer
AXENS
Type
Molecular Sieve 5A
Volume, m3 (1) (2)
13.7 (6.85x2) m3
30 hours (per bed)
Life period
3 years (estimated)
Notes: (1) Total requirement for: 73-DR-01 A/B.
Manufacturer
Type
Volume, m3 (1) (2)
Life period
AXENS
Molecular sieve 13X
3.38 (1.69x2) m3
30 hours (per bed)
3 years (estimated)
Notes: (1) Total requirement for: 73-DR-02 A/B.

d) Chloride guard bed Adsorbents
Manufacturer
Type
Volume, m3 (1)(2)
Life Period
JOHNSON MATTHEY
Puraspec 6250
2.44
3 years (estimated)
Puraspec 6255
9.56
Note: (1) Total requirement for: 73-V-06,

e) Alumina Balls
Manufacturer
Type
Volume, m3 (1)
Type
Volume, m3 (1)
AXENS
Inert Ceramic Balls
12.10
Inert Ceramic Balls
10.81
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Notes: (1) Total requirement for all vessels.

11.4
CHEMICALS DURING NORMAL OPERATION
11.4.1. Chloriding agent

Type
C2Cl4
Quality
Not stabilised (1)
Purity
99.9 wt%
Water Content
< 25 wt ppm
Stabilizers
< 10 wt ppm
Oxygen and Nitrogen compounds
< 15 wt ppm
Halogens
< 1 wt ppm
MW
165.8
Specific Gravity
1.623
o
Viscosity (15 C)
0.95 cP
Estimated consumption
71 (Tons/year)
Notes: - (1) In order to have decomposition of C2Cl4 in HCl at reactor operating
conditions.
11.4.2. Neutralizing Solution
Type
Aqueous Caustic
Quality
NaOH 10 wt%
Estimated Consumption
1100 tons/year (1)
Notes: - (1) Based on spent caustic composition of 2 wt%
11.5
CHEMICALS DURING TRANSIENT OPEARTION
11.5.1. ACIDIZING GAS

Type
Quality
Purity
Cl2 + Br2
CCl4
H2 + CO + CO2 + N2
Estimated Consumption
HCl
Anhydrous
> 99.8 vol %
< 20 ppm
< 150ppm
< 1500 ppm
2670 kg (1)

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Notes:- (1) one time requirement , used during initial start-up of the reaction section,
removing water and oxide scales from reaction circuit.
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SECTION-12
UTILITY CONSUMPTION SUMMARY
12.1
INTERMITTENT CONSUMPTIONS FOR ISOMERIZATION SECTION
Start up requirement
The estimated consumptions are based on a normal start-up sequence.
Intermittent operation can be assumed to occur once every 24 months.
Start-up instrument air
The instrument air is used for tightness test after catalyst loading.
Estimated consumption:
Isomerization section: 900 Nm3.
Start-up nitrogen
Nitrogen gas is necessary to get the unit free of oxygen.
Start up hydrogen
At start-up, after 1st leak test, the reaction section is pressurized with hydrogen make-up.
Remark for Isomerization section: Hydrogen is needed during initial start-up to perform
acidizing at 60% of normal H2 flowrate. Moreover, in case of sulfur catalyst poisoning, it
is necessary to strip catalyst with hydrogen. In order to ensure a good hydrogen
distribution through the catalyst bed, it is recommended to process at a minimum
flowrate of 1000 Nm3/h.
Start-up hydrotreated naphtha:
For start-up, light hydrotreated naphtha is required to perform naphtha circulation in the
unit and to reach temperature in the unit.

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Estimated required volume = 2 x estimated unit volume.
MP Steam
MP steam will be used as driving fluid of the start-up ejector 73-J-01 to inert reactor
section at the start-up.
LP Steam
LP steam will be used for steam purge out of the equipments and also as snuffing steam
on the flanges.

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SECTION-13
SAMPLING PROCEDURE AND LABORATORY ANALYSIS REQUIREMENT
13.1
GENERAL
Control tests provide the information to the operating staff for making necessary
adjustments to get the maximum output and on-spec quality products. The control
tests are to be made at all steps to monitor the intermediate and final products whether or
not they are at the desired specification. Samples are taken and analyzed at regular
intervals such that the operation of the plant are monitored and any deviation (from
specification will indicate some maloperation / malfunction of the plant which can be
spotted and rectified in time without undue loss of time and product. Sometimes,
samples are taken to find out the effect of certain changes brought about in the operating
conditions. The samples are to be taken with great care so that the samples are
representative samples. The frequency of sampling, the type of analysis and points
where samples are to be taken are generally specified by t he process licensor. During
guarantee tests some additional samples can be taken at higher frequencies, which will
be specified, in the technical procedures prior to test run. The following guidelines
should be followed while collecting samples.
13.2
SAMPLING PROCEDURE
a) Liquid Sampling Procedure (Non-Flashing Type)

i)
The person taking samples should wear proper or appropriate safety clothing like
face shields, aprons, rubber gloves etc. to protect face, hands and body.
ii)
Whenever hot samples are taken, check cooling water flow in the sample cooler
is circulating properly.
iii)
Sample points usually have two valves in series. One gate valve for isolation
(tight shutoff) and other globe valve for regulating the flow. Open gate valve first
and then slowly open the globe valve after properly placing the sample
containers. After the sampling is over, close the globe valve first and then the
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gate. Then again open the globe valve and drain the hold up between the gate and
globe valve in case of congealing liquid.
iv)
Sample valve should be slowly opened, first slightly to check for plugging. If the
plugging is released suddenly, the liquid will escape at a dangerously
uncontrolled rate. Never tap the line to release the plugging. Call the
maintenance gang to properly unplug the line. In case of congealing type
samples, sample point should be equipped with copper coil type steam tracer. It
should be ensured that steam-tracing line is functioning normally.
v)
The operator taking the sample should be careful to stand in a position such that
the liquid does not splash on him and he has unobstructed way out from the
sample point in case of accident.
vi)
While taking dangerous toxic material for sampling, it will act as an observer for
safety. Proper gas mask is to be used. It is advisable to stand opposite to wind
direction in case of volatile toxic liquid.
vii)
Sample should be collected in clean, dry and stoppered bottle. In case of

congealing samples use clean dry ladle.
viii)
Rinsing of the bottle should be thorough before actual collection.
ix)
Before collecting, ensure that the line content has been drained and fresh sample
is coming.
x)
Gradually warm up the sample bottle / metallic can by repeated rinsing before
collecting the sample.
xi)
Stopper the bottle immediately after collection of sample.
xii)
Attach a tag to the bottle indicating date, time, and name of the product and tests
to be carried out.
xiii)
A few products suffer deterioration with time.
xiv)
For example, the color of the heavier distillates slowly deteriorates with time. So
these samples should be sent to laboratory at the earliest after collection.
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The samples after collection should be kept away from any source of ignition to
minimize fire hazard.
Volatile samples (e.g. naphtha) should be collected in bottles and kept in ice particularly
for some critical test like RVP.
b) High Pressure Hydrocarbon Liquid Samples (Flashing Type)
i)
The person taking sample should use personal protection appliances like apron,
gas mask and hand gloves to protect himself.
ii)
Ensure that sample bomb is empty, clean and dry.
iii)
Connect the sample bomb inlet valve to the sample point with a flexible hose.
iv)
Open the inlet and outlet valves of the sample bomb. Hold the sample bomb.
Hold the sample bomb outlet away from person. Keep face away from
hydrocarbon vapor and stand in such a way that prevalent wind should blow
hydrocarbon vapor away. Open the gate valve of sample point slowly till full
open. Then slowly cracks open the regulating valve. One should be careful at the
time of draining, because chance of icing is there. As a result, the formation of
solid hydrates is a continuing process, which leads to the plugging of valves.
v)
When all the air in the hose and bomb are displaced as seen by the hydrocarbon
vapor rising from the outlet of sample bomb close the sample outlet valve. Allow
a little quantity of liquid to spill to make sure that the bomb is receiving liquid.
Frosting will be an indication of liquid spillage.
vi)
Allow liquid hydrocarbon to fill the bomb. When the bomb is full up to the
specified level, close both the valves on sample point. Close inlet valve on the
sample point.
vii)
Carefully disconnect the hose from the sample bomb. To allow for some vapor
space in the bomb for thermal expansion in case of overfilling, crack open the
outlet valve of bomb and discharge a small part of the liquid. Close outlet valve.
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viii)
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Page 184 of 221
Closed sampling facilities are provided at some locations where it is not

desirable to waste the costly product or if the material is toxic. For filling the
sampling bomb, pressure drop across a control valve is usually utilized or across
pump discharge & suction. Air is expelled from the bomb after it is connected to
upstream of control valve or pump discharge side. The sample is then collected
and bomb is detached after closing valves on both sides.
ix)
Send sample bomb to laboratory for analysis. Protect the bomb from heat
exposure.
c) Gas Sample
For collection of gas sample, which are not under high pressure and temperature, rubber
bladders are used. For the operations under vacuum or low pressure, aspirator is used.
For representative sample, purge the bladder 3 to 4 times with the gas and then take t he
final sample. Use of 3 ways valve with bladder / aspirator will facilitate purging and
sampling.
Sample bombs are to be used for taking gas samples from high pressure and high
temperature source. Procedure mentioned under high-pressure liquid sampling (flashing
type) is to be used.
13.3
LABORATORY TEST METHOD AND SCHEDULE
Recommended Methods and Frequency

The frequencies given below are routine related to a normal operation. During start-up
and test runs more analysis will be required.
C5/C6 Feed
Property
Specific Gravity
Method
ASTM D 1298
Frequency
1 per day
Distillation Curves
ASTM D 86
2 per week
IFP 9301
1 per day
Chemical Composition
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Property
Total Sulfur
Water Content
Rev. A
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Method
ASTM D 4045
Frequency
1 per day
On line analyzer (also check

upstream of dryers with portable
1 per week
analyzer)**
Total Nitrogen
ASTM D 4629
1 per week
IFP 9316
As required
Bromine Index
ASTM D 2710
As required
Arsenic Content
IFP 9312
As required
Copper Content
IFP 9507
As required
Lead Content
IFP9406
As required
Nickel Content
IFP 9507
As required
ASTM D 2699
As required
Chlorine Content
RON Clear
MON Clear
ASTM D 2700
As required
** PANAMETRICS is selling this kind of analyzer with the defined range of detection.
Hydrogen Make-up Gas
Property
Method
Frequency
IFP 9622
1 per week
Dragger (tube CH 298)
1 per day
on-line analyzer
Hydrogen Chloride
As required
Ammonia
As required
Composition
Hydrogen Sulfide
Water Content
Isomerate Product
Specific Gravity
ASTM D 1298
1 per day

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Distillation Curve
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ASTM D 86
1 per day
IFP 9301
1 per day
Chloride Content
IFP 9316
1 per day
RVP
ASTM D 323
1 per day
Bromine Index
ASTM D 2710
As required
RON Clear
ASTM D 2699
1 per day
MON Clear
ASTM D 2700
1 per day
Isomerization Reactor Effluents (1st and 2nd stage)

Composition
IFP 9301
1 per week
1 per day
Stabilizer Off-Gas
Hydrogen Sulfide
LPG product
Property
Chloride Content
Specific Gravity @ 15C
Method
ISO 7941
IFP 9316
ASTM D 1298
Frequency
1 per day
1 per day
1 per day
Scrubber Off -Gas

Hydrogen Chloride
H2
HC
Drger ( tube CH 295)

On-line analyzer
On-line analyzer
1 per day
pH meter (lab)
1 per day
Circulating Caustic
NaOH Wt %

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Caustic Make Up to Scrubber

NaOH Wt %
pH meter (lab)
As required
ASTM D 3178
Brunauer, Emmett and
As required
As required
Catalyst
Carbon
Specific surface
Metals content
Teller method
IFP 9315
As required
Stabilizer bottoms
Chloride content
IFP 9316
1 per day
IFP 9316
1 per day
IFP 9316
1 per day
LPG stripper bottoms

Chloride content
LPG product
Chloride content
SECTION -14
SAFETY PROCEDURE
14.1
INTRODUCTION
Safety of personnel and equipment is very important. Ignorance of the details of the unit or
the techniques of safe and efficient operation reduces the margin of safety of personnel and
subjects the equipment to more hazardous conditions. All the operating and maintenance
crew therefore must be fully familiar with the equipment and materials being handled in the
unit, and recognize the hazards involved in handling them and the measures taken to ensure
safe operations.
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Since the unit handles with one of the most potential source of fire and explosion, H 2,
Naphtha and chemical like caustic, therefore adherence of safety rules should be given
uphill importance.
14.2
SAFETY OF PERSONNEL
General safety rules which shall be practised and enforces for all personnel who enter the
unit are summarized below:
a. Safety helmets and boots shall be worn by all personnel at all times in the plant. They
may be removed when inside rooms or buildings which do not have overhead or other
hazards.
b. Smoking shall be permitted only in specified areas which are clad as non-hazardous
and are pressurized through a ventilation system. Failure of the ventilation system
automatically cancels the smoking privilege until the system is repaired, inspected and
authorized operation.
c. Each employees assigned to work in the unit shall know where the safety and fire
suppression equipment is located and how to operate this equipment.
d. Safety glasses, goggles or face shields shall be worn while performing work which
could result in eye or face injury.
e. Operations personnel golden rule
Do not open or close any valve without first determining the effect.
Note:-Treat each piece of equipment or piping as if it is under pressure.
14.3
WORK PERMIT PROCEDURE
A work permit system must be issued by the appropriate operations group before
commencing any maintenance work affecting the operation of the unit. The work permit
is issued for Hot and Cold work. The Hot work permit must include as a
minimum, a precise description and mode of execution of Hot works, the equipment
to be used, the expected time which Hot works is scheduled to start and expected
completion, an exact location of the Hot works and precautions to be taken.
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Unit areas are generally identified as hazardous areas as far as the threat of fire is
concerned. Therefore, in order to carryout works within these areas, a written work
permit is required. The work permit, when approved, indicates that a specific work can
be carried out in safe conditions provided that all safety precautions are observed.
a) Permit for Hot work
Permits of hot works are required for any work involving the use of or generation of heat
sufficient to ignite flammable substances.
Typical sources of ignition are:
-
Electric and gas welding
Any machine capable of producing a spark
Not explosion-proof electrical equipment
Internal combustion engines
Ferrous tools, both hand operated and pneumatic or other type
b) Permits for Cold-Work

Permits for cold-work are required for any work not involving the use of a local ignition
source.
Typical examples of cold-work are:
-
Disconnecting of lines for the insertion of blinds etc.
Opening of any equipment such as vessels, filters, etc.
c) Entry permits
Entry permits are required for entering enclosed spaces such as vessels, sewer, pits,
trenches, etc.
The use of any tool or machinery, which could provide a source of ignition, is forbidden.
Also, prior to entry it should be ensured that area is well ventilated and the oxygen
content in air is about 21% by volume. Fresh air flow is to be ensured in the enclosed
space through out the duration of work. A gas test for H 2S and flammable gases should
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also be performed before entry. A person should also be on alert outside the enclosed
space for rescue in case of emergency. Procedure for carrying out work and rescue plan
shall be formulated before commencement of work.
d) Guidelines for release of permits
-
The equipment item, on which works have to be carried out, shall be clearly
indicated. During the shutdown of any system, permits covering the whole section
with above mentioned item shall be issued, if possible. The type of work permitted
shall be clearly indicated.
The date and the period of validity of the permit shall also be indicated. If the work
does not get over within the period of validity of the permit, the permit can be
extended provided that, at each start of the works the safety conditions are checked
again and signed by the operator in-charge and by safety officer. Beyond this
extended period, a next permit will have to be issued. The explosiveness test and the
check of toxic gases shall be performed always at the last moment before each start
of the work and subsequently every time the work is resumed or whenever doubts
arise.
The validity of the permit can be cancelled at any moment by the operator or by
safety officer; in case they deem that the conditions are not safe.
The conditions to be complied with shall include special precautions, such as the use
of protective clothing, breathing apparatus, safety equipment and the tools to be used
etc.
No one shall be allowed to enter the vessel or other enclosed spaces without suitable
protective clothing and until the vessels or the enclosed spaces become safe for entry
by means of proper isolation, proper ventilation and suitable check of the
atmosphere inside and availability of rescue person outside the enclosed equipment.
If welding or hot work is to be done ensure that:-
Fire fighting system is ready
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Close the neighbouring surface drains with wet gunny bags
Keep water flowing in the neighbouring area to cool down any spark.
Responsible operation supervisor should be present at the place of hot work till the first
torch is lighted.
14.4
PREPARATION OF EQUIPMENT FOR MAINTENANCE
a) Process Equipment: Towers, Vessels etc.

Before opening any equipment, it should be purged to render the internal atmosphere
non-explosive and breathable. Operations to be carried out are: -
Isolation with valves and blinds.
Draining and depressurisation.
Replacement of vapours or gas by steam, water or inert gas.
Take care about instrument tapping.
Washing of towers and vessels with water.
Ventilation of equipment.
Opening of top manhole.
Testing of inside atmosphere with explosive meter.
Complete opening if inside atmosphere is satisfactory.
Analyse the atmosphere inside for O2 content and any poisonous gas.
Note: Open a vent on the upper part of the vessel to allow gases to escape during filling
and to allow air inside the vessel during draining. Ensure proper ventilation inside
the vessel by opening all manholes. For hydrocarbon or other gases, pressurise the
vessel with N2 or gas and fill in the liquid and drain under pressure. This is to avoid
hydrocarbon going to atmosphere.
b) Precautions Before Handing Over Equipment
Following items should be checked by a responsible operating supervisor before the
equipment is handed over for maintenance after it has been purged.
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Ascertain that equipment is isolated by proper valves and blinds.
Ascertain that there is no pressure of hydrocarbons in the lines, vessels and equipment.
Purge the system with N2 first and later by air and check for O 2 content at vent and
drain to ensure that the vessel is full of air.
Check that steam injection lines and any inert line connections are disconnected or
isolated from the equipment.
Provide tags on the various blinds to avoid mistakes. Maintain a register for blinds.
Check for pyrophoric iron and if existing, keep this wet with water.
Keep the surrounding area cleaned up.
Get explosive meter test done in vessels, lines, equipment and surrounding areas.
If welding or hot work is to be done, also:

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

ISOMERISATION UNIT,
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14.5
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PREPARATION FOR VESSEL ENTRY
The most common potential hazards in vessel entry are:

-
Unit Checkout Prior to Start-up
Turnaround Inspections
Reactor Loading
Reactor Unloading
The precautions apply equally to entry into all forms of vessels, including those enclosed
areas which might not normally be considered vessels.
Examples include:
Reactors, Columns, Separators, Receivers, Clay treater, Fired heaters, Sumps
Positive Vessel Isolation
Every line connecting to a nozzle on the vessel to be entered must be blinded at the
vessel. This includes drains connecting to a closed sewer, utility connections and all
process lines. The location of each blind should be marked on a master piping and
instrumentation diagram (P&ID), each blind should be tagged with a number and a list
of all blinds and their locations should be maintained. One person should be given
responsibility for the all blinds in the unit to avoid errors.
The area around the vessel manways should also be surveyed for possible sources of
dangerous gases which might enter the vessel while the person is inside. Examples
include acetylene cylinders for welding and process vent or drain connections in the
same or adjoining units.
Any hazards found in the survey should be isolated or
removed.
Vessel Access
Safe access must be provided both to the exterior and interior of the vessel to be entered.
The exterior access should be a solid, permanent ladder and platform or scaffolding

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strong enough to support the people and equipment who will be involved in the work to
be performed.
Access to the interior should also the strong and solid. Scaffolding is preferred when the
vessel is large enough. The scaffolding base should rest firmly on the bottom of the
vessel and be solidly anchored.
If the scaffolding is tall, the scaffolding should be supported in several places to prevent
sway. The platform boards should be sturdy and capable of supporting several people
and equipment at the same time and also be firmly fastened down. Rungs should be
provided on the scaffolding spaced at a comfortable distance for climbing on the
structure.
If scaffolding will not fit in the vessel a ladder can be used. A rigid ladder is always
preferred over a rope ladder and is essential to avoid fatigue during lengthy periods of
work inside a vessel. The bottom and top of the ladder should be solidly anchored. If
additional support is available, then the ladder should also be anchored at intermediate
locations. When possible, a solid support should pass through the ladder under a rung,
thereby providing support for the entire weight should the bottom support fail. Only one
person at a time should be allowed on the ladder.
When a rope ladder is used, the ropes should be thoroughly inspected prior to each new
job. All rungs should be tested for strength, whether they be made of metal or wood.
Each rope must be individually secured to an immovable support. If possible, a solid
support should pass through the ladder so that a rung can help support the weight and the
bottom of the ladder should be fastened to a support to prevent the ladder from
swinging. As with the rigid ladder, only one person should climb the ladder at a time.
Wearing of a Safety Harness
Any person entering a vessel should wear a safety harness with an attached safety line.
The harness is not complete without the safety line. The harness should be strong and
fastened in such a manner that it can prevent a fall in the event the man slips and so that it
can be used to extricate the man from the vessel in the event he encounters difficulty. A
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parachute type harness is preferred over a belt because it allows an unconscious person to
be lifted from the shoulders, making it easier to remove him from a tight place such as an
internal manway.
A minimum of one harness for each person entering the vessel and at least one spare
harness for the people watching the manway should be provided at the vessel entry.
Providing a Manway Watch
Before a person enters a vessel, there should be a minimum of two people available
outside of the vessel, one of whom should be specifically assigned responsibility to
observe the activity of the people inside of the vessel. The other person must remain
available in close proximity to the person watching the man way so that he can assist the
or go for help, if necessary. He must also be alert for events outside of the vessel which
might require the people inside to come out of the vessel, for example, a nearby leak or
fire. These people should not leave their post until the people inside have safely
evacuated the vessel.
A communication system should be provided for the man way watch so that they can
quickly call for help in the event that the personnel inside of the vessel encounter
difficulty. A radio, telephone, or public address system is necessary for that purpose.
Providing Fresh Air

The vessel must be purged completely free of any noxious or poisonous gases and
inventoried with fresh air before permitting anyone to enter.
The responsible
department, usually the safety department, must test the atmosphere within the vessel for
toxic gases, oxygen and explosive gases before entry. This must be repeated every 4
hours while there are people inside the vessel. Each point of entry and any dead areas
inside of the vessel, such as receiver boots or areas behind internal baffles, where there
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Fresh air can be circulated through the vessel suing an air mover, a fan, or, for the cases
where moisture is ca concern, the vessel can be purged using dry certified instrument air
from a hose or hard piped connection. When an air mover is used, make certain that the
gas driver uses plant air, not nitrogen, and direct the exhaust of the driver out of the
vessel to guarantee that this gas does not enter the vessel. When instrument air is used,
it must be confirmed that a check of the supply header is made to ensure that it is
properly lined up and that there are no connections where nitrogen can enter the system
(nitrogen improperly used as a backup for instrument air by some refiners). The fresh
air purge should be continued throughout the time that people are inside of the vessel.
The responsible control room should be informed that instrument air is being used for
breathing so that if a change to nitrogen is required the people are removed from the
affected vessel.
A minimum of one fresh air mask for each person entering the vessel and at least one
spare mask for the hole watcher should be provided at the vessel entry. These masks
should completely cover the face, including the eyes, and have a second seal around the
mouth and nose. When use of the mask is required, it must first be donned outside of
the vessel where it is easy to render assistance in order to confirm that the air supply is
safe. Each mask must have a backup air supply that is completely independent of the
main supply. It must also be independent of electrical power. This supply is typically a
small, certified cylinder fastened to the safety harness and connected to the main supply
line via a special regulator that activates when the air pressure to the mask drops below
normal. The auxiliary supply should have an alarm which alerts the user that he is on
backup supply and it should be sufficiently large to give the user 5 minutes to escape
from danger.
Preparation of Vessel Entry Permit
Before entering the vessel a vessel entry permit must be obtained. A vessel entry permit
ensures that all responsible parties know that work is being conducted inside of a vessel
and establishes a safe preparation procedure to follow in order to prevent mistakes

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which could result in an accident. The permit is typically issued by the safety engineer
or by the shift supervisor. The permit should be based on a safety checklist to be
completed before it is issued. The permit should also require the signatures of the safety
engineer, the shift supervisor, and the person that preformed the oxygen toxic and
explosive gas check on the vessel atmosphere. Four copies of the permit should be
provided. One copy goes to the safety engineer, one to the shift supervisor, one to the
control room, and one copy should be posted prominently on the man way through
which the personnel will enter the vessel. The permit should be renewed before each
shift and all copies of the permit should be returned to the safety engineer when the
work is complete. Additional requirements or procedures may be imposed by the
refiner, but the foregoing is considered the minimum acceptable for good safety practice.
Checkout Prior to New Unit Start-up
The risk of exposure to hydrocarbon, toxic or poisonous gases, and catalyst dust is low
during a new unit checkout; the primary danger is nitrogen. There will be pressure
testing, line flushing, hydrotesting, and possibly chemical cleaning being conducted in
the unit and nitrogen may be used during any of these activities. Some of the equipment
may have been inventoried with nitrogen to protect the internals from corrosion. An
additional hazard is posed by operations in other parts of the plant which may be beyond
the control of the people entering the vessel so that action taken at a remote location
could admit nitrogen, fuel gas, steam, or other dangerous material through a connecting
process line into the vessel which is being entered. For these reasons vessel entry
procedures must still be rigorously followed during the checkout of a new unit.
The oxygen content of the atmosphere inside of the vessel should be checked before
every entry and the vessel should be blinded. Independent blinds at each vessel nozzle
are preferred. However, in the event that many vessels are to be entered in a new unit
which is separate from the rest of the plant, the entire unit can be isolated by installing
blinds at the battery limits rather than by individually isolating every vessel nozzle.

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Inspections During Turnarounds

In turnaround inspections, the possibility that vessels will contain dangerous gases is
much higher. Equipment which has been in service must be thoroughly purged before
entry. The vessel should have been steamed out unless steam presents a hazard o the
internals and then fresh air circulated through it until all traces of hydrocarbons are
gone. If liquid hydrocarbon remains or if odors persist afterwards, repeat the purging
procedure until the vessel is clean. The service history of the vessel must also be
investigated before entry so that appropriate precautions may be taken. The service may
require a neutralization step or a special cleaning step to make the vessel safe. Internal
scale can trap poisonous gases such as hydrogen sulfide or hydrogen fluoride which may
be released when the scale is disturbed. If this sort of danger is present, fresh air masks
and protective clothing may be required to be worn while working inside of the
equipment.
In a turnaround inspection, every vessel nozzle must be blinded at the vessel with
absolutely no exceptions. There will always be process material at the low and high
points in the lines connecting to the vessel because it is not possible to purge them
completely clean. The blinds must all be in place before the vessel is purge.
Another factor to be cautious of, especially if entering a vessel immediately after the unit
has been shut down, is heat stress. The internals of the vessels can still be very hot from
the steam-out procedure or from operations prior to the shutdown. If that is the case, the
period of time spent working inside of the vessel should be limited and frequent breaks
should be taken outside of the vessel.
14.6
HAZARDOUS CHEMICAL HANDLING
Hazardous properties of chemicals and their handling procedure are available in Material
Safety Datasheet. Hazards and handling procedure of some the material is discussed below.
14.6.1 HYDROGEN SULFIDE (H2S)
A hazard and handling procedures of H2S is as follows:

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A) Potential For Exposure

The existence of H2S concentration with the fluids normally handled in this unit constitutes
an additional hazard to operating personnel that demands special attention. The properties
of H2S make exposure to even very low concentrations extremely dangerous. However,
many years of industry experience in handling the problems associated with H 2S have
resulted in procedures which, if properly implemented, permit a reasonable level of safety
for unit personnel.
The danger of exposure of H2S cannot be lessened. The potential for exposure can only be
minimized.
The procedures and precautions contained within this section and elsewhere in this manual
constitute minimal requirements for dealing with H2S only. The implementation of
additional safety measures which can be found in various industry manuals is encouraged.
B) Properties of H2S (Hydrogen Sulphide)
The chemical formula H2S represents a compound which is made up of two hydrogen
atoms and one sulphur atom.
H2S (Hydrogen Sulphide) is a colourless (transparent), gas heavier than air.
Hydrogen sulphide is a poisonous gas that can paralyse the breathing system and kill a
person in minutes. In small amounts it is dangerous to health. This risk is increased by heat
or hot weather.
At low concentrations (small amounts) H2S has an offensive odour similar to rotten eggs.
At slightly higher concentrations (small amounts), H 2S may have a sick-sweet odour. At
high concentrations no smell can be detected, because H 2S rapidly deadens the sense of
smell by paralysis of the Olfactory-Nerve. Consequently the sense of smell cannot be
depended upon to detect H2S.
Characteristics of H2S
Hydrogen sulphide has the following characteristics:
- Deadly-extremely toxic gas.
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- Colourless.
- Heavier than air tends to settle in low lying areas.
- Readily dispersed by wind movement of air currents.
- Burns with a blue flame, producing Sulphur Di-oxide (SO2), which is also a toxic gas.
- Odour of rotten eggs. Only in low concentrations rapidly deadens the sense of smell.
Do not depend on the sense of smell to detect H2S
- Highly corrosive to certain metals.
- More deadly than Carbon Monoxide (CO), and almost as toxic as Hydrogen Cyanide
(HCN) gas.
Property table OF H2S
- Auto ignition Temperature
500F(260C)
- Boiling Point @ 1 atm
-76.6F(-60.33C)
- Critical Density
0.349 g/ml
- Critical Pressure
1309 psig (89.05
atm)
92 kg/cm2, absolute
- Critical Temperature
212.7F (100.4C)
- Density, gas @ 0C 1 atm
1.5392 g/l
- Density, Liquid @ b.p.
0.993 g/l
- Flammable Limits in Air
4.3-4.5% (by volume)
- Freezing Point @ 1 atm

- Latent Heat of Fusion @ m.p.
-121.9F (-85.49C)
508cal/mole (16.7 cal/g)
- Latent Heat of Vaporization @ b.p. 4.463kcal/mole

(131 cal/g)
- Molecular Weight
- Solubility in Water @0C 1 atm
34.08
0.672 g/100 ml water
- Specific Heat, Gas @ 25C 1 atm

Cp = 0.240 cal/ (g) (C)
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Cv = 0.181 cal/ (g) (C)

- Specific Gravity Gas
1.1895 15C, 1atm (Air = 1)
- Specific Heat Ratio, Gas
1.32@25C, 1 atm, Cp/Cv

0.305 cal/(Sec)(Cm2) (C/cm)
- Thermal Conductivity @ 0C
252 psig (17.7 kg/cm2g)
- Vapour Pressure @ 70F

- Specific Volume @ 70F, 1 atm
-
11.23 cu ft/lb (701 ml/g)

Viscosity of Gas @ 0C 1 atm
0.01166 centipoise
- Explosive limits:
- Lower 4% volume in air upper 44% volume in air
C) Effects of H2S on Personnel
Itemized concentrations of Hydrogen Sulphide as prepared by American National
Standards Institute (ANSI Standard No. Z37.2-1972) are tabled below:
0.13 ppm
Minimal perceptible odour
4.60 ppm
Easily detectable, moderate odour
10 ppm
Beginning eye irritation
27.0 ppm
Strong, unpleasant odour, but not intolerable
100 ppm
Coughing, eye irritation, loss of sense of smell after

2-15 minutes.
200-300 ppm
Marked conjunctivitis (eye inflammation) and

respiratory tact irritation after one hour of exposure.
500-700 ppm
Loss of consciousness, possible death in 30 minutes

to 1 hour.
700-1000 ppm
Rapid unconsciousness, cessation (stopping or

pausing) of respiration and death.
1000-2000 ppm
Unconsciousness at once, with early cessation of

respiration and death in few minutes. Death may
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occur even if individual is removed to fresh air at

once.
ppm parts of gas per million part of air by volume.
D) H2S handling procedure
General Procedures:
Industry practice mandates that the following precautions procedures should be followed
by all personnel:
-
When approaching the work area it is necessary to take the following precautions to
insure safe entry
1. Observe Condition signs and observe for audio/visual alarms.
2. Check for wind direction.
3. Look for personnel and their activity.
4. Enter work area slowly.
Maintain mental image of two (at least) escape routes preferably cross wind.
Continuous atmosphere monitoring or detecting equipment is required along with an

adequate audio/visual alarm warning system. Portable detectors and combustible gas
meters give an additional degree of safety.
Gas ignition hazard must be eliminated and No Smoking regulations strictly

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

atmospheric contamination by H2S, move upwind/cross wind from source, not
downwind.
Select a partner and use the Buddy System for mutual safety.
Maintain and observe warning signs.
Post emergency numbers in a conspicuous place. Maintain reliable communication

systems.
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Locate emergency stations a minimum of 250 feet or as far from the H 2S source as
practical. During an emergency all personnel will assemble at the briefing stations for
instructions and for refilling air bottles.
Hazardous concentrations of H2S can be disposed of by discharging through flare

stacks with automatic ignitions.
Note: Burning H2S produces Sulphur Dioxide (SO2), a deadly toxic gas that is heavier than
H2S. Because of the heat it rises and disperses into the upper atmosphere.
Maintenance Procedure:
There are two basic areas of maintenance operations which are inherently dangerous from
the standpoint of H2S exposure. These are venting / draining of piping and confined space
entry.
-
Depressurisation of piping, valves, fittings, strainers, etc. in H2S service represents a

safety hazard in the unit, since the vent and drain valves are not hard-piped to a
closed vent or drain header.
Without exception, breathing air respirators are to be worn when opening piping, removing
valves or performing any operation which might permit vapours to enter the immediate
area. When valves are removed, install blind flanges.
- Confined space entry is entrance into areas such as tanks, vessels, etc. This is one of
the most dangerous activities of the unit and should be avoided whenever possible.
When it is absolutely necessary that a confined entry be made, entry should be made only
after the following safety conditions have been met.
-
Entry permit form has been filled out and signed.
Space contains at least 19.5% of oxygen by volume.
Sample does not contain combustible vapours above L.E.L.
Space does not contain toxic gas contaminants above the limit of appropriate threshold
values for the substance.
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Even if the above mentioned conditions are met, personnel entering such enclosed
spaces shall be equipped with self contained breathing apparatus (SCBA) pressure
demand type.
Rescue equipment must be in close vicinity of the confined space.
All personnel entering the confined space must wear safety harness and reflective tape.
An adequate number of personnel must be stationed outside for emergency assistance.
Communications must be clearly established and a system of safety signs and signals
understood by all.
Any battery operated or electrical communications system such as hand-held walkietalkie or throat type microphone, if used in a hazardous environment must be
intrinsically safe.
There are a number of other safety precautions and equipment to be considered when a
confined space entry must be made such as:
Resuscitation equipment, litter, safety lanterns or chemical lights, tripped for hoisting over
hatches, instrument calibration, mechanical ventilation, cascade systems, continuous
monitoring, houseline units, separate means of access where possible, emergency team and
plan and proper training.
Remember the fact that any entry into a confined space is inherently dangerous.
E) Emergency Procedures
If all the above procedures have been adhered to strictly, a catastrophic release of H2S
should never occur. In the unlikely event such a release does occur, the emergency
procedures detailed in this section should be followed.
a) Egress
H2S is a dangerous, deadly gas, however serious injury or death can be avoided by simply
evacuating the contaminated area and moving to a safe area upwind. Therefore, the most
important things to remember are to Stay Claim and Get Away.
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Precise emergency escape procedures will be defined by the operations management of the
complex, however the following general procedures should be followed:
-
Remain Calm-Do Not Panic
Hold your breath
Extinguish all fires
Alert the rest of the crew
Make a quick, cursory check of the area to see if the source of the gas is obvious.
Do not spend time looking for a leak
Observe windsock to determine wind direction. Move upwind or crosswind, not

downwind, until the safe breathing area is reached.
Active alarms if not already done.
Once assembled at the safe briefing area, the foreman will make a head count to
determine if all personnel have evacuated safely.
b) Rescue and First Aid

Although H2S is a dangerous, deadly gas, its effects are readily reversible provided the
appropriate action is taken in a timely manner. In the event of, a fellow worker is down or
overcome by H2S, the necessity of an immediate and effective rescue effort is or utmost
importance. A natural reaction is to unthinkingly rush to the side of the downed victim,
which could be a fatal action.
Instead, before proceeding into the hazardous area to rescue a downed victim, stop, think
and:
-
Put on an appropriate safe breathing apparatus.
Move quickly, but carefully to the victim, side. Move the victim to a safe area;
either upwind or crosswind from the hazardous area. Do not evacuate in a
downwind direction.
Begin mouth-to-mouth artificial respiration if the victim has stopped breathing.

Check the victims pulse periodically to ensure that the victims heart is still
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beating. If the victims heart stops beating, administer CPR. Artificial respiration or
CPR should be continued until:
-
The victim begins to breathe and, if applicable, the heart begins to beat.
He is pronounced dead by a doctor.
He is dead beyond any doubt.
Seek assistance at the first opportunity and make arrangements for transportation to a
medical facility to seek medical attention by a physician.
c) Abatement Procedure
Once the safety of all personnel has been determined, the next order or business is to
determine the source of H2S and stop it, if possible.
Control Room Personnel
-
Control Room personnel Stay in the Control Room since it is equipped with a positive
ventilation system pulling suction from a higher elevation. Since H2S is heavier than
air, the Control Room should be safe.
If leak can be located, activate the deluge system for that area.
Field Personnel
-
Use breathing apparatus (Respirator).
Establish communication with Control Room.
Communicate with first personnel to sound alarm/notice of the H2S.
To determine the general area of the source, slowly begin searching the source from the
upwind side.
14.6.2 HYDROGEN
Hydrogen is a colourless, tasteless, odourless and highly flammable gas and is the
lightest element. Since hydrogen is lighter than air, less danger exists of it collecting in
pockets in low areas. However, the potential danger from fire or explosion is high.
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Gaseous fuels such as hydrogen can mix with air or oxygen in all proportions. However,
the proportions must be within certain limits before those mixtures will burn. The
limiting proportions are referred to as flammable limits or explosive limits and are
expressed as the percentage by volume of the fuel in the air-fuel mixture. Fuel-air
mixtures outside of the flammable range will not explode. Hydrogen has a very wide
range (4-75%) of flammability or explosive limits in air at atmospheric pressure. In
addition to, the flammability range becomes wider at higher pressure or if oxygen is
substituted for air. Thus, explosions can occur over a very wide range of hydrogen
concentrations in air. The safest approach to safeguard against possible fires or
explosions is to make sure that hydrogen leaks do not develop.
The auto ignition temperature of a substance is the lowest temperature required to
initiate or cause self-sustained combustion in the absence of a spark or flame. The auto
ignition temperature of hydrogen in air is 580C at atmospheric conditions. However,
other factors such as the nature, size, and shape of the igniting surface can affect this
temperature.
Unlike most gases, which cool when expanded or bled off, hydrogen heats up when
expanded and great care must be exercised when bleeding down lines or compressors to
the atmosphere. In its pure state, hydrogen burns with a bluish white flame (almost
invisible) that is extremely hot. Such a hot flame can weaken any support beams or lines
on which it may impinge. Any leaks should be put under a steam blanket immediately to
prevent the possibility of a fire. Be aware, however, that many leaks can auto ignite and
will be difficult to see. Replacing the source of the hydrogen with a nitrogen or steam
purge is the most effective way of combating a hydrogen fire.
Hydrogen, although a not a poisonous gas itself, is an asphyxiant (i.e. cuts off oxygen
supply to the body by displacing air in the lungs) and can cause unconsciousness and
even death if the victim falls and remains in a high hydrogen atmosphere.
Because of the small size of hydrogen molecules, a pressure check with air or nitrogen
or a hydrostatic test will not always show all leaks that will occur with hydrogen.
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FIRE FIGHTING SYSTEM
The operating personnel should be fully conversant with Fire Fighting system provided in
the unit. All of them should have adequate fire fighting training and will serve as an
auxiliary Fire Squad in the event of a fire breakout. It will be the primary responsibility of
unit personnel to fight the fire at the very initial stage and, at the least, localize it.
Major Fire fighting facilities provided in the unit comprise the following:
i)
Fire Water System
Water is most important fire fighting medium. Water is used for fire extinguishment,
control, equipment cooling & exposure protection of equipment/personnel from heat
radiation.
An elaborate fire water distribution network is provided around unit.
Fire Water
Hydrants/Monitors are provided around unit, which give coverage to most of equipment.
ii)
Foam System
For containing large Hydrocarbon fires, foam systems are useful. They have inherent
blanketing ability, heat resistance and security against burn back. Low expansion foam is
used for hydrocarbon oil fire.
Foam can be applied over burning oil pool with the help of foam tenders/foam delivery
system.
iii) Portable Fire Extinguishers
Fire should be killed at the incipient stage. Portable fire extinguishers are very useful in
fighting small fires. All extinguishers in the unit must be located in specified places only.
The operating crew should be acquainted with exact location of the extinguishers. They
also must know most suitable type, which, when and how to use an extinguisher. For
example, electrical fires should be put out with CO2 or dry power extinguishers; water and
foam should not be used. The used extinguishers should be checked and restored by fire
station personnel.
iv) Fire Signal
Break Glasses have been provided at strategic locations of unit to see fire alarm in fire
station. if a fire is sighted, glass of window should be smashed, causing fire alarm switch
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to actuate.
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This is an emergency call & should be periodically tested for proper
functioning.
v)
Steam Smothering
LP Steam hose connections have been provided at every convenient point inside unit.
Steam lances of standard 15M length can be fitted with these hose stations. Where ever
hydrocarbon leakage is detected which is likely to catch fire, Steam blanketing may be
done. Apart from diluting combustible hydrocarbons, steam prevents atmospheric oxygen
from taking part in combustion, thus help in extinguishing fire. However, steam should
never be applied on large pool of hydrocarbon fire. Direct application of steam on burning
oil may result in spillage of burning hydrocarbon & spread of fire. Similarly use of fire
water on hot oil surfaces may cause sputtering & spread of fire.
14.8
USE OF LIFE SAVING DEVICE
Safety of the personnel should the prime concern. Life saving device is to be used for
personnel protection. Important life saving devices which are required to be used are given
below:
Head protection:
Safety helmets shall be worn by all personnel at all times in the plant for protection of the
head. They may be removed when inside rooms or buildings which do not have overhead
or other hazards.
Eye and face protection
Safety glasses, goggles or face shields shall be worn while performing work, which could
result in eye or face injury.
Hand Protection
Proper hand protective gloves should be worn.
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Foot protection
Safety shoes are to be worn for foot protection.
Ear protection
Whenever personnel are required to be work in noisy areas proper ear protection device
such as ear plug etc, is to be used.
Breathing apparatus
Whenever
persons
are
toxic/aromatic/hydrocarbon
required
vapor
to
work
concentration,
or
enter
wear
an
area
appropriate
of
high
respiratory
protection, such as self-contained breathing apparatus or an air mask with an external air
supply.
SECTION -15
GENERAL OPERATING INSTRUCTIONS FOR EQUIPMENT
15.1
GENERAL
This section covers the general procedure for operation and trouble shooting of commonly
used equipment like pumps, heat exchangers and furnace etc. For specific information and
more detail refer to vendor's manuals.
15.2
CENTRIFUGAL PUMPS
15.2.1. Start-up
-
Inspect and see if all the mechanical jobs are completed.
Establish cooling water flow where there is such provision. Also open steam for seal
quenching in pumps having such facilities.
Check oil level in the bearing housing, flushing may be necessary if oil is dirty or
contains some foreign material.
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Rotate the shaft by hand to ensure that it is free and coupling is secure. Coupling guard
should be in position and secured properly.
Open suction valve. Ensure that the casing is full of liquid. Bleed, if necessary, from the
bleeder valve.
Energise the motor. Start the pump and check the direction of rotation. Rectify the
direction of rotation if it is not right.
Check the discharge pressure. Bleed if necessary to avoid vapour locking.
Open the discharge valve slowly. Keep watch on the current drawn by the motor, if
ammeter is provided. In other cases check at motor control centre.
In some pumps a by-pass has been provided across the check valve and discharge valve to
keep the idle pump hot. In such pumps, the by-pass valve should be closed before starting
the pump. It should be ensured that casing of these pumps are heated up sufficiently prior
to starting of the pump to guard against damage of the equipment and associated piping due
to thermal shock.
15.2.2. Shutdown
-
Close discharge valve fully.
Stop the pump
a)
If pump is going to remain as standby and has provision for keeping the pump hot,
proceed as follows:
-
Open the valve in the by-pass line across the discharge valve and check valve.
The circulation rate should not be so high to cause reverse rotation of idle pump
and also overloading of the running pump.
b)
If pump is to be prepared for maintenance, proceed as follows:

-
Close suction and discharge valves.
Close valve on check valve by-pass line, if provided.
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 212 of 221
Close cooling water to bearing, if provided. Also shut off steam for seal quenching,
if provided.
Slowly open pump bleeder and drain liquid from pump if the liquid is very hot
allow sufficient time before draining is started. Ensure that there is no pressure in
the pump. Also drain pump casing.
Blind suction and discharge and check valve by-pass line and flare connection if any.
Cut-off electrical supply to pump motor prior to handling over for maintenance.
15.2.3. Trouble Shooting

i.
Pump not developing pressure

-
Bleed to expel vapour/air
Check the lining up in the suction side.
Check the suction strainer.
Check the liquid level from where the pump is taking suction.
Check pump coupling and rotation.
Get the pump checked by a technician.
ii.
iii.
Unusual Noise
-
Check the coupling guard if it is touching.
Check for proper fixing of fan and fan cover.,
Check for pump cavitation.
Get the pump checked by a technician.

Rise of Bearing Temperature
Generally the bearing oil temperature upto 80C or 50C above ambient whichever is
lower, can be tolerated.
-
Arrange lubrication if bearing is running dry or oil level is low.
Adjust cooling water to the bearing housing, if there is such provision.
Stop the pump, if temperature is too high, call the pump technician.
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
iv.
Rev. A
Page 213 of 221
Hot Gland
-
Adjust cooling water if facility exists.
Slightly loosen the gland nut, if possible.
Stop the pump and hand over to maintenance.
Arrange external cooling if pump has to be run for sometime.
v.
Unusual Vibration
-
Check the foundation bolts.
Check the fan cover for looseness.
vi.
Leaky Gland
-
Check the pump discharge pressure.
Tighten the gland nut slowly, if possible.
Prepare the pump for gland packing or adjustment/replacement of mechanical seal

as the case may be.
vii.
Mechanical Seal Leak

-
15.3
Stop and isolate the pump and hand over to maintenance.

POSITIVE DISPLACEMENT PUMPS
15.3.1. Start-up
i.
Check if all mechanical jobs are completed.
ii.
Flush and renew oil in pump gear box.
iii.
Check whether suction strainer is installed.
iv.
Check for proper lining up including the pressure safety valve in the discharge.
Open suction valve fully.
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
v.
Rev. A
Page 214 of 221
Check that the motor shaft is reasonably free and coupling secured. Coupling guard
should be in position.
vi.
Energise motor. Open discharge valve. Start the motor and check direction of
rotation. Stop and rectify if direction of rotation is wrong.
vii.
Adjust the pump stroke and run the pump at different settings. Watch discharge
pressure and check the rate of pumping using the flow meter or by taking suction
from the calibration pot. In case the pumps is provided with a pressure controller
adjust it to obtain the required discharge pressure.
viii.
Care should be taken to avoid dry running of pump and back flow of liquid. Bleed
if necessary to expel vapour/air.
ix.
Check for unusual noise, vibrations, rise of temperature of both motor and gears.
15.3.2. Shutdown
-
Stop the pump.
Close the suction and discharge valves.
Drain the liquid if maintenance jobs are to be carried out on the pump.

i.
Insufficient Discharge Pressure

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

High Discharge Pressure

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Check the line up on the discharge side.
Check pressure control valve opening.
iii.
Doc No. Draft

Rev. A
Page 215 of 221
Leak Gland
-
Check for normal pump discharge pressure.
Tighten the gland nut slowly if possible.
Hand over the pump for replacing gland packing.
iv. Unusual Vibrations

-
Check the foundation bolts.
Check motor fan cover for looseness.
15.4
CENTRIFUGAL COMPRESSOR
The pre-commissioning of the centrifugal compressor should follow the equipment

manufacturers recommended procedures. The following general procedures shall not be
construed as a replacement for the manufacturer procedures.
Verify that the lubrication, seal gas, and coolant systems are clean and free of
contamination and that all control systems function properly. The pre-commissioning of
these package units should follow the manufacturers recommended procedures.
Verify that the shutdown system on the compressor function according to design. The
temporary strainers on the suction should be removed prior to full-time operation.
Verify that the compressor rotate freely.
15.4.1. Start-up
i.
Ensure all mechanical jobs have been completed on the compressor that is to be
started including suction line passivation.
ii.
No load run of the motor to be completed before the compressor is coupled.

After no load run, de-energize the electrical supply. Couple the motor and
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 216 of 221
compressor. Check the rotating element of the compressor for free rotation
turning slowly by hand. If the rotor rubs, rotation should be stopped immediately
and the difficulty located and repaired.
iii.
Check oil level in lube oil tank and refill as required bringing the oil level to the
high mark on the sight glass. Do not overfill.
iv.
Line-up and start seal and lube oil circulation to make certain that bearings of the
compressor and driver are well lubricated.
v.
Establish the pressure of lubricating oil in bearings and seal oil to seal.
Note: Seal system is to be in operation whenever any pressure is in the compressor, even
though the machine is idle.
vi.
Bar the unit over once to be sure all moving parts are clear.
vii.
Make sure that water cooler and air coolers coming in compressor circuit are in
operation.
viii.
Ensure that compressor casing has also been purged with inert gas. Pressurise the
compressor with nitrogen and leak test.
ix.
Open suction valve/discharge valve and line up to the system. Remove any
accumulated liquid from the casing by opening casing drain.
x.
Start the drive as per the vendors recommendations and run the compressor.
xi.
Allow the oil to warm up to 40o C. Watch compressor motor amperage. Listen for
unusual noise or vibration during the warm up period.
xii.
Auxiliary motor driven lube oil pump will be stopped when shaft-driven pump
develops normal oil pressure and kept ready for auto start.
xiii.
When the unit is warmed up and determined to be operating satisfactorily,

gradually start throttling the valve beyond surge requirements of the compressor.
xiv.
Load the compressor to the required capacity in the above mentioned manner.
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 217 of 221
Note: The compressor before trial run on the actual medium may be tried on air with
suction and discharge open to atmosphere. While attempting to run the
Compressor on air, Vendor's instructions and recommendations are to be
followed. It is to be noted that scaling arrangement may be required to be
changed to suit the machine running on air.
15.4.2. Shutdown
i.
Stop the drive.
ii.
Start the oil pump to lubricate the bearing till required.
iii.
Close the discharge valve.
iv.
Close the suction valve.
v.
Turn off cooling water to oil cooler as applicable.
vi.
If the compressor is to be given for maintenance, isolate, depressurise and purge

with inert gas to make the compressor free of hydrocarbons.
15.4.3. Normal Operation

i.
Check oil level in lube oil tank and add oil as required to maintain the proper
level as indicated on sight glass. Periodically check level in emergency
lubricating oil overhead tank.
ii.
Log all temperatures, pressures, levels, flows.
iii.
Adjust cooling water flows to compensate for changes in inlet water temperature
or ambient temperature.
iv.
Listen for any unusual noise while the machine is operating. These should be
investigated immediately.
v.
Periodically drain from suction pot etc.
vi.
Watch differential pressure across oil filter to check cleanliness; change over
filter, if necessary and arrange cleaning of choked filter.
vii.
Keep the exterior of the compressor and the compressor room floor clean.
Doc No. Draft

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Rev. A
Page 218 of 221
Follow vendor's recommendations. However, some general guide lines are given below:
i.
SURGING
-
Restricted flow due to plant operating at partial load or throttling at discharge.
Blocked suction due to strainer choking or line choking if a permanent strainer

is not provided.
ii.
Liquid carry over from suction K.O. drum.

HEAVY VIBRATIONS IN MACHINE
Misalignment
Bent rotor
Damaged rotor
Imbalance
Weak foundation
Mechanical Loosening etc.
Bearing damage
15.5
HEAT EXCHANGERS
GENERAL
The unit has a number of heat exchangers, air coolers. Suitable valve arrangement for
bypassing and isolation is provided wherever necessary to offer the required operational
flexibility.
The exchangers have been provided with draining and flushing connections. The coolers
and condensers have been provided with TSV's on the cooling water side to guard against
possible rise of pressure due to faulty operations with the safety release to atmosphere.
Temperature gauges or thermo wells have been provided at the inlet and outlet of
exchangers. Where water is the cooling medium, no temperature measurement is provided
for water inlet temperature which is the same as cooling water supply header temperature.

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
Doc No. Draft

Rev. A
Page 219 of 221
AIR COOLERS
The air coolers/condensers comprise of a fin tube assembly running parallel between the
inlet and outlet headers. These are of the forced draft type. The forced draft fans
provided have auto variable speed rotors in which the fan speeds are adjusted during
rotation. This allows variation in air flow as per the cooling requirements. A high
vibration switch is provided with alarm to indicate any mechanical damage.
EXCHANGERS
Shell and Tube type heat exchangers can be broadly classified into following types: -
Water Coolers/condensers
Steam heaters (reboiler)
Exchangers
Start-up /shut down procedures for each unit shall vary slightly from case to case.
However, general start-up /shut-down procedures are discussed in the following
paragraphs.
15.5.1.
Start-Up
After the heat exchanger has been pressure tested and all blinds removed, proceed as
follows:
i.
Open cooling medium vent valve to displace non-condensable (air, fuel gas, inert
gas etc.) from the system. Ensure the drain valves are capped. For high pressure
system, drain valves should be flanged. This activity is not required if gas is the
medium.
ii.
Open cooling medium inlet valve. Close vent valve when liquid starts coming
out through it, then open cold medium outlet valve and fully open the inlet valve
also. Where cold medium is also hot, warming up of cold medium side gradually
is also essential.

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
iii.
Doc No. Draft

Rev. A
Page 220 of 221
Open hot medium side vent valve to displace non condensable (air, fuel inert gas
etc.). Check that the drain is closed and capped. This activity is not required if
gas is the medium.
iv.
Crack open hot medium inlet valve. When liquid starts coming out from the vent
valve, close it. Open hot medium inlet valve and then open the outlet valve fully.
In case of steam heaters, initially the condensate shall be drained to sewer till
pressure in the system builds up to a level where it can be lined up to the return
condensate header.
v.
In case by passes are provided across shells and tube side, gradually close the
bypass on the cold medium side and then the bypass across the hot medium side.
vi.
Check for normal inlet and outlet temperatures.
Check that TSVs are not
popping.
vii.
The operation of inlet and outlet valves should be done carefully ensuring that
the exchangers are not subjected to thermal shock.
viii.
In case of coolers/condensers, adjust the water flow to maintain the required

temperatures at the outlet.
ix.
For avoiding fouling, velocity of water should be at least 1 m/sec in a

cooler/condenser.
15.5.2. Shutdown
Shut down of an exchanger, coolers, condenser is considered when the equipment is to be
isolated for handling over to maintenance while the main plant is in operation. The
following is the suggested procedure for isolation of the piece of equipment
i.
Isolate the hot medium first. In case both hot and cold medium are from process
streams, exchanger shall remain in service till the hot stream has cooled down
enough.
ii.
In case of a cooler, adjust cooling water flow to the cooler which is in line so that
product temperature is within allowable unit.
iii.
Isolate the cold medium next.

ISOMERISATION UNIT,
VRCFP, HPCL VISAKH
iv.
Doc No. Draft

Rev. A
Page 221 of 221
Drain out the shell and tube sides to OWS/Sewer/Closed blow down system as
applicable. In case flushing oil connection is given flush the exchanger to CBD.
Ensure that the CBD drum has sufficient level to receive the flushing of the
exchanger
v.
Depressurize the system to atmosphere/flare/blow down system as applicable.
vi.
Purge/flush if required. This is particularly important in congealing services.
vii.
Blind inlet and outlet lines before handing over the equipment for maintenance.

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ISOMERIZATION UNIT PROCESS SYSTEM:..........................................................................30

FIRST START UP..........................................................................................................................60

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WATER BREAKTHROUGH FROM THE DRYERS............................................................170

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CATALYSTS LOADING UNDER N2....................................................................................175

INTERMITTENT CONSUMPTIONS FOR ISOMERIZATION SECTION.........................189

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Isomar Unit is designed for a capacity of 228641 T/yr.

The facility is designed for 8000 operating hours per year.

The facility is capable of operating at 50 percent of design feed capacity, while

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2.5.1. Light Hydrotreated Naphtha

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impurities are considered to be irreversible poisons such as water and nitrogen

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5 ppm vol max

1.0 ppm wt max.

(1) At the outlet of the hydrogen dryers.

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Light Isomerate product

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