RFCC PDF

Vendor Document No. Rev.
Page
ARAMIS Development Ltd
TPC-DQR-002-TRM-OPS-015 A 1 of 323
TRAINING MODULE
RESIDUE FLUID CATALYTIC CRACKER (RFCC)
UNIT: 15
VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

DUNG QUAT REFINERY (DQR) PROJECT
DUNG QUAT, VIETNAM
Requisition Number: 8474L-000-CFB-XXXX-0001 Stamp
Purchase Order Number: 8474L-000-CS01-17061
Equipment / Item Tag: Not Applicable
Equipment / Item Description: Not Applicable
TPC Document Number: 8474L-015-A5016-0000-001-005

Comment given in this document does not relieve vendor of his/her responsibility for the
Document Class: X correct engineering design and fabrication. This equipment or product shall be made as per
the codes, requisition, specification, project procedures, and international standards.
A 06-DEC-07 Issue for review Benoit Rabaud Paul Walsh JB Guillemin

Date Written By Check By Approved By
Rev Status
DD-MMM-YY (name & visa) (name & visa) (name & visa)
Pages changed in this revision:
Sections changed in last revision are identified by a vertical line in the margin
DOCUMENT REVISIONS
TRAINING MODULE DOC NO: 8474L-015-A5016-0000-001-005
RESIDUE FLUID CATALYTIC
REV: A DATE: 06/12/07
CRACKER (RFCC)
TRAINING MODULE
UNIT: 15
A 06/12/07 Benoit Rabaud Paul Walsh JB Guillemin

REV DATE PREPARED BY CHECKED BY APPROVED BY
TRAINING DURATION VENUE
ATTENDANCE
ATTENDEES REQUIREMENTS
MODULE OBJECTIVES
INSTRUCTORS NAME/POSITION
SUMMARY/AGENDA
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CRACKER (RFCC)
IMPORTANT
THIS TRAINING MODULE HAS BEEN PREPARED BY ARAMIS FOR THE DUNG QUAT
REFINERY.
THIS MODULE MUST BE RECOGNIZED AS A TOOL AND GUIDE ONLY. IT WOULD BE

IMPOSSIBLE TO ANTICIPATE AND PRESENT ALL POTENTIAL VARIABLES AND
PROCESS CONDITIONS THAT OPERATIONAL PERSONNEL MIGHT BE EXPOSED TO.
IT IS IMPERATIVE THAT THE READER ALWAYS AS CERTAIN THAT REFERENCE

MATERIALS UTILIZED, WHILE PERFORMING OPERATIONAL DUTIES, CONFORM AT A
MINIMUM TO THE LATEST ISSUE OF STANDARD OPERATING PROCEDURES, SAFETY
CODES, ENGINEERING STANDARDS, AND GOVERNMENT REGULATIONS.
SOME DESIGN FIGURES MIGHT NOT BE IN LINE DURING THE START-UP OF THE
REFINERY.
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CRACKER (RFCC)
TABLE OF CONTENT
SECTION 1 : GENERAL description ........................................................................................... 14

1.1. Purpose of the Unit ................................................................................................ 17
1.2. Basis of Design ...................................................................................................... 24
1.2.1. Duty of Plant ............................................................................................... 24
1.2.2. Feed Characteristics ................................................................................... 25
1.2.2.1. Atmospheric Residue Properties................................................... 25
1.2.2.2. CDU Stabilizer Off Gas ................................................................. 25
1.2.2.3. NHT Stripper off gas to RFCC....................................................... 26
1.2.2.4. CDU LPG Rich Stream.................................................................. 27
1.2.2.5. Slops feed to RFCC ...................................................................... 27
1.2.3. Product Specifications ................................................................................ 27
1.2.3.1. Distillation Specifications............................................................... 27
1.2.3.2. Gas Recovery Targets .................................................................. 28
1.2.3.3. Flue Gas Specifications................................................................. 28
1.2.3.4. Fuel Gas Specification .................................................................. 28
1.2.3.5. Decant Oil Specification (after Slurry Separation) ........................ 28
1.2.3.6. Estimated Product Properties........................................................ 29
1.2.3.7. LPG Composition .......................................................................... 32
1.2.4. Utility/Power/Chemicals/Catalyst consumption .......................................... 33
1.2.4.1. Utility Consumption ....................................................................... 33
1.2.4.2. Catalysts & Chemicals .................................................................. 43
1.3. Glossary of terms and Acronyms........................................................................... 47
1.3.1. Acronyms .................................................................................................... 47
1.3.2. Glossary ...................................................................................................... 50
SECTION 2 : Process Flow Description ...................................................................................... 52
2.1. Feed Section .......................................................................................................... 52
2.2. Reaction Section .................................................................................................... 53
2.2.1. Feed Injection Zone .................................................................................... 53
2.2.2. Riser/Reactor .............................................................................................. 54
2.2.3. Stripper........................................................................................................ 55
2.2.4. Spent Catalyst Transfer .............................................................................. 56
2.3. Catalyst Regeneration Section .............................................................................. 56
2.3.1. Air blower and air heaters........................................................................... 57
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2.3.2. First stage regenerator ............................................................................... 57

2.3.3. Second stage regenerator .......................................................................... 58
2.3.4. Combustion Air Rings ................................................................................. 59
2.3.5. Regenerated catalyst transfer..................................................................... 59
2.3.6. Catalyst handling ........................................................................................ 59
2.4. Flue gas treatment ................................................................................................. 61
2.4.1. Phosphate injection .................................................................................... 65
2.5. Fractionation Section ............................................................................................. 66
2.5.1. Fractionator bottom section ........................................................................ 66
2.5.2. HCO section................................................................................................ 67
2.5.3. LCO section ................................................................................................ 68
2.5.4. MTC and heavy naphtha section ................................................................ 69
2.5.5. Top section ................................................................................................. 70
2.5.6. Fractionator overhead section .................................................................... 70
2.6. Gas Recovery section ............................................................................................ 71
2.6.1. Wet gas compressor and HP condenser.................................................... 71
2.6.2. Stripper condenser and high pressure separator drum.............................. 71
2.6.3. Primary absorber T-1551............................................................................ 72
2.6.4. Stripper........................................................................................................ 72
2.6.5. Secondary absorber T-1553 ....................................................................... 73
2.6.6. Fuel gas absorber ....................................................................................... 73
2.6.7. Debutanizer................................................................................................. 74
2.6.8. LPG amine absorber T-1556 ...................................................................... 75
SECTION 3 : Process control ...................................................................................................... 77
3.1. Control narrative & operating parameters.............................................................. 77
3.1.1. Feed Oil Temperature Control .................................................................... 77
3.1.2. UC-001 Feed Injector ................................................................................. 79
3.1.3. UC-028 MTC INJECTOR............................................................................ 81
3.1.4. Riser Outlet Temperature Control .............................................................. 83
3.1.5. Catalyst Stripper Level Control ................................................................... 86
3.1.6. Catalyst Regenerators Level Control.......................................................... 87
3.1.7. Catalyst Regenerators Pressure Control.................................................... 89
3.1.8. Disengager Pressure Control ..................................................................... 91
3.1.9. Catalyst Regeneration Air and Total Flue gas to Stack Control................. 91
3.1.10. Catalyst Draw-Off Control ......................................................................... 94
3.1.11. Slurry Pumparound Return Control........................................................... 96
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3.1.12. Feed Pumps Automatic Start-up............................................................... 98

3.1.13. UY-405, Slurry Pumparound (PA) Return Control .................................... 98
3.1.14. UC-414, E-1505 Slurry PA flow balance control..................................... 100
3.1.15. UC-413, E-1503 Slurry PA flow balance control..................................... 102
3.1.16. Steam Generation 3 Elements Control ................................................... 104
3.1.17. Split Range Control of Surge Drum ........................................................ 105
3.1.18. Main Fractionator Pressure Control ........................................................ 107
3.1.19. HCO Pumparound Heat Removal Control.............................................. 107
3.1.20. HCO Recycle and HCO Recycle MP steam generator E-1508.............. 108
3.1.21. HCO LP Steam Generator E-1510 Controls........................................... 108
3.1.22. HCO Flushing Oil Pumps Auto-start Control .......................................... 109
3.1.23. LCO and Heavy Naphta Pumparound Heat Removal Control ............... 111
3.1.24. Heavy Naphta Product Draw-Off and T-1501 Overheads Temperature
Control 111
3.1.25. Water Draw Off and Recirculation .......................................................... 112
3.1.26. Wet Gas Compressor Control................................................................. 112
3.1.27. First Stage KO Drum D-1551 Level Control ........................................... 112
3.1.28. Stripper.................................................................................................... 113
3.1.29. Debutanizer ............................................................................................. 114
3.1.30. LPG Amine Absorber .............................................................................. 114
3.1.31. Control Narrative for the Slurry Separator Package X-1504 .................. 114
3.1.32. Tempered Water for E-1507 A-D ............................................................ 116
3.1.33. Amine Closed Drain Recovery Drum Pump P-1564............................... 117
3.1.34. RFCC lift station No.1 & No.2 Pits Pumps Control ................................. 118
3.1.35. Inter-Unit Controls & Interfaces............................................................... 118
3.1.35.1. RFCC Feed Control ................................................................... 118
3.1.35.2. Temperature of Lean Amine from the ARU............................... 120
3.1.36. Operating Parameters............................................................................. 122
3.2. Instrument List...................................................................................................... 122
3.3. Main Equipment ................................................................................................... 123
3.3.1. Reactor Riser, Stripper, Disengager and Catalyst Stand Pipe................. 123
3.3.1.1. Riser Outlet Separation System .................................................. 126
3.3.1.2. Catalyst Stripper .......................................................................... 129
3.3.2. 1st Stage Regenerator D-1502.................................................................. 131
3.3.3. 2nd Stage Regenerator D-1503................................................................. 133
3.3.4. Aeration and Fluidization Systems ........................................................... 137
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CRACKER (RFCC)
3.3.5. Special Valves .......................................................................................... 138

3.3.6. Air Heaters ................................................................................................ 142
3.3.7. CO Boiler / Waste Heat Boiler Package H-1503 ...................................... 144
3.3.8. Electrostatic Precipitator X-1507 .............................................................. 151
3.3.9. Main Fractionator ...................................................................................... 153
3.3.10. Stripper T-1552 & Primary Absorber T-1551 .......................................... 155
3.3.11. Debutanizer T-1554 ................................................................................ 159
3.3.12. LPG Amine Absorber .............................................................................. 161
3.3.13. Secondary Absorber T-1553................................................................... 163
3.3.14. Fuel Gas Absorber T-1555...................................................................... 165
3.3.15. Slurry Separator ...................................................................................... 167
3.3.16. Air Blower, C-1501 .................................................................................. 168
3.3.17. Wet Gas Compressor C-1551................................................................. 171
SECTION 4 : Safeguarding devices .......................................................................................... 175
4.1. Alarms and Trips .................................................................................................. 175
4.2. Safeguarding Description..................................................................................... 175
4.2.1. Logic UX-001 – Reaction Stop ................................................................. 175
4.2.2. Logic UX-002: Catalyst Circulation Stops................................................. 178
4.2.3. Logic UX-003: First Regenerator Air Heater Trip ..................................... 179
4.2.4. Logic UX-004: Second Regenerator Air Heater Trip ................................ 180
4.2.5. Logic UX-005: Air Blower Protection ........................................................ 181
4.2.6. Logic UX-008: COB/WHB 1st Regenerator Flue Gas Bypass Operation . 182
4.2.7. Logic UX-009: Steam Drum D-1512 overfilling protection ....................... 183
4.2.8. Logic UX-010: COB/WHB 2nd Regenerator Flue Gas Bypass Operation 184
4.2.9. Logic UX-013: Economizer Bypass Cooling............................................. 185
4.2.10. Logic UX-421: Feed Surge Drum D-1513 overfilling protection ............. 186
4.2.11. Logic UX-422: Feed Pumps P-1501 A/B Protection ............................... 186
4.2.12. Logic UX-423: T-1501 & P-1507 A/B inventory isolation........................ 187
4.2.14. Logic UX-425: Slurry pumps P-1519 A/B/C protection........................... 189
4.2.15. Logic UX-426: T-1501 & P-1519 inventory isolation............................... 190
4.2.17. Logic UX-428: Heavy Naphta Product Pumps P-1515 A/B protection ... 194
4.2.18. Logic UX-429: LCO Stripper Pumps P-1511 A/B protection .................. 194
4.2.19. Logic UX-430: D-1514, P-1516 A/B & P-1518 A/B inventory isolation... 195
4.2.20. Logic UX-431: D-1524, P-1517 A/B inventory isolation.......................... 196
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CRACKER (RFCC)
4.2.21. Logic UX-432: D-1515 overfilling protection ........................................... 197

4.2.22. Logic UX-433: Slurry Product Pumps P-1504 A/B protection................. 198
4.2.23. Logic UX-434: Backflush Oil Recycle Pumps P-1506 A/B protection .... 198
4.2.25. Logic UX-436: Backflush Oil Pumps P-1505 A/B protection .................. 199
4.2.27. Logic UX-438: HCO Flushing Oil Pumps P-1521 A/B protection ........... 200
4.2.28. Logic UX-439: LCO Flushing Oil Pumps P-1522 A/B protection ............ 201
4.2.30. Logic UX-441: Light Slops Pumps P-1526 A/B protection...................... 201
4.2.32. Logic UX-443: Heavy Slops Pumps P-1527 A/B protection ................... 202
4.2.33. Logic UX-444: Tempered Water Pumps P-1528 A/B Protection ............ 203
4.2.34. Logic UX-705: C-1551 Isolation and Protection...................................... 203
4.2.35. Logic UX-706: Interstage drum pump P-1551 A/B Protection ................ 204
4.2.36. Logic UX-707: HP separator drum D-1553 Interface Isolation ............... 205
4.2.37. Logic UX-708: HP separator drum D-1553 Inventory Isolation .............. 205
4.2.38. Logic UX-709: Lean Oil Coalescer Interface Isolation............................ 206
4.2.39. Logic UX-710: T-1555 Interface Isolation ............................................... 207
4.2.40. Logic UX-712: Debutanizer T-1554 Inventory Isolation .......................... 207
4.2.41. Logic UX-713: D-1554 Interface Isolation............................................... 208
4.2.42. Logic UX-714: Debutanizer Reflux Drum D-1554 Inventory Isolation .... 209
4.2.43. Logic UX-715: T-1556 Interface Isolation ............................................... 210
4.2.44. Logic UX-716: LPG amine coalescer D-1555 Interface Isolation ........... 210
4.2.45. Logic UX-717: LPG amine absorber T-1556 depressurization............... 211
4.2.46. Logic UX-718: Fuel Gas Absorber Outlet KO Drum D-1559 Interface
Isolation ................................................................................................................ 211
4.2.47. Logic UX-719: D-1553 depressurization ................................................. 212
4.2.48. Logic UX-861 Wet Gas Compressor C-1551 Protection ........................ 212
4.3. Safeguarding Equipment ..................................................................................... 214
4.3.1. Pressure Safety Devices .......................................................................... 214
SECTION 5 : Fire & Gas Systems............................................................................................. 225
5.1. Fire & Gas detection ............................................................................................ 225
5.2. Fire Protection...................................................................................................... 225
SECTION 6 : Quality control...................................................................................................... 227
6.1. Sampling Analysis................................................................................................ 227
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CRACKER (RFCC)
6.1.1. Feed Oil .................................................................................................... 227

6.1.2. Catalyst ..................................................................................................... 227
6.1.3. Light Cycle Oil........................................................................................... 228
6.1.4. Heavy Cycle Oil ........................................................................................ 228
6.1.5. Clarified Oil ............................................................................................... 228
6.1.6. Slurry......................................................................................................... 229
6.1.7. Absorber Gas............................................................................................ 229
6.1.8. Heavy Naphta ........................................................................................... 229
6.1.9. LPG ........................................................................................................... 229
6.1.10. Sour Water .............................................................................................. 230
6.1.11. Sampling Connections ............................................................................ 230
6.2. On-line analyzers ................................................................................................. 233
SECTION 7 : Causes and effect................................................................................................ 237
7.1. Cause & Effect Matrix: ......................................................................................... 237
7.1.1. Example from Cause and Effect Chart ..................................................... 237
7.1.1.1. Sheet 18: UX-426: T-1501 & P-1519 inventory isolation ............ 237
SECTION 8 : Operating practices.............................................................................................. 243
8.1. Normal Operation................................................................................................. 243
8.1.1. Operating conditions................................................................................. 243
8.1.2. Operating Parameters .............................................................................. 271
8.2. Start-up Procedure............................................................................................... 271
8.2.1. Pre-commissioning Activities .................................................................... 272
8.2.2. Initial Start-up............................................................................................ 272
8.2.2.1. Status of the Unit prior to first start-up ........................................ 272
8.2.2.2. Chronology of first Start-up ......................................................... 273
8.2.3. Initial & Normal Start-Up ........................................................................... 274
8.2.3.1. Start-up summary of the Reaction Section ................................. 274
8.2.3.2. Start-up summary of the Fractionation & Gas Recovery Sections
279
8.3. Shutdown Procedures.......................................................................................... 284
8.3.1. Normal Shutdown ..................................................................................... 284
8.3.1.1. Normal Shutdown Summary of Reactor & Regenerator............. 284
8.3.1.2. Normal Shutdown Summary of Fractionation and Gas Recovery
Section 288
8.4. Emergency Shutdown .......................................................................................... 290
8.4.1. General emergency shutdown.................................................................. 290
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8.4.2. Power failure ............................................................................................. 290

8.4.3. Instrument air failure ................................................................................. 291
8.4.4. Fluidization / Aeration / Purge Air and FG failure ..................................... 292
8.4.5. Steam failure............................................................................................. 293
8.4.6. Boiler feed water failure ............................................................................ 294
8.4.7. Cooling water failure ................................................................................. 295
8.4.8. Sea water failure ....................................................................................... 295
8.4.9. Air blower failure ....................................................................................... 295
8.4.10. Feed pump failure ................................................................................... 297
8.4.11. Other pump failure .................................................................................. 297
8.4.12. Fuel gas failure........................................................................................ 297
8.4.13. Wet gas compressor failure .................................................................... 298
8.4.14. Catalyst slide valve / plug valve failure ................................................... 299
8.4.15. Loss of regenerators pressure control (flue gas slide valve failure) ....... 299
8.4.16. Control system failure ............................................................................. 300
8.4.17. Oil reversal .............................................................................................. 300
8.4.18. Low riser outlet temperature (ROT) ........................................................ 300
8.4.19. Plugged catalyst circulation .................................................................... 301
8.4.20. Downstream unit failure .......................................................................... 301
8.4.21. Fire emergency ....................................................................................... 301
8.4.22. Emergency shutdown of Fractionator and Gas Recovery Section - General
302
8.4.23. Steam failure for the Fractionation/Gas Recovery Section..................... 302
8.4.24. Instrument air failure for the Fractionation/Gas Recovery Section......... 302
8.4.25. Boiler feed water failure for the Fractionation/Gas Recovery Section.... 303
8.4.26. Fuel gas failure for the Fractionation/Gas Recovery Section ................. 303
8.4.27. Electrical power failure for the Fractionation/Gas Recovery Section ..... 303
8.4.28. Cooling water failure for the Fractionation/Gas Recovery Section......... 304
8.4.29. Sea water failure for the Fractionation/Gas Recovery Section............... 304
8.4.30. Wet gas compressor failure for the Fractionation/Gas Recovery Section
304
SECTION 9 : HSE...................................................................................................................... 306
9.1. Hazardous Areas ................................................................................................. 306
9.2. Safety Equipment................................................................................................. 306
9.3. Specific PPE ........................................................................................................ 306
9.3.1. Catalyst ..................................................................................................... 306
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9.3.2. Flue gas .................................................................................................... 307

9.3.2.1. Carbon Monoxide ........................................................................ 307
9.3.3. H2S ........................................................................................................... 307
9.3.4. Nickel passivator – NALCO NICKEL PASSIVATION PLUS EC9192 ...... 308
9.3.5. Corrosion Inhibitor - CHIMEC 1430.......................................................... 308
9.3.6. Antifoam CHIMEC 8045 ........................................................................... 309
9.3.7. Phosphate NALCO 7208 .......................................................................... 309
9.4. Chemical Hazards................................................................................................ 309
9.4.1. Hazardous Properties of Catalyst............................................................. 310
9.4.2. Flue gas .................................................................................................... 310
9.4.2.1. Hazardous properties of carbon monoxide (CO) ........................ 310
9.4.3. Hazardous Properties of Cracked hydrocarbons ..................................... 311
9.4.4. Hazardous Properties of Hydrogen Sulfide Toxicity................................. 311
9.4.4.1. Acute Hydrogen Sulfide Poisoning.............................................. 312
9.4.4.2. Subacute Hydrogen sulfide Poisoning ........................................ 313
9.4.5. Hazardous Properties of NALCO NICKEL PASSIVATION PLUS EC9192
313
9.4.6. Hazardous Properties of Corrosion Inhibitor - CHIMEC 1430.................. 314
9.4.7. Hazardous Properties of Antifoam CHIMEC 8045 ................................... 314
9.4.8. Hazardous Properties of Phosphate NALCO 7208 .................................. 315
SECTION 10 : Reference documents index.............................................................................. 317
10.1. Operating Manual/ Licensor Documentation ....................................................... 317
10.2. Arrangement Drawings, Layouts and Plot Plans ................................................. 317
10.3. Process Flow Diagrams ....................................................................................... 317
10.4. Piping and Instrumentation Diagrams.................................................................. 317
10.5. Equipment list....................................................................................................... 320
10.6. Main Equipment Data Sheet ................................................................................ 320
10.7. Instrument List...................................................................................................... 321
10.8. Cause & Effect Matrix .......................................................................................... 321
10.9. Safety Logic diagram ........................................................................................... 321
10.10. Fire & Gas Cause & Effect Chart .............................................................. 321
10.11. Fire & Gas Detectors Layout..................................................................... 321
10.12. Fire Protection Layout ............................................................................... 321
10.13. Hazardous Area Classification.................................................................. 322
10.14. MSDS ........................................................................................................ 322
10.15. Vendors Documentation............................................................................ 322
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TRAINING MODULE
UNIT: 15
Course Content:
Section 1 - General Description
X
Section 2 - Process Flow Description
Section 3 - Process Control
Section 4 - Safeguarding Devices
Section 5 - Fire & Gas Systems
Section 6 - Quality Control
Section 7 - Cause & Effects
Section 8 - Operating Procedures
Section 9 - HSE
Section 10 - Reference Document Index
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CRACKER (RFCC)
SECTION 1 : GENERAL DESCRIPTION
The Residue Fluid Catalytic Cracking (RFCC) converts various residues from CDU to lower
boiling, high value products: Naphtha sent to NTU (unit 17), Light Cycle Oil sent to LCO HDT
(unit 24) and intermediate storage and LPG sent to the LTU (unit 16).
As by-products of the reaction, fuel gas, slurry oil, and coke are also generated in the reactor-
riser. The resulting Decanted Cycle Oil from these by-products will then be incorporated in the
Fuel oil Blend.
The majority of the RFCC reaction section equipment handles catalyst / vapour product
separation and removal of the coke from the catalyst, while only a small portion of the system is
directly used for the cracking reaction.
The RFCC is also provided with a Fractionation Section to distillate the vapour product from the
reaction section, as well as a Gas recovery Section which process the overhead of the
Fractionation Section
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Figure 1: 2D Refinery Plot Plan
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CRACKER (RFCC)
Figure 2: 3D Refinery Plot Plan
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CRACKER (RFCC)
1.1. Purpose of the Unit

The purpose of the Residue Fluid Catalytic Cracker (RFCC) R2R process is to convert
various reduced crudes to lower boiling, high value products, primarily C3-C4 LPG,
gasoline and light cycle oil.
This is achieved using vapour phase chemical reactions in the presence of specialized
FCC cracking catalyst during which the long molecular chain of the reduced crude is
cracked into shorter chain molecules. Heat for the cracking process is supplied by the hot
regenerated catalyst which vaporizes the finely atomized oil feed and sets the stage for
the rapid and selective cracking process. The vaporization and cracking reactions occur
in the reactor riser in about 2 seconds.
As by-product of the reaction, fuel gas, slurry oil, and coke are also generated in the
reactor riser.
The RFCC has been designed by AXENS to offer maximum flexibility. The reaction
section of this unit particularly includes a 2-stage catalyst regeneration system, a unique
feed injection system, mixed temperature control, an efficient riser termination system
and effective air/steam distribution devices.
The Fractionation section of the RFCC fractionates the vapour product from the reaction
section into clarified oil, LOC and heavy naphta. The fractionator overhead vapour and
liquid streams are further processed in the Gas Recovery section, which produces light
gasoline, amine treated fuel gas and amine treated LPG.
For the Maximum Gasoline Operation, the heavy naphta is combined with the light
gasoline from the Gas Recovery Section. For the maximum Distillate Operation, the
heavy naphta combined with LCO products.
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Figure 3: Refinery Plot Plan
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North East View
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CRACKER (RFCC)
North West View
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South East
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South West
Figure 4: RFCC 3D Drawings
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CRACKER (RFCC)
1.2. Basis of Design
1.2.1. Duty of Plant

The Residue Fluid Catalytic Cracking (RFCC) is designed for 2 atmospheric
residues from Bach Ho and Bach Ho/Dubai crudes mixture:
• The RFCC design capacity is 3,256,000 tones per annum of Bach Ho
370+°C crude distillation residue (from unit 11), which is equivalent to a
volumetric flowrate of 69,700 BPSD, based on the RFCC operation of 8 000
hours operation per year.
• The RFCC is also designed to process a residue based on the CDU (from
unit 11) processing a sour crude blend in the ratio of 1.0 million tones of
Dubai crude to 5.5 million tones of Bach Ho crude. The sour residue blend
capacity is also 3,256,000 tones per annum, which is equivalent to a
volumetric flowrate of 69,700 BPSD, based on 8 000 hours operation per
year.
The RFCC is also designed to process both the Bach Ho and sour crude mix
residues in2 modes of operation:
• Maximize RFCC Naphtha (Max Gasoline)
• Maximize LCO (Max Distillate)
NOTE:
The product guarantees are based on RFCC operating in the maximum distillate
mode of operation.
The RFCC is designed to process 100% hot feed direct from the Crude Distillation
Unit and is capable of processing up to 100% cold feed from storage.
In addition to the above, the RFCC Gas Plant can process the following streams:
• CDU Stabilizer Off-gas
• CDU LPG rich stream
The RFCC shall also treat the off-gas stream from the Naphtha hydrotreater
(NHT).
Page 24 of 323
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CRACKER (RFCC)
1.2.2. Feed Characteristics
1.2.2.1. Atmospheric Residue Properties
Crude (Sour) 100% (Sweet) ASTM Test

Property
Blend Bach Ho Method
Cut Range, TPB (°C) 370+ 370+
Vol% on Crude 46.6 47.3
Wt% on Crude 50.0 50.1
API Gravity 2695 28.9
Specific Gravity at 15/4°C 0.893 0.882
Nitrogen (wt ppm) 1800 1300
Sulphur (wt%) 0.55 0.05 D-1266
Conradson Carbon (wt%) 2.66 1.57 D189
Vanadium (wt ppm) 10.5 0 D2787
Nickel (wt ppm) 5 1
Sodium (wt ppm) 1.6 1.6 D2788
Viscosity at 50°C (cSt) 43.4 43.4 D445
Viscosity at 100°C (cSt) 8.8 9
Pour Point (°C) 50 52 D97
Asphaltenes (wt%) 2.0 1.0 D128
Wax Content (wt%) N/A 41
Hydrogen (wt%) 12.7 12.84 D1018
Neutralization No. (mg KOH/gm) 0.05 0.05 D3242
Characterization “K” Factor 12.58 12.78
ASTM Distillation (°C)
IBP 263 262
10% 379 379 D-1160 at 760
30% 435 437 mmHg
50% 475 480
Vol% above 550°C 32.4 32.5
1.2.2.2. CDU Stabilizer Off Gas

The following gas stream is fed from the CDU Stabilizer, directly to the
suction of the wet-gas compressor in the RFCC Gas Plant:
Page 25 of 323
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CRACKER (RFCC)
Property Crude (Sour) Blend [1] 100% (Sweet) Bach Ho

Flowrate (kg/hr) 339.0 291.0
Composition
N2 (mol%) - -
H2S (mol%) - -
C1 (mol%) - 0.7
C2 (mol%) 6.3 4.8
C3 (mol%) 37.0 22.7
iC4 (mol%) 14.3 16.0
nC4 (mol%) 40.6 53.5
iC5 (mol%) 0.4 0.4
nC5 (mol%) - -
C6+ (mol%) - -
H2O (mol%) 1.4 1.9
Total (mol%) 100.0 100.0
Molecular Weight 50.6 52.6
Note:
[1]: Sour Crude Blend data based on 100% Dubai Crude.
1.2.2.3. NHT Stripper off gas to RFCC
Component Content
H2O (kg mol/h) 0.13
H2S (kg mol/h) 0.32
NH3 (kg mol/h) Trace
H2 (kg mol/h) 13.17
C1 (kg mol/h) 1.69
C2 (kg mol/h) 1.37
C3 (kg mol/h) 0.83
iC4 (kg mol/h) 0.06
nC4 (kg mol/h) 0.40
IC5 (kg mol/h) 0.10
C6+ (kg mol/h) 0.63
Total (kg mol/h) 18.84
Total (kg/h) 243
Page 26 of 323
REV: A DATE: 06/12/07
CRACKER (RFCC)
1.2.2.4. CDU LPG Rich Stream
Property Crude (Sour) Blend [1] 100% (Sweet) Bach Ho

Flowrate (kg/hr) 6206 2071
Specific Gravity at 15°C 0.565 0.572
Composition
Ethylene (mol%) - -
Ethane (mol%) 1.2 0.8
Propene (mol%) - -
Propane (mol%) 19.3 10.7
Butene (mol%) - -
iC4 (mol%) 16.5 16.1
nC4 (mol%) 61.7 71.0
iC5+ (mol%) 1.3 1.4
Total (mol%) 100.0 100.0
1.2.2.5. Slops feed to RFCC

Provision is made to allow the re-running of slops through the RFCC main
fractionator.
Heavy slops: 5000 BPSD
Light slops: 5000 BPSD
1.2.3. Product Specifications
1.2.3.1. Distillation Specifications
Product Property Max. Gasoline Max. Distillate

TBP cut points C5 - 205°C C5 - 165°C
Gasoline
RVP (kPa) 60 max.
TBP cut point 205 – 360°C 165 – 390°C
LCO
Flash Point 65°C min.
TBP cut point 360+°C 390+°C
Slurry
Flash Point 100°C min.
Page 27 of 323
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CRACKER (RFCC)
1.2.3.2. Gas Recovery Targets
Component Value
C3 overall recovery 95% min.
C4 overall recovery 96% min.
C5+ content in LPG 0.7% wt max.
H2S content in LPG 25 ppm wt max.
1.2.3.3. Flue Gas Specifications

The following describes the flue gas properties downstream of the
electrostatic precipitator and the DeSOx unit:
Component Value
NOx 1000 mg/Nm3 max
SOx 500 mg/Nm3 max
Catalyst fines 50m/Nm3 max
CO content 300 mg/Nm3 max
NOTE:
DeSOx unit will be provided in the future.
Indeed, the unit will be initially operated with Bach Ho Crude only, thus
producing SO2 content smaller than 500 mg/Nm3.
1.2.3.4. Fuel Gas Specification

H2S content: 50 wt ppm MAX.
1.2.3.5. Decant Oil Specification (after Slurry Separation)

Catalyst content: 100 wt ppm MAX.
Page 28 of 323
REV: A DATE: 06/12/07
CRACKER (RFCC)
1.2.3.6. Estimated Product Properties
Mixed Bach Ho Mixed Bach Ho

MG MG MD MD
LPG
Specific Gravity 15/15 0.565 0.566 .565 0.565
Mercaptans (wt ppm) 78 7.1 78 1.7
COS (wt ppm) 5.0 5.0 5.0 5.0
Total Sulphur (wt ppm) 3786 332 4260 383
Butadiene (wt ppm) 3012 1647 1358 1063
Gasoline (C5 – 165°C)
Sulphur (wt ppm) 230 10
RON clear 92.0 91.7
MON clear 79.5 79.2
True Vapour Pressure (g/cm2) 498 531
Reid Vapour Pressure (kPa) 48 51
Specific Gravity (15/15) 00.719 0.715
D-86
IBP 35 34
5 43 42
10 47 46
30 60 58
50 72 70
70 1 89
90 129 129
95 144 143
EBP 159 156
Olefins (wt %) 43 45
Gasoline (C5 – 205°C)
Sulphur (wt ppm) 340 10
RON clear 92.1 91.8
MON clear 79.9 79.6
2
True Vapour Pressure (g/cm ) 337 363
Reid Vapour Pressure (kPa) 32 34
Specific Gravity (15/15) 0.736 0.732
Page 29 of 323
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CRACKER (RFCC)

MG MG MD MD
D-86
IBP 39 39
5 50 49
10 55 54
30 71 70
50 90 87
70 116 113
90 160 159
95 176 175
EBP 197 197
Olefins (wt %) 34 35
Light Cycle Oil (165 – 390°C)
Sulphur (wt %) 0.45 0.04
Cetane Number 33.9 38.4
Cloud Point (°C) -1.8 -0.9
Viscosity at 100°C (cSt) 1.02 1.02
Pour Point (°C) -17.3 -18.9
Flash Point (°C) 67 67
Specific Gravity 15/15 0.881 0.864
D-86
IBP 189 189
5 203 204
10 212 212
30 239 239
50 263 264
70 291 292
90 333 334
95 349 350
EBP 373 374
Light Cycle Oil (205 – 360°C)
Sulphur (wt %) 0.619 0.055
Cetane Number 24.4 28.1
Page 30 of 323
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CRACKER (RFCC)

MG MG MD MD
Cloud Point (°C) -6.1 -5.3
Pour Point (°C) -12.8 -14.0
Flash Point (°C) 76 74
D-86
IBP 188 180
5 221 220
10 230 230
30 24 245
50 263 262
70 287 286
90 323 322
95 336 335
EBP 353 353
Slurry (390+°C)
Sulphur (wt %) 0.835 0.07
Conradson Carbon (wt %) 12.5 9.5
Viscosity at 50°C (cSt) 110 45
Pour Point (°C) 15-20 15-20
Slurry (390+°C)
Sulphur (wt %) 1.03 0.10
Conradson Carbon (wt %) 15.7 12.7
Viscosity at 50°C (cSt) 160 140
Pour Point (°C) 15-20 15-20
Page 31 of 323
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CRACKER (RFCC)
1.2.3.7. LPG Composition
Mixed MG Bach Ho MG Mixed MD Bach Ho MD

Component LPG Rate LPG Rate LPG Rate LPG Rate
(kg/h) (kg/h) (kg/h) (kg/h)
H2 S 1 1 1 2
H2 0 0 0 0
C1 0 0 0 0
C2 449 333 444 349
Ethylene 9 6 9 7
C3 6124 5179 6627 5793
Propylene 20251 14145 19626 14621
iC4 14681 11273 13689 10839
nC4 5801 4221 7858 6560
Isobutylene 6579 4679 6758 5170
1-Butene 6317 4706 5922 4653
Cis-2-Butene 6482 4751 5909 4592
Trans-2-Butene 9862 7245 8964 6975
Butadiene 106 50 184 64
20-50 541 399 540 424
TOTAL: 77203 56988 76530 60049
Component LPG (kmol/h) LPG (kmol/h) LPG (kmol/h) LPG (kmol/h)

H2 S 0.04 0.03 0.04 0.06
H2 0.00 0.00 0.00 0.00
C1 0.00 0.00 0.00 0.00
C2 14.94 11.07 14.77 11.62
Ethylene 0.31 0.21 0.32 0.24
C3 138.87 117.44 150.28 131.37
Propylene 481.23 336.14 466.37 347.44
iC4 252.58 193.94 235.51 186.49
nC4 99.81 72.63 135.20 112.86
Isobutylene 117.26 83.39 120.45 92.15
1-Butene 112.59 83.88 105.54 82.93
Page 32 of 323
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CRACKER (RFCC)
Mixed MG Bach Ho MG Mixed MD Bach Ho MD

Cis-2-Butene 115.53 84.68 105.32 81.84
Trans-2-Butene 175.76 129.12 159.76 124.31
Butadiene 1.96 0.93 3.41 1.18
20-50 8.07 6.10 8.00 6.47
TOTAL: 1518.96 1119.56 1504.96 1178.96
Mercaptans (wt ppm) 7 7 78 78

COS (wt ppm) 5 5 5 5
Temperature (°C) 40 40 40 40
Pressure (kg/cm2g) 18 18 18 18
Density (P; T) 530.2 530.1 529.8 529.8
Density (15°C) 563.3 563 562.8 562.7
Note: Dry Liquid.
1.2.4. Utility/Power/Chemicals/Catalyst consumption
1.2.4.1. Utility Consumption

The following describes the utility consumption of the RFCC based on the
Estimated Utility Consumption Documents:
8474L-015-CN-0003-511 Bach Ho – Max Gasoline – Normal case
8474L-015-CN-0003-512 Bach Ho – Max Distillate – Normal case
8474L-023-CN-0003-513 Mixed Crude – Max Gasoline – Normal
case
8474L-023-CN-0003-514 Mixed Crude – Max Distillate – Normal
case
8474L-015-CN-0003-521 Bach Ho – Max Gasoline – Design case
8474L-015-CN-0003-522 Bach Ho – Max Distillate – Design case
8474L-023-CN-0003-523 Mixed Crude – Max Gasoline – Design
case
8474L-023-CN-0003-524 Mixed Crude – Max Distillate – Design
case
Page 33 of 323
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CRACKER (RFCC)
Only the Bach Ho – Max Distillate – Normal case is described in the

following. For the other cases, refer to the abovementioned documents.
Note:
In the following subsections:
( ): Intermittent Producer/Consumer
+: Indicates Quantity Produced
-: Indicates Quantity Consumed
1.2.4.1.1. Electrical Power

Electric Power, kW
Item No. Description Motor Mech. Elec.
Load/ Running Oper.
Rating Load Load
H-1503 COB/WHB package -0.3 -0.3
C-1502A Forced Draft Air Fan 1230 -683.0 -697.0
C-1501 Air Blower 3 -3.0 -3.0
P-1529A C-1501 Turbine Condensate Pump 55 -39.0 -43.3
P-1529B C-1501 Turbine Condensate Pump 55 (-39.0) (-43.3)
- C-1501 Lube oil Pump (Main) 37 -18.5 -20.6
- Turbine Gear Motor 15 -15.0 -15.0
C-1551 Wet Gas Compressor -1.5 -1.5
P-1559A C-1551 Turbine Condensate Pump 18.5 -13.9 -14.8
P-1559B C-1551 Turbine Condensate Pump 18.5 (-13.9) (-14.8)
- C-1551 Lube Oil Pump (Main) 30 -16.0 -17.8
P-1501A Feed Pump 600 -476.0 -500.5
P-1501B Feed Pump 600 (-476.0) (-500.5)
P-1504A Slurry Product Pump 55 -42.7 -45.1
P-1504B Slurry Product Pump 55 (-42.7) (-45.1)
P-1505A Backflush Oil Pump 22 -15.0 -16.5
P-1505B Backflush Oil Pump 22 (-15.0) (-16.5)
P-1506A Backflush Oil Recycle Pump 11 -7.4 -8.4
P-1506B Backflush Oil Recycle Pump 11 (-7.4) (-8.4)
P-1507A HCO Recycle Pump 150 -128.0 -142.2
P-1508B HCO Recycle Pump 150 (-128.0) (-142.2)
P-1508A HCO Pumparound Pump 220 -179.4 -188,4
P-1508B HCO Pumparound Pump 220 (-179.4) (-188.4)
Page 34 of 323
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CRACKER (RFCC)
Electric Power, kW
Load/ Running Oper.
Rating Load Load
P-1509A HCO Product Pump 15 -9.1 -10.1
P-1509B HCO Product Pump 15 (-9.1) (-10.1)
P-1510A LCO Pumparound Pump 335 -303.0 -316.0
P-1510B LCO Pumparound Pump 335 (-303.0) (-316.0)
P-1511A LCO Stripper Pump 90 -73.4 -76.9
P-1511B LCO Stripper Pump 90 (-73.4) (-76.9)
P-1512A MTC Recycle Pump 75 0.0 0.0
P-1512B MTC Recycle Pump 75 (0.0) (0.0)
P-1513A Lean Oil Pump 75 -55.0 -58.1
P-1513B Lean Oil Pump 75 (-55.0) (-58.1)
P-1514A Naphta Pumparound Pump 225 -203.0 -213.9
P-1514B Naphta Pumparound Pump 225 (-203.0) (-213.9)
P-1515A Heavy Naphta Product Pump 55 -39.4 -41.6
P-1515B Heavy Naphta Product Pump 55 (-39.4) (-41.6)
P-1516A Fractionator Reflux Pump 110 -96.0 -101.3
P-1516B Fractionator Reflux Pump 110 (-96.0) (-101.3)
P-1517A Overhead Sour Water Pump 30 -25.5 -27.6
P-1517B Overhead Sour Water Pump 30 (-25.5) -(27.6)
P-1518A Overhead Liquid Pump 250 -206.0 -228.9
P-1518B Overhead Liquid Pump 250 (-206.0) (-228.9)
P-1521B HCO Flushing Oil Pump 110 (-80.9) (-84.4)
P-1522A LCO Flushing Oil Pump 30 -18.4 -19.9
P-1522B LCO Flushing Oil Pump 30 (-18.4) (-19.9)
P-1526A Light Slops Pump 37 -16.1 -27.9
P-1526B Light Slops Pump 37 (-16.1) (-27.9)
P-1527A Heavy Slops Pump 37 -27.9 -29.8
P-1527B Heavy Slops Pump 37 (-27.9) (-29.8)
P-1528A Tempered Water Pump 15 -10.5 -11.7
P-1528B Tempered Water Pump 15 (-10.5) (-11.7)
P-1551A Interstage Drum Pump 150 -134.0 -142.3
P-1551B Interstage Drum Pump 150 (-134.0) (-142.3)
Page 35 of 323
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CRACKER (RFCC)
Electric Power, kW
Load/ Running Oper.
Rating Load Load
P-1552A KO Drum Liquid Pump 4 -1.2 -1.4
P-1552B KO Drum Liquid Pump 4 (-1.2) (-1.4)
P-1553A Stripper Feed Pump 132 -112.0 -117.9
P-1553B Stripper Feed Pump 132 (-112.0) (-117.9)
P-1554A Gasoline Recycle Pump 55 -44.0 -47.7
P-1554B Gasoline Recycle Pump 55 (-44.0) (-47.7)
P-1556A Debutanizer Overhead Pump 225 -185.0 -194.9
P-1556B Debutanizer Overhead Pump 225 (-185.0) (-194.9)
P-1560A RFCC Closed Drain Pump 22 (-16.5) (-18.1)
P-1560B RFCC Closed Drain Pump 22 (-16.5) (-18.1)
P-1561 RFCC Lift Station No.1 Sump Pump 7.5 (-4.9) (-5.4)
P-1562 RFCC Lift Station No.2 Sump Pump 7.5 (-4.9) (-5.4)
P-1563 Oily Water Lift Pump – Common Spare 7.5 (-4.9) (-5.4)
P-1564 Amine Closed Drain Pump 15 (-10.8) (-12.0)
E-1514 LCO Air Cooler 120 -97.6 -106.2
E-1517 Heavy Naphta Air Cooler 33 -20.4 -23.1
E-1519 Overhead Air Condenser 960 -736.0 -800.9
E-1521 Heavy Naphta Pumparound Air Cooler 120 -99.6 -108.4
E-1530 Tempered Water Air Cooler 22.5 -15.0 -17.8
E-1551 Wet Gas Compressor Intercooler 240 -190.4 -207.2
E-1553 HP Condenser 180 -134.4 -146.2
E-1558 Gasoline Air Cooler 120 -92.8 -101.0
X-1504 Slurry Separator -230.0 -230.0
X-1505 Corrosion Inhibitor Injection Package
P-1520 Corrosion Inhibitor Pump 0.55 -0.40 -0.44
X-1507 Electrostatic Precipitator 491 -379.0 -379.0
Intermittent Users in X-1507 88 (-53) (-53)
X-1508 DeSOx Unit (Future) (-270.0) (300.0)
X-1509 Metal Passivation Injection Package
P-1502A Metal Passivation Pump 0.55 0.00 0.00
P-1502B Metal Passivation Pump 0.55 (0.00) (0.00)
Page 36 of 323
REV: A DATE: 06/12/07
CRACKER (RFCC)
Electric Power, kW
Load/ Running Oper.
Rating Load Load
X-1510 Phosphate Injection Package 6.05 -4.36 -4.84
X-1551 Antifoam Injection Package
P-1557 Anti-Foaming Pump 0.55 (-0.40) (-0.44)
P-1558 Anti-Foaming Pump 0.55 (-0.40) (-0.44)
EJ-1501 Catalyst Hoppers Steam Ejector
SV-1501 Regenerated Catalyst Slide Valve 4.0 -3.0 -3.3
SV-1502 Spent Catalyst Slide Valve 4.0 -3.0 -3.3
SV-1503 1st Regenerator Flue Gas Slide Valve 4.0 -3.0 -3.3
SV-1504 2nd Regenerator Flue Gas Slide Valve 4.0 -3.0 -3.3
PV-1501 Plug Valve 4.0 -3.0 -3.3
- Oil Mist Generator 3.0 -3.0 -3.0
TOTAL(excluded Future DeSOx): 10066 -5225.9 -5526.7

TOTAL(included Future DeSOx): 10066 -5495.9 -5836.7
Page 37 of 323
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CRACKER (RFCC)
1.2.4.1.2. Steam, Condensate & Boiler Feed Water
Steam (T/h) Condensate (T/h) BFW (T/h) Losses

Item No. Description (T/h)
HP MP LP HP MP LP COLD HP LP Cold
STM STM STM COND COND COND COND BFW BFW BFW
H-1503 COB/WHB Package (with 219.3 -0.7 6.2
0.7 -225.5
Economizer)
C-1502B Forced Draft Air Fan (-21.0) (21.0)
C-1502B Hot Standby -1.7
E-1534 BFW Heater -7.0 7.0
C-1501 Air Blower -68.7 -0.3 -0.1 0.0 68.7 0.3
- C-1501 Lube Oil Pump (Spare) (-2.6) (2.6)
C-1551 Wet Gas Compressor -30.4 -0.4 30.4 0.4
- C-1551 Lube Oil Pump (Spare) (-2.1) (2.1)
D-1501 Disengager / Stripper -34.7 34.7
- COB/WHB LP Blowdown Drum 0.5 -0.5
D-1527 LP Blowdown Drum 0.2 -0.2
T-1503 LCO Stripper -3.0 3.0
T-1504 HCO Stripper -0.5 0.5
P-1519A Slurry Pumparound Pump -10.3 10.3
P-1519B Slurry Pumparound Pump -10.3 10.3
P-1519C Slurry Pumparound Pump (-10.3) (10.3)
P-1519C Hot Standby -0.8 0.8
Page 38 of 323
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CRACKER (RFCC)

P-121A HCO Flushing Oil Pump -3.7 3.7
E-1503 Slurry HP Steam Generator 0.0 0.0
E-1504 Slurry HP Steam Generator 18.0 -18.5 0.5
E-1505 Slurry MP Steam Generator 13.8 -14.2 0.4
E-1506 Slurry LP Steam Generator 1.3 -1.4 0.1
E-1508 HCO Recycle MP Steam -6.7 0.2
6.5
Generator
E-1510 HCO LP Steam Generator 2.9 -3.0 0.1
LCO Product LP Steam
E-1513 8.6 -8.9 0.3
Generator
E-1522 MP steam Feed Heater [1] -6.5 6.5
HCO Pumparound MP Steam
E-1523 7.3 -7.5 0.2
Generator
E-1524 HP Steam Feed Heater [2] -11.3 11.3
st
SPR- 1 Regenerator Torch Oil
(-0.3) (0.3)
1501 Sprayer
SPR- 2nd Regenerator Torch Oil
(-0.3) (0.3)
1502 Sprayer
SPR- Water Spray for D-1502 Flue
(-1.5) (-22.8) (-24.3)
1503 Gas Bypass
SPR- Water Spray for D-1503 Flue
(-1.5) (-14.0) (-15.5)
1504 Gas Bypass
Page 39 of 323
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CRACKER (RFCC)

SPR-
Water Spray for Economizer (-1.5) (-5.2) (-6.7)
1505
X-1507 Electrostatic Precipitator -0.3 0.3
EJ-1501 Catalyst Hoppers Steam Ejector (-0.9) (0.9)
st
1 Regenerator Flue Gas Slide
SV-1503 -0.1 0.1
Valve
- Steam Trace -2.0 2.0
TOTAL: 100.1 -20.6 31.8 11.3 13.5 2.1 99.1 -244.0 -42.4 0.0 49.1
Notes:
[1]: Cold Feed Case: -16.4 T/h MPS
[2]: Cold Feed Case: -20.7 Y/h HPS
Page 40 of 323
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CRACKER (RFCC)
1.2.4.1.3. Cooling water & Seawater
Cooling Water Seawater

Item no. Description
ΔT (°C) m3/hr ΔT (°C) m3/hr
E-1518 Heavy Naphta Trim Cooler 6.0 -20
E-1520 A-H Overhead Trim Condenser 8.0 -1743
E-1531 Surface Condenser 8.8 -7285
E-1532 Blowdown Cooler 13.0 -15
E-1533 Blowdown Cooler 15.0 -24
Wet gas Compressor Trim 8.0 -225
E-1552 A/B
Cooler
E-1554 A-D Stripper Condenser 6.0 -650
E-1559 Gasoline Cooler 6.0 -138
E-1561 A/B Debutanizer Condenser 12.0 -1159
E-1562 LPG Cooler 6.0 -49
E-1564 Lean Oil Cooler 6.0 -196
E-1565 Fuel Gas Cooler 6.0 -6
E-1566 Lean Amine Cooler 6.0 -53
E-1567 Turbine Condenser 8.8 -2300
Pump / Compressor -95
Cooling
H-1503 COB/WHB Package 15.0 -3
- C-1501 Gland Condenser -76
- C-1501 Oil Cooler -32
- C-1501 Main Oil Cooler 6.0 -60
- C-1501 Gland Condenser 6.0 -50
TOTAL -4594 -9585
Note:
[1]: Peak consumption of 12.9 Nm3/hr with temperature rise of
13°C
Page 41 of 323
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CRACKER (RFCC)
1.2.4.1.4. Instrument & Plant Air
Instrument Plant Air (Nm3/h)

Item No. Description
Air (Nm3/h) Continuous Intermittent
H-1503 COB/WHB Package -120 -50 (-125)
X-1507 Electrostatic Precipitator -26 -8 (-85)
X-1504 Slurry Separator -1
Oil Mist Generator -165
X-1502 Fresh Catalyst Feeder -3 -60 (-40)
X-1503 Auxiliary Catalyst Feeder (-3) (-60) (-40)
C-1501 Air Blower -22
C-1551 Wet Gas Compressor 6
PV-1501 Plug Valve -611
nd
2 Regenerator Catalyst Slide
SV-1504 -134
Valve
Primary Plant Air for Regeneration
Section (form instrument air -4230
header)
Secondary Plant Air for
(-2320)
Regeneration Section
Miscellaneous Users -340
TOTAL: -5658 -118 0
1.2.4.1.5. Nitrogen
Item No. Description Nitrogen Nm3/h

Continuous Intermittent
C-1551 Wet Gas Compressor -71 (-280)
SV-1501 Regenerated Catalyst Slide Valve -84
SV-1502 Spent Catalyst Slide Valve -36
Miscellaneous Users -160 (-560)
TOTAL: -351 0
Page 42 of 323
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CRACKER (RFCC)
1.2.4.1.6. Furnaces & Boilers
Item No. Description Fuel Fired

H-1501 1st Regenerator Air Heater Start-Up Approx. 4.5 T/h
H-1502 2nd Regenerator Air Heater Start-Up Approx. 4.5 T/h
H-1503 COB/WHB Package -110 MW
1.2.4.2. Catalysts & Chemicals
1.2.4.2.1. Catalysts
The proper selection of catalyst is very important for successful
residue cracking operations. Several catalyst properties should
be examined for a particular feed.
The Axens recommendation for use in R2R residue cracking unit

is low sodium, Ultra-Stable Hydrogen Y type (USHY) zeolite.
For detailed information on the catalyst properties and

recommendations, refer to the licensor operating manual doc.
No. 8474L-015-ML-001.
Catalyst Inventory and Addition Rate:

Catalyst Inventory: 675 tons
Fresh Catalyst Addition Rate:
• Mixed Crude: 15.2 Tons/day (dry basis)
• Bach Ho Crude: 5.2 Tons/day (dry basis)
Fresh Catalyst Selection

The fresh catalyst will be specifically designed to maximize
middle distillate (LCO) and metal resistance. The target for the
MAT activity associated with the corresponding delta coke is
given hereafter and linked to the metal concentration to be
sustained.
Mixed Mixed Bach Ho Bach Ho

Max. Gasoline Max. Distillate Max. Gasoline Max. Distillate
Ni Content (ppm) 3213 1776
V Content (ppm) 6748 -
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Mixed Mixed Bach Ho Bach Ho

Max. Gasoline Max. Distillate Max. Gasoline Max. Distillate
Equilibrium Catalyst
MAT Activity (wt %) 68 55 75 60
Delta Coke (Wt %) 1.22 0.99 0.94 0.91
2 catalyst lines fit appropriately with the operation objectives:

• Albemarle (Former Akzo), COBRA RMR DQ1
• GRACE Davison, GDC-1825
The final guarantee catalyst will be selected by AXENS after

evaluation of the best candidates proposed by Vendors.
1.2.4.2.2. Antimony (Nickel passivator, only in Mixed Crude Case)

Metal Passivator is injected into the fresh feed just ahead of the
feed nozzles from the Metal Passivator Injection Package X-1509
acts to inhibit the undesirable effects of nickel on the catalyst in
the feed. It is required for Mixed Crude Feed case only.
Used in: RFCC Feed Section

Type: NALCO EC9192A or equivalent
Antimony content: 23%
Injection rate: ratio Sb/Ni in feed: 0.5
Normal consumption: 109 kg/day Mixed Case
0 kg/day Bach Ho Case
Maximum consumption: 15 kg/h
1.2.4.2.3. Corrosion inhibitor

Used in: Fractionator overhead
Type: CHIMEC 1430
Normal consumption: 60 kg/day
Maximum consumption: 120 kg/day
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1.2.4.2.4. Amine antifoaming agent

Antifoaming agent is injected batch wise in either the fuel gas
absorber T-1551 or the LPG amine absorber T-1556 of when
foaming is experienced.
Once foaming is settled, stop injection to avoid over-dosing of
chemical. It should be noted that injection of antifoaming agent is
the last resolution.
Used in: Gas recovery Section in LPG / Fuel

gas amine absorber
Type: CHIMEC 8045
Normal consumption: 10 kg/day:
Maximum consumption: 20 kg/day
1.2.4.2.5. Amine (outside battery limit)

Lean amine if supplied from the ARU (unit 19) to absorb H2S
contained in both the fuel gas and the LPG recovered in the Gas
Recovery Section of the RFCC. Lean amine if fed to the Fuel Gas
Absorber T-1555 and the LPG Amine Absorber T-1556. The rich
amine leaving these 2 towers is then returned to the ARU for
regeneration.
Type DEA: 20% wt di-ethanolamine

H2S content: 0.022 mole/mole DEA
Lean Amine Flowrate: Bach Ho: 50382 kg/hr
Mixed Crude: 77623 kg/hr
Rich Amine Flowrate: Bach Ho: 50926 kg/hr
Mixed Crude: 78145 kg/hr
During amine absorber operation, lean amine temperature should

be always 15°C higher than feed gas to avoid condensation of
hydrocarbon inside of the fuel gas absorber.
1.2.4.2.6. Phosphate for Steam Generation

Phosphate is injected to buffer the water in order to minimize pH
fluctuation. It also precipitates calcium or magnesium into a soft
deposit rather than a hard scale. Additionally, it helps to promote
the protective layer on steam generators metal surfaces.
The following phosphate quantities will be used for steam
generation:
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RFCC HPS and MPS Generation 7.0 kg/day

RFCC Waste Heat Boiler 24.0 kg/day
Total 31.0 kg/day
Phosphate injection rate depends on blow down flow rate and

phosphate level in the steam drum or generator.
The above rate is based on 1.0 % of blow down from the steam
generation system, and marinating 30 wt ppm of phosphate
concentration.
For LPS steam generation, it is not required to operate blow

down operation, and thus phosphate injection is also not
required.
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1.3. Glossary of terms and Acronyms
1.3.1. Acronyms
COMPANIES/ORGANISATIONS
DQR Dung Quat Refinery

Dung Quat Industrial Zone
DQIZMB Management Board
EVN Electricity Authority of Vietnam
FW Foster Wheeler Energy Limited
MOC Ministry of Construction
Ministry of Science, Technology
MOSTE and Environment
Ministry of Planning and
MPI Investment
SRV Socialist Republic of Vietnam
TPC Technip Consortium
OTHERS
ACE Application Control Environment MC Marshalling Cabinet

Analyser Data Acquisition
ADAS MCB Main Control Building
System
ADP Alarm Display Panel MCC Motor Control Center
AER Application Engineers Room MCR Main Control Room
MCS
MOV
AI Analyser Indicator MOV Control System
Control
System
AIT Auto Ignition Temperature MDF Main Distribution Frame
Management Information
AMS Asset Management System MIS
System
American National Standards
ANSI MMS Machine Monitoring System
institute
Minimum Maintained
APC Advanced Process Control MMT
Temperature
API American Petroleum Institute MOC Madrid Operating Center
ARU Amine Regeneration Unit MOM Minutes of Meeting
ASC Analyser Speciality Contractor MOV Motor Operated Valve
American Society of
ASME MP Medium Pressure
Mechanical Engineers
Minimum Pressurization
ASP Analyser Systems Package MPT
Temperature
American Society of Testing
ASTM MR Material Requisition
and Materials
ATM Asynchronous Transfer Mode MRR Marshalling Rack Room
BCS Blending Control System MSD Material Selection Diagram
BEDD Basic Engineering Design Data MSDS Material Safety Data Sheet
BFD Block Flow Diagram MTBF Mean Time Between Failures
BFW Boiler Feed Water MTTR Mean Time To Repair
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BL Battery Unit MTO Material Take-Off

BOM Bill of Materials MTPA Metric Tonnes per Annum
Multi Vendor Interface
BPC Blending Properties Control MVIP
Program (Honeywell)
National Association of
BPCD Barrels per Calendar Day NACE
Corrosion Engineers
BPSD Barrels per Stream Day NCR Non Conformance Report
BRC Blending Ratio Control NDE Non Destructive Examination
National Fire Protection
CAD Computer Aid Design NFPA
Association
CALM Catenary Anchor Leg Mooring NHT Naphtha Hydrotreater (Unit)
CBT Commercial Bid Tabulation NIR Near Infrared Spectroscopy
Control Complex Auxiliary
CCAR NPSH Net Positive Suction Head
Room
CCC Central Control Complex NPV Net Present Value
CCR Continuous Catalytic Reformer NTU Naphtha Treater Unit
CCTV Closed Circuit Television OAS Oil Accounting System
CD Chart Datum OJT On Job Training
Oil Movement and Storage
CDU Crude Distillation Unit OM&S
Control System
European Committee for Oil Movement and Storage
CENELEC OMSA
Electrotechnical Standardization automation
CFC Chlorofluorocarbons OOS Operation Override Switch
Cooperative Fuel Research Operations Planning and
CFR OPSS
(Engine) Scheduling System
C&I Control and Instrumentation OSBL Outside Battery Limit
Computerized Maintenance
CMMS OTS Operator Training Simulator
Management System
(Spent) Caustic Neutralization Private Automatic Branch
CNU PABX
Unit Exchange
Public Address / General
CPI Corrugated Plate Interceptor PAGA
Alarm
CSI Control Systems Integrator PCB Printed Circuit Board
DAF Dissolved Air Flotation PFD Process Flow Diagram
DAU Data Acquisition Unit PFM Path Find Module
DCS Distributed Control System PDB Project Documents Base
Process Gas Chromatograph
DEA Diethanolamine PGC
(Analysers)
Detailed Environmental Impact
DEIA PHD Plant History Database
Assessment
DMDS Dimethyldisulfide PI Plant Air
DMS Document Management System PIB Process Interface Building
Piping and Instrument
DNV Det Nork Veritas PID
Diagram
Design, Pressure, Temperature Project Implementation
DPTD PIM
Diagram Manual
Dung Quat Management Process Knowledge System
DQMIS PKS
Information System (Honeywell DCS)
DQRP Dung Quat Refinery Project PLEM Pipeline End Manifold
DVM Digital Video Manager PLG Planning
DWT Dead Weight Tonnes PMC Project Management
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Consultant
EL Equipment List PMI Positive Material Identification
EOR End of Run PMT Project Management Team
Electronic Document
EDMS PO Purchase Order
Management System
EMC Electromagnetic Compatibility POC Paris Operating Center
Engineering Procurement,
EPC Construction and PP Project Procedure
Commissioning
ERP Enterprise Resource Planning PPB Parts per Billion
ES Ethernet Switch PPM Parts per Million
ESD Emergency Shut Down PRU Propylene Recovery Unit
ETP Effluent Treatment Plant PWHT Post Weld Heat Treatment
ETS Effluent Treatment System QA Quality Assurance
EWS Engineering Work Station QC Quality Control
FDC Feed Development Contract RA Risk Analysis
FAP Fire Alarm Panel R&D Research and Development
Real Time Database
FAT Factory Acceptance Test RDBMS
Management System
Residue Fluid Catalytic
FEL Front End Loading RFCC
Cracking
F&G Fire and Gas System RFSU Ready for Start-Up
FIU Field Interface Unit RLU Remote Line Unit
FIC Flow Indicating Controller ROW Right of Way
Refinery Performance
FM Factory Mutual (Approval body) RPMS
Management System
Resistance Temperature
FOTC Fibre Optic Termination Cabinet RTD
Detector
Fail Safe Controller (Honeywell Real Time Data Base
FSC RTDB
ESD) (System)
FTE Fault Tolerant Ethernet RTU Remote Terminal Unit
GC Gas Chromatograph SAT Site Acceptance Test
GFT Ground Fault SBT Segregated Ballast Tanks
Software Bypass Management
HAZAN Hazard Analysis Study SBMS
System
Supervisory Control and Data
HAZOP Hazard and Operability Study SCADA
Acquisition
HDT Hydrotreater SCC Satellite Control Complex
Simulation Control
HEI Heat Exchange Institution SCE
Environment
HHP High High Pressure (Steam) SCR Satellite Control Room
HGO Heavy Gas Oil SDH Synchronous Digital Hierarchy
HIC Hydrogen Induced Cracking SE Safety Earth
HP High Pressure S&E Safety & Environmental
HSE Health, Safety and Environment SGS Safeguarding System
Heating Ventilation Air
HVAC SOE Sequence of Events
Conditioning
IA Instrument Air SOR Start of Run
International Civil Aviation
ICAO SOW Scope of Work
Organisation
ICE Instrument Clean Earth SP Specification
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Spare Parts and

ICS Integrated Control System SPIR
interchangeability Record
IIP Initial Interface Plan SPM Single Point Mooring
I/O Input/Output SR Scope of Supply
IP Institute of Petroleum SRU Sulphur Recovery Unit
Instrumented Protective
IPS STC Construction Standard
System
IRP Interposing Relay Panel STD Design Standard
IRR Internal Rate of Return STEL Short Term Exposure Limit
Shelter Ventilation and Air
IS Intrinsically Safe SVAC
Conditioning
ISA Instrument Society of America System (Analyser houses)
ISE Intrinsically Safe Earth SWS Sour Water Stripping (Unit)
ISBL Inside Battery Limit TAS Terminal Automation System
ISOM Isomerisation Unit TBT Technical Bid Tabulation
Temporary Construction
ITB Invitation to Bid TCF
Facilities
ITP Inspection and Test Plan TCM Task Control Module
Tubular Exchanger
JB Junction Box TEMA
Manufacturers' Association
Temperature Gauge Indication
JCC Jetty Control Complex TGIF
Facilities (Tankage)
JCR Jetty Control Room TLCR Truck Loading Control Room
JSD Job Specification for Design TLCS Truck Loading Control System
JSS Job Specification for Supply TN Transmittal Note
Total Plant Solution
JVD Joint Venture Directorate TPS
(Honeywell)
KLOC Kuala Lumpur Operating Center TQM Total Quality Management
KTU Kerosene Treatment Unit TS Terminal Server
LAN Local Area Network TWA Time Weighted Average
LCO Light Cycle Oil UFD Utility Flow diagram
LCOHDT LCO Hydrotreater U/G Underground
Underwriter Laboratories
LDE Lead Discipline Engineer UL
(Approval body)
Lower Exposition Limit (F&G,
LEL UPS Uninterruptible Power Supply
Analysers)
LGO Light Gas Oil VDU Visual Display Unit
Laboratory Information
LIMS VPU Vendor Package Unit
Management System
Weight Average Bed
LIS Laboratory Information System WABT
Temperature
LLU Local Line Unit WBS Wash Breakdown Structure
LP Low Pressure WHB Waste Heat Boiler
LPG Liquefied Petroleum Gas YOC Yokohama Operating Center
LTU LPG Treater Unit
1.3.2. Glossary
Refer to separate glossary.
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TRAINING MODULE
UNIT: 15
Course Content:

X
Section 9 - HSE
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SECTION 2 : PROCESS FLOW DESCRIPTION
Drawing to be inserted here

Figure 5: RFCC Block Flow Diagram
Figure 6: RFCC Process Flow Scheme
2.1. Feed Section

Figure 7: RFCC Feed Section
Long residue is normally fed directly to the unit from the Crude Unit (CDU) at 115°C.
Alternatively part, or all, of the feed can be fed from storage at 70°C. Indeed, the preheat
system of the feed is also designed to process 100% cold feed.
Hot feed straight from the CDU and cold feed from storage enters the battery limits and
flows to the Feed Surge Drum D-1513 on level control by LIC-042 with a split range level
control signal to the controller inside the CDU or to the flow controller on the cold feed
from storage. The pressure in the Feed Surge Drum is maintained at 1 kg/cm2g by either
admitting Fuel Gas or venting excess off gas to the Flare header. In D-1513, water
contained in the feed is separated and sent to the OWS.
The feed is then pumped from the feed Surge Drum by the Feed Pumps P-1501 A/B to
the feed preheat train, in which the way feed is preheated depends on the type of crude
used:
• Bach Ho Case:
Feed is 1st pumped to the LCO Pumparound Feed Preheat Exchangers E-1512 A-
D, in which the feed is preheated against LCO pumparound pumped by the LCO
Pumparound Pumps P-1510 A/B from the tray #25 of the main fractionator T-
1501.
Then the feed is further heated against MP steam first in the MP Steam Feed
Heater E-1522 and secondly against HP steam in the HP steam Feed Heater E-
1524.
The Residue Feed is finally heated against Slurry in the 1st Feed Preheat Slurry
Exchangers E-1502 A/B/C and the 2nd Feed Preheat Slurry Exchangers E-1501
A/B, from where feed exits at the temperature of 290°C. Slurry is feed to the tube
sides of the 1st and 2nd feed preheat slurry exchangers by means of the Slurry
Pumparound Pumps P-1519 A/B/C from the bottom of the Main Fractionator T-
1501.
• Mixed Crude Case

In the case of Mixed Crude feed, the feed is pumped by the Feed Pumps P-1501
A/B to E-1512 A/B/C/D where it is preheated to the required temperature of 170°C
by the LCO pumparound when 100% of the feed to the surge drum is hot.
Additionally, the feed is heated against MP steam downstream of the LCO
Pumparound Preheat Exchangers only when the feed is all or partly cold. This is
required to obtain the required temperature of 170°C.
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Downstream of the preheat train, preheat feed is mixed with HCO recycle from above the
Bed #4 of the main fractionator. Before being mixed with the feed, HCO recycle is cooled
against Boiler Feed Water in the HCO Recycle MP steam Generator E-1508.
Depending upon the operating case, a different quality of recycle to feed is used.
In Mixed Crude Max Gasoline (MG) operation, a heavy naphtha recycle is used in order
to adjust the feed viscosity and further improve the feed atomization. An additional effect
is to decrease the heavy oil partial pressure leading to a better vaporization. In MD
operation, a HCO recycle is used in order to improve the bottom (HCO and heavier)
conversion.
The combined feed is then sent to the reaction section via the Feed Line Static Mixer M-
1501.
The LCO pumparound used in E-1512 A/B/C/D is then returned to the main fractionator
above the Bed #2.
The Slurry used in the 2nd Feed Preheat Slurry Exchangers is returned to the main
fractionator above the Bed #5 and so is part of the slurry used in the 1st Feed Preheat
Slurry Exchangers. The remaining part of the Slurry used in E-1501 A/B is sent back to
the quench zone of T-1501.
NOTE:
When processing mixed crude feed, the slurry preheat exchangers are not required.
These exchangers should have the slurry flushed out of them to avoid settling of catalyst
fines and because of the high viscosity and high pour point of the slurry.
2.2. Reaction Section

Figure 8: RFCC Reaction Section
2.2.1. Feed Injection Zone

The specially designed feed injection system insures the reaction is carried out
efficiently to minimize the production of coke, gas and slurry oil.
Oil feed to the riser is preheated before entering the reaction system. Preheat
temperature along with regenerated catalyst temperature is controlled to result in
an optimum catalyst to oil ratio.
The preheated feed mixture is sent to the base of the riser D-1501 and divided into
equal flows by the flow controllers FIC-003 A-F to each of the six feed nozzles I-
1501 A-F.
Metal Passivator is injected into the fresh feed just ahead of the feed nozzles from
the Metal Passivator Injection Package X-1509 by means of the Metal Passivation
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Pumps P-1502 A/B and acts to inhibit the undesirable effects of nickel on the
catalyst in the feed. It is required for Mixed Crude Feed case only.
Shutdown valves will stop the flow of feed to the riser and divert it back to the feed
surge drum D-1513 in case of certain emergencies.
Dispersion steam is supplied to each of the six feed nozzles to promote
atomization and vaporization of the feed. The flow of MP steam to each of the feed
nozzles is adjusted by flow controllers FIC-005 A-F.
Heavy FCC naphta is injected to the riser above the feed injection zone through
the MTC (Mix Temperature Control) injectors I-1502 A-D, where it is mixed with
medium pressure dispersion steam.
MTC plays an important role in the heat balance control and heavy feed
vaporization. The key is to achieve a higher temperature in the fresh feed mixing
zone. The MTC is designed to face the two main challenges encountered when
processing very heavy, highly contaminated feeds:
• Achieve a satisfactory vaporization of the feed so as to eliminate the
unnecessary coke production resulting from an incomplete vaporization
• To keep the desired heat balance while maintaining the conversion at the
optimum level
MTC flow and dispersion steam flow to each of the four injectors are adjusted by
flow controllers FIC-010 A-D and FIC-011 A-D respectively.
Upstream the feed injection, stabilization steam is injected in the riser, through the
four stabilization steam injectors I-1503 A-D, in order to promote a smooth and
homogeneous catalyst flow at the feed injection point. The flow to each of the
injectors is adjusted by flow controllers FIC-007 A-D.
Upon emergency shutdown the steam flow control valves on all injectors
automatically open to clear the riser of oil and catalyst with steam.
Finally Backflush oil is pumped by the backflush oil recycle pumps P-1506 A/B
from the backflush oil receiver in the fractionation a section to the riser,
downstream of the MTC injectors.
Backflush oil is injected into the riser and mixed with MP dispersion steam via the
backflush oil injector I-1504. The flow of backflush oil and dispersion steam to the
injector is controlled by FIC-012 and FIC-013 respectively.
2.2.2. Riser/Reactor
The sensible heat, heat of vaporization and heat of reaction required by the feed is
supplied by the hot regenerated catalyst. From the withdrawal well, hot
regenerated catalyst flows to the riser wye, to be mixed with the feed, via the
regenerated catalyst slide valve SV-1501. The riser outlet temperature is
controlled by the amount of regenerated catalyst admitted to the riser through SV-
1501.
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In the wye section at the base of the riser, steam is injected via a steam ring to
keep the regenerated catalyst in a fluid state at all times.
The small droplets of feed contact hot regenerated catalyst in a counter current
way and vaporize immediately. The vaporized oil intimately mixes with the catalyst
particles and cracks into lighter, more valuable products along with slurry oil, coke
and gas.
The cracking reactions take place during the 2 seconds residence time in the riser
as the reaction mixture (composed of the products and the catalyst) accelerates
toward the Riser Outlet Separator System (ROSS) at the top of the riser.
To prevent the continuation of reactions which produce gas at the expense of
gasoline the catalyst is quickly separated from the hydrocarbon/steam vapors in
the ROSS separator located at the end of the riser. This system drastically
reduces the post riser catalyst/vapors contact time.
After exiting the ROSS separator, the vapors pass through high efficiency single
stage Disengager Cyclones CY-1501 A/B/C/D/E/F to complete the separation of
catalyst from vapors, thus minimizing the amount of catalyst lost into the product.
The ROSS separator and disengager cyclones CY-1501A-F separate the product
vapors from spent catalyst and return the catalyst to the stripper bed.
The reactor product vapors, containing a small amount of inerts, catalyst and
steam, flow to the quench zone of the main fractionator T-1501. The small amount
of catalyst contained in the product vapors is carried away from the fractionator in
the bottom slurry product.
The reactor pressure "floats on" the main fractionator pressure and as such is not
directly controlled at the reaction section: A pressure control at the main
fractionator reflux drum D-1514 allows achieving a steady operating pressure in
the reaction system.
2.2.3. Stripper
Catalyst exiting the ROSS separator is pre-stripped with MP steam from a steam
ring located immediately at the exit of the separator diplegs. This is an important
feature for reducing coke yield.
The catalyst is further stripped by steam from the main steam ring as the catalyst
flows down the Disengager/stripper D-1501. 2 additional rings are also provided in
addition to the main ring:
• The upper ring, above the main ring, achieves a second stage of pre-
stripping of the catalyst before it enters the stripper.
• The lower ring is located in the bottom head of the stripper to achieve a
stable fluidization at the inlet of the spent catalyst standpipe.
The steam rate for this ring is part of the total steam required for good
stripping but its prime function is to aerate the catalyst entering the spent
catalyst standpipe. This is important for adequate head build-up to maintain
an adequate slide valve differential pressure for controlling the stripper
level.
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The total steam flow is designed to provide about 6 kg of steam per ton of catalyst
circulated.
The contact between catalyst and steam is enhanced by the presence of fluidized
bed packing permitting cross and counter current flow of steam and catalyst. The
fluidized bed packing is located between the main ring and the lower ring.
It allows efficient contact between the catalyst and steam to displace the volatile
hydrocarbons contained on and in the catalyst particles before they enter the 1st
stage regenerator D-1502, where coke will be burnt off.
2.2.4. Spent Catalyst Transfer

Downstream of the main ring, stripped catalyst flows down the spent catalyst
standpipe where the spent catalyst is aerated by means of fuel gas from the fuel
gas header (or Nitrogen) to maintain proper density and fluid characteristics of the
spent catalyst. Aeration gas injectors are distributed al along the spent catalyst
stand pipe.
While aerated, the catalyst flows down through the spent catalyst line expansion
joint EX-1501 and then the spent catalyst slide valve SV-1502, which regulates the
level of the stripper by regulating the flow of catalyst leaving it.
Then the spent catalyst flows into the 1st stage regenerator D-1502 through a
distributor which ensures that the entering coke-laden catalyst is spread across
the regenerator bed.
2.3. Catalyst Regeneration Section

The first stage regenerator D-1502 burns 50 to 80% of the coke and the remainder is
burned in the second stage regenerator D-1503. This two stage approach to regeneration
adds considerable flexibility to the process as potential heat is rejected in the first stage
regenerator in the form of CO. When running heavy feeds, the need for heat rejection is
higher; the amount of coke burned in the first stage regenerator is increased, thereby
lowering the final temperature of the regenerated catalyst. When running lighter feeds the
amount of coke burned in the first stage regenerator D-1502 is reduced, thus increasing
the regenerated catalyst temperature. The amount of coke burned in the first stage can
be varied by adjusting the air flowrate in order to achieve operating flexibility on the unit
for different feedstocks.
The heat of combustion released by the combustion of coke is transferred to the catalyst
which will later supply the heat required to the reactor D-1501. The heat balance of the
unit is much more flexible than in single stage regeneration systems because potential
energy in the form of carbon monoxide from the first stage regenerator D-1502 can be
adjusted while complete regeneration of the catalyst is accomplished in the second
stage.
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2.3.1. Air blower and air heaters

The combustion air required for the combustion reactions in the 1st and 2nd
catalyst regenerators D-1502 and D-1503 is supplied by the steam turbine driven
air blower C-1501.
Atmospheric air is introduced to the air blower C-1501 through an intake filter and
silencer F-1501. At C-1501 discharge, the blower air is distributed to a header
system providing combustion air to the downstream equipment as follow:
• Combustion air is supplied to the inner air rings and outer air rings at the
bottom of the 1st Catalyst Regenerator D-1502 via the 1st regenerator air
heater H-1501 which heats the blower to the required temperature. The
outer air ring and inner air ring are designed to handle about 70% and 30%
of the combustion air to the first stage regenerator D-1502 respectively.
• Combustion air is supplied on flow control to the unique air ring located at
the bottom of the 2nd regenerator D-1503 via the 2nd regenerator air heater
H-1502, which also heats the blower to the required temperature for coke
burning in D-1503.
• Blower air is also used as lift air and is supplied on flow control to the
bottom of the lift line of the 1st regenerator in order to transfer partly
regenerated catalyst from D-1502 to D-1503. Air is injected through the
hollow stem of the plug valve PV-1501 which regulates the amount of
catalyst transferred to the 2nd stage regenerator.
• Blower air is also injected in the catalyst loading line at the bottom of each
regenerator as fluidizing medium.
• Finally blower air is supplied in the withdrawal ring of the withdrawal well
downstream of the point where the hot regenerated catalyst is discharged
to the well, also as fluidizing medium.
C-1501 surging is prevented by venting air using a sophisticated anti-surge

controller. Also, power assisted check valves at the blower discharge prevent
back-flow of catalyst in the event of blower shutdown.
The air heaters are working on propane and are used during start-up to heat-up
the equipment including dry out of refractory.
Instrumentation is provided to prevent overheating the equipment during air heater
operation and a flame safety package is included to prevent unsafe conditions
during burner operation.
2.3.2. First stage regenerator

Spent catalyst containing roughly 1 to 1.5 wt % coke flows from the spent catalyst
distributor and is spread across the bed in the first stage regenerator D-1502. Part
of the coke is burned by combustion air supplied from the outer and inner air rings.
This regenerator operates in a counter current (air inlet at bottom and spent
catalyst inlet at top) to prevent catalyst overheating.
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In order to limit hydrothermal deactivation of the catalyst, the regeneration

conditions are mild: 1st stage regenerator total combustion air is controlled to limit
the temperature in this 1st stage to maximum 730°C.
The partially regenerated catalyst flows down through the first stage regenerator
bed to the entrance of the air lift. Aeration by a fluffing ring is supplied in the
vicinity of the air lift to ensure smooth flow of catalyst to the lift. A hollow stem plug
valve PV-1501 regulates the flow of catalyst to the lift line and is controlled by the
level in the first stage regenerator D-1502 via LIC-004. Blower air injected through
the hollow stem of the plug valve into the air lift is flow controlled at a rate
sufficient to lift the catalyst in a dilute phase up to the second stage regenerator D-
1503. Emergency air is provided through blast connections to clear the lift in the
event of plugging.
2 stage cyclones (CY-1502A-F / CY-1503A-F) separate entrained catalyst from
the flue gas exiting the 1st stage regenerator D-1502 towards the CO Incinerator
H-1503 where the incineration of the CO in the flue gas is then accomplished.
At the exit of the regenerator, the flue gas pressure is reduced through a double
disc flue gas slide valve SV-1503 controlling the regenerator pressure.
During the start-up, torch oil is used to heat the regeneration process to its
operating temperature. Oil and steam on flow control (FIC-069/077A-C) are
directed to three nozzles SPR-1501A-C which spray into the bed of air preheated
catalyst.
A continuous catalyst withdrawal is necessary to maintain the unit catalyst

inventory in the normal operating region. Equilibrium catalyst is continuously
withdrawn from D-1502 through the Catalyst Draw-Off System X-1501 and is sent
either to the spent catalyst hopper D-1506 or the Auxiliary Catalyst Hopper D-
1507.
2.3.3. Second stage regenerator

The partially regenerated catalyst flows up the lift line through the expansion joints
between the regenerators EX-1502 and enters the 2nd stage regenerator D-1503
below the air ring. A distributor at the end of the lift provides for efficient
distribution of catalyst and air from the lift.
Catalyst is then completely regenerated to less than about 0.05% carbon through
combustion at more severe conditions than in the first stage regenerator D-1502.
Very little carbon monoxide is produced in the 2nd stage and excess oxygen is
regulated by flow control of the combustion air from C-1501 (FIC-164) for efficient
and complete combustion.
Because most of the hydrogen in coke was removed in the 1st stage, very little
water vapor is produced in the second stage. This limits hydrothermal deactivation
of the catalyst as higher regeneration temperatures are experienced.
External refractory lined cyclones CY-1504A-D are used on the 2nd stage flue gas
outlet to remove entrained catalyst. The cyclone dip legs are external to the
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regenerator. Catalyst recovered in the cyclones is returned to the regenerator bed

below the normal operating level by way of the diplegs.
Aeration is supplied to the diplegs to maintain a smooth fluidized catalyst flow and
the diplegs outlets are equipped with flapper (trickle) valves to prevent catalyst
and gas backflow into the cyclones.
Flue gas from the 2nd stage regenerator then flows to the Waste Heat Boiler H-
1503 through the 2nd Regenerator Flue gas Slide Valve SV-1504 and the 2nd
Regenerator Flue gas Block Valve BV-1502 A.
The second stage regenerator pressure is controlled by the flue gas double disc
slide valve SV-1504, through differential pressure between the first and second
stage regenerators PDIC-172.
2.3.4. Combustion Air Rings

The combustion air rings distribute the combustion air evenly across the bed in the
regenerators. A well distributed source of combustion air is essential for good,
evenly distributed catalyst regeneration without after burn. The rings are designed
to operate satisfactorily at the minimum turndown design for the unit.
The pressure drop across the ring is kept above 0.07 bar at turndown to maintain
adequate distribution and prevent intrusion of catalyst into the ring and avoid
associated erosion.
2.3.5. Regenerated catalyst transfer

The hot regenerated catalyst flows from the 2nd stage regenerator D-1503 through
a lateral into the withdrawal well. In the withdrawal well a stable bed is established
at proper standpipe density by introduction of a controlled amount of fluidizing air
from the withdrawal well ring.
A smooth stable flow of catalyst down the standpipe is provided by injection of
aeration Plant Air at several elevations on the regenerated catalyst standpipe. As
the head pressure increases down the standpipe and the fluidized catalyst is
compressed, these aeration points are used to replace the lost volume to ensure a
continuity of fluid catalyst flow properties.
At the bottom of the regenerated catalyst standpipe the regenerated catalyst slide
valve SV-1501 controls the flow of hot catalyst. The Riser Outlet Temperature sets
the position of the slide valve which regulates the flow of hot regenerated catalyst.
The regenerated catalyst passes to the wye section at the base of the riser D-
1501 where a steam ring fluidizes the catalyst. The wye steam and fluidization
points in the wye section ensure that the catalyst flow to the feed injection point is
stable and smooth in order for the feed injection system to perform at its optimum.
2.3.6. Catalyst handling

The catalyst handling system includes hoppers for storage of fresh catalyst and
spent catalyst, loading devices for catalyst addition and a draw-off device for
continuous equilibrium catalyst withdrawal.
Three hoppers are installed:
• The fresh catalyst hopper D-1505,
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• The spent catalyst hopper D-1506

• The auxiliary catalyst hopper D-1507, which provides flexibility in the
operation for different options:
o Storage of imported equilibrium catalyst reused as part of the make-
up catalyst,
o Storage of excess spent catalyst,
o Storage of a 2nd grade of fresh catalyst for make-up.
The spent and fresh catalyst hoppers are sized to contain the entire unit inventory.
Each hopper is provided with one cyclone and with aerations in the bottom cone to
assist the catalyst circulation to the transfer lines.
Hoppers loading and unloading

Fresh catalyst or equilibrium catalyst, delivered in trucks, are loaded into the fresh
catalyst hopper D-1505 for fresh catalyst, and spent catalyst hopper for equilibrium
catalyst, using either the truck compressor or the steam ejector EJ-1501 supplied
for reducing the hopper pressure.
Spent catalyst is unloaded from the spent catalyst hopper D-1506 to the flexible
bag by hopper pressurizing with plant air.
Unit loading and unloading

Before start-up, equilibrium catalyst is loaded into the spent catalyst hopper D-
1506 as described above.
When the unit warm-up is completed, the catalyst is loaded into the unit through
the first regenerator D-1502. The hopper is pressurized with plant air. Air from the
blower C-1501 is injected into the catalyst addition line to D-1502 to act as motive
fluid to transport the catalyst.
After shutdown, the spent catalyst is unloaded from the unit into the spent catalyst
hopper by reducing the pressure in the hopper using the steam ejector EJ-1501.
Catalyst addition and withdrawal

To maintain the catalyst inventory during normal operation, fresh catalyst is
automatically added (batchwise) at the desired rate into the unit through the 1st
regenerator D-1502 by means of either of the batch catalyst feeders: X-1502 for
the fresh catalyst hopper D-1505 or X-1503 for the auxiliary Catalyst Hopper D-
1507. Each batch catalyst feeder can be adjusted for batch size and frequency of
additions.
As most of the time, catalyst addition is higher than the catalyst losses from the
unit, catalyst must be withdrawn to keep the unit inventory constant. This
operation is achieved by a catalyst draw-off system X-1501 provided on the first
regenerator D-1502: Hot catalyst is withdrawn, cooled down through a finned tube
and sent to the spent catalyst hopper D-1506 at a temperature below 400°C.
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2.4. Flue gas treatment

Figure 9a: Flue Gas Treatment Section
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Figure 9b: COB/WHB Package Flow Scheme
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The flue gas coming from the first regenerator contains CO and some unburned
products. It is sent to the CO incinerator H-1503, via flue gas slide valve SV-1503
for combustion completion.
The incinerator burner is supplied with combustion air via the duty motor driven
forced draft air fans C-1502 A/B. The CO Boiler is provided with burners for fuel
gas and also fuel oil in order to obtain a complete combustion of CO into CO2.
The flue gas from the CO Boiler is routed to the Waste Heat Boiler H-1503 for HP
steam regeneration.
The flue gas coming from the second regenerator D-1503 is sent straight to the
waste heat boiler H-1503 via the second regenerator flue gas slide valve and SV-
1504 and the COB/WHB 2nd regenerator flue gas block valve BV-1502 A.
The flue gas exiting the waste heat boiler H-1503 is sent to an electrostatic
precipitator X-1507 before flowing through the economizer E-1525 section of the
CON/WHB package, and DeSOx unit (X-1508, for future), and then to a stack SK-
1501.
Heat released in WHB H-1503 is used for HP steam generation:

HP boiler feed water is fed from the battery limits to the heavy naphta boiler feed
water heater E-1516 where HP BFW is heated in the tube side against heavy
naphta product (in the shell side) pumped by the heavy naphta product pumps P-
1515 A/B.
The heated BFW is then sent to the LCO Pumparound BFW heater E-1511 where
the BFW (tube side) is heated against LCO pumparound (shell side) drawn off
from the main fractionator and pumped by the LCO Pumparound Pumps P-1510
A/B.
The preheated HP BFW leaving E-1511 is then split into 2 streams:
• Part of the preheated BFW is fed to:
o The Slurry HP Steam Generators E-1503 A/B/C in which preheated
HP steam is generated against slurry pumparound pumped by P-
1519 A/B/C from the bottom of the main fractionator.
o The slurry HP Steam Generators E-1504 A/B in which HP steam is
generated against slurry pumparound pumped by P-1519 A/B/C from
the bottom of the main fractionator
The HP Steam leaving E-1503 A/B/C and E-1504 A/B is then recombined
before being fed to the HP steam superheater of the waste heat boiler.
• The other part of the preheated BFW is sent to the economiser section of
the COB/WHB Package H-1503. Preheated HP BFW is then heated (tube
side) against MP steam (Shell side) in the BFW Preheater E-1534. before
being fed to the economizer E-1525. In the economizer, the flue gas
coming from the electrostatic precipitator X-1507 is used as heating
medium. The steam leaving the economizer is then fed to the Steam Drum
D-1512
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Phosphate is also injected into the Steam Drum D-1512 by means of either of the
Phosphate injection Pumps A-1502-P-01-A/B from the Phosphate Tank A-1502-
TK-01.
Phosphate is injected to buffer the water in order to minimize pH fluctuation. It also
precipitates calcium or magnesium into a soft deposit rather than a hard scale.
Additionally, it helps to promote the protective layer on boiler metal surfaces.
However, phosphate forms sludge as it reacts with hardness; So blowdown or
other procedures need be established to remove the sludge during a routine boiler
shutdown.
Boiler water then exits the bottom of the steam drum via 3 lines, the inlet of each
being equipped with a vortex breaker, and flows to the 4 Evaporator Coil Banks of
the WHB H-1503. In each of the Evaporator Coil Banks, steam is generated (tube
side) by means of the flue gas exiting the HP superheater of the WHB H-1503.
The mixture of steam and boiler water at the outlet of each evaporator coil bank is
then routed back to the steam drum via 4 dedicated lines.
Boiler water from the steam drum is also fed to the Screen Steam Generator
upstream the HP steam Superheater in the Waste Heat Boiler. The steam/boiler
water stream generated by the flue gas exiting the CO Combustion exits the
Screen Steam Generator and is routed back to the Steam Drum D-1512.
Saturated steam from D-1512 is sent to the HP Steam Superheater after being
mixed with HP steam from the E-1503 A/B/C and E-1504 A/B. In the Superheater,
flue gas exiting the Screen Steam Generator generates Superheated HP steam
(tube side). The superheated HP steam generated is then de-superheated by
means of HP BFW prior to being sent to the Superheated HP steam header. Part
this HP steam is also sent to the turbine of the standby forced draft fan C-1502 B.
A continuous blowdown from the steam drum is sent to the continous blowdown
drum D-1531. The LP steam recovered in D-1531 is sent to the LP steam header
while the water collected is sent to the intermittent blowdown drum D-1532. The
water in D-1532 is cooled down against cooling water in the Blowdown Cooler E-
1533 before being sent to the oily water sewer.
Superheated MP steam is also generated in the WHB:

LP Boiler Feed Water is fed to the following MP steam generators in parallel:
• HCO recycle MP steam generator E-1508 where LP BFW is heated (shell
side against HCO recycle drawn-off from the main fractionator and pumped
by the HCO recycle pumps P-1507 A/B.
• HCO Pumparound MP steam generator E-1523 where LP BFW is heated
(shell side) against HCO pumparound drawn off from the main fractionator
and pumped by the HCO Pumparound pumps P-1508 A/B.
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• Slurry MP steam generators E-1505 A/B where LP Boiler Feed Water is

heated (shell side) against slurry from the HP steam generators E-1504 A/B
The MP steam streams leaving in the above exchangers are then recombined and
the MP steam stream is fed to the MP steam superheater downstream of the 4th
Evaporator Coil Bank. There, the MP steam is superheated against the flue gas
leaving the evaporator. Superheated MP steam is then de-superheated against LP
BFW prior to being discharged to the MP steam header.
The flue gas leaving the WHB H-1503 is then routed to the Electrostatic
Precipitator X-1507 where the content of catalyst dust contained in the flue gas
leaving the COB/WHB package is decreased to meet the environmental
specification. The dust fine content at precipitator outlet shall not exceed 50
mg/Nm3 dry basis.
The principle of operation is to provide high voltage electric for collection of dust
by corona effect. (Refer to the section 4 of the present document for more
information on X-1507 package.)
In case of trip of the COB/WHB package, the flue gas from the 1st and 2nd
regenerators is sent directly to the electrostatic precipitator package X-1507
through the bypass valves BV-1501B (1st regenerator flue gas) and BV-1502B (2nd
regenerator flue gas). In such an event, H-1503 is isolated by closure of the
associated block valves BV-1501A (1st regenerator flue gas) and BV-1502A (2nd
regenerator flue gas).
The flue gas leaving the electrostatic precipitator is then fed to the Economizer E-
1525 before being finally sent to the stack. In the future, the flue gas leaving the
Economizer will undergo another stage of processing with the DeSOx unit before
running to the stack.
2.4.1. Phosphate injection

For the same reasons than for the phosphate injection in the steam drum D-1512
(see previous paragraph), phosphate solution, from the tank TK-1510 in the
phosphate injection package X-1510, is injected to the BFW fed to the following
steam generators:
• Slurry HP steam generators E-1503 A/B/C by means of the metering
pumps P-1531A/B/C respectively;
• Slurry HP steam generators E-1504 A/B by means of the phosphate
injection pumps P-1531 D/E respectively;
• Slurry MP steam generators E-1505 A/B by means of the phosphate
injection pumps P-1532 A/B respectively;
• HCO LP steam generator E-1510, also from the discharge of the phosphate
injection pump P-1532B
• HCO pump pumparound MP steam generator E-1523, Slurry LP steam
generators E-1506 A/B and LCO product LP steam generator E-1513 by
means of the phosphate injection pump P-1532C
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• HCO recycle MP steam generator E-1508 by means of the phosphate

injection pump P-1532D
2.5. Fractionation Section

Figure 10: Fractionation Section
2.5.1. Fractionator bottom section

The reactor effluent from the disengager of the reaction section is sent to the
bottom of the main fractionator T-1501 below the Bed #5.
The bottom slurry pumparound is circulated by Slurry Pumparound Pumps P-
1519A/B/C to the downstream equipment depending on the operating case:
• In the case of Bach Ho feed, a large proportion of the bottom pumparound

duty is used to preheat the feed in the 1st & 2nd Feed Preheat Slurry
Exchangers E-1502 A/B/C and E-1501 A/B.
The remaining duty is used to generate HP steam in HP steam generators
E-1504 A/B and then MP steam in MP steam generators E-1505 A/B, prior
to being sent back to T-1501 in the Quench Zone on flow control reset by
the bottoms temperature controller (TIC-439) at the suction of the slurry
pumparound pumps P-1519 A/B/C. Part of the slurry from E-1505 A/B is
also sent back to T-1501 above the Bed #5 on flow control reset by the
temperature controller TIC-443 above Bed #4.
Meanwhile, the slurry used to preheat the feed in E-1502 A/B/C and part of
the slurry exiting E-1502 A/B/C are then sent back to T-1501 in the grid
section (Bed #5) after being mixed with the portion of Slurry Pumparound
bypassing all the exchangers and steam generators. The remaining part of
the slurry leaving E-1502A/B/C is sent to the Quench Zone of T-1501 on
flow control reset by the bottoms temperature controller (TIC-439) at the
suction of the slurry pumparound pumps P-1519 A/B/C. This quench is
used to maintain the bottoms temperature to around 349°C in order to
minimize coking
• For the Mixed Crude feed case, E-1501A/B and E-1502 A/B/C are not in
service. In this case the slurry pumped by P-1519 A/B/C is sent to the
Slurry HP steam generators E-1503 A/B/C, where HP steam is generated
shell side with BFW fed from E-1511.
The main part of this cooled slurry pumparound is returned to the grid
section (Bed #5) on flowrate control (FIC-425) reset by the temperature
controller TIC-443 below the HCO draw-off tray.
In the Grid Section of the Main Fractionator the reactor effluent is
desuperheated and the bottom slurry product is condensed.
Part of the cooled slurry is returned to the bottom of the column to quench
the bottoms temperature TIC-439 to around 340°C to minimize coking. The
remaining quench is taken from the discharge of the MP steam generator
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on flow control reset by the bottoms temperature controller as described for

the Bach Ho case.
• A constant total flowrate (controlled by FIC-426) to the grid is maintained by

by-passing hot slurry from the discharge of the slurry pumparound pumps.
The slurry product is taken from the discharge of the MP steam generators E-1505
A/B on flow control reset by T-1501 bottoms level controller (LIC-448) and flows to
slurry draw-off drum D-1515. The pressure in D-1515 is maintained constant by
either admitting fuel gas inside the vessel or venting excess off gas to the flare.
The slurry product is pumped by the Slurry Product Pumps P-1504 A/B and is
cooled in the Slurry LP Steam Generator E-1506 A/B, in which BFW is feed to
generated LP steam shell side. Downstream of E-1506 A/B, the cooled slurry
flows to the Slurry Separator X-1504 where catalyst fines are removed. The
clarified oil leaving the slurry separator is finally cooled in tempered water coolers
E-1507 A/B/C/D before going to storage on flow control reset by the level
controller of the slurry draw off drum D-1515.
The slurry separator X-1504 consists of 10 modules. These are automatically and
sequentially taken out of service for back-flushing while the others remain in
service. The modules are back-flushed by P-1505 A/B with Backflush Oil (HCO)
from the Backflush Oil Draw Off Drum D-1516.
The flush oil from the separator, containing a high concentration of catalyst fines,
goes to back-flush oil receiver D-1517 after being mixed with HCO. The pressure
in D-1517 is maintained constant by either admitting fuel gas inside the vessel or
venting excess off gas to the flare.
From D-1517, the back-flush oil is returned to the reactor riser at constant rate by
the Backflush oil recycle pumps P-1506 A/B.
2.5.2. HCO section

Heat is removed at high level in the HCO pumparound section. HCO flushing oil
and HCO recycle are also taken from this section.
HCO products and pumparound are taken from the draw off tray above the Bed #4
of the main fractionator T-1501.
HCO pumparound is circulated by the HCO Pumparounds Pumps P-1508 A/B to
the following equipment in parallel:
• The tube side of the Debutanizer Reboilers E-1560 A/B
• The shell side of the Heavy Naphtha Stripper Reboiler E-1509
• The tube side of MP Steam Generator E-1523
The cooled HCO leaving E-1560 A/B, E-1509 and E-1523 is then recombined
before being returned to the main fractionator above the Bed #3.
The total pumparound flow is maintained constant by controlling the flow of HCO
by-passing the above equipments with (FIC-419) at P-1508 A/B discharge. Heat
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removal in the pumparound circuit is controlled by the flow controller at the outlet
of E-1523 reset by the temperature controller TIC-446 on the recombined
pumparound return line to T-1501.
HCO for flushing oil is also taken from the draw off tray above the Bed #4 and is
then stripped in the HCO stripper T-1504 by LP steam on flow control. The stripper
vapour is returned to T-1501 above the pumparound return, Bed #3. The stripped
HCO is pumped from T-1504 bottom by the HCO products pumps P-1509 A/B to
the tube side of the LP Steam Generator E-1510 where it is used as heating
medium to generate LP Steam from BFW in the shell side. The cooling of the HCO
is controlled with TIC-474 on the HCO outlet by resetting the pressure controller of
the LP steam generated to adjust the quantity of LP steam leaving E-1510.
Part of the HCO goes to Backflush Oil Receiver D-1516 on flow control by FIC-469
reset by D-1516 level controller LIC-464. The pressure in D-1516 is maintained
constant by either admitting fuel gas inside the vessel or venting excess off gas to
the flare.
The remaining part goes to:
• The HCO flushing oil system for flushing of slurry pump seals and for
instrument flushing.
• The Backflush Oil Receiver D-1517, on flow control reset by the level
controller in D-1517, after being mixed with flush oil from the slurry
separator X-1504.
For maximum distillate mode operation, HCO is recycled to the reactor feed. The
HCO recycle is taken from the draw off tray above the Bed #4 and is pumped by
P-1507 A/B to the tube side of the MP Steam Generator E-1508 where it is used
as heating medium to produce MP steam from BFW in the shell side. The cooling
of the HCO in E-1508 is controlled by TIC-425 on the HCO recycle line to the feed
section by adjusting the amount of HCO bypassing the MP Steam Generator.
HCO is then mixed with the feed upstream of the feed temperature control point,
as described previously.
2.5.3. LCO section

This section of T-1501 consists of six fractionating trays, trays 25 to 30, and a
packed pumparound bed, Bed #2.
LCO product and LCO pumparound are drawn off from the pumparound draw-off
tray below the bed#2 of T-1501. LCO pumparound is circulated by the LCO
pumparound pumps P-1510 A/B to the following equipment in parallel:
• Shell Side of the Stripper 2nd Reboiler E-1557,
• Tube Side of the LCO pumparound Feed Preheat Exchangers E-1512
A/B/C/D,
• Shell Side of the LCO pumparound BFW Heater E-1511.
The cooled LCO leaving E-1557, E-1512 A/B/C/D and E-1511 is then recombined
before being returned to the main fractionator above the Bed #2.
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The total pumparound flow is maintained constant by controlling the flow of LCO
by-passing the above equipments with (FIC-411) at P-1510 A/B discharge. Heat
removal in the pumparound circuit is controlled by the flow controller at the outlet
of E-1511 reset by the temperature controller TIC-452 on the recombined LCO
pumparound return line to T-1501.
LCO product is taken as a slip stream at the suction of the LCO pumparound
pumps P-1510 A/B and is sent to the LCO stripper T-1503 on level controller of
the stripper bottoms by LIC-436. The LCO is stripped by LP stream on flow control
(FIC-452).
The stripper vapor is returned to T-1501 above the pumparound, Bed #2. Stripped
LCO is pumped by the LCO Stripper Pumps P-1511 A/B and is cooled on
temperature control in LCO Product LP Steam Generator E-1513 and the air
cooler E-1514 before going to the LCO Hydrotreater unit or to storage.
For maximum gasoline operation this is the total LCO product. For maximum LCO
operation (maximum distillate operation), heavy naphtha from the Heavy Naphta
Trim Cooler E-1516 is mixed with this stream before being sent to the LCO
Hydrotreater unit.
In case of LCO Hydrotreater shut down, the LCO is sent directly to storage.
2.5.4. MTC and heavy naphtha section

This section consists of 14 fractionating trays, trays 11 to 24, and heavy naphtha
pumparound bed, Bed #1.
MTC is drawn off from tray 19. The MTC (Mix Temperature Control) has a
composition between the light end of the LCO and the heavy end of the heavy
naphtha. This cut is recycled to the riser in the Mixed Crude Maximum Gasoline
case. The MTC is pumped by the MTC Recycle Pumps P-1512 A/B to the riser
injection nozzle on flow control.
Heavy naphtha pumparound and heavy naphta product are drawn off from the tray
below the bed #1. Heavy naphta pumparound is circulated by the naphta
pumparound pumps P-1514 A/B to the following equipment in parallel:
• Tube side of the Stripper Feed Preheater E-1555,
• Heavy Naphtha Pumparound air cooler E-1521
• E-2107 & E-2108 in the Propylene Recovery Unit (PRU) for reboiling
purpose.
The air cooler E-1521 is designed for the case when the PRU is not in operation.
The cooled heavy naphta leaving E-1555, E-1521 and the PRU is then
recombined before being returned to the main fractionator above the Bed #1.
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The total pumparound flow is maintained constant by controlling the flow of heavy
naphta by-passing the above equipments with (FIC-412) at P-15114 A/B
discharge. Heat removal in the pumparound circuit is controlled by the flow
controller at the outlet of E-1521 reset by the temperature controller TIC-430 on
the recombined heavy naphta pumparound return line to T-1501.
Heavy naphta product is taken as a slip stream of the pumparound draw-off at the
suction of the P-1514 A/B and is sent to the heavy naphta stripper T-1502 on level
controller of the stripper bottoms by LIC-439. The heavy naphta stripper bottoms is
reboiled in the reboiler E-1509, using HCO pumparound as heating medium. The
stripper vapor is returned to T-1501 above the pumparound bed, Bed #1.
Stripped heavy naphtha is pumped by the Heavy Naphta Product Pumps P-1515
A/B. It is first cooled by preheating HP boiler feed water in E-1516 and is then
cooled in air cooler E-1517 and trim water cooler E-1518.
For maximum LCO case, the heavy naphtha is mixed with LCO and for maximum
gasoline case it is mixed with debutanized gasoline in the Gas Recovery Section.
Heavy naphtha is also drawn off at the suction of P-1514 A/B as lean oil for the
secondary absorber in the Gas recovery Section. The lean oil is pumped by P-
1513 A/B on flow control FIC-718 in the Gas Recovery Section where it is first
cooled in Lean Oil / Rich Oil Exchanger E-1563 before cooling in Lean Oil Cooler
E-1564.
2.5.5. Top section

This section of T-1501 consists of 10 fractionation trays, trays 1 to 10.
Rich oil from the bottom of the secondary absorber in the Gas Recovery Section is
fed to tray 9. A partial draw-off accumulator tray is provided below the top tray.
The accumulator tray is designed to separate water and hydrocarbon. Any water is
drawn-off under interface level control LIC-416 and flows by gravity to the inlet of
overhead condenser E-1519.
2.5.6. Fractionator overhead section

The overhead vapor from T-1501 is partially condensed in the overhead air
condenser E-1519 and cooling water exchanger E-1520A-H before flowing to the
fractionator reflux drum where the liquid hydrocarbon, water and vapor phases are
separated.
Off-gas streams from CDU and NHT Units are also fed to D-1514.
Part of the liquid hydrocarbon is sent back to the tray #1 of the main fractionator
as a reflux by means of the Fractionator Reflux Pumps P-1516 A/B. The overhead
naphtha cut point is controlled by the overhead temperature controller TIC-461
resetting this reflux rate.
Part of the wash water is recycled from the fractionator reflux drum D-1514 boot to
the inlet of the overhead condenser E-1519 by means f the overhead sour water
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pumps P-1517 A/B on flow control (FIC-459) in order to minimize corrosion in the
condenser. From the discharge of P-1517 A/B, the remaining water is sent to:
• The SWS (unit 18) on flow control reset by the interface level controller LIC-
446 of the D-1514 boot;
• To the wet gas compressor inter cooler on flow control (FIC-703) to be used
as wash water.
Corrosion inhibitor is also injected into the overhead line of T-1501, upstream of
the overhead condensers E-1519, from the corrosion inhibitor tank TK-15101 by
means of either of the corrosion inhibitor pumps P-1520 A/B.
The net overhead liquid product is pumped by the Overhead Liquid Pumps P-1518
A/B, under flow control FIC-455 reset by the level controller of the Main
Fractionator Reflux Drum LIC-443, to the primary absorber in the Gas Recovery
Section.
The overhead vapor from D-1514 flows to the first stage KO drum of the wet gas
compressor D-1551, while excess off gas is vented to flare on pressure control.
2.6. Gas Recovery section

Figure 11: Gas Recovery Section
2.6.1. Wet gas compressor and HP condenser

Wet gas from the Main Fractionator Reflux Drum D-1514 flows to the wet gas
compressor first stage knock-out drum D-1551 where entrained and condensed
liquids are separated. The liquid collected in D-1551 is pumped by the KO drum
liquid pumps P-1552 A/B back to the fractionator reflux drum D-1514.
The gas from D-1551 is compressed in the 1st stage of the compressor C-1551
and is then cooled in wet gas compressor intercooler E-1551 and trim cooler E-
1552 A/B. Sour water from the Fractionation Section is injected at the inlet of E-
1551 to minimize corrosion.
The cooled vapor and condensed liquid from E-1552 are separated in the
interstage KO drum D-1552. The vapor from D-1552 is compressed in the 2nd
stage of compressor C-1551.
The liquid phase in D-1552, hydrocarbon and water, is pumped by P-1551 A/B
and is re-contacted with the compressor discharge vapor. This combined stream is
partially condensed in HP air condenser E-1553 before being fed to the Stripper
Condensers E-1554 A/B/C/D.
A slip stream of this combined stream is recycled back to the inlet of the wet gas
compressor intercooler E-1551.
2.6.2. Stripper condenser and high pressure separator drum

The outlet from E-1553, the primary absorber T-1551 bottom liquid and the
stripper T-1552 overhead vapour are combined before entering stripper water
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condensers E-1554A/B. An LPG stream from the CDU is also fed to the inlet of E-
1554 A/B.
The mixed phase outlet from E-1554A/B is separated into water and hydrocarbon
liquid phases and a vapor phase in HP separator drum D-1553. The sour water is
sent on D-1553 boot interface level control to the sour water stripper (unit 18).
The hydrocarbon liquid phase is pumped by the stripper feed pumps P-1553 A/B
and after preheating in E-1555 by heavy naphta pumparound is fed to the top of
stripper T-1552.
The vapor phase from D-1553 is fed to the primary absorber T-1551, below the
bottom tray.
2.6.3. Primary absorber T-1551

The primary absorber T-1551 recovers most of the C3 and C4 from D-1553 vapor.
The overhead liquid from the Fractionation Section is fed to the top tray of T-1551.
For other than Bach Ho Max Gasoline case, gasoline is also recycled from the
bottom of the debutanizer T-1554:
After being cooled in the stripper first reboiler E-1556, the gasoline air cooler E-
1558 and the gasoline cooler E-1559, recycle gasoline is pumped by the Recycle
Gasoline Pumps P-1554 A/B to be mixed with the overhead liquid from the
fractionation section and is fed to the to tray of T-1551.
This Gasoline recycle enables required recovery of C3 and C4.
The absorber bottom rich oil flows to the inlet of E-1554 under level control.
2.6.4. Stripper
The LPG and gasoline mixture is fed from HP separator drum D-1553 to the top
tray of the stripper by means of the stripper feed pumps P-1553 A/B and after
cooling in the stripper feed preheater E-1555 against heavy naphta pumparound.
The purpose of the stripper is to remove H2S, C2 and lighter from The LPG and
gasoline mixture.
The stripper feed temperature is controlled by the temperature of the stripper at

the outlet of E-1555 with TIC-723 adjusting the flowrate of heavy naphta
pumparound leaving E-1555.
The necessary heat to perform the stripping operation is supplied by two reboilers
in series:
• In the 1st stripper reboiler E-1556, the stripper bottoms are heated against
debutanizer bottoms.
• In the 2nd stripper reboiler E-1557, the stripper bottoms leaving E-1556 are
heating by LCO pumparound from the Fractionation Section.
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The heat input to E-1557 is controlled by the stripper overhead vapor rate FIC-
709. This rate, and hence the reboiler duty, is set to meet the C2 specification in
the debutanizer overheads.
The overhead vapor leaving the stripper is returned to and condensed in E-1554.
The bottom liquid of the stripper is fed to the debutanizer T-1554 on flow control
FIC-714 reset by the stripper bottoms level controller LIC-712.
2.6.5. Secondary absorber T-1553

The secondary absorber T-1553 recovers gasoline light fractions contained in the
overhead gas from primary absorber T-1551, by means of stripping with a heavy
naphta stream from the fractionation section. The overhead gas from the primary
absorber is sent straight to the secondary absorber T-1553 where it enters below
the tray #20.
The lean oil used for the absorption is a heavy naphtha stream is drawn off from
the main fractionator T-1501 and pumped by P-1513 A/B to the lean oil/rich oil
exchanger E-1563, where the lean oil is cooled by exchange with the bottoms of
T-1553. Lean oil is then further cooled in the lean oil water cooler E-1564. The
cooled liquid flows through lean oil coalescer D-1556 to remove entrained water
before it is fed to the top tray of T-1553 on flow control FIC-718.
Sour water collected in the boot of the lean oil coalescer D-1556 is sent to the
SWS (unit 18) on boot interface level control.
The rich oil from the bottom of the secondary absorber T-1553 flows under level
control of T-1553 bottoms (by LIC-720) to the lean oil/rich oil exchanger E-1563
where it recovers heat before being recycle to the tray #9 of the Main Fractionator
T-1501.
The stripped overhead gas leaving T-1553 is cooled in the fuel gas water cooler E-
1565 and flows to fuel gas absorber K.O. drum D-1557.
2.6.6. Fuel gas absorber

The fuel gas absorber T-1555 removes H2S and CO2 from the gas leaving the
secondary absorber by contact with lean amine (DEA) fed from the ARU (unit 19).
The small amount of liquid in the effluent from E-1565 is separated in the K.O.
drum D-1557. The liquid is sent to mixing with rich oil at the inlet of the lean oil/rich
oil exchanger E-1563 on level control of the absorber feed KO drum (LIC-726).
The overhead gas of the FG absorber feed KO drum is fed to the bottom of the
Fuel Gas Absorber T-1555, while the lean amine is fed to the top tray on flow
control.
In order to avoid hydrocarbon condensation, the temperature of the lean amine is
controlled by TDIC-746 to maintain the lean amine at a fixed temperature
difference above the inlet gas.
Once treated by the lean amine, the overhead gas is sent to the Fuel Gas
Absorber Outlet K.O. drum D-1559, where entrained and condensed liquid are
separated before the treated fuel gas is sent to the fuel gas system. The gas
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leaving D-1559 is sent to the fuel gas system on pressure control of the secondary
absorber overheads by PIC-733.
The rich amine leaving the bottom of the fuel gas absorber is sent to the amine
regeneration unit (ARU) under T-1555 level control by LIC-730. Any amine
accumulated in K.O. drum D–1559 also goes to the ARU on level control of D-
1559 by LIC-733.
2.6.7. Debutanizer
The debutanizer separates LPG from gasoline.
The bottom of the stripper T-1552 is fed to the tray #22 of the debutanizer T-1554.
The heat required to perform the separation is provided by the debutanizer
reboilers E-1560 A/B in which the debutanizer bottoms are heated by HCO
pumparound. The reboilers duty is controlled by adjusting the flow of HCO leaving
the reboilers with FIC-722 and is set to ensure that the C4 specification in the
gasoline is met.
The overhead vapor leaving the debutanizer is totally condensed in the
debutanizer condensers E-1561 A/B. The pressure in T-1554 is controlled with
PIC-745 by bypassing part of the overhead vapor around E-1561 A/B to the reflux
drum D-1554. The condensed liquid is pumped from D-1554 by P-1556 A/B:
• Part of the liquid from the debutanizer KO drum is sent to the tray #1 of the
debutanizer as a reflux. The reflux rate is flow controlled by FIC-721 reset
by the temperature controller TIC-754 on the sensitive tray (tray #8) in the
top section of the column. This control loop determines the C5 specification
in the overhead product.
• The remaining overhead liquid, LPG product, is sent to the LPG Amine
Absorber T-1556 after being cooled against cooling water in the LPG
Cooler E-1562. The flow of LPG product being sent to T-1556 from the
discharge of the Debutanizer Overheads Pumps P-1556 A/B is controlled
by FIC-723 located downstream of the water cooler and reset by the level
controller of the Debutanizer Reflux Drum LIC-742.
The water collected in the boot of the debutanizer reflux drum is sent to the SWS
on interface level control.
The gasoline product from the bottom of the debutanizer column is first cooled in
stripper reboiler E-1556, then in air cooler E-1558 and finally in gasoline water
cooler E-1559, before being split into 2 streams:
Part of the cooled gasoline is pumped on flow control by the gasoline recycle
pumps P-1554 A/B to the primary absorber as supplementary lean oil when
required.
The net gasoline product is sent to the Gasoline Treating Unit on flow control by
FIC-715 reset by the debutanizer level controller LIC-736. For maximum Gasoline
operation the heavy naphtha from the Fractionation section is combined with this
stream.
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2.6.8. LPG amine absorber T-1556

The LPG amine absorber T-1556 removes H2S by contact with lean amine (DEA)
from the ARU (unit 19).
T-1556 is a packed column. The LPG enters at the bottom and flows up through
the amine. Lean amine from the ARU is fed to the LPG amine absorber after being
cooled against cooling water in E-1566.
The LPG amine interface level control LIC-746 above the top packed section is
maintained by controlling rich amine flow leaving the bottom of the absorber. The
overhead LPG liquid flows to the LPG amine coalescer D-1555, where amine
carry-over is separated:
• The amine collected in the boot of the LPC amine coalescer is sent to the
rich amine stream from the absorber bottom on boot interface level control
by LIC-749.
• The overhead LPG from the drum goes to the LPG Treating Unit.
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TRAINING MODULE
UNIT: 15
Course Content:

X
Section 9 - HSE
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SECTION 3 : PROCESS CONTROL
The following is a description of the main control loops of the RFCC unit. For a detailed
description of the control loops and the controllers, refer to the process control narrative, 8474L-
015-SP-1511-001.
3.1. Control narrative & operating parameters
3.1.1. Feed Oil Temperature Control

The feed oil temperature control is the prime process parameter for the reactor
riser temperature after the Riser Outlet Temperature Control.
In the Bach Ho case preheating of feed is by the LCO pumparound, MP and HP
steam exchangers and finally by slurry to obtain the feed temperature of 290°C. In
the case of Mixed Crude feed, the feed is preheated to the required temperature of
170°C by the LCO pumparound when 100% of the feed to the surge drum is hot.
Additionally, MP steam heating is required when the feed is all or partly cold.
The temperature is controlled by TIC-002 at the outlet of the preheat train,

downstream of the point where the feed is mixed with HCO Recycle. The output of
TIC-002 is sent to the selector switch HS-002 which is used to select between the
different modes of operation:
• Position 1: “Bach Ho Crude”:
The output from TIC-002 is routed to TV-002 which regulates the flow of
feed bypassing the 1st and 2nd feed preheat slurry exchangers E-1502 A-C
and E-1501 A/B respectively. This way TIC-002 controls the final
temperature of the feed.
The preheat duty in LCO Pumparound Feed Exchanger in E-1512A/B/C/D
is set by flow control of the total LCO pumparound via FIC-417, which acts
on FV-417: Flow of LCO pumparound bypass.
The duty of E-1522 is set by flow control of the MP Steam via FIC-410
acting on FV-410.
The Duty of E-1524 is set by flow control of the HP Steam via FIC-411 reset
by the temperature of the feed directly at the outlet of this exchanger (TIC-
411).
• Position 2: “Mixed Crude-1” (Hot Feed)
The output from TIC-002 is used to reset the flow controller FIC-409 at the
LCO pumparound outlet of E-1512 A/B/C/D. FIC-409 adjusts the duty of the
LCO Pumparound Feed Preheat Exchangers by acting on FV-409: LCO
Pumparound return to main fractionator.
• Position 3: “mixed Crude-2” (Cold Feed)
The output from TIC-002 is used to reset the flow controller FIC-410 which
controls the duty of the MP steam supply to E-1522 by acting on FV-410: E-
1522 MP steam inlet.
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Figure 12: Feed Oil Temperature Control
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A constant pressure is maintained on the feed to the reactor feed control valves by
the pressure control valve PV-410 upstream of E-1502A/B/C with PIC-410 located
upstream of the point where the recombined feed is mixed with HCO recycle. This
pressure control ensures that the HCO recycle can enter the feed line. The
location of the pressure control valve also facilitates the by-pass temperature
control.
3.1.2. UC-001 Feed Injector

The feed injection control system provides even distribution of the total feed flow
(feed + recycle) to the 6 distributor nozzles I-1501 A/B/C/D/E/F.
The total feed flow to each of the 6 feed nozzles I-1501 A-F is respectively
controlled by FIC-003 A-F acting on FV-003 A-F at the nozzles inlet.
Flowrate of the different feed sources, raw oil flow controller FIC-001 and HCO
Recycle Oil flow controller FIC-002 are sent to the master controller UC-024 which
sums the contributions from FIC-001 and FIC-002 and divides the total set flow by
the number of feed injectors (6). UC-024 then provides this new set point (Total
set flow/6) to each feed nozzle flow controller FIC-003 A-F which adjust the
position of their feed nozzle flow valve accordingly.
The process variable of UC-024 is the output from UY-020. UY-020 calculates the
total measured feed flowrate to the riser with outputs from the 6 feed nozzles flow
controllers FIC-003 A-F
Total set flow = FIC-001 + FIC-002

Set value to FIC-003A= (Total set flow)/6
Set value to FIC-003B= (Total set flow)/6
Set value to FIC-003C= (Total set flow)/6
Set value to FIC-003D= (Total set flow)/6
Set value to FIC-003E= (Total set flow)/6
Set value to FIC-003F= (Total set flow)/6
Total measure flow= FIC-003A + FIC-003B + FIC-003C + FIC-003D + FIC-003E +
FIC-003F
Each flow controller FIC-003 A-F is temperature compensated with TI-003.
HS-013 is provided for selection of signal from FIC-001 to FV-001, which is used
for start-up operation of RFCC, when feed oil is circulating to the feed surge drum.
During normal operation, HS-013 is selected to set flow rate of FIC-001 to UC-
024.
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Figure 13: Feed Injector Distribution Control
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The feed dispersion steam injected at each of the feed nozzles I-1501
A/B/C/D/E/F to mix with the feed is flow controlled by 6 controllers FIC-005
A/B/C/D/E/F (1 per feed nozzle) acting on their respective steam inlet valve FV-
005 A/B/C/D/E/F. The total flow of MP steam supplied to the feed injectors is
computed and displayed via FI-005.
3.1.3. UC-028 MTC INJECTOR

MTC (Mix Temperature Control) injectors I-1502A-D are provided above the feed
injection zone to inject recycled heavy FCC naphtha. MTC plays an important role
in the heat balance control and heavy feed vaporization. The key is to achieve a
higher temperature in the fresh feed mixing zone.
MTC injection is required for Maximum Gasoline Mode of Mixed Crude. MTC
flowrate is set to maintain the desired temperature at the fresh feed injection point.
A thermocouple located upstream of the MTC injectors measure the catalyst/vapor
mixture temperature.
The MTC Recycle flow to the 4 injectors I-1502 A/B/C/D is evenly distributed and
controlled by the flow controllers FIC-010 A/B/C/D:
A signal representing the flow of MTC recycle to the riser is sent by FI-009 to UC-
028, the late being the master controller for each individual controllers FIC-010 A-
D. UC-028 divides the flowrate signal from FI-009 by the number of MTC injectors
(4) and sends the resulting value to each of the 4 flow controllers FIC-010 A/B/C/D
as their new setpoint. Then FIC-010 A/B/C/D adjust the flow of MTC recycle to
their respective injector by acting on FV-010 A/B/C/D respectively.
The process variable of UC-028 is the output from UY-014. UY-014 calculates the
total measured MTC flowrate to the riser with outputs from the 4 MTC injectors
flow controllers FIC-010 A-D.
Total measured flow= FIC-010A+FIC-010B+FIC-010C+FIC-010D

Set value to FIC-010A= (Total measured flow by FI-009)/4
Set value to FIC-010B= (Total measured flow by FI-009)/4
Set value to FIC-010C= (Total measured flow by FI-009)/4
Set value to FIC-010D= (Total measured flow by FI-009)/4
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Figure 14: MTC Injector Distribution Control
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The MTC dispersion steam injected at each of the MTC injectors I-1502 A/B/C/D
to mix with the MTC is flow controlled by 4 controllers FIC-005 A/B/C/D (1 per feed
nozzle) acting on their respective MP steam inlet valve FV-005 A/B/C/D.
3.1.4. Riser Outlet Temperature Control

The most critical control loop on the Reactor and Regenerator is the Riser Outlet
Temperature Control TIC-010. The temperature should be controlled within ± 1°C
of the setpoint. A thermocouple located near the outlet of the riser measures the
reaction temperature. Since the temperature is a function of the amount of catalyst
admitted to the riser by the Regenerated Catalyst Slide Valve SV-1501, the Riser
Outlet Temperature controls the regenerated catalyst slide valve in order to
provide sufficient flow of hot catalyst to maintain the riser at the desired
temperature. Reaction temperature is basic to conversion of RFCC feedstocks.
At the bottom of the regenerated catalyst standpipe the regenerated catalyst slide
valve controls the flow of hot catalyst to the wye section at the base of the riser D-
1501. The Riser Outlet Temperature sets the position of the slide valve which
regulates the flow of catalyst.
The Regenerated Catalyst Slide Valve position can be set by either of the
following temperature controllers:
• Riser Outlet Temperature Controller TIC-020
• TIC-015 located above the Upper Steam Stripping Ring above the fluidized
bed packing in the stripper section of the riser
The operator selects between these controllers via HS-004. In normal operation,
the output of TIC-020 is selected.
The output of the temperature controller TIC-020 is then sent to the low switch
selector UY-020 which selects between this input and the output of the differential
pressure controller PDIC-247. The later receives the measure of the differential
pressure across SV-1501 by PDT-247.
In the event the differential pressure across the slide valve falls to 0.1 bar then the
signal from PDIC-247 will be selected by UY-020 in order to re-adjust the slide
valve differential to its normal value (0.3 to 0.5 bar). Normal valve differential is
essential to provide safe operation as well as stable control. Negative differentials
should never happen.
Note:
In the event that PDIC-015 is less than 0.15 barg, then the output of PDIC-247 will
be 0% to close SV-1501.
The operator enables the low selector switch by means of HS-015 which has 2
positions: Enable/Disable. When HS-015 selects “Disable”, Low Selector Switch
UY-012 will exclusively select the output of HS-004.
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The output of UY-012 is then sent to the software switch HS-028 which is used to
select between this input and the output of the Software Hand Controller HIC-029
(which can be tuned in the range 0-100%). Software switch HS-028 has 2
positions: Auto & Manual:
• When AUTO is selected, then the output of HS-028, UY-017, is the signal
from the low selector UY-017 and is sent to the PLC of the Regenerated
Catalyst Slide Valve (Signal to UV-017).
• In the case MANUAL is selected then the output of HS-028, UY-017, is the
signal from the software hand controller HIC-029 and is sent to the PLC of
the Regenerated Catalyst Slide Valve (Signal to UV-017).
HS-008 is used to activate the standby mode of the accumulator.
Figure 15: SV-1501
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A Riser Outlet Temperature (ROT) is chosen based on the type of feedstock

processed and the type of yields distribution desired. The heat of reaction, the
coke make, catalyst circulation rate, and the regenerator temperature change as
the Riser Outlet Temperature is varied. The feed preheat temperature, MTC oil
flow rate, can be manipulated to control these operating parameters within their
optimum ranges.
The optimum ROT operation varies with feedstock and operational goals.
If the feed temperature is reduced, more hot regenerated catalyst will be required
to heat the reaction mixture. The regenerated catalyst slide valve will open and the
catalyst to oil ratio will increase. Coke make will increase because of the increased
catalyst to oil ratio. The lower heat input into the RFCC, from the feed preheat
exchangers will be made up by burning the extra coke. As the regenerator
temperature increases the catalyst/oil ratio will find a new equilibrium. Thus, feed
temperature can be adjusted to affect conversion at the expense of coke make.
If the feed quality changes such that coke make begins to increase the
regenerator temperature will rise and the regenerated catalyst slide valve will
close slightly as it senses the increasing temperature of the riser outlet. The
catalyst-to-oil ratio then decreases, conversion decreases, and coke make
decreases. Although the unit is now in a new, stable, equilibrium operating point,
an adjustment of some other operating variable may be necessary to maintain the
desired product distribution at the new heat balanced level.
If the percentage of residue in the feedstock gets too high there may be no
remaining flexibility for the heat balance. In this case, coke make due to the nature
of the feed becomes the predominant source of coke and changes in catalyst-to-
oil ratio have a smaller effect on overall coke make. In this case, an increase in the
feed preheat may cause very high regenerator temperatures as the coke level
builds up on the catalyst and significantly reduces the catalyst-to-oil ratio.
Unacceptably poor conversion will result.
If the MTC oil rate is increased, the Riser Outlet Temperature begins to decrease
and the regenerated catalyst slide valve will open slightly as it senses the lower
ROT. The catalyst-to-oil ratio then increases, mix zone temperature increases,
conversion increases, and coke / slurry oil production decreases.
When the set point of the riser outlet temperature is changed, the regenerated
catalyst slide valve will immediately vary the catalyst-to-oil ratio to satisfy the new
riser heat demand. Before the system reaches steady state and the regenerator
equilibrates at a new temperature, the system will go through a transition stage
due to the large catalyst inventory. During the transition, operating signals can be
confusing. For example, a higher riser outlet temperature demands a higher
catalyst circulation rate and a higher coke make. But the catalyst takes time to
travel through the riser, disengager, stripper and the spent catalyst transfer line to
reach the regenerator. The temperature in the regenerator will decline initially
because of the immediate extra heat demand in the riser. Eventually, the unit will
heat balance by producing more coke, and the regenerator temperature will rise.
This higher temperature will cause the catalyst circulation rate to decrease. The
system can eventually be returned to the optimal catalyst to oil ratio if the feed
preheat temperature is adjusted to offset the additional riser heat demand.
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3.1.5. Catalyst Stripper Level Control

The spent catalyst slide valve controls the catalyst stripper level by modulating the
flow of spent catalyst from the catalyst stripper to the first stage regenerator. The
catalyst level in the stripper is measured by differential pressure instruments and
sends a signal to the controller which sets the position of the slide valve. A
minimum level is required in the catalyst stripper to ensure good stripping of
hydrocarbons from the catalyst and a seal at the diplegs outlet of the Riser Outlet
Separation System.
Figure 16: SV-1502
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The selector HS-005 is provided to select between either of the level controller of
the catalyst stripper LIC-002 and LIC-003. The Level controller output selected is
then sent to the low signal selector UY-011 which selects between this input and
the output from PDIC-103. The later receives the differential pressure across SV-
1502 as measured by PDT-103 as input. In the event the differential pressure
across the slide valve falls to 0.1 bar then the signal from PDIC-103 will be
selected by UY-011 in order to re-adjust the slide valve differential to its normal
value (0.3 to 0.5 bar). Normal valve differential is essential to provide safe
operation as well as stable control. Negative differentials should never happen.
The software switch HS-014 is provided to enable or disable the low selector
switch. HS-014 has only 2 positions: Enable and Disable. When HS-014 selects
“Disable”, Low Selector Switch UY-011 will exclusively select the output of HS-
005.
The output of UY-011, (in normal operating conditions: either of the level
controllers of the catalyst stripper) is sent to the software switch HS-025 which is
used to select between UY-011 output and the manual control of the slide valve
via software hand controller HIC-025.
Software switch HS-025 has only 2 positions, Auto & Manual:
• When AUTO is selected, then the output of HS-024, UY-015, is the signal
from the low selector UY-011 and is sent to the PLC of the Spent Catalyst
Slide Valve (Signal to UV-015).
This way, in normal operation, the position of the spent catalyst slide valve
is controlled by either of the level controller of the catalyst stripper.
the Spent Catalyst Slide Valve (Signal to UV-015).
3.1.6. Catalyst Regenerators Level Control

The level in the first stage regenerator is measured by a differential pressure
instrument LT-004 and is sent to the level controller of the 1st stage regenerator
LIC-004 which resets the position of the air lift plug valve PV-1501.
The plug valve modulates the flow of catalyst from the first stage regenerator into
the lift to the second stage regenerator.
A minimum level must be maintained in the first stage regenerator to ensure good
regeneration and to seal the cyclone diplegs. A low level in the regenerator may
unseal the diplegs which could result in backflow of flue gas up the diplegs and
loss of catalyst fines with the flue gas.
A high level in the first stage regenerator can also result in catalyst carryover from
the cyclones because of higher entrainment from the bed and re-entrainment from
the cyclone dust bowls.
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During normal operation, the second stage regenerator level LIC-007 is not
controlled, but follows the unit inventory. This level is monitored and adjusted by
continuous withdrawal as the level builds through catalyst addition. The level in the
second stage regenerator must be held within certain limits for the same reasons
as stated above for the first stage regenerator.
Figure 17: Air Lift Plug Valve PV-1501 Control
In normal operation, the air lift plug valve is controlled by LIC-004, however, HS-
004 is provided to select between LIC-004 and LIC-007. The output of HS-006,
(=output of LIC-004 in normal operation) is then sent to the software switch HS-
026 which is used to select between this input and the manual operation of the
plug valve PV-1501 via HIC-027.
Software switch HS-027 has only 2 positions, Auto & Manual:
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• When AUTO is selected (=normal operation), then the output of HS-026,

UY-016, is the signal from the low selector UY-006 and is sent to the PLC
of the Air Lift Plug Valve (Signal to UV-016).
This way, in normal operation, the position of the spent catalyst slide valve
is controlled by either of the level controller of the catalyst stripper.
the Air Lift Plug Valve (Signal to UV-016).
3.1.7. Catalyst Regenerators Pressure Control

The regenerators pressures are controlled by flue gas slide valves SV-1503/1504
which throttle the flow of flue gas from the vessels.
The pressure of the first stage regenerator is directly controlled by the first
regenerator flue gas slide valve SV-1503 with PIC-146.
Figure 18: First Regenerator Flue Gas Slide Valve SV-1503 Control
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The output of the pressure controller PIC-146 located at the top of the 1st
regenerator D-1502 is sent to the software switch HS-030 which is used to select
between this input and the manual operation of the slide valve via HIC-031. In
normal operation, PIC-146 controls the operation of the slide valve SV-1503 and
its output is sent to UY-018, which forwards 2 identical signals, UY-018 A and UY-
018 B and identical to the selected signal in HS-030, to the PLC of the double disc
slide valve (UY-018A is sent to UV-018A and UY-018B is sent to UV-018B). This
way PIC-146 commands both discs of the slide valve SV-1503.
Software switches HS-040 A and B are provided to activate the standby mode of
the valve accumulator A & B respectively.
The differential pressure PDIC-172 between the first stage and second stage
regenerators is controlled by the second regenerator flue gas slide valve SV-1504.
This differential pressure is set to provide adequate pressure drop across the plug
valve PV-1501 for stable control of the regenerators levels.
Figure 19: 2nd Regenerator Flue Gas Slide Valve SV-1504 Control
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PDIC-172 measures and controls the differential pressure between the top of the
1st regenerator and the bottom of the 2nd regenerator.
The output of PDIC-172 is sent to the software switch HS-032 which is used to
select between this input and the manual operation of the slide valve via HIC-033.
In normal operation, PDIC-172 controls the operation of the 2nd regenerator slide
valve SV-1504 and so its output is sent to UY-019. The later forwards 2 identical
signals, UY-019 A and UY-019 B and identical to the selected signal in HS-032, to
the PLC of the double disc slide valve (UY-019A is sent to UV-019A and UY-019B
is sent to UV-019B). This way PDIC-172 commands both discs of the slide valve
SV-1504.
3.1.8. Disengager Pressure Control

The disengager pressure rides on the main fractionator pressure which is
controlled at the main fractionator overhead receiver D-1514. The objective in
operation is usually to set the main fractionator pressure to a base level for
efficient operation and the regenerator vessel pressures to result in approximately
equal differentials across the catalyst slide valves.
3.1.9. Catalyst Regeneration Air and Total Flue gas to Stack Control
The pressure of blower air to the 1st Regeneration Air Heater H-1501 is controlled
by PIC-311 located at the blower discharge and acting on the pressure valve PV-
311 on the blower air line to H-1501, upstream of the 1st regenerator air ring
assisted check valve CV-1501.
The flow of air to H-1501 is monitored by FIC-161 (Venturi Tube) just upstream of
PIC-311. The output of FIC-161 is sent to the air blower C-1501 speed controller
SC-803 via the selector unit HS-827.
The flow of blower air to the 2nd regeneration air heater H-1502 is controlled by
FIC-164 (Venturi Tube) with FV-164 on the air blower line to H-1502, upstream of
the 2nd regenerator air ring assisted check valve CV-1502.
The flow of blower air to the air lift plug valve PV-1501 of the first regenerator D-
1502 is controlled by FIC-166 (Venturi Tube) with FV-166 on the air blower line to
PV-1501, upstream of the air lift assisted check valve CV-1503.
The flow of blower air to the withdrawal well is controlled by FIC-169 with FV-169
on the blower air line to the withdrawal well.
All above mentioned flow controllers are pressure and temperature compensated
by PIC-311 and TI-821 respectively.
The total Regeneration Air Flow is calculated by FI-162 which receives the signals
from FIC-161, FIC-164, FIC-166 and FIC-169 as inputs:
FI-162 (PV) = FIC-161(PV) + FIC-164(PV) + FIC-166(PV) + FIC-169(PV)
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The total flue gas to RFCC stack is calculated by the summing device UY-110 in
order to monitor the emissions.
The Total Flue Gas from COB H-1503 is calculated as per the following:
[Flue Gas from COB] = FI-902(PV) + FI-920(PV) + FI-923(PV) + FI-908(PV) [kg/h]
• FI-902: Total combustion air to COB (kg/hr)
• FI-920: Total fuel gas used for COB combustion (kg/hr)
• FI-923: Total fuel oil used for COB combustion (kg/hr)
• FI-908: Total MP Steam used for atomising COB combustion (kg/hr)
The total Regeneration air is calculated from FI-162 by multiplying with a factor to
take into account air to the flue gas from the regeneration section as coke burning
in the regenerators, and by converting from Nm3/h to kg/h.
UY-110 calculates the total flue gas flow by summing the total regeneration air
flow and the flow of flue gas from H-1503. The total flue gas flow is then displayed
by FI-110 which converts the results from kg/h to Nm3/h.
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Figure 20: Regeneration Air and Total Flue Gas to Stack
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3.1.10. Catalyst Draw-Off Control

The catalyst draw-off system allows the transfer of equilibrium catalyst from the 1st
regenerator to the spent catalyst hopper. The hot catalyst is withdrawn through
ON/OFF valve UV-021 actuated by timer and cooled down through a finned pipe.
The catalyst flow rate is set by a Restriction Orifice RO-161.
For catalyst conveying and line cleaning, plant air is injected into the catalyst line
downstream of the restriction orifice by another ON/OFF valve UV-023 actuated
by timer. The total amount of catalyst withdrawal is adjusted by the timer setting
taking into account the operation requirement for overall catalyst balance.
One cycle of catalyst draw off is fixed at 60min.
The total daily amount of catalyst withdrawal is adjusted by timer HIC-018 setting
taking into account the operation requirements for the overall catalyst balance.
Figure 21: Catalyst Draw Off Control
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• HIC-018: Set Point of Opening Time (Range: 0 – 30 min/cycle). This setting

value is used for timer set point of T-2 and T-4 (see DCS sequence below).
• HIC-042: Set Point of Frequency (Range: 3 – 24 cycle/day (Integer number
only to be used)) .This setting value is used for timer set point of T-5 (see
DCS sequence here after).
The sequence can be stopped locally with HS-043 or remotely with the DCS
software switch HS-044.
The flow of catalyst to the catalyst hopper is monitored via TI-029. In the event of
high temperature alarm from TI-029, then the drawoff sequence will also be
stopped.
DCS Draw-Off Sequence:

(1) Sequence Start
Sequence shall be started by activation of HS-043 at local panel.
(2) Timer Setting

T-1: Timer of Cleaning (UV-021: Close, UV-022: Open, UV-023: Open)
T-1 = 5min
This timer is started when HS-043 is activated or T-5 is up.
When timer T-1 is up, T-2 will start.
T-2: Timer of Conveying (UV-021: Open, UV-022: Open, UV-023: Open)
T-2 = HIC-018 (Set Point) [min]
T-3: Timer of Cleaning (UV-021: Close, UV-022: Open, UV-023: Open)
T-3 = 5min
T-4: Timer of Free of Catalyst
T-4 = 60 – (T-1) – (T-3) - HIC-018 (SP) [min]
T-5: Timer of Interval
T-5 = {{24 – HIC-024(SP)} x 60} / HIC-024(SP) [min]
When this timer is up, T-1 will start.
(3) Sequence in Progress

Total time of conveying will be shown on DCS graphic, when sequence is in
progress. This total time will reset at the end of the day.
HIC-018 and HIC-042 can be changed during sequence in progress. New setting
will be applied to the next cycle.
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(4) Sequence Stop

The causes of sequence stop can be:
• HS-044: Normal Stop
• TAH-029: Temperature High
• Valve Discrepancy Alarm (UV-021/022/023)
When sequence is stopped by any of the above events, the sequence goes to
cleaning mode (UV-021: Close, UV-022: Open, UV-023: Open) for 5min, then, all
valves (UV-021/022/023) will be in the closed position and sequence will stop,
then skip to the end (T0).
The sequence will start, only when HS-043 is activated.
3.1.11. Slurry Pumparound Return Control

The purpose of this control is to maintain a constant total flowrate of hot slurry
pumparound bypass to the grid of Bed #5 of the main fractionator.
It is essential to have an adequate flow to the grid of No.5 bed to ensure good
distribution, and maintain liquid flow on the bed to minimize coking-up of the
packing bed. The hot by-pass flow by FIC-426 and HIC-427 allow for this constant
flow to the grid whistle permitting changes in heat removal from the heat
exchangers.
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Figure 22: Catalyst Draw Off Sequence
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3.1.12. Feed Pumps Automatic Start-up

The feed pump P-1501 A or B on standby is automatically started when Low low
flow alarm FALL-404 at the pumps discharge is activated.
HS-401 is provided for the duty/standby selection.
3.1.13. UY-405, Slurry Pumparound (PA) Return Control

The purpose of this controller is to maintain the total flow rate of Slurry PA return
to Bed No.5 of the main Fractionator. It is essential to have adequate flow to the
grid of No.5 bed to ensure good distribution, and maintain liquid flow on the bed to
minimize coking-up of the packing bed.
The hot by-pass flow by FIC-426 and HIC-427 allow for constant flow to the grid
whistle permitting changes in heat removal from the heat exchangers.
The total flowrate of Slurry PA is set by the operator via the software hand
controller HIC-427. This value is sent to UY-405 which also receives the following
signals:
• FI-539 output: Total flowrate of slurry pumparound from the 2nd feed
preheat slurry exchangers E-1501 A/B returned to the grid. The flowrate of
slurry pumparound leaving E-1501 A is controlled by FIC-406 with FV-406
on the slurry returned line to the PA return header. Meanwhile, the flowrate
of LCO pumparound leaving E-1501 B is controlled by FIC-501 with FV-501
on the slurry returned line to the PA return header. The output of FIC-406
and FIC-501 are summed in UY-539 and the result is sent to FI-539, which
in turns forward the total slurry PA return flowrate to UY-405.
• FIC-408 output: FIC-408 controls the flow of slurry pumparound leaving the
last feed preheat slurry exchanger E-1501 A with FV-408 on the slurry PA
return line to the PA header.
• FIC-425 output: FIC-425 controls the flow of slurry pumparound flowing
through the HP steam generators E-1503 A/B/C with FV-425 located on the
return line to the pumparound header.
• FIC-440 output: FIC-440 controls the flow of slurry pumparound leaving the
MP steam generators E-1505 A/B and flowing through the slurry
pumparound header back to the bed #5 of the main fractiontator.
The output of FI-539, FIC-408, FIC-425 and FIC-440 are summed in UX-405. The
result of this summation is substracted to the total pumparound flowrate value set
via HIC-427, which gives the setpoint of the hot bypass flow controller FIC-426.
The later adjusts the position of FV-426 on the hot bypass line accordingly.
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Figure 23: Slurry Pumparound (PA) Return Control
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3.1.14. UC-414, E-1505 Slurry PA flow balance control

The function of this controller is to balance evenly the slurry pumparound flow
through the 2 branches of the steam generators:
• Branch A: E-1504A and E-1505A
• Branch B: E-1505 adnd E-1505B
The basic function is that UC-414 selects the highest valve opening request. One
of the flow control valves should then be fully opened by manual. The other valve
will be then throttled as required to maintain equal flow through each exchanger
train.
The intent of the design is not to maintain a particular flow through the exchangers
but to balance the flows through the exchangers. If there is an increase/decrease
in flows downstream of these control valves then the flow rate through all
exchangers will increase/decrease and the flow balancing will act to open to
maximum one valve and throttle the others. As one valve is always fully open, the
pressure drop through these control valves is always minimized. The operation of
these valves should, therefore, not interfere with the downstream control.
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Figure 24: E-1505 Slurry PA flow balance control

The flow of slurry leaving the MP steam generator E1505A is controlled by FIC-
438 with FV-438. The output of FIC-438 is sent to both the flow control valve FV-
438 and the summing device UY-410.
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The flow of slurry leaving the MP steam generator E1505b is controlled by FIC-
43y with FV-437. The output of FIC-437 is sent to both the flow control valve FV-
437 and the summing device UY-410.
The controllers 015-FIC-437 and 015-FIC-438 can not be in Auto mode
simultaneously: One of them must be in manual mode with its control valve fully
open.
UY-410 sums the flowrate of slurry pumparound through each of the 2 branches of
E-1504 A/B and E-1505 A/B. The total flowrate obtained is then sent to the master
controller UC-414 which divides it by the number of heat exchangers (2), to get the
new setpoint of the flow controllers. The output of UC-414 is sent to FIC-438 or
FIC-437 whichever is in auto mode. The flow controller in AUTO mode will in turn
adjust the flow of slurry through its branch of the exchangers to half of the total
flow measured, by means of its control valve.
The slurry pumparound leaving the MP steam exchangers E-1505 A/B is then
divided into 3 streams:
• Part of the slurry is sent to the slurry draw-off drum D-1515 on flow control
by FIC-462 with FV-462 on the slurry draw-off line to D-1515 inlet. To
maintain the normal level in the bottom of T-1501, the setpoint of FIC-462
is reset by the main fractionator bottoms level controller LIC-411.
• Another part of the slurry leaving the MP steam generators E-1505 A/B
flows to the quench zone of the main fractionator. The flow of slurry from
E-1505 A/B sent to the quench zone is controlled by FIC-439 which is
reset by the temperature controller TIC-439 of the main fractionator
bottoms via software switch HS-426.
HS-426 is provided to select either the flow control of the slurry PA to the
quench from E-1505 A/B (FIC-439) or the flow control of the slurry PA to
the quench from E-1503 A/B/C (FIC-424).
• The last part of the slurry PA from the MP steam generators E-1505 A/B is
sent back to the Bed #5 of the main fractionator via the PA return header.
This slurry PA return flow is controlled by FIC-440 reset by the
temperature controller TIC-443 on the Bed #4 of the main fractionator, via
PA return from E-1505 A/B (FIC-440) or the flow control of the slurry PA to
the PA return from E-1503 A/B/C (FIC-425).
3.1.15. UC-413, E-1503 Slurry PA flow balance control

The function of this controller is to balance evenly the slurry pumparound flow
through the 3 steam generators E-1503 A, B and C.
The basic function is that UC-413 selects the highest valve opening request. One
of the three flow control valves should then be fully opened by manual control. The
other valves are then throttled as required to maintain equal flow through each
exchanger train.
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The intent of the design is not to maintain a particular flow through the exchangers
but to balance the flows through the exchangers. If there is an increase/decrease
in flows downstream of these control valves then the flow rates through all
exchangers will increase/decrease and the flow balancing will act to open to
maximum one valve and throttle the others. As one valve is always fully open the
pressure drop through these control valves is always minimized. The operation of
these valves should, therefore, not interfere with the downstream control.
Figure 25: E-1503 Slurry PA flow balance control
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The flow of slurry leaving the slurry HP steam exchanger E-1503A is controlled by
FIC-428 with FV-428 on the discharge line back to T-1501. The output of FIC-428
is sent both to its flow control valve and to the summing function UY-409.
The flow of slurry leaving the slurry HP steam exchanger E-1503B is controlled by
The flow of slurry leaving the slurry HP steam exchanger E-1503A is controlled by
The controllers FIC-428, FIC-429 and FIC-430 can not be in Auto mode
simultaneously: One of them must be in manual mode with its control valve fully
open.
UY-409 sums the flowrate of slurry pumparound through each HP steam
generator. The total flowrate obtained is then sent to the master controller UC-413
which divides it by the number of heat exchangers (3), to get the new setpoint of
each of the flow controllers. The output of UC-413 is sent to FIC-428, FIC-429
and/or FIC-430, whichever is in auto mode, as the new setpoint. The flow
controller in AUTO mode will in turn adjust the flow of slurry through its HP steam
generator to 1/3 of the total flow measured, by means of its control valve.
Downstream of the slurry HP steam generators, the flow of slurry returned to the
main fractionator is divided in 2 streams:
• Part of the slurry leaving the HP steam generators E-1503 A/B/C flows to
the quench zone of the main fractionator on flow control by FIC-424. The
later is reset by the temperature controller TIC-439 of the main fractionator
bottoms via software switch HS-426.
quench from E-1505 A/B (FIC-439) or the flow control of the slurry PA to
the quench from E-1503 A/B/C (FIC-424).
• Another part of the slurry leaving the HP steam generators E-1503 A/B/C
is sent back to the Bed #5 of the main fractionator via the PA return
header. This slurry PA return flow is controlled by FIC-425 reset by the
temperature controller TIC-443 on the Bed #4 of the main fractionator, via
PA return from E-1505 A/B (FIC-440) or the flow control of the slurry PA to
the PA return from E-1503 A/B/C (FIC-425).
3.1.16. Steam Generation 3 Elements Control

Three element controls are provided for the kettle type steam generators E-1503
A/B/C and E-1503 A/B. This scheme has the objective to control the level on the
kettle steam generator at a constant set point, based on the high-pressure steam
flow rate as major disturbance, like a feedfoward variable, that impact the level.
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Since the flow rate of steam increases, the level decreases, with the consequent
action to increase the boiler feed water flow rate.
Figure 26: Steam Generation 3 Elements Control
The summing function receives the linearized steam flowrate signal and adds or
subtracts from the steam signal a signal which is the difference between the steam
drum level controller output and a bias signal (the level setpoint) set at 50% signal.
The resultant output signal from the summing function is the setpoint signal to the
boiler feed water flow controller.
The system is designed so that for every weight unit of steam make a weight unit
of feed water is introduced and the level controller signal is only used to
compensate for blowdown and error in steam to water ratio.
3.1.17. Split Range Control of Surge Drum

The pressure of the following surge drums is maintained constant by means of
split range pressure controller PIC-XXX with 2 control valves: One to admit fuel
gas in the surge drum and the other one to vent off gas from the surge drum to the
flare
If the pressure inside the feed surge drum is lower than the setpoint of the
pressure controller, Then the pressure controller will send an output in the low
range (0-50%). In that case the control valve for fuel gas in will open while the
control valve to flare will remain closed. The opening of control valve for fuel gas
will increase when the output of the pressure controller decreases in the 0-50%
range.
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If the pressure inside the feed surge drum is higher than the setpoint, then the
pressure controller will send an output in the high range (50-100%). In this case,
the control valve for fuel gas in will remain closed while the control valve to flare
will open. The opening of the later will increase when the output of the controller
increases (and so the pressure) in the 50-100% range.
Figure 27: Feed Surge Drum Pressure Control
The above pressure control scheme is valid for the following drums:
Drum Tag No. Controller Tag No. PV for Fuel Gas In PV to Flare
D-1513 PIC-403 PV-403A PV-403B
D-1515 PIC-468 PV-468A PV-468B
D-1516 PIC-479 PV-479A PV-479B
D-1517 PIC-475 PV-475A PV-475B
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Drum Tag No. Controller Tag No. PV for Fuel Gas In PV to Flare
D-1518 PIC-483 PV-483A PV-483B
D-1519 PIC-489 PV-489A PV-489B
D-1522 PIC-505 PV-505A PV-505B
D-1523 PIC-510 PV-510A PV-510B
3.1.18. Main Fractionator Pressure Control

The main fractionator pressure is controlled at the reflux drum D-1514 via PIC-456
by speed control of the wet gas compressor C-1551 in the gas recovery section.
A signal proportional to the pressure in the Main Fractionator Reflux Drum D-1514
is sent by the pressure controller PIC-456 to the software selector HS-702 which is
used to select between this input and the output of the pressure controller PIC-068
at the Disengager section of the riser D-1501. In normal operation, the signal from
PIC-456 is selected. HS-702 then forwards the selected signal to the speed
controller SIC-861 of the wet gas compressor C-1551 in the gas recovery section.
SIC-861 then adjusts the speed of C-1551 accordingly to maintain the adequate
pressure in D-1514.
Pressure is not a process variable from an operation point of view and is not
adjusted to correct product specifications.
The unit has been designed to operate with a pressure of 0.4 kg/cm²g in the
fractionator reflux drum. This pressure sets the pressure in the reactor, where low
pressure is desirable to achieve good feed vaporization.
The output of the software selector switch is also routed to the low selector switch
UY-701 which selects the lowest signal between this input and the output of the
pressure controller PIC-707 at the gas outlet of the interstage KO drum D-1552 to
the 2nd stage compressor. The lowest signal is then routed to the compressor anti-
surge control UC-861
3.1.19. HCO Pumparound Heat Removal Control

The HCO pumparound provides heat to the debutanizer reboiler E-1560A/B and
heavy naphtha stripper reboiler E-1509. Constant heat removal in the pumparound
is controlled by controlling these 2 variables:
• Total pumparound flow with FIC-419 at the discharge of P-1508 A/B,
which adjusts the HCO pumparound bypass flow by acting on FV-419 on
the bypass line. This HCO pumparound bypass flow is routed directly to
the PA return from the discharge of the HCO pumparound pumps.
• Return pumparound temperature with TIC-446 located on the HCO PA
return line to the Bed #3. The output of the temperature controller TIC-446
is used to reset the flow controller FIC-420, which controls the flow of HCO
pumparound leaving the HCO Pumparound MP Steam Generator E-1523
with FV-420. The flow of HCO PA exiting E-1523 is measured and
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transmitted to FIC-420 by FT-420A in the high range and FT-420B in the

low range.
3.1.20. HCO Recycle and HCO Recycle MP steam generator E-1508

For maximum distillate mode operation, HCO is recycled to the reactor feed after
being cooled in the HCO recycle MP steam generator E-1508.
The temperature of the cooled HCO is controlled via TIC-425 on the HCO outlet of
E-1508 by adjusting the amount of HCO bypassing E-1508 with TV-425 on the
bypass line.
The differential pressure between the LCO inlet and outlet of the heat exchanger
is controlled by PDIC-420 with PDV-420 on the LCO inlet line.
The level in the MP steam generator is controlled and maintained constant by LIC-
408 cascaded on the flow controller FIC-415 of the BFW supply to the heat
exchanger.
Figure 28: HCO Steam Generator Controls
3.1.21. HCO LP Steam Generator E-1510 Controls

The temperature of the HCO leaving the LP steam generator E-1510 is controlled
by TIC-474, at the HCO outlet of E-1510, cascaded on the pressure controller
PIC-447 on the steam side of the HCO LPS generator E-1510. When the HCO
temperature at TIC-474 is above the setpoint, then the setpoint of PIC-447 will be
decreased to command the opening of the pressure valve PV-447
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The level in E-1510 is controlled by LIC-435 cascaded on the flow controller FIC-
450, which adjust the flow of BFW fed to the LPS generator with FV-450.
Figure 28: HCO Steam Generator Controls
3.1.22. HCO Flushing Oil Pumps Auto-start Control

HCO flushing oil is sent from the LCO HP steam generator E-1510 to the HCO
flushing oil drum D-1518. From D-1518, HCO is pumped by the HCO flushing oil
pumps P-1521 A/B to the HP flush oil header after being filtered in either of the
HCO flushing oil filters F-1502 A/B.
There are 2 HCO flushing oils pumps:
• P-1521 A is HP-LP steam backpressure turbine driven
• P-1521 B is motor driven
The selection between these pumps is made via the software switch HS-404.
The flow to the HCO flushing oil filters is controlled at the pumps discharge by
means of FIC-461 which regulates the flow of HCO recycled back to the HCO
flushing oil drum D-1518 with FV-461 on the spillback line.
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The minimum pressure at the pumps discharge is controlled by PIA-487: In case

the pressure at the pumps discharge falls to the low pressure setting PAL-487,
then the standby pump is automatically started.
The turbine driven pump P-1521A is provided with 3 position switch (XHSO-
468/XHSC-468-XHSM-468) to have a similar function as HOA (Hand-Off-Auto)
switch of motor. This function is configured as part of the ESD function UX-438
(see section 4) acting on the valve XV-468. Indeed, since this pump is steam
turbine driven, the opening/closing of valve XV-468 in the steam inlet line drive this
pump:
• When XHSO-468 is selected, then the valve will open, allowing the steam
to flow through the turbine and so the pump starts.
• When XHSC-468 is selected, then the valve XV-468 will close, thereby
stopping the pump by cutting off the steam supply.
• WhenXHSM-468 is selected, then the pump P-1561A will start remotely \.
The ESD trip logic UX-438 will take precedence over any manual valve open or
remote (auto start) command.
Figure 29: HCO Flushing Oil Pumps Auto-Start
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3.1.23. LCO and Heavy Naphta Pumparound Heat Removal Control

In a similar manner than the HCO PA heat removal, constant heat removal in the
LCO pumparound is controlled by controlling these 2 variables:
• Total pumparound flow with FIC-417 at the discharge of P-1510 A/B, which
adjusts the LCO pumparound bypass flow by acting on FV-417 on the
bypass line.
• Return pumparound temperature with TIC-452 (located on the LCO PA
return line to the Bed #2) cascaded on the flow controller FIC-418 which
controls the flow of LCO PA leaving the LCO PA BFW Heater E-1511.
In the same way, constant heat removal in the heavy naphta pumparound is
controlled by controlling:
• The total pumparound flow with FIC-412 at the discharge of P-1514 A/B,
which adjusts the LCO pumparound bypass flow by acting on FV-412 on
the PA bypass line back to T-1501 Bed #1.
• The return pumparound temperature with TIC-430 (located on the Heavy
Naphta PA return line to the Bed #1) cascaded on the flow controller FIC-
414 controlling the flow of heavy naphta PA leaving the Heavy Napht
Pumparound Cooler E-1521.
3.1.24. Heavy Naphta Product Draw-Off and T-1501 Overheads Temperature Control
Heavy naphtha product is also drawn off with the heavy naphtha pumparound.
The cut point between LCO and heavy naphtha is controlled by the temperature
controller TIC-454 below the heavy naphtha draw tray. TIC-454 resets the heavy
naphtha flow controller FIC-453 (via software switch HS-428) which controls the
flow of heavy naphta leaving the unit with FV-453 downstream of the heavy
naphta trim cooler E-1518.
The cut point between heavy naphtha and overhead distillate is controlled by
fractionator overhead temperature controller TIC-461 resetting reflux flow
controller FIC-427 (via software switch HS-429) with FV-427 downstream of the
Fractionator Reflux Pumps P-1516 A/B.
HS-428 is provided to forward the output of TIC-454 either to FIC-453 (normal
condition) or HS-429. HS-429 is provided to select between the output of TIC-461
(normal condition) and the one from HS-428. So alternatively, the heavy naphtha
draw rate can be fixed on flow control and the temperature controller below Bed 1
can be switched to reset reflux flow via HS-428 and HS-429.
For Maximum Distillate operation the overhead cut point is critical to ensure that
the combined LCO flash point specification is met. Even with maximum reboiling
of the heavy naphtha stripper T-1502, the flash point specification will not be met if
the overhead cut point is too low. This temperature should be adjusted based on
operating experience, in order to maximize total LCO product while meeting the
flash point specification.
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3.1.25. Water Draw Off and Recirculation

A water draw-off tray is provided below the top tray. In normal operation, water is
continuously drawn off from the main fractionator. The flow of water draw-off is
controlled by the software hand controller HIC-418 acting on the control valve LV-
416 located on the wash water line to E-1519.
The normal overhead temperature is approximately 15°C to 20°C above the water
dew point. If the column is operated at or near the overhead water dew point,
water will condense (risk of corrosion). This can occur during start-up with the unit
at turndown as the steam rates are not reduced proportionately to feed rate. In
that case, water is drawn off under interface level control by LIC-416 acting on LV-
416.
Software switch HS-417 is provided to select between the output of LIC-416 or the
output of HIC-418 to control the opening of LV-416.
Part of the wash water is recirculated from the boot of D-1514 back to the inlet of
E-1519 on flow control by FIC-459 at the overhead sour water pumps P-1517 A/B
discharge.
Another part of the sour water from D-1514 boot is sent to the inlet of the wet gas
compressor intercooler E-1551 on flow control by FIC-703, while the remaining
sour water is sent to the SWS on flow control by FIC-456 at P-1517 discharge
FIC-456 is reset by the interface level controller LIC-446 of D-1514.
3.1.26. Wet Gas Compressor Control

The wet gas compressor operation is controlled by the pressure controller on the
fractionator reflux drum, as described in the section 3.1.18 of this document.
This pressure sets the operating pressure on the reaction section. The pressure
controller is set at the normal value. It is not an operating variable for the gas plant
and is not normally adjusted.
The primary control on the compressor is speed control of the steam turbine within
the operating speed range: In normal operation, the compressor speed is
controlled by the pressure controller PIC-456 of the fractionator reflux drum D-
1514 which is cascaded on the compressor speed controller SIC-861 via HS-702.
The secondary control is the spill-back control on the two compressor stages by
UV-702 (controlled by the anti-surge controller UC-862) on the spillback line from
the 2nd stage compressor back to the inlet of the wet gas intercooler E-1551.
The compressor is protected from surge by the compressor anti-surge control
system UC-861/862.
3.1.27. First Stage KO Drum D-1551 Level Control

The liquid level on the drum D-1551 is controlled by starting/stopping the KO drum
liquid pump P-1552 A/B based on the level controller LIA-701 of the KO drum:
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Figure 30: D-1551 Level Control
The duty pump will be automatically started when LAH-701 is activated and
stopped when LAL-701 is activated. HS-701 is provided for duty / stand-by
selection.
3.1.28. Stripper
The level in the HP separator Drum D-1553 is controlled by LIC-717, the output of
which is used to reset the flow controller FIC-711 controlling the flow of stripper
feed downstream of P-1553 A/B with FV-711.
Correct operation of the stripper T-1552 is critical to the operation of the gas
recovery section. The feed preheat temperature is controlled by TIC-723 on the
feed outlet of the stripper feed preheater E-1555. TIC-723 controls the duty of E-
1555 by regulating the flow of heavy naphta leaving E-1555 with TV-723: If the
feed temperature at the outlet of E-1555 is higher than the setpoint then TIC-723
will command the closing of TV-723.
If the feed temperature is too low, there may be water condensation in the stripper.
If it is too high it can reduce C3 recovery.
The duty of the 2nd stripper reboiler E-1557 is controlled by the stripper overhead
flow controller FIC-709 on the overhead line back to the stripper condensers E-
1554 A-D. FIC-709 reset the flow controller FIC-710 on the LCO pumparound inlet
of E-1557, which adjust the flow of LCO entering the 2nd stripper reboiler with FV-
710 accordingly: In case the flow of stripper overheads is higher than the setpoint,
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then FIC-709 will decrease the setpoint of FIC-709 which will in turn reduce the
opening of FV-710 to reduce the duty of the 2nd reboiler.
If the reboil rate is too high, and hence the stripping rate, the primary absorber can
be overloaded, resulting in reduced C3/C4 recovery. If the reboil rate is too low,
the C2 and H2S rates going to the debutanizer will be too high. The set point of
the stripper overhead flowrate should be adjusted to optimize C3 recovery, while
maintaining acceptable H2S and C2 concentrations in the debutanizer overheads.
As an alternative to controlling reboiler rate by the overhead flowrate, the reboiler
duty can be fixed based on operating experience.
3.1.29. Debutanizer
The debutanizer is designed to separate the LPG from gasoline. The two
specifications to be met are the vapor pressure of the gasoline and the C5 content
of the LPG. Additionally, there is an overall C4 recovery specification. Generally, if
this recovery specification is met, the gasoline RVP specification will also be met.
The column operating variables are the reflux rate FIC-721 and the reboiler duty:
• The overhead C5 specification is controlled by the temperature controller
TIC-745 in the top section of the column (tray #8). The output of TIC-745 is
used to reset FIC-721 which controls the reflux flow from P-1556 A/B with
FV-721. Decreasing the temperature controller set point decreases C5
concentration in the LPG.
• The reboilers duty is controlled by FIC-722 located on the HCO PA inlet of
E-1560 A/B. FIC-722 maintains the duty of the reboilers by keep the flow of
HCO PA constant with FV-722 on the HCO PA return line to the main
fractionator. The reboilers duty should be set manually to obtain the
gasoline RVP specification and/or the overall C4 recovery.
3.1.30. LPG Amine Absorber

The LPG amine absorber removes H2S from the LPG prior to LPG treatment for
the removal of mercaptans.
The LPG-amine interface level above the top packed section is maintained by the
interface level controller LIC-746 regulating the flow of rich amine leaving the
absorber to the ARU.
The lean amine flow entering the absorber is controlled by FIC-724 with FV-724
downstream of the lean amine cooler E-1566 to meet the H2S specification and
also to maintain a maximum H2S to DEA mole ratio of 0.4 in the rich DEA.
3.1.31. Control Narrative for the Slurry Separator Package X-1504
The slurry separator is a system with 10 cylindrical modules. Special glass beads
fill each module. High voltage is pressured to the internal of module. When slurry
oil containing catalyst passes through the module, the catalyst particles are
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separated into positive/negative charge and transfer to the oil. Then the charges
are absorbed by the glass beads (dielectric migration) while the slurry oil passes
through the glass beads with minor pressure drop.
This system is provided with a backflushing sequence using LCO. The control of
the slurry separator system is as follow:
1. The system is ready to operate when 400 VAC power is applied to both local
panels and 230 VAC is applied to the Unit Control Panel from either UPS #1 or
UPS #2, or both.
2. The operator uses the Panelview Display Unit to input commands. Operator
commands are:
a) System Run
b) System Stop
c) Unit Bypass Select [1, 2, 3, 4, 5, 6, 7, 8, 9, 10]
d) Alarm reset
e) Overload Acknowledge
The operator ca also set the Backflush Time, the High Voltage Delay Time and
Pause Time.
3. When the operator issues a System Run Command, if there is no PLC fault
alarm, then the PLC generates a Start Permissive Signal, and the Start
Permissive Lights on both local panels are turned on. The system is now ready
for automatic operation. The automatic operation is initiated by placing the
Stop/Start switch in the Start Position at the local Panel.
4. When the Stop/Start Switch is placed in the Stop position, the system is
inactive; all solenoids are de-energized and all high voltage power supplies are
off.
5. When the Stop/Start switch is placed in the Start Position, after the Start
Permissive is received, automatic operation of the system starts and will
continue until stopped by one of the following:
a) A system Stop command
b) The Stop/Start Switch being placed in the Stop Position
c) Loss of the Start Permissive Signal
6. With the system in automatic operation, each unit (module) is selected in
sequence for an operational cycle. Each cycle proceeds as follow:
a) For the unit selected, the high voltage is off and the feed solenoid and
backflush solenoid are energized. Backflushing takes place until the
backflush time expires.
b) When the backflushing time expires, separation begins. The feed
solenoid and the backflushing solenoid are de-energized and the high
voltage delay time starts. Also, the unit count advances and the next
unit in the sequence is selected. If any unit is bypassed, the system will
advance to the next unit. Units are selected by the system in numerical
order, with unit 1 following unit 10.
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c) As soon as the count advances, Pause Time starts. When Pause Time
is complete the unit that was just selected will begin backflushing,
thereby starting a new cycle. The process continues until stopped as
described above.
Whenever the Start/Stop Switch is in the Start position, all high voltage power
supplies are monitored. If any of the power supplies indicates a high temperature,
high pressure or overload, an alarm will be generated and the high voltage power
supply for that module will not be allowed to turn on. In the case of an overload, an
overload latch is set for that unit. The overload latch will reset when the overload is
cleared, the unit is selected, the system is backflushing, and the operator issues
an overload acknowledge command.
3.1.32. Tempered Water for E-1507 A-D

Tempered water is provided from the tempered water surge drum D-1524 to the
slurry clarified oil coolers E-1507 A-D, where it is used as cooling medium, by
means of the tempered water pumps P-1528 A/B. Tempered water leaving E-1507
A-D is then cooled down in the tempered water air cooler E-1530 on temperature
control of the water leaving E-1530 by TIC-525 acting the flow of water bypassing
the cooler with TV-525 on the bypass line. The differential pressure across the
cooler is controlled by PDIC-514 acting on PDV-514 in the water inlet line.
Cooled tempered water is then recycled back to E-1507 A-D by means of P-1528
A/B.
The flow of tempered water pumped to the slurry clarified oil coolers is controlled
by FIC-487 which adjusts the amount of tempered water sent from the discharge
of P-1528 A/B back to the pumps’ suction line with FV-487.
The duty pump is selected by means of HS-488. In case of low low flow (FALL-
488) activated then the standby pump will automatically kick-in.
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Figure 31: Tempered Water Pumps Control
RFCC Closed Drain Pumps P-1560 A/B

Closed drain hydrocarbon liquid is collected in the RFCC closed drain vessel D-
1560, which is equipped with 2 vertical pumps P-1560 A/B (one on duty and one
on standby) to empty the closed drain drum by pumping the slop oil to storage.
Software switch HS-601 is provided to for standby/duty selection. Each pump P-
1560 A/B can be selected in manual or auto operation by means of MHS-601B
and MHS-602B respectively.
In AUTO mode, the standby pump will be automatically started when the high level
alarm of the closed drain drum LAH-601 is activated and stopped when the low
level alarm LAL-601 of the drum level controller LIC-602 is activated.
Both pumps will be automatically stopped when the low low level alarm LALL-603
in the closed drain drum is activated.
3.1.33. Amine Closed Drain Recovery Drum Pump P-1564

The amine recovery closed drain drum D-1561 recovers amine from several
locations in the gas recovery section of the RFCC through the closed drain amine
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header. The amine recovered in D-1561 is then pumped to the ARU for
regeneration by means of the pump P-1564 and on level control of the drum:
P-1564 will automatically start when the high level alarm LAH-769 of the amine
closed drain drum D-1560 is activated. Likewise, the pump will automatically stop
when the low level alarm LAL-769 of the drum is activated.
Also the pump will automatically stop in case the low low level trip LALL-774 is
activated.
3.1.34. RFCC lift station No.1 & No.2 Pits Pumps Control
Oily water from west area is collected in the No.1 Pit XP-1501 while oily water
from east area is collected in the No.2 Pit XP-1502. The oily water is pumped from
the pits XP-1501 and XP-1502 to the Effluent Treatment Plant (ETP) by means of
P-1561 and P-1562 respectively. The pumps operated on level control of their
sump just like for the amine closed drain drum D-1560:
P-1561 starts automatically when the high level alarm of XP-1501 LAH-770 is
activated and stops when the level in the sump has reached the low level setting
of the level controller LIC-770, that is when LAL-770 is activated. The pump will
stop in case the low low level alarm of the sump LALL-770 is activated
Likewise, P-1562 starts automatically when the high level alarm of XP-1502 LAH-
772 is activated and stops when the level in the sump has reached the low level
setting of the level controller LIC-772, that is when LAL-772 is activated. The
pump will stop in case the low low level alarm of the sump LALL-772 is activated
3.1.35. Inter-Unit Controls & Interfaces
3.1.35.1. RFCC Feed Control

The objective of the control of the atmospheric residue from the CDU to
the RFCC to control the level in the bottom of the Main Fractionator of the
CDU and route as much of the outgoing atmospheric residue to the
RFCC as required.
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Figure 32: RFCC Feed Control

The level in the Main Fractionator, T-1101 is controlled by a 3 way split
range level controller 011-LIC-007 (direct acting):
• In the low range (0 -33%) the signal from 011-LIC-007 goes to 011-
LY-082, then to low selector 011-LY-007B, which selects between
011-LIC-007 and the feed requirement of the RFCC (015-LIC-402)
to control the flow to the RFCC.
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• In the mid range (33-67%) 011-LIC-007 resets the setpoint of

011-FQIC-026.
• In the high range (67-100%) 011-LIC-007 resets the setpoint of
011-FQIC-027.
011-FQIC-026 and 011-FQIC-027 are parallel controllers used to regulate

the flow of residue to storage. 011-FV-026 is a smaller valve than 011-FV-
027 and will normally be sufficient to control the amount of residue to
storage whilst the RFCC is on-line. In the event that the RFCC is off-line
then 011-FQIC-026 will be fully open and 011-FQIC-027 will control the
flow to storage. The sum of flow of atmospheric residue to storage and
RFCC is indicated to operator by signal 011-FI-065. The total flow of
atmospheric residue is indicated to operator by signal 011-FI-167.
The RFCC feed is controlled by a split range level controller 015-LIC-402,

which takes flow preferentially from the CDU by cascading onto 011-
FQIC-029 via 011-LY-007B (low range output of the feed surge drum
level controller). If there is not enough flow coming from the CDU (high
range output of the feed surge drum level controller) then flow is taken
from storage by acting on 015-FIC-402, flow controller in the line from
storage.
3.1.35.2. Temperature of Lean Amine from the ARU

The temperature of the lean amine fed from the Amine Regeneration Unit
to the RFCC (and LCO HDT) is controlled such that there is a fixed
minimum temperature differential between the fuel gas and lean amine in
the Fuel Gas Absorbers T-1555 in the RFCC Unit (and T-2402 in the LCO
HDT Unit).
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Figure 33: Temperature Control of Lean Amine from the ARU
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The ΔT between the temperature of the fuel gas entering the fuel gas
absorber T-1555 from the FG Absorber Feed KO Drum D-1557 and the
temperature of the lean amine fed to the top of the Fuel Gas Absorber is
controlled by 015-TDIC-746.
This ΔT is controlled by TDIC-087 in the LCO HDT.
Signals from both 015-TDIC-746 in RFCC and 024-TDIC-087 in LCO
HDT are directed to a low signal selector 019-TDY-019D in the ARU, in
order to ensure that the lean amine temperature is always controlled at
5°C above the higher fuel gas temperature, to prevent hydrocarbon
condensation.
The lowest signal simultaneously acts on the control valves around the
Amine Air-Cooler E-1904 via -019-TDY-019 A/B/C (direct acting for amine
flow to aircooler and reverse acting for air-cooler by-pass valve so that
one valve will close when the other opens). This arrangement will allow
adjusting the required temperature difference with minimum flow/pressure
variation of the lean amine supplied to the Refinery users.
3.1.36. Operating Parameters

For the operating conditions of the RFCC refer to the following Process Flow
Diagrams:
8474L-015-PFD-0010-101 Reactor / Regeneration Section – Case: Bach Ho
8474L-015-PFD-0010-102 Flue Gas Treatment Section – Case: Bach Ho
8474L-015-PFD-0010-103 Feed Section – Case: Bach Ho
8474L-015-PFD-0010-104 Fractionation Section – Case: Bach Ho
8474L-015-PFD-0010-105 Gas Recovery Section – Case: Bach Ho
8474L-015-PFD-0010-106 Material Balance Table – Case: Bach Ho MG
8474L-015-PFD-0010-107 Material Balance Table – Case: Bach Ho MD
8474L-015-PFD-0010-111 Reactor / Regeneration Section – Case: Mixed Crude
8474L-015-PFD-0010-112 Flue Gas Treatment Section – Case: Mixed Crude
8474L-015-PFD-0010-113 Feed Section – Case: Mixed Crude
8474L-015-PFD-0010-114 Fractionation Section – Case: Mixed Crude
8474L-015-PFD-0010-115 Gas Recovery Section – Case: Mixed Crude
8474L-015-PFD-0010-116 Material Balance Table – Case: Mixed Crude MG
8474L-015-PFD-0010-117 Material Balance Table – Case: Mixed Crude MD
3.2. Instrument List

Refer to attached extracted instrument list: Unit 015 extracted instrument list.xls
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3.3. Main Equipment
3.3.1. Reactor Riser, Stripper, Disengager and Catalyst Stand Pipe

The cracking reactions between the feed mixture and the catalyst take place in the
riser, within the 2 sec. residence time.
The riser is provided with (from bottom to top)
• Riser wye where the hot regenerated catalyst is injected from the
withdrawal well
• Riser Bottom Ring where MP steam is injected to fluidize the catalyst
• 4x Stabilization MP Steam injectors I-1503 A-D to promote smooth and
homogeneous catalyst flow at the feed injection point.
• 6x Feed Injectors I-1501 A-F where the feed is finely atomized and mixed
with dispersion steam
• 4x MTC injectors I-1502 A-D to inject recycled heavy naphta. The MTC
plays an important role in the heat balance control and heavy feed
vaporization.
It is the key to achieve a higher temperature in the fresh feed mixing zone:
With MTC, it is possible to raise the mix temperature while maintaining the
Riser Outlet Temperature or even lowering it. Thus the optimum catalyst
temperature, the target catalyst circulation, and the desired catalytic
cracking reactions can be adjusted separately.
The MTC technology offers the possibility of operating the feed injection
zone at a higher temperature thereby promoting vaporization without
reaching over-cracking conditions in the riser whose outlet is maintained at
a lower temperature. MTC provides additional heat removal. Cooling is
carried out by vaporization of the liquid hydrocarbons introduced at the
MTC level.
• Backflush Oil injector I-1504 for the slurry recycle
• Riser Outlet Separator System (ROSS), located at the outlet of the riser,
where the catalyst is quickly separated from the hydrocarbon / steam
vapour.
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Riser
Position Vertical
Normal/MAX. Operating Temperature (°C) 772 / 815
Normal/MAX. Operating Pressure (kg/cm2g) 2.2 / 2.6
Design Conditions:
Shell 350°C and 5.2 kg/cm2g
Internals Normal/Max. Temperature (°C): 560 / 840
Insulation Refractory Lining
Materials:
Shell / Heads: CS A516 Cr 70
Internals Stainless Steel
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Figure 34: Reactor Riser
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Figure 35: injectors Arrangement
3.3.1.1. Riser Outlet Separation System

The principle of the patented AXENS Riser Outlet Separation System
(ROSS) is a symmetrical structure of separation chambers and collecting
chambers alternatively arranged around the top of the riser.
The separation chambers are connected in their upper section to the riser
and the vapor + catalyst mixture follows a 45° turn downwards around an
inlet baffle. The vapor outlets to the collecting chambers are located
underneath the inlet baffle in the perpendicular direction of the incoming
stream. This geometry provides simultaneously both the centrifugal effect
and the inertial effect which are key factors for catalyst separation.
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The catalyst separated is collected in a hopper prolonged by a dip leg

which achieves the necessary seal between the riser and the stripper
vessel. The vapor exiting the separation chamber is then mixed in the
collecting chamber with the steam evolved from the stripper vessel. The
collecting chambers are then connected to a center pipe collector which
distributes the vapor to the disengager cyclones for final catalyst
separation.
This system achieves in a single device an extra-short time of vapor
disengagement of about 1 second (45° turn, no vortex) and an efficient
catalyst separation in two chambers arranged in series. The main
chamber which is the separation chamber itself and the secondary
chamber which is the vapor collecting chamber providing an additional
safety buffer volume for further catalyst disengagement in case of catalyst
carry-over.
Figure 36: Cyclones Orientation
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Figure 37: Separator Arrangement
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3.3.1.2. Catalyst Stripper

The purpose of this section of D-1501 is to strip the catalyst exiting the
ROSS with steam to reduce coke yield.
In order to provide an efficient stripping, the stripper is provided with the
following steam rings:
• Pre-stripping steam ring (I1 on the figure) located immediately at
the exit of the separator diplegs
• Upper Stripping Ring (I2 on the figure) located just upstream of the
fluidized bed packing
• Stripper Main Ring (I3 on the figure) located just downstream of the
fluidized bed packing
• Lower Stripping Ring (I4 on the figure) located at the bottom of the
stripper to achieve a stable fluidization at the inlet of the spent
catalyst standpipe.
• The steam rate for this ring is part of the total steam required for
good stripping but its prime function is to aerate the catalyst
entering the spent catalyst standpipe. This is important for
adequate head build-up to maintain an adequate slide valve
differential pressure for controlling the stripper level.
The stripper is also provided with a fluidized bed packing allowing for
cross and counter current flow of steam and catalyst and enhancing the
contact between the catalyst and the steam.
Stripper
Position Vertical
Design Conditions:
Materials:
Internals CS A516 Cr 70
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Figure 38: Stripper Arrangement
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3.3.2. 1st Stage Regenerator D-1502

The purpose of the 1st stage regenerator is to burn part of the coke by combustion
air from the air rings provided at the bottom of the vessel. Combustion air to the
first stage regenerator D-1502 is split between two air rings: The outer air ring and
inner air ring, which are designed to handle about 70% and 30% of the
combustion air to the first stage regenerator D-1502 respectively.
This regenerator operates in a counter current (air in at bottom and spent catalyst
in at top) mode which helps prevent catalyst overheating. The regeneration
conditions are mild to limit hydrothermal deactivation of the catalyst. First stage
regenerator total combustion air is controlled to limit the temperature in the first
stage to maximum 730°C.
The first regenerator D-1502 is equipped with an air lift to transfer the catalyst from
the bottom of D-1502 to the 2nd regenerator D-1503. The flow of catalyst transfer
is regulated by means of the air lift plug valve PV-1501 (see special valves)
A set of 6 two-stage cyclones is provided at the top of the first stage regenerator to
separate entrained catalyst from the flue gas leaving D-1502. A double-disc flue
gas slide valve (SV-1503) is provided at the outlet of the 1st stage regenerator to
reduce the pressure of the flue gas upstream of the CO Combustor H-1503.
1st Stage Regenerator D-1502

Position Vertical
Design Conditions:
Materials:
Internals SS A240-304H
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Figure 39: 1st Stage Regenerator
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Figure 40: 1st Stage Regenerator Two-Stage Cyclones Arrangement
3.3.3. 2nd Stage Regenerator D-1503

In the 2nd stage regenerator, the partly regenerated catalyst from D-1502 is
completely regenerated to less than about 0.05% by means of combustion air and
at more severe conditions than in D-1502. The combustion air is provided at the
bottom head of the regenerator.
A set of 4 external refractory lined cyclones CY-1504 A-D are provided to remove
entrained catalyst from the 2nd stage flue gas. This design expands the operating
envelope for regenerator temperatures. The cyclone dip legs are external to the
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Aeration is supplied to the diplegs to provide for smooth fluidized catalyst flow and
the diplegs outlets are equipped with flapper (trickle) valves to prevent catalyst
and gas backflow into the cyclones.
At the flue gas outlet of the 2nd stage regenerator is provided a flue gas double
disc slide valve SV-1504 to control the pressure of the flue gas flowing to the
waste heat boiler H-1503.
2nd Stage Regenerator D-1503

Position Vertical
Design Conditions:
Materials:
Internals SS ASTM A240-304H
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Figure 41: 2nd Stage Regenerator
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Figure 42: 2nd Stage Regenerator Cyclones
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Figure 43: 2nd Stage Regenerator Cyclones Arrangement
3.3.4. Aeration and Fluidization Systems

The catalyst fluidization and aeration systems play a vital role in the stability of
catalyst circulation.
The standpipe aeration systems on the unit are designed to handle a wide range
of conditions and still provide the smooth, stable, catalyst flow required for proper
operation. This is essential for stable and adequate catalyst slide valve
differentials.
The system includes aeration points located along the vertical portions of the
standpipes with a rotor meter or flow orifice provided for each tap. The flows to the
taps are initially set equally to replace the volume of interstitial gas compressed by
head pressure.
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It is important to note the difference between aeration and fluidization systems:

• Aeration is the process of replacing, with the injection of gas, the volume
lost to compression by head pressure in a column of fluidized catalyst.
Aeration medium is necessary to keep the catalyst from becoming non
fluidized and developing unstable flow characteristics. The taps on
standpipes are located such that there are twice the numbers required for
an adequate aeration. If one becomes plugged the neighboring tap will
continue to ensure stable operation.
• Fluidization taps are employed when the direction of catalyst flow changes.
In the R2R unit, 45° angle changes are used to redirect catalyst flow
whenever possible. As the catalyst flows into a 45° line the fluidization
media is injected to assist in the turn. On the other hand, when catalyst
flows from a 45° line, the fluidization media is added to smooth the turn and
to penetrate the denser catalyst layer at the wall to allow easier entrance. A
smooth, stable flow of catalyst into vertical standpipes is very important.
Therefore, fluidization taps are either doublets or triplets
Two locations merit special notice:

• The regenerated catalyst standpipe handles catalyst without any coke and
is at high temperatures. Catalyst at these conditions is inherently more
difficult to maintain fluidized.
• The second location to note is the second stage cyclone dip leg aeration.
Instrument purges provide a large part of the required aeration. The
fluidization in the slanted portions of the diplegs is very important. The
penetration of the dense catalyst layer near the regenerator wall is
necessary to ensure smooth flow of fines returning to the regenerator.
Without proper aeration in the diplegs the cyclones may flood and catalyst
losses will increase.
3.3.5. Special Valves

Two types of valves are used in the R2R process: catalyst slide valves and plug
valve. Slide valves are carefully designed with abrasion resistant protection for
improving the valves reliability. Internal insulation allows to use carbon steel for
the body of the valves.
The valves are provided with appropriate purges, on the stem and body, to clear
catalyst particles from the valves. Internal inlet shapes are designed to provide
smooth operation.
The plug valve design includes a stuffing box, an insulation sleeve and an air
purge which provides efficient protection against catalyst blockage. Thrust limiter
and seat and plug angles have been optimized to overcome the thermal
expansion of the air lift.
All valves are provided with independent hydraulic oil system to ensure a reliable
and stable operation.
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Regenerated Catalyst Slide Valve SV-1501

Location Bottom of withdrawal well
Fluid FCC Catalyst
Purpose To regulate the amount of hot regenerated catalyst flowing from the
withdrawal well to the reactor riser, thereby controlling the reactor
outlet temperature.
Direction of Flow Vertical Down
Inlet Pressure (kg/cm2g) Normal: 2.66 / Max.: 3.06
Pressure Drop (kg/cm2g) 0.48
Fluid Temperature (°C) Normal: 712 / Max.: 815
Spent Catalyst Slide Valve SV-1502

Location Bottom of spent catalyst stand pipe
Fluid FCC Catalyst
Purpose To control the level in the stripper D-1501 by regulating the flow of
spent catalyst flowing from the bottom of the stripper to the 1st stage
regenerator D-1502 via the spent catalyst stand-pipe.
Pressure Drop (kg/cm2g) 0.41
Fluid Temperature (°C) Normal: 545 (650°C for 6 hours during start-up) / Max.: 511
Flue Gas Double Disc Slide Valve SV-1503

Location Flue Gas outlet of 1st regenerator
Fluid 1st Regenerator Flue Gas
Purpose To reduce the pressure of the flue gas leaving the 1st stage
regenerator to the CO combustor H-1503, thereby controlling
the pressure in D-1502.
Operating Temperature (°C) 678 / 730
Outlet Pressure (kg/cm2g) 0.085
Valve Pressure Drop (kg/cm2g) 1.28 / 1.57
Variable Orifice Pressure Drop 0.765 / 0.875
(kg/cm2g)
Total Pressure Drop (kg/cm2g) 2.045 / 2.445
Flowrate wet basis (kg/h) Normal: 282,084 / Min.: 178,544
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Flue Gas Double Disc Slide Valve SV-1504

Location Flue Gas outlet of 2nd regenerator
Fluid 2nd Regenerator Flue Gas
Purpose To control the 2nd stage regenerator pressure (and
maintaining the adequate ΔP across the 2 regenerators) by
regulating the flow of flue gas leaving D-1503 to the waste
heat boiler H-1503.
Operating Temperature (°C) Normal: 772 / Max.: 840
Valve Pressure Drop (kg/cm2g) 0.68 / 0.95
Variable Orifice Pressure Drop 0.475 / 0.605
(kg/cm2g)
Total Pressure Drop (kg/cm2g) 1.155 / 1.555
Flowrate wet basis (kg/h) Normal: 138,674 / Min.: 86,941
Air Lift Plug Valve PV-1501

Location Bottom head of the 1st regenerator
Fluid Combustion air from blower
Purpose To control the catalyst level in the first regenerator by allowing
the transfer of catalyst from the 1st regenerator to the 2nd
regenerator.
Regenerator Pressure at valve Normal: 2.56 / Max.: 2.92
(kg/cm2g)
Catalyst Flow (Ton/min) Normal: 43.61
Pressure Drop (Catalyst Side) 0.35
(kg/cm2g)
Catalyst Temperature (°C) Normal: 646
Air temperature (°C) Normal: 216 / Max.: 238
Air Flowrate (kg/hr) 47,832
Inlet Air Pressure (kg/cm2) 2.46
COB/WHB 1st Regenerator Flue Gas Block Valve and Bypass Valve BV-1501 A/B
Fluid Flue gas from the 1st regenerator
Service This system of 2 valves is installed on the flue gas line
coming from the first regenerator. It allows to isolate the
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COB/WHB 1st Regenerator Flue Gas Block Valve and Bypass Valve BV-1501 A/B
COB/WHB and bypass the flue gas to the Electrostatic
Precipitator in case of trip
Operating conditions for Design Case (Mixed Crude Max Gasoline)
Inlet Pressure (kg/cm2g) 0.085
Valves Pressure Profile Block Valve (A) Block Valve (B)
Normal Situation (kg/cm2): Nil 0.03
Trip Situation (kg/cm2g): 2.68 2.68
Flowrate wet basis (kg/hr) 282084
Catalyst Concentration in Flue 446.4
Gas (mg/Nm3)
COB/WHB 2nd Regenerator Flue Gas Block Valve and Bypass Valve BV-1502 A/B
Fluid Flue gas from the 2nd regenerator
Service This system of 2 valves is installed on the flue gas line
coming from the second regenerator. It allows to isolate the
COB/WHB and bypass the flue gas to the Electrostatic
Precipitator in case of trip
Operating conditions for Design Case (Mixed Crude Max Gasoline)
Inlet Pressure (kg/cm2g) 0.085
Valves Pressure Profile Block Valve (A) Block Valve (B)
Normal Situation (kg/cm2): Nil 0.03
Trip Situation (kg/cm2g): 1.7 1.7
Flowrate wet basis (kg/hr) 138,674
Catalyst Concentration in Flue 665.5
Gas (mg/Nm3)
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3.3.6. Air Heaters

2 air heaters H-1501 and H-1502 are provided downstream of the air blower C-
1501. The purpose of H-1501 and H-1502 is to preheat the combustion air
supplied to the air rings of 1st regenerator and the 2nd regenerator respectively. In
order to burn the coke off the spent catalyst.
These heaters are also used during start-up of the plant to dry-out the
regenerators as well as to heat-up the catalyst.
H-1501
Heater Data
Type Air Heater – Horzontal
Type of Fuel Gas Propane (LPG)
Air Allowable Pressure Drop (kg/cm2g) 0.05
Chamber External Diameter (mm) 2624
Chamber Length (mm) 6950
Internal Design Pressure (kg/cm2) 5.2
Internal Operating Pressure (kg/cm2g) 2.98
Design Temperature (°C) 350
Operating Temperature (°C) BH MG BH MG MC MG MC MD
Inlet 238 232 216 223
Outlet 651 636 683 646
Air Flowrate (kg/hr) 180946 166001 261266 214783
Burner Data
Number of Burners 1
Burner Type Low NOx Forced Draft
Firing Position Horizontal Fired
Connection to heater Flanged
Design Burner Duty (MW) 46.57
Normal Burner Duty (MW) 44.36
MIN. Burner Duty (MW) 4.65
Excess Air at Design Capacity 20%
Max Flame Dimension (mm) Length: 5500 Diameter: 1800
Pilot/Ignition Data
Type Forced draft with compressed air
Pilot Liberation (kW) 30
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H-1501
Fuel Gas Pressure Required (kg/cm2g) 0.5
Compressed air pressure required (kg/cm2g) 2
Ignition Method High tension, by electric spark rod
Emission Levels
NOx (mg/Nm3) 140
CO (mg/Nm3) 30
H-1502
Heater Data
Type Air Heater – Horzontal
Type of Fuel Gas Propane (LPG)
Air Allowable Pressure Drop (kg/cm2g) 0.05
Chamber External Diameter (mm) 2000
Chamber Length (mm) 7800
Internal Design Pressure (kg/cm2) 5.2
Internal Operating Pressure (kg/cm2g) 2.03
Operating Temperature (°C) BH MG BH MG MC MG MC MD
Inlet 232 238 216 223
Outlet 713 695 762 712
Air Flowrate (kg/hr) 38773 31685 79610 57261
Burner Data
Number of Burners 1
Burner Type Low NOx Forced Draft
Firing Position Horizontal Fired
Connection to heater Flanged
Design Burner Duty (MW) 14.22
Normal Burner Duty (MW) 13.55
MIN. Burner Duty (MW) 1.42
Excess Air at Design Capacity 20%
Max Flame Dimension (mm) Length: 3500 Diameter: 1200
Pilot/Ignition Data
Type Forced draft with compressed air
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H-1502
Pilot Liberation (kW) 30
Fuel Gas Pressure Required (kg/cm2g) 0.5
Compressed air pressure required (kg/cm2g) 2
Ignition Method High tension, by electric spark rod
Emission Levels
NOx (mg/Nm3) 140
CO (mg/Nm3) 30
3.3.7. CO Boiler / Waste Heat Boiler Package H-1503

The purpose of the CO Boiler is:
• To completely convert as efficiently as possible the CO of the 1st
regenerator into CO2. This conversion will be accomplished by firing
auxiliary fuel gas in order to achieve the SOX emission specification.
• To recover a maximum of heat from the resultant products of combustion,
for the following services:
o Preheating of the boiler feed water fed to the Economizer
o Steam Generation of the CO Boiler itself
o Superheating of the different steam production of the main
fractionator section as required.
In case of emergency, the CO boiler can be bypassed while the unit is still
operating at full capacity.
H-1503 consists of the following elements:

1) CO incinerator with forced draft fans, where the CO contained in the flue gas
fed from the 1st regenerator is converted into CO2
2) Waste Heat Boiler, where the flue gas from the CO incinerator is routed along
with the flue gas from the 2nd regenerator. The Waste Heat Boiler recovers the
heat of these flue gas streams to produce superheated HP and MP steam
through the following elements:
a. HP Superheater and HP de-superheater
b. MP Superheater and MP de-superheater
c. HP Generator
d. Economizer
e. Steam Drum D-1512
f. HP BFW Preheater E-1534
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The following elements are also provided in H-1503 package:

• Phosphate dosing package A-1502 comprising of the Phosphate tank A-
1502-TK-01 and the Phosphate injection pumps A-1502-P-01 A/B
• Continuous and intermittent blowdown drums D-1531 and D-1532
respectively.
• Stack
• Water Sprayers
• Flue Gas Block valves:
o COB/WHB 1st regenerator flue gas block valve BV-1501 A
o COB/WHB 2nd regenerator flue gas block valve BV-1501 B
• Flue Gas Bypass valves
o COB/WHB 1st regenerator flue gas bypass valve BV-1502 A
o COB/WHB 2nd regenerator flue gas bypass valve BV-1502 B
The auxiliary burners and forced draft fans provided with H-1503 are designed for
the production of 250 ton/hr of superheated steam under normal operation.
One is motor driven for normal operation. The second one, in standby, is HP-LP
back pressure turbine driven. Both blowers are equipped with auto-start device.
Part of the generated superheated HP steam from H-1503 is supplied to the
turbine driver of the forced draft fan.
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Design Normal Start-up (Fres

CO Max CO Min Bach HO MG Bach Ho MD Mix Crude MG Mix Crude MD LPG/H2 rich fu
gas firing only
1st Regeneration gas
Flowrate 9kg/h) 310292 310292 194650 178544 383084 231506 -
Temperature (°C) 730 730 641 631 678 646 -
CO Oxidizer (CO Boiler)
Combustion Air (kg/h) 146,168 96674 224520 235302 140077 178120 315000 / 21116
Fuel / Normal Gas (kg/h) 703 1560 7621 8346 3788 5987 8072 / 3044
Heat Release (kW) 9260 20560 100100 109960 49900 78880 102300 / 70000
Total Flowrate (kg/h) 457163 408527 426790 439192 425948 415613 323073 / 21421
Temperature (°C) 1183 100 1178 1173 1130 1197 1000 / 1000
Residence Time (sec.) 0.9 1.1 1.0 1.0 1.0 1.0 -
CO content (mg/Nm3) <300 <300 <300 <300 <300 <300 -
NOx content (mg/Nm3) <1000 <1000 <1000 <1000 <1000 <1000 -
nd
2 Regeneration Gas
Flowrate (kg/h) 152541 152541 94603 86941 138674 114689 -
Temperature (°C) 772 772 733 720 772 734 -
nd
CO oxidizer + 2 Regeneration Gas
Flowrate (kg/hr) 609,704 561068 521393 526133 564622 530302 323073 / 21421
Composition (mol %)
N2 72.49 71.59 72.26 72.44 72.00 71.95 75.70 / 73.45
CO2 13.36 14.17 11.38 10.76 13.48 12.63 5.00 / 1.33
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gas firing only
SOx 0.07 0.06 0.01 0.01 0.05 0.05 0.00 / 0.00
H2O 12.29 12.39 12.66 12.66 12.69 13.16 7.09 / 12.82
O2 1.78 1.78 4.13 4.13 1.77 2.21 12.21 / 12.40
CO <300 <300 <300 <300 <300 <300 -
NOx
<1000 <1000 <1000 <1000 <1000 <1000 -
Flue Gas Temperature (°C)
WHB Inlet 1080 938 1097 1098 1042 1097 1000 / 1000
WHB Outlet 326 309 318 314 318 313 297 / 280
Economizer Outlet 242 235 237 236 238 237 227 / 214
Flue Gas Pressure (mm H2O g)
1st Regenerator gas inlet 1075 min 910 min 733 min 728 min 898 min 774 min -
2nd Regenerator gas inlet 966 min 808 min 700 min 697 min 823 min 726 min -
WHB inlet 923 767 680 679 787 701 220 / 98
WHB Outlet 728 616 534 528 624 551 172 / 76
BFW & Steam Flowrate
Economizer (kg/hr) 238600 183553 211153 211153 211153 211153 115696 / 76868
Generator (Total) 6949530 5346210 6150000 6150000 6150000 6150000 2528741 / 1691
Steam @ Generator Out 231651 178207 205000 205000 205000 205000 112327 / 74629
Import HP steam 61019 18092 10285 18092 61019 57527 -/-
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gas firing only
Total HP steam 292670 196299 215285 223092 266019 262527 112327 / 74629
Import MP Steam 14788 27666 8631 27666 14788 37331 -/-
Blowdown 6949 5346 6153 6153 6153 6153 3370 / 2239
BFW & Steam/Temperature (°C)
Economizer Inlet 165 165 165 165 165 165 165 / 165
Generator Inlet 257.7 257.7 257.7 257.7 257.7 257.7 257.7 / 257.7
HP steam Outlet 422 435 459 453 416 424 483 / 497
HP steam after desuperheater 380 380 380 380 380 380 380 / 380
MP steam Outlet 311 274 315 276 303 264 -
MP steam after desuperheater 250 250 250 250 250 250 -
BFW & Steam Pressure (kg/cm2g)
BFW Preheater Inlet 50 50 50 50 50 50 50
HP steam after desuperheater 42.3 42.3 42.3 42.3 42.3 42.3 42.3
MP steam after desuperheater 14.1 14.1 14.1 14.1 14.1 14.1 -
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Heating Tube Design HP superheater MP superheater HP generator HP Economizer

Material (ASTM) SA335 GrP9 SA106 GrB SA 106 GrB SA 106 GrB
PWHT Yes No No No
Tube type Bare Bare Bare Bare
Outside diameter (mm) 60.3 60.3 60.3 60.3
Thickness (mm) 6.35 Avg wall 5.54 Avg wall 5.54 Avg wall 5.54 Avg wall
Orientation Vertical vertical Vertical Horizontal
Layout Staggered Staggered Staggered Staggered
Flow pass No. 88 30 Screen: 192 / Main: 1536 34
Effective Length (m) 13.99 13.99 13.99 10.55
Number of tubes per row 22 30 Screen: 24 / Main: 32 34
Number of Row 16 4 Screen: 8 / Main: 48 26
Heating area (m2) 933 318 Screen: 509 / Main: 4072 1769
Guide/Support Space (m) 2.4 2.3 2.4 2.3
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Steam Drum D-1512

Design Pressure (kg/cm2g) 49.92
Material
Shell / heads (ASTM) 516 Gr.70
I.D. (mm) 2000
TL to TL Length (mm) 17500
Holding Time 5 minutes (NLL to Empty)
PSV 2
Burner
Number 5
Heat Release per Burner (kW) 23700
Turn Down / Gas 5:1
Turn Down / Oil 3:1
Gas Pressure (kg/cm2) 2.0 at burner
Oil Pressure (kg/cm2g) 10.3 at burner
Steam Pressure 9kg/cm2g) 11.3 at burner
Steam Consumption 265 kg/hr per burner for peak firing
Fan
Number 2 (one operation + one standby)
Design/Normal Air Flow (kg/h) 315000 / 262500
Design/Normal Outlet Pressure (kg/cm2g) 1030/715
Operation range 120% to 30% (by volume)
Speed (RPM) 1485
BHP (kW) 683
Motor Rated (kW) 1230
Turbine (Rated / Normal) (kW) 1165 / 1059
Steam Consumption at rated (kg/h) 34300
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Soot Blower
Type Retractable
Number 52 Total
Min Clearance to Tube (mm) 550 MIN.
Max Row of Tube 8
Steam Consumption (kg/hr each) 4536
Motor (kW/each) 0.75
3.3.8. Electrostatic Precipitator X-1507

The Electrostatic Precipitator is provided to decrease catalyst dust from the flue
gas from the Regenerator via COB/WHB package, to meet the environmental
specification. The dust fine content at precipitator outlet shall not exceed 50
mg/Nm3 dry basis. The principle of operation is to provide high voltage electric for
collection of dust by corona effect.
The electrostatic precipitator comprises of 2 electrostatic precipitators (ESP), ESP

1 and ESP 2, in parallel and ash handling facilities. The flue gas inlet and outlet of
each ESP is provided with an expansion joint and a motorized inlet damper.
Dust laden flue gas from the waste heat boiler H-1503 is directed through the
energized fields of the precipitator in which the discharge and collector electrodes
are situated. A dedicated transformer rectifier se applies a variable, negative
potential, high DC voltage to each field of the discharge electrodes. The collecting
electrodes within each field are supported directly from the casing steelwork and
are therefore at positive or earth potential.
Each ESP of the package X-1507 comprises of 2 systems of discharge and
collecting electrodes: first are the inlet discharge and collector electrodes, and
downstream of them are the outlet discharge and collector electrodes. Each
system is provided with its own dedicated transformer.
Commencing from the minimum setting, the voltage is steadily increased until a
current begins to flow from the discharge electrodes to the collecting electrodes.
This is called “corona discharge”. Increasing the voltage further causes this
current to rise until a maximum point is reached at which sparking or flashover
occurs between the electrodes. The gas flowing between the electrodes becomes
ionized by the corona current and the dust particles become negatively charged.
The electrostatic field causes the charged particles to migrate to the earthed
collector sheets where they adhere and give up their negative charge.
The optimum electrical precipitator conditions are at the point where the voltage is
just below that at which sparking takes place. A low rate of sparking is desirable
and this is used as a basis for the design of the automatic voltage controller (AVC)
that optimizes the output from each transformer rectifier set. The optimum voltage
varies considerably with changing gas and dust conditions but the ESP will
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typically operate at 55 kV on clean ambient air and at between 50 kV and 65 kV

on dust laden flue gases at normal operating temperatures.
As dust cannot accumulate indefinitely on the discharge and collecting electrode
systems without a loss of precipitator performance, they must be rapped on a
regular basis.
Each electrode (discharge and collector) within each ESP has its own individually
sequenced rapping equipment comprising of a geared drive motor, chain driven
cam shaft and a series of hammers arranged to operate singularly in sequence
across the width of the precipitator.
The dust released when the discharge and collecting electrodes are sequentially
rapped falls into the hoppers below each respective field where the ash is
collected and subsequently removed by an ash conveying system. Each ESP is
provided with 4 hoppers, 2 for the inlet field and 2 for the outlet field.
The dust is conveyed by means of air preheated in the steam air preheater X-
1507-E-01. The conveying air flows trough the bottom of each of the 8 hoppers in
series. The dust collected is then sent to the bag filter X-1507-F-01 operated
under a vacuum and provided with steam coil. Heated air is also provided from a
steam air heater X-1507-E-02 to help remove any moisture from the dust. The
heated air is sucked by the ash vacuum pumps X-1507-P-01 A/B to the air water
separators X-1507-S-01 A/B where the separated water is finally sent to the oily
water sewer.
The dried dust retained by the bag filter then falls into the transfer hopper X-507-
TK-02 where it undergoes another stage of drying by means of heated air from X-
1507-E-02 and the a steam coil. The ashes finally falls into the Ash Storage Silo
X-1507-TK-01, where ash is stored under warm and fluidized conditions by means
of a steam coil and heated air introduced at the bottom of the silo. The ash storage
silo X-1507-TK-01 is provided with a vent filter X-1507-F-02 and an exhaust fan X-
1507 to vent the air out of the silo.
Ash is finally removed from the bottom of the silo and is discharged into flexible
bags.
There is a tendency for a small proportion of the liberated dust to be re-entrained

into the gas flow during rapping and this is minimized by maintaining a low gas
velocity within the treatment fields. Additional design features such as the use of
vertical channel profiles on the collector electrodes, adjustable rapping intensity
and reduced rapping frequency in the outlet fields also assist the overall efficiency
of the precipitator.
X-1507
Design Volume (Am/s) 301.18
Operating Gas Temperature (°C) 326
Gas Pressure in inlet duct (kg/cm2g) 0.055
3
Inlet dust load (mg/Nm ) (dry) Normal: 370 Upset: 1700 mg/Nm3
Outlet Dust Emission (mg/Nm3) (dry) Normal ≤ 50 Upset: 180 mg/Nm3
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X-1507
One ESP: 200
Gas Moisture Content (% v/v wet) 12.30
ESP Pressure Drop (Flange to Flange) (kg/cm2g) 0.020
Casing design pressure (kg/cm2g) 0.200
3.3.9. Main Fractionator

The purpose of the main fractionator T-1501 is to separate the different products
contained in the effluents leaving the disengager/stripper D-1501 in the reaction
section. The Main fractionator can be divided into 5 zones (from bottom to top):
• Slurry & Quench zone (bottoms)
• Heavy Cycle Oil (HCO)
• Light Cycle Oil (LCO)
• Heavy Naphta (HVN)
• Overheads (OVHD)
Main Fractionator
Height (TL to TL) (mm): 64100
Internal Diameter (mm): Top to bed #5: 7400 Bottom: 3700
Internals: 5 beds + 30 trays
Bed Height (mm) 2000
Packing Type / Material:
Bed #1 Structured / 11/13 Cr
Bed #2 Structured / 11/13 Cr
Bed #3 Structured / SS TP 304
Bed #4 Structured / SS TP 304
Bed #5 Grid / SS TP 304
Trays 11/13 Cr
Loading Point: Below bed #5
Bach Ho MG Bach Ho MD Mixed MG Mixed MD
Bottoms temperature (°C) 340 340 340 340
Top Temperature (°C) 102 96 103 100
Bottoms Pressure (kg/cm2g) 1.15 1.15 1.15 1.15
Top Pressure (kg/cm2g) 0.85 0.85 0.85 0.85
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Main Fractionator T-1501

Section Operating Design Insulation Material
Temp. (°C) Temp. (°C) Thickness (mm)
Bottom section, up to HCO 520 545 210 1 ¼ CR 0.5 Mo
PA return (top of Bed #3)
Top of Bed #3 up to LCO PA 315 340 100 Carbon Steel
return (top of Bed #2)
Top of Bed #2 up to HVN PA 215 250 60 Carbon Steel
return (top of Bed 1)
Top Section 150 200 30 HIC Resistant
Carbon
Figure 44: Main Fractionator
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3.3.10. Stripper T-1552 & Primary Absorber T-1551

In the primary absorber T-1551, most of the propane, propylene, butane and
butylene are recovered from the gas stream fed from the high pressure separator
drum D-1553. The overhead liquid from the bottom of the fractionation section is
fed to the top tray of T-1551. For other than Bach Ho MG, gasoline is also recycle
from the bottom of the bottom of the debutanizer in order to obtain the required
recovery of C3 and C4.
The purpose of the stripper T-1551 is to strip H2S, C2 and lighter from the LPG
and gasoline mixture which is fed to the top tray from the HP separator D-1553.
The heat required for stripping is provided by 2 reboilers in series, working on
debutanizer bottoms (1st one) and LCO pumparound (2nd one).
The primary absorber and the stripper are physically located in the same vessel,
with T-1551 on top of T-1552.
Primary Absorber T-1551

Height (TL to TL) (mm) 23700
Internal Diameter (mm) 2400
Number of trays / Type 31 / valve
Material Shell / Internals: Wet H2S resistant CS
Trays: 11/13 Cr
Parameter Bach Ho MG Bach Ho MD Mixed MG Mixed MD
FG Product Flow (kg/hr) 13817 12519 18619 14509
Liquid Flow Out (kg/hr) 160094 127834 159206 126788
Top pressure (kg/cm2g) 14.8 14.8 14.8 14.8
Bottom Pressure (kg/cm2g) 15.1 15.1 15.1 15.1
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Figure 45: Primary Absorber T-1551
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Stripper T-1552
Internal Diameter (mm) Tray #1 to Tray#30: 3700
Bottoms: 5000
Number of trays / type 30 / valve
Material Shell / Internals: Wet H2S resistant CS
Trays: 11/13 Cr
Flow IN (kg/hr) 297311 243294 295531 244437
Product Flow (kg/hr) 267774 220591 264456 220318
Ovhd Gas Flow (kg/hr) 29537 22703 31075 24119
Bottom Temperature (°C) 122 126 120 122
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Figure 46: Stripper T-1552
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3.3.11. Debutanizer T-1554

The purpose of the debutanizer is to separate LPG from the gasoline in the liquid
stream fed from the stripper bottoms.
The heat required for the separation is provided by the reboilers E-1560 A/B using
HCO pumparound as heating medium.
Debutanizer T-1554
Internal Diameter (mm) Tray #1 to #21: 3300
Tray #22 to #40: 4000
Number of trays / type 40 / Valve
Material Shell / Internals: Killed Carbon Steel
Trays: 11/13 Cr
Stripper Bottoms Flow IN (kg/hr) 267774 220591 264456 220318
Reflux Flow IN (kg/hr) 113168 106325 107154 100630
Gasoline Flow (kg/hr) 190498 163547 187358 159741
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Figure 47: Debutanizer T-1554
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3.3.12. LPG Amine Absorber

The purpose of the LPG absorber is to remove H2S in the LPG stream from the
debutanizer by contacting the LPG with lean amine (DEA) from the ARU. LPG and
amine are flows in counter-current flow in this packed tower.
LPG Absorber T-1556

Number of Packing Beds / Type 2 / PALL RINGS
Packing Beds Height (mm) 3500
Material Shell: Wet H2S resistant Killed Carbon Steel
Internals: Stainless Steel 304L
Packing: Stainless Steel 304L
LPG Flow IN (kg/hr) 77276 57044 77098 60577
DEA Flow IN (kg/hr) 31606 23331 31533 24776
DEA Flow OUT (kg/hr) 31631 23352 32055 25269
LPG Product Flow (kg/hr) 77251 57023 76576 60084
Temperature (°C) 50 50 50 50
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Figure 48: LPG Absorber T-1556
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3.3.13. Secondary Absorber T-1553

The purpose of the secondary absorber is to recover light fractions from the
overhead gas fed from the primary absorber T-1551 by using heavy naphta from
the fractionation section as lean oil. Lean oil and overhead gas flow counter in this
tower.
Secondary Absorber T-1553

Number of Tray / Type 20 / Valve
Material Shell / Internals: Wet H2S resistant Carbon Steel
Trays: 11/13 Cr
Primary Absorber OVHD (kg/hr) 13817 12519 18619 14509
Lean Sponge Oil (kg/hr) 34993 34990 34996 34990
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Figure 49: Secondary Absorber T-1553
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3.3.14. Fuel Gas Absorber T-1555

The purpose of the fuel gas absorber is to remove H2S and CO2 from the gas fed
from the secondary absorber by contact with lean amine (DEA) in counter current
flow.
The fuel gas absorber is provided with FG absorber feed KO drum D-1557 and FG
absorber outlet KO drum D-1559 to remove any entrained/condensed liquid in the
gas.
The above 3 vessels are physically located in one unique vessel with T-1555 in
between D-1557 (below T-1555) and D-1559 (above T-1555).
Fuel Gas Absorber T-1555

Number of Tray / Type 20 / Valve
Material Shell / Internals: Wet H2S resistant Carbon Steel
Trays: Stainless Steel 304L
Treated Fuel Gas OUT (kg/hr) 9812 8661 13231 9720
Lean Amine IN (kg/hr) 18776 18127 44919 40654
Rich Amine OUT (kg/hr) 19225 18630 46090 41743
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Figure 50: Fuel Gas Absorber T-1555
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3.3.15. Slurry Separator

The Slurry Separator is provided to decrease catalyst fine in the Fractionator
Bottom and produce Clarified Oil for fuel oil production (backflush oil recycled to
the riser). The design capacity is 30.7 ton/hr of slurry oil. The catalyst fine in the
slurry oil is maximum 4,300 PPM at peak, and outlet catalyst fine maximum is
targeting to 100 PPM.
The Slurry Separator package consist 10 module filters with automatic back-
washing facilities by flushing oil.
Parameter Bach Ho MD Mixed Crude MG

Slurry HCO Slurry HCO
Backflush Backflush
Normal Flowrate (kg/hr) 27930 3000 30674 3000
Design Flowrate (% normal) 120 120 -
Operating Temperature (°C) 170 170 170 170
(controllable) (controllable)
Operating Pressure (kg/cm2g) 12.9 4.5 12.9 4.5
Pressure Drop (kg/cm2g) 2.0 3.0 2.0 3.0
Sulphur Content (wt%) 0.1 1.03
Catalyst Fines Content (wt.ppm)

Inlet (average) 1100-1700
Inlet (Peak) 4300
Outlet (Peak) 100
LCO For Cleaning

Operating Temperature (°C) 150
Operating Pressure (kg/cm2g) 6.0
Design Pressure (kg/cm2g) 17.0
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Figure 51: General Arrangement of X-1504
3.3.16. Air Blower, C-1501

The air Blower C-1501 is a centrifugal compressor to supply the necessary
amount of air to burn all the coke off the catalyst and some of the resulting CO to
CO2. Depending upon the mode of operation and other factors such as feed
quality, the required air amounts to the regenerator is supplied from this Air
Blower. The design capacity is 340,483 NM3/h, and 25 MW shaft power. The
machine type is axial compressors with steam condensing turbine driven. The
capacity of air flow rate is mainly controlled by speed of turbine.
C-1501 is provided with an antisurge system.
The manufacturer of the compressor is MAN TURBO AG, model: AG090.
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The major operating conditions are as follows:
Parameter Design Mix MG Mix MD Bach Ho MG Bach Ho MD

Flowrate (Nm3/h) 340,432 309,483 254,808 213,247 195,748
Suction Pressure
1.008 1.008 1.008 1.008 1.008
(kg/cm2g)
Suction Temp. (°C) 36 36 36 36 36
Discharge Pressure
4.66 4.26 4.26 4.26 4.26
(kg/cm2g)
Discharge Temp.
227 210 223 232 238
(°C)
The following are design data for the turbine of C-1501:
Parameter Value
First Critical Speed of C-1501 (RPM) 2179
First Critical Speed of Turbine (RPM) 2324
Normal Speed (RPM) 4400
Rated Speed (RPM) 4,661 (100%)
Min. Continuous Speed (RPM) 3,263 (70%)
Max. Continuous Speed (RPM) 4,894 (105%)
Trip Speed (RPM) 5,383 (115%)
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Figure 52: Combustion Air Blower
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3.3.17. Wet Gas Compressor C-1551

The Wet Gas Compressor is a multi-stage centrifugal compressor to boost-up the
main fractionator overhead gas pressure from atmospheric level to 14-15 kg/cm2g
for Gas Recovery Section. The machine consists two stages compressor, with
external cooling (interstage cooler E-1551 and trim cooler E-1552). The Wet Gas
Compressor is driven by condensing steam turbine. The driver capacity is 8,100
kW. The capacity is mainly controlled by turbine speed, and the wet gas
compressor is provided with an anti-surge control system.
The manufacturer of the wet gas compressor is Elliott/Ebara, Model: 56M81.
The major operating conditions are as follows:
Bach Ho MG Mixed Crude MG

Parameter
Normal Design Normal Design
1st Stage
Flowrate (Nm3/h) 65326 75127 67578 77715
Wet Flow (kg/hr) 138964 159809 139263 160152
MW 47.68 47.68 46.19 46.19
Suction Pressure (kg/cm2A) 1.33 1.33 1.33 1.33
Suction Temperature (°C) 41.9 41.9 41.9 41.9
2
Discharge Pressure (kg/cm g) 5.13 5.09 5.2 5.19
Discharge Temperature (°C) 96.5 97 98.7 99.5
2nd Stage
Flowrate (Nm3/h) 43794 50363 48195 55424
Wet Flow (kg/hr) 80749 92861 86739 99750
MW 41.33 41.33 40.34 40.34
Suction Pressure (kg/cm2A) 4.43 4.39 4.5 4.49
Suction Temperature (°C) 41.9 41.9 41.9 41.9
Discharge Pressure (kg/cm2g) 17.1 17.1 17.1 17.1
Discharge Temperature (°C) 111.3 112 112 112.6
The following are design data of the turbine of C-1551:
Parameter Value
Normal Speed (RPM) 5,134
Rated Speed (RPM) 5,458
Max. Continuous Speed (RPM) 5,731
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Parameter Value
Trip Speed (RPM) 6,304
st
1 Critical Speed (RPM) 2,600-2,700
2nd Critical Speed (RPM) 11,000
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Figure 53: Wet Gas Compressor
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TRAINING MODULE
UNIT: 15
Course Content:

X
Section 9 - HSE
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SECTION 4 : SAFEGUARDING DEVICES
4.1. Alarms and Trips

Refer to attached list:
Unit 015 Alarms & Trips List.xls
4.2. Safeguarding Description

The Emergency Shutdown System (ESD) provides trips and interlocks for preventing or
controlling emergency situations which could give rise to hazardous situations leading to
injuries to personnel, significant economic loss and/or undue environmental pollution.
Uncontrolled loss of containment is prevented by the provision of pressure safety relief
valves and by the ESD system which automatically bring the relevant part of the Unit to a
safe condition.
Trip/interlock is composed of one or more initiators and one or more actions for
preventing hazards. Each trip/interlock shall be provided with a reset and an operational
override for start-up, where necessary.
In general, if interlock is invoked, the interlock action shall be held on until all initiators
have returned to the safe state and the interlock reset has been pressed.
The following is a description of all the safety logics provided in the RFCC unit. For each
logic, the first table describes the initiators of the logic. The second table indicate each
action taken and what are the initiators triggering each action.
4.2.1. Logic UX-001 – Reaction Stop

Initiators:
No. Initiator Tag No. P&ID Description
1 UXHS-001A 121 Hardwire ESD switch active
2 UXHS-001B 121 Hardwire ESD switch active (ESD Bypass switch)
3 FXALL-405 121 Feed Flow Low Low (time delay of 10 seconds)
4 UX-002 121 Logic UX-002 activated: Catalyst Circulation Stopped
5 XHSC-002A 121 Software switch active (DCS operation is not allowed when
UX-001 is activated)
6 XHSO-002A 121 Software switch active (DCS operation is not allowed when
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Actions:
No. Action Tag No. Initiated by P&ID Description
initiator No:
1a XSY-002 1, 2, 3, 4, 5 121 CLOSE XV-002 to stop the .flow of feed to
the feed injectors I-1501 A to F
1b XSY-002 6 121 OPEN XV-002 to allow feed to flow to the
feed injectors !-501 A to F
2 FSY-001 1, 2, 3, 4 121 OPEN FV-001 to re-route feed to the feed
surge drum
3a XSY-003 1, 2, 3, 4, 7 122 CLOSE XV-003 to stop the flow of MTC to
the MTC injectors I-1502 A to D
3b XSY-003 8 122 OPEN XV-003 to allow the MTC to flow to
the MTC injectors I-1502 A to D
4a XSY-004 1, 2, 3, 4, 9 122 CLOSE XV-004 to stop the flow of
backflush oil to the backflush oil injector I-
1504
4b XSY-004 10 122 OPEN XV-004 to the backflush oil to flow to
the backflush oil injector I-1504
5 MXS-001 1, 2, 3, 4 121 Trip the metal passivator injection pumps P-
1502A
6 MXS-002 1, 2, 3, 4 121 Trip the metal passivator injection pumps P-
1502B
7 MXS-439 1, 2, 3, 4 305 Trip the MTC recycle pump P-1512A
8 MXS-440 1, 2, 3, 4 305 Trip the MTC recycle pump P-1512B
9 MXS-481 1, 2, 3, 4 306 Trip the HCO recycle pump P-1507A
(Tripped by UX-423)
10 MXS-482 1, 2, 3, 4 306 Trip the HCO recycle pump P-1507A
(Tripped by UX-423)
11 MXS-464 1, 2, 3, 4 324 Trip the backflush oil recycle pump P-1506A
(Tripped by UX-424)
12 MXS-465 1, 2, 3, 4 324 Trip the backflush oil recycle pump P-1506B
(Tripped by UX-424)
13 FSY-005A 1, 2, 3, 4 121 OPEN FV-005A to allow MP steam to flow
to the feed injector I-1501 A
14 FSY-005B 1, 2, 3, 4 121 OPEN FV-005B to allow MP steam to flow
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initiator No:
to the feed injector I-1501 B
15 FSY-005C 1, 2, 3, 4 121 OPEN FV-005C to allow MP steam to flow
to the feed injector I-1501 C
16 FSY-005D 1, 2, 3, 4 121 OPEN FV-005C to allow MP steam to flow
to the feed injector I-1501 C
17 FSY-005E 1, 2, 3, 4 121 OPEN FV-005E to allow MP steam to flow
to the feed injector I-1501 E
18 FSY-005F 1, 2, 3, 4 121 OPEN FV-005F to allow MP steam to flow
to the feed injector I-1501 F
19 FSY-007A 1, 2, 3, 4 122 OPEN FV-007A to allow MP steam to flow
to the Stabilization injector I-1503 A
20 FSY-007B 1, 2, 3, 4 122 OPEN FV-007B to allow MP steam to flow
to the Stabilization injector I-1503 B
21 FSY-007C 1, 2, 3, 4 122 OPEN FV-007C to allow MP steam to flow
to the Stabilization injector I-1503 C
22 FSY-007D 1, 2, 3, 4 122 OPEN FV-007D to allow MP steam to flow
to the Stabilization injector I-1503 D
23 UXA-001B 1, 2, 3, 4 121 Activate the reaction stop alarm (ADP)
24 FIC-001 1, 2, 3, 4 121 FIC-001 is forced to manual mode and
output 100% to OPEN FV-001
25 FIC-003 1, 2, 3, 4 111 FIC-003 A/B/C/D/E/F is forced to manual
A/B/C/D/E/F mode and output 0% to CLOSE FV-003
A/B/C/D/E/F respectively
26 FIC-005 1, 2, 3, 4 111 FIC-005 A/B/C/D/E/F is forced to manual
A/B/C/D/E/F mode and output 100% to OPEN FV-005
A/B/C/D/E/F respectively
27 FIC-007 A/B/C/D 1, 2, 3 ,4 111 FIC-007 A/B/C/D is forced to manual mode
and output 100% to OPEN FV-007 A/B/C/D
28 FIC-010 A/B/C/D 1, 2, 3 ,4 111 FIC-010 A/B/C/D is forced to manual mode
and output 100% to OPEN FV-010 A/B/C/D
29 FIC-012 1, 2, 3, 4 122 FIC-012 is forced to manual mode and
output 0% to CLOSE FV-012
Reset:
• DCS software switch UHSR-001 (PID No.121) resets all above actions.
• XV-002, XV-003 and XV-004 need to be reset locally by XHSR-002, XHSR-
003 and XHSR-004 respectively.
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4.2.2. Logic UX-002: Catalyst Circulation Stops

Initiators:
2 UXHS-002B 125 Hardwire ESD switch active (bypass switch)
3 PDXLL-064 124 D-1501 Stripper Differential Pressure low low (2 out of2
voting system)
4 PDXLL-104 125 Spent Catalyst Slide Valve SV-1502 differential pressure
low low (2 out of 2 voting system)
5 LXALL-010 131 Withdrawal well level low low (10 seconds average is used
as input)
6 PDXLL-242 131 Hot regenerated catalyst slide valve SV-1501 differential
pressure low low (10 seconds average is used as input)
7 FXALL-170 132 Low low air flow to first regenerator heater (10 seconds off-
delay timer)
8 FXALL-171 132 Low low air flow to the 2nd regenerator heater H-1502
9 FXALL-172 132 Low low air flow to the 1st regenerator D-1502
10 PXALL-363 138 Low low pressure of MP steam supply
11 UX-005 132 MAB Protection active
Actions:
initiator No:
1 USY-1502 ALL 125 CLOSE the spent catalyst slide valve SV-
1502, and generate a discrepancy alarm
2 USY-017 ALL 131 CLOSE the regenerated catalyst slide valve
SV-1501, and generate a discrepancy alarm
3 USY-016 ALL 127 CLOSE the Air lift plug valve PV-1501 of the
first regenerator
4 UX-001 ALL 121 Activate the Logic UX-001: Reaction Stop
5 UX-008 ALL 201 Activate the logic UX-008: COB/WHB 1st
regenerator flue gas bypass operation
6 UX-010 ALL 202 Activate the logic UX-010: COB/WHB 2nd
regenerator flue gas bypass operation
7 UXA-002B ALL 125 Activate catalyst circulation stop alarm
(ADP)
8 LIC-002 ALL 124 LIC-002 switch to manual mode and output
0% to CLOSE SV-1502
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initiator No:
0% to CLOSE SV-1502
0% to CLOSE PV-1501
0% to CLOSE PV-1501
12 PDIC-103 ALL 125 PDIC-103 switch to manual mode and
output 0% to CLOSE SV-1502
13 TIC-015 ALL 123 TIC-015 switch to manual mode and output
0% to CLOSE SV-1501
0% to CLOSE SV-1501
Reset:
DCS software reset switch UHSR-002 resets actions 1 to 6.
4.2.3. Logic UX-003: First Regenerator Air Heater Trip

Initiators:
2 TXAHH-069 133 High high temperature in the first regenerator heater H-
1501
3 PXALL-321 134 Low low pressure of fuel gas supply from the fuel gas
header
4 FXALL-170 132 Low low combustion air flow to first regenerator heater H-
1501
5 BXALL-003 133 No pilot flame in H-1501
6 BXALL-004 133 No main flame in H-1501
7 XS-801 132 Main Air Blower Trip (logic UX-801 activated)
8 UXHS-003B 133 Local panel ESD hardwire switch active
9 UXHS-003C 133 Local panel ESD hardwire switch active
Actions:
initiator No:
1 XSY-016 ALL 133 CLOSE XV-016 to stop the fuel gas supply
to the 1st regenerator heater H-1501
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initiator No:
to the 1st regenerator heater H-1501
3 XSY-019 ALL 133 OPEN XV-019 to vent the fuel gas to flare
4 UXA-003B 1 to 8 133 Activate the first regenerator heater H-1501
trip alarm (ADP)
0% to CLOSE TV-068
Once all the initiators are healthy, the logic UX-003 can be reset by:
• DCS software switch UHSR-003 resets actions 1, 2 and 3.
• The valves XV-016, XV-017 and XV-019 need to be reset locally by means
of the local hardwire switch XHSR-016, XHSR-017, XHSR-019
4.2.4. Logic UX-004: Second Regenerator Air Heater Trip

Initiators:
2 TXAHH-072 134 High high temperature in the second regenerator heater H-
1502
3 PXALL-321 134 Low low pressure of fuel gas supply from the fuel gas
header
4 FXALL-171 132 Low low combustion air flow to first regenerator heater H-
1502
5 BXALL-001 134 No pilot flame in H-1501
6 BXALL-002 134 No main flame in H-1501
7 XS-801 132 Main Air Blower Trip (logic UX-801 activated)
8 UXHS-004B 134 Local panel ESD hardwire switch active
9 UXHS-004C 134 Local panel ESD hardwire switch active
Actions:
initiator No:
to the 2nd regenerator heater H-1502
to the 2nd regenerator heater H-1502
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initiator No:
3 XSY-020 ALL 134 OPEN XV-020 to vent the fuel gas to flare
4 UXA-004B 1 to 8 134 Activate the second regenerator heater H-
1501 trip alarm (ADP)
0% to CLOSE TV-071
• DCS software switch UHSR-004 resets actions 1, 2 and 3.
• The valves XV-014, XV-015 and XV-020 need to be reset locally by means
of the local hardwire switch XHSR-014, XHSR-015, XHSR-020
4.2.5. Logic UX-005: Air Blower Protection

Initiators:
2 UXHS-005B 132 Hardwire ESD switch active (ESD bypass switch)
3 XS-801 132 Air Blower trip active (logicUX-801 active)
Actions:
initiator No:
1 XSY-163 1&3 133 CLOSE 1st Regenerator air ring assisted
check valve CV-1501 and generate
discrepancy alarm.
2 XSY-165 1&3 133 CLOSE 2nd Regenerator air ring assisted
discrepancy alarm.
3 XSY-167 1&3 132 CLOSE air lift assisted check valve CV-
1503 and generate discrepancy alarm.
4 XSY-168 1&3 132 CLOSE other blower air users assisted
discrepancy alarm.
5 UX-002 1&3 125 Activate the logic UX-002: Catalyst
circulation stop
6 XS-802 ALL 132 OPEN the air blower blow-off valves (logic
UC-802)
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Once all the initiators are healthy, the logic UX-005 can be reset by DCS software
switch UHSR-005.
In case of air blower ESD or automatic shutdown, the following actions will be
done automatically:
1) 015-XV-800 turbine chest valve is closed (only for ESD)
2) 015-SV-802 turbine control valve is closed (only for ESD)
3) 015-UV-822 blower blow off valve is open
6) 015-UV-825 blower interstage blow-off flap is open
7) 015-ZC-826 blower guide vanes are moved in start-up position (normal
position)
8) The flow controller 015-FIC-161 is switched off.
9) Turning gear is switched on by SSXX 803A.
Note:
For a complete description of the air blower interlocks, refer to the blower vendor
cause & effect diagram, doc. No. 8474L-015-A3505-1040-001-063.
4.2.6. Logic UX-008: COB/WHB 1st Regenerator Flue Gas Bypass Operation
Initiators:
1 UXHS-008 201 DCS software switch active (hardwire signal from DCS to
ESD)
2 TXAHH-089 A/B 201 1st regenerator flue gas bypass temperature high high (1
out of 2 voting system)
3 UX-002 125 Logic UX-002 active: Catalyst circulation stop
4 XS-941 203 Logic UX-907 active: COB/WHB trip
5 MZSO-024B 201 1st regenerator flue gas bypass valve BV-1501B fully open
6 MZSO-023B 201 1st regenerator flue gas block valve BV-1501A fully open
7 XHSO-058AA 201 DCS software switch active (DCS operation is not allowed
when UX-008 is tripped)
8 XHSC-058AA 201 DCS software switch active (DCS operation is not allowed
9 XHSO-058BA 201 DCS software switch active (DCS operation is not allowed
10 XHSC-058BA 201 DCS software switch active (DCS operation is not allowed
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Actions:
initiator No:
1a MXSY-024 1, 2, 3, 4 201 OPEN the first regenerator flue gas bypass
valve BV-1501B
1b MXSY-024 6 201 ALLOW the opening of the first regenerator
flue gas bypass valve BV-1501B
2a MXSY-023 1, 2, 3 201 CLOSE the first regenerator flue gas block
valve BV-1501A
2b MXSY-023 5 201 ALLOW the closure of the first regenerator
flue gas block valve BV-1501A
3a XSY-058A 1, 2, 3, 7 201 OPEN the LP BFW injection valve XV-058A
in bypass line (start flue gas bypass
cooling)
3b XSY-058A 8 201 CLOSE the LP BFW injection valve XV-
058A in bypass line (stop flue gas bypass
cooling)
4a XSY-058B 1, 2, 3, 9 201 OPEN the LP BFW injection valve XV-058B
cooling)
4b XSY-058B 10 201 CLOSE the LP BFW injection valve XV-
058B in bypass line (stop flue gas bypass
cooling)
5 XSY-059 1, 2, 3 201 OPEN the atomizing steam injection valve
XV-059 in bypass line
• DCS software switch UHSR-008
• The valves XV-058A, XV-058B and XV-059 need to be reset locally by
means of the local hardwire switch XHSR-058A, XHSR-058B and XHSR-
059 respectively.
4.2.7. Logic UX-009: Steam Drum D-1512 overfilling protection

Initiators:
1 XS-944 202 H-1503 hardwire trip switch active
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Actions:
initiator No:
1 XSY-062 1 205 CLOSE XV-062 to stop the supply of BFW
to D-1512
switch UHSR-009
4.2.8. Logic UX-010: COB/WHB 2nd Regenerator Flue Gas Bypass Operation
Initiators:
1 UXHS-010 202 DCS software switch active (hardwire signal from DCS to
ESD)
2 TXAHH-082 A/B 202 2nd regenerator flue gas bypass temperature high high (1
out of 2 voting system)
3 UX-002 125 Logic UX-002 active: Catalyst circulation stop
4 XS-941 203 Logic UX-907 active: COB/WHB trip
5 MZSO-026B 202 2nd regenerator flue gas bypass valve BV-1502B fully open
6 MZSO-025B 202 2nd regenerator flue gas block valve BV-1502A fully open
7 XHSO-056AA 202 DCS software switch active (DCS operation is not allowed
8 XHSC-056AA 202 DCS software switch active (DCS operation is not allowed
9 XHSO-056BA 202 DCS software switch active (DCS operation is not allowed
10 XHSC-056BA 202 DCS software switch active (DCS operation is not allowed
Actions:
initiator No:
1a MXSY-026 1, 2, 3, 4 202 OPEN the 2nd regenerator flue gas bypass
valve BV-1502B
1b MXSY-026 6 202 ALLOW the opening of the 2nd regenerator
flue gas bypass valve BV-1502B
2a MXSY-025 1, 2, 3 202 CLOSE the 2nd regenerator flue gas block
valve BV-1502A
2b MXSY-025 5 202 ALLOW the closure of the 2nd regenerator
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initiator No:
flue gas block valve BV-1502A
3a XSY-056A 1, 2, 3, 7 202 OPEN the LP BFW injection valve XV-056A
cooling)
3b XSY-056A 8 202 CLOSE the LP BFW injection valve XV-
056A in bypass line (stop flue gas bypass
cooling)
4a XSY-056B 1, 2, 3, 9 202 OPEN the LP BFW injection valve XV-056B
cooling)
4b XSY-056B 10 202 CLOSE the LP BFW injection valve XV-
056B in bypass line (stop flue gas bypass
cooling)
5 XSY-057 1, 2, 3 202 OPEN the atomizing steam injection valve
057 respectively.
Note:
For a detailed description of the COB/WHB trip, refer to the cause & effect matrix
of H-1503, doc No. 8474L-015-A3505-0160-001-156.
4.2.9. Logic UX-013: Economizer Bypass Cooling

Initiators:
1 XS-943 205 Logic UX-906 active: Economizer bypass
2 XHSO-060AA 205 DCS Software Switch Active
3 XHSC-060AA 205 DCS Software Switch Active
4 XHSO-060BA 205 DCS Software Switch Active
5 XHSC-060BA 205 DCS Software Switch Active
Actions:
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initiator No:
1a XSY-060A 1&2 205 OPEN the LP BFW injection valve XV-060A
in the bypass line
1b XSY-060A 3 205 ALLOW the opening of the LP BFW
injection valve XV-060A in the bypass line
2a XSY-060B 1&4 205 OPEN the LP BFW injection valve XV-060B
in the bypass line
2b XSY-060B 5 205 ALLOW the opening of the LP BFW
injection valve XV-060B in the bypass line
3 XSY-061 1 205 OPEN the atomizing steam injection valve
Once all the initiators are healthy, the logic UX-013 can be reset by
061 respectively
4.2.10. Logic UX-421: Feed Surge Drum D-1513 overfilling protection

Initiators:
1 LXAHH-404 301 High high level in the feed surge drum D-1513 (2 out of 3
A/B/C voting system)
Actions:
initiator No:
1 XSY-404 1 301 Close XV-404 to the stop the flow of residue
to D-1513
switch UHSR-421.
4.2.11. Logic UX-422: Feed Pumps P-1501 A/B Protection

Initiators:
1 LXALL-403 301 Low low level in the feed surge drum D-1513
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Actions:

initiator No:
1 MXS-435 1 301 Feed Pump P-1501 A tripped
MXS-436 1 301 Feed Pump P-1501 B tripped
switch UHSR-422.
4.2.12. Logic UX-423: T-1501 & P-1507 A/B inventory isolation

Initiators:
2 UXHS-423B 306 Hardwire LOCAL switch active
3 XZSM-406 306 70% limit switch of P-1507A suction valve XV-406 active
4 XZSO-406 306 OPEN limit switch of P-1507A suction valve XV-406 active
5 XZSM-405 306 70% limit switch of P-1507B suction valve XV-405 active
6 XZSO-405 306 OPEN limit switch of P-1507B suction valve XV-405 active
7 UXHS-423C 306 Hardwire local switch active
8 UXHS-423D 306 Hardwire local switch active
9 UXHS-423E 306 Hardwire local switch active
Actions:
initiator No:
1a MXS-481 1, 2, 3, 7, 8, 9 306 TRIP the HCO recycle pump P1507 A
1b MXS-481 4 306 ALLOW the HCO recycle pump P1507 A to
be restarted:
The pump is tripped when XV is less than
70% open and can only be restarted when
XV is fully open.
2a MXS-482 1, 2, 5, 7, 8, 9 306 TRIP the HCO recycle pump P1507 B
2b MXS-482 6 306 ALLOW the HCO recycle pump P1507 B to
be restarted:
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initiator No:
XV is fully open.
3 XSY-405 1, 2, 7, 8, 9 306 CLOSE P-1507B suction motor operated
valve XV-405
4 XSY-406 1, 2, 7, 8, 9 306 CLOSE P-1507A suction motor operated
valve XV-406
5 XSY-407 1, 2, 7, 8, 9 306 CLOSE P-1507B discharge motor operated
valve XV-407
6 XSY-408 1, 2, 7, 8, 9 306 CLOSE P-1507A discharge motor operated
valve XV-408
7 XXA-405 1, 2, 7, 8, 9 306 Activate XV-405 trip alarm
• DCS software switch UHSR-423;
• The motor operated valves must be reset locally: XV-405/406/407/408 are
reset by XHSR-405/406/407/408 respectively.

Initiators:
Actions:
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initiator No:
1a MXS-444 1, 2, 3, 7, 8, 9 308 TRIP the HCO pumparound pump P1508 A
1b MXS-444 4 308 ALLOW the HCO pumparound pump P1508
A to be restarted:
XV is fully open.
2a MXS-445 1, 2, 5, 7, 8, 9 308 TRIP the HCO pumparound pump P1508 B
2b MXS-445 6 308 ALLOW the HCO pumparound pump P1508
B to be restarted:
XV is fully open.
valve XV-409
valve XV-410
valve XV-411
valve XV-412
4.2.14. Logic UX-425: Slurry pumps P-1519 A/B/C protection

Initiators:
1 LXALL-414 310 Low low level in the main fractionator T-1501
Actions:
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initiator No:
1 XSY-451 1 321 Activate logic UX-432
CLOSE XV-451 to stop the flow of slurry
product to D-1515
2 FIC-462 1 321 FIC-462 switch to manual mode and output
0% to close FV-462
switch UHSR-425.
4.2.15. Logic UX-426: T-1501 & P-1519 inventory isolation

Initiators:
7 XZSM-415 311 70% limit switch of P-1519C suction valve XV-415 active
8 XZSO-415 311 OPEN limit switch of P-1519C suction valve XV-415 active
9 HS-419 311 DCS software switch active (DCS/Local operation is not
allowed when UX-426 is tripped)
10 XHSO-419B 311 LOCAL software switch active (DCS/Local operation is not
11 XHSC-419B 311 LOCAL software switch active (DCS/Local operation is not
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18 UXHS-426C 311 LOCAL hardwire switch active
19 UXHS-426D 311 LOCAL hardwire switch active
20 UXHS-426E 311 LOCAL hardwire switch active
21 UXHS-426F 311 LOCAL hardwire switch active
22 UXHS-426G 311 LOCAL hardwire switch active
Actions:
initiator No:
1a XSY-419 1, 2, 3, 9, 11, 311 CLOSE the slurry pumparound pump P-
18, 19, 20, 1519A turbine HP steam valve XV-419
21, 22
1b XSY-419 10 311 OPEN the slurry pumparound pump P-
1519A turbine HP steam valve XV-419
1c XSY-419 4 311 ALLOW the opening of the slurry
pumparound pump P-1519A turbine HP
steam valve XV-419:
Turbine of pump is automatically stopped
when XV is less than 70% open and can
only be restarted when XV is fully open.
2a XSY-421 1, 2, 5, 12, 311 CLOSE the slurry pumparound pump P-
14, 18, 19, 1519B turbine HP steam valve XV-421
20, 21, 22
1519B turbine HP steam valve XV-421
pumparound pump P-1519B turbine HP
steam valve XV-421:
17, 18, 19, 1519C turbine HP steam valve XV-423
20, 21, 22
1519C turbine HP steam valve XV-423
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initiator No:
steam valve XV-423:
4 XSY-413 1, 2, 18, 19, 311 CLOSE P-1519A suction motor operated
20, 21, 22 valve XV-413
5 XSY-414 1, 2, 18, 19, 311 CLOSE P-1519B suction motor operated
20, 21, 22 valve XV-414
6 XSY-415 1, 2, 18, 19, 311 CLOSE P-1519C suction motor operated
20, 21, 22 valve XV-415
7 XSY-416 1, 2, 18, 19, 311 CLOSE P-1519A discharge motor operated
20, 21, 22 valve XV-416
8 XSY-417 1, 2, 18, 19, 311 CLOSE P-1519B discharge motor operated
20, 21, 22 valve XV-417
9 XSY-418 1, 2, 18, 19, 311 CLOSE P-1519C discharge motor operated
20, 21, 22 valve XV-418
10 XXA-413 1, 2, 18, 19, 311 Activate XV-413 trip alarm
20, 21, 22
20, 21, 22
20, 21, 22
20, 21, 22
20, 21, 22
20, 21, 22
• The motor operated valves must be reset locally: XV-413/414/415/416/417/
418 are reset by XHSR-413/414/415/416/417/418 respectively.
Initiators:
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7 LXALL-432 316 Low low level in the HCO stripper T-1504
Actions:
initiator No:
1a MXS-446 1, 2, 3, 7, 8, 316 TRIP the HCO product pump P-1509 A
9, 10
1b MXS-446 4 316 ALLOW the HCO product pump P-1509 A to
be restarted:
XV is fully open.
2a MXS-447 1, 2, 5, 7, 8, 316 TRIP the HCO product pump P-1509 B
9, 10
2b MXS-447 6 316 ALLOW the HCO product pump P-1509 B to
be restarted:
XV is fully open.
valve XV-430
valve XV-431
valve XV-432
valve XV-433
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initiator No:
4.2.17. Logic UX-428: Heavy Naphta Product Pumps P-1515 A/B protection
Initiators:
1 LXALL-440 317 Low low level in the heavy naphta stripper T-1502
Actions:
initiator No:
1 MXS-450 1 317 TRIP the heavy naphta product pump P-
1515A
2 MXS-451 1 317 TRIP the heavy naphta product pump P-
1515B
switch UHSR-428.
4.2.18. Logic UX-429: LCO Stripper Pumps P-1511 A/B protection

Initiators:
1 LXALL-437 318 Low low level in the LCO stripper T-1503
Actions:
initiator No:
1 MXS-452 1 318 TRIP the LCO stripper pump P-1511A
2 MXS-453 1 318 TRIP the LCO stripper pump P-1511B
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CRACKER (RFCC)
switch UHSR-429.
4.2.19. Logic UX-430: D-1514, P-1516 A/B & P-1518 A/B inventory isolation
Initiators:
3 XZSM-444 320 70% limit switch of P-1516 A/B & P-1518 A/B suction shut-
off valve XV-444 active
4 XZSO-444 320 OPEN limit switch of P-1516 A/B & P-1518 A/B suction
shut-off valve XV-444 active
5 LXALL-444 320 Low low level in the main fractionator reflux drum D-1514
6 XHSO-444B 320 Hardwire LOCAL switch active
7 XHSC-444B 320 Hardwire LOCAL switch active
Actions:
initiator No:
1a MXS-456 1, 2, 3, 5 320 TRIP the fractionator reflux pump P-1516A
1b MXS-456 4 320 Allow the fractionator reflux pump P-1516A
to be restarted:
XV is fully open.
2a MXS-457 1, 2, 3, 5 320 TRIP the fractionator reflux pump P-1516B
2b MXS-457 4 320 Allow the fractionator reflux pump P-1516B
to be restarted:
XV is fully open.
3a MXS-460 1, 2, 3, 5 320 TRIP the overhead liquid pump P-1518A
3b MXS-460 4 320 Allow the overhead liquid pump P-1518A to
be restarted:
XV is fully open.
4a MXS-461 1, 2, 3, 5 320 TRIP the overhead liquid pump P-1518B
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initiator No:
4b MXS-461 1, 2, 3, 5 320 Allow the overhead liquid pump P-1518B to
be restarted:
XV is fully open.
5a XSY-444 1, 2, 7 320 CLOSE P-1516 A/B & P-1518 A/B suction
shut-off valve XV-444
5b XSY-444 6 320 OPEN P-1516 A/B & P-1518 A/B suction
shut-off valve XV-444
6 XXA-444 1, 2, 7 320 Activate XV-444 trip alarm
• The shut-off valve XV-444 must be reset locally XHSR-444 respectively.
4.2.20. Logic UX-431: D-1524, P-1517 A/B inventory isolation

Initiators:
1 LXALL-447 320 Low low level in the main fractionator reflux drum boot
4 XZSM-445 320 70% limit switch of P-1517 A/B suction shut-off valve XV-
445 active
5 XZSO-445 320 OPEN limit switch of P-1517 A/B suction shut-off valve XV-
445 active
6 XHSO-445B 320 Hardwire LOCAL switch active
7 XHSC-445B 320 Hardwire LOCAL switch active
Actions:
initiator No:
1a MXS-458 1, 2, 3, 5 320 TRIP the overhead sour water pump P-
1517A
1b MXS-458 4 320 ALLOW the overhead sour water pump P-
1517A to be restarted:
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initiator No:
XV is fully open.
2a MXS-459 1, 2, 3, 5 320 TRIP the overhead sour water pump P-
1517B
2b MXS-459 4 320 ALLOW the overhead sour water pump P-
1517B to be restarted:
XV is fully open.
3a XSY-445 2, 3, 7 320 CLOSE P-1517 A/B suction shut-off valve
XV-445
3b XSY-445 6 320 OPEN P-1517 A/B suction shut-off valve
XV-445
4 XXA-445 2, 3, 7 320 Activate XV-445 trip alarm
• The shut-off valve XV-445 must be reset locally XHSR-445 respectively.
4.2.21. Logic UX-432: D-1515 overfilling protection

Initiators:
1 LXAHH-478 321 Low low level in D-1515
Actions:
initiator No:
1 XSY-451 1 321 CLOSE XV-451 to stop the flow of slurry
product to D-1515;
Activate logic UX-425
0% to close FV-462
Reset:
switch UHSR-432.
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4.2.22. Logic UX-433: Slurry Product Pumps P-1504 A/B protection

Initiators:
1 LXALL-450 321 Low low level in D-1515
Actions:
initiator No:
1 MXS-462 1 321 TRIP the slurry product pump P-1504A
2 MXS-463 1 321 TRIP the slurry product pump P-1504B
Reset:
switch UHSR-432.
4.2.23. Logic UX-434: Backflush Oil Recycle Pumps P-1506 A/B protection
Initiators:
1 LXALL-458 324 Low low level in the backflush oil receiver D-1517
Actions:
initiator No:
1 MXS-464 1 324 TRIP the Backflush Oil Recycle Pump P-
1506A
2 MXS-465 1 324 TRIP the Backflush Oil Recycle Pump P-
1506B
Reset:
switch UHSR-434.

Initiators:
1 LXAHH-459 324 High high level in the backflush oil receiver D-1517
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Actions:
initiator No:
1 XSY-459 1 324 CLOSE XV-459 to stop the flow of HCO
product from E-1510 to D-1517
Reset:
switch UHSR-435.
4.2.25. Logic UX-436: Backflush Oil Pumps P-1505 A/B protection

Initiators:
1 LXALL-462 325 Low low level in the backflush oil draw off drum D-1516
Actions:
initiator No:
1 MXS-466 1 325 TRIP the Backflush Oil Pump P-1505A
2 MXS-467 1 325 TRIP the Backflush Oil Pump P-1505B
Reset:
switch UHSR-436.

Initiators:
1 LXAHH-463 325 High high level in the backflush oil draw off drum D-1516
Actions:
initiator No:
1 FSY-467 1 325 CLOSE FV-467 to stop the flow of HCO
product from E-1510 to D-1516
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initiator No:
0% to close FV-467
Reset:
switch UHSR-437.
4.2.27. Logic UX-438: HCO Flushing Oil Pumps P-1521 A/B protection
Initiators:
1 LXALL-468 326 Low low level in HCO flushing oil drum D-1518
2 HS-468 326 DCS software switch active (DCS operation is not allowed
3 XHSO-468B 326 Hardwire local switch active (DCS operation is not allowed
4 XHSC-468B 326 Hardwire local switch active (DCS operation is not allowed
5 PAL-487 326 Low flushing oil pressure at the discharge of P-1521 A/B
6 XHSM-468B 326 Hardwire local switch active
Actions:
initiator No:
1a XSY-468 1, 2, 4 326 CLOSE XV-468 to stop the MP steam
supply to the turbine of P-1521A
1b XSY-468 3, 5 326 OPEN XV-468 to allow the MP steam
supply to the turbine of P-1521A
1c XSY-468 6 326 ACTIVATE the HCO flushing oil pump P-
1521A
2 MXS-468 1 326 TRIP the HCO flushing oil pump P-1521B
Reset:
switch UHSR-438.
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4.2.28. Logic UX-439: LCO Flushing Oil Pumps P-1522 A/B protection
Initiators:
1 LXALL-471 327 Low low level in the LCO Flushing Oil Drum D-1519
Actions:
initiator No:
1 MXS-469 1 327 TRIP the LCO Flushing Oil Pumps P-1522A
2 MXS-470 1 327 TRIP the LCO Flushing Oil Pumps P-1522B
Reset:
switch UHSR-439.

Initiators:
1 LXAHH-485 329 High high level in the light slops drum D-1522
Actions:
initiator No:
1 XSY-485 1 329 CLOSE XV-485 to stop the flow of light
slops to D-1522
2 LIC-484 1 329 LIC-484 switch to manual mode and output
0% to close LV-484 on the light slops line
from storage.
Reset:
switch UHSR-440.
4.2.30. Logic UX-441: Light Slops Pumps P-1526 A/B protection
Initiators:
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1 LXALL-486 329 Low low level in the light slops drum D-1522
Actions:
initiator No:
1 MXS-473 1 327 TRIP the Light Slops Pumps P-1526 A
2 MXS-474 1 327 TRIP the Light Slops Pumps P-1526 B
Reset:
Once all the initiators are healthy, the logic UX-441can be reset by DCS software
switch UHSR-441.

Initiators:
1 LXAHH-491 330 High high level in the heavy slops drum D-1523
Actions:
initiator No:
1 XSY-491 1 330 CLOSE XV-491 to stop the flow of heavy
slops to D-1523
0% to close LV-490 on the heavy slops line
from storage.
Reset:
switch UHSR-442.
4.2.32. Logic UX-443: Heavy Slops Pumps P-1527 A/B protection

Initiators:
1 LXALL-492 330 Low low level in the heavy slops drum D-1523
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Actions:
initiator No:
1 MXS-475 1 330 TRIP the Heavy Slops Pumps P-1527 A
2 MXS-476 1 330 TRIP the Heavy Slops Pumps P-1527 B
Reset:
switch UHSR-443.
4.2.33. Logic UX-444: Tempered Water Pumps P-1528 A/B Protection

Initiators:
1 LXALL-498 331 Low low level in the tempered water surge drum D-1524
Actions:
initiator No:
1 MXS-478 1 331 TRIP the Tempered Water Pump P-1528A
2 MXS-479 1 331 TRIP the Tempered Water Pump P-1528B
Reset:
switch UHSR-444.
4.2.34. Logic UX-705: C-1551 Isolation and Protection

Initiators:
1 UXHS-705AA 402 ESD hardwire switch active
2 UXHS-705B 402 LOCAL hardwire switch active
3 LXAHH-704 401 High high level in the 1st stage KO drum D-1551 (2 out of 3
A/B/C voting system)
4 LXAHH-709 403 High high level in the interstage KO drum D-1552 (2 out of
A/B/C 3 voting system)
5 XS-861 403 Activate the logic UX-861: TRIP the wet gas compressor
due to low low speed.
XS-861 ALLOW the closing of the MOVs when C-1551
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rotating speed is less than 250 RPM. C-1551 cannot be
restarted until MOVs are opened fully.
6 TXAHH-631 402 C-1551 discharge temperature high high
7 TXAHH-632 402 C-1551 discharge temperature high high
8 MZSO-703B 402 OPEN limit switch of MOV-703
Actions:
initiator No:
1 XS-862 1, 2, 3, 4, 6, 402 ACTIVATE C-1551 trip
7, 8, 9, 10, 11
2a MXSY-703 1, 2 402 CLOSE C-1551 first stage suction valve
MOV-703
2b MXSY-703 5 402 ALLOW the closing of C-1551 first stage
suction valve MOV-703
3a MXSY-704 1, 2 402 CLOSE C-1551 first stage discharge valve
MOV-704
3b MXSY-704 5 402 ALLOW the closing of C-1551 first stage
discharge valve MOV-704
4a MXSY-705 1, 2 402 CLOSE C-1551 second stage suction valve
MOV-705
4b MXSY-705 5 402 ALLOW the closing of C-1551 second stage
suction valve MOV-705
5a MXSY-706 1, 2 402 CLOSE C-1551 second stage discharge
valve MOV-706
5b MXSY-706 5 402 ALLOW the closing of C-1551 second stage
discharge valve MOV-706
Reset:
switch UHSR-705.
4.2.35. Logic UX-706: Interstage drum pump P-1551 A/B Protection

Initiators:
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1 LXALL-707 403 Low low level in the interstage KO drum D-1552
Actions:
initiator No:
1 MXS-714 1 403 TRIP the interstage KO drum pump P1551A
2 MXS-715 1 403 TRIP the interstage KO drum pump P1551B
Reset:
switch UHSR-706.
4.2.36. Logic UX-707: HP separator drum D-1553 Interface Isolation

Initiators:
1 LXALL-716 404 Low low level in HP separator drum D-1553
Actions:
initiator No:
1 XSY-716 1 404 CLOSE XV-716 to stop the sour water draw
off from D-1553
0% to close LV-714
Reset:
switch UHSR-707.
4.2.37. Logic UX-708: HP separator drum D-1553 Inventory Isolation

Initiators:
1 UXHS-708A 404 ESD hardwire switch active
3 XZSM-719 404 70% limit switch of the stripper feed pumps suction valve
Page 205 of 323

REV: A DATE: 06/12/07
CRACKER (RFCC)

XV-719 active
4 XZS0-719 404 OPEN limit switch of the stripper feed pumps suction valve
XV-719 active
5 LXALL-719 404 Low low level in the HP separator drum D-1553
6 XHSO-719B 404 LOCAL hardwire switch active
7 XHSC-719B 404 LOCAL hardwire switch active
Actions:
initiator No:
1a MXS-717 1, 2, 3, 5 404 TRIP the Stripper Feed Pump P-1553A
1b MXS-717 4 404 ALLOW the stripper feed pump P-1553A to
be restarted:
XV is fully open.
2a MXS-718 1, 2, 3, 5 404 TRIP the Stripper Feed Pump P-1553B
2b MXS-718 4 404 ALLOW the stripper feed pump P-1553B to
be restarted:
XV is fully open.
3 XSY-719 1, 2, 6, 7 404 CLOSE the stripper feed pumps suction
valve XV-719
4 XXA-719 1, 2, 6, 7 404 Activate XV-719 trip alarm
Reset:
switch UHSR-708.
4.2.38. Logic UX-709: Lean Oil Coalescer Interface Isolation

Initiators:
1 LXALL-725 407 Low low interface level in D-1556
Actions:
Page 206 of 323

REV: A DATE: 06/12/07
CRACKER (RFCC)

initiator No:
off from D-1556
0% to close LV-723 on the sour water draw
off line
Reset:
switch UHSR-709.
4.2.39. Logic UX-710: T-1555 Interface Isolation

Initiators:
1 LXALL-732 408 Low low interface level in T-1555
Actions:
initiator No:
1 XSY-732 1 408 CLOSE XV-732 to stop the rich amine draw
off from T-1555
0% to close LV-730 on the lean amine
return to ARU
Reset:
switch UHSR-710.
4.2.40. Logic UX-712: Debutanizer T-1554 Inventory Isolation

Initiators:
3 XZSM-738 409 70% limit switch of the gasoline recycle pumps suction
valve XV-738 active
Page 207 of 323

REV: A DATE: 06/12/07
CRACKER (RFCC)

4 XZS0-738 409 OPEN limit switch of the stripper feed pumps suction valve
XV-738 active
5 LXALL-738 409 Low low level in the Debutanizer T-1554
Actions:
initiator No:
1a MXS-720 1, 2, 3, 5 406 TRIP the gasoline recycle pump P-1554A
1b MXS-720 4 406 ALLOW the gasoline recycle pump P-1554A
to be restarted:
XV is fully open.
2a MXS-721 1, 2, 3, 5 406 TRIP the gasoline recycle pump P-1554B
2b MXS-721 4 406 ALLOW the gasoline recycle pump P-1554B
to be restarted:
XV is fully open.
3 XSY-738 1, 2, 6, 7 409 CLOSE XV-738 on the debutanizer bottom
line
Reset:
• XV-738 need to be reset locally by means of the local hardwire switch
XHSR-738.
4.2.41. Logic UX-713: D-1554 Interface Isolation

Initiators:
1 LXALL-741 410 Low low interface level in debutanizer reflux drum D-1554
Actions:
Page 208 of 323

REV: A DATE: 06/12/07
CRACKER (RFCC)

initiator No:
off from D-1554 boot
Reset:
UHSR-713.
4.2.42. Logic UX-714: Debutanizer Reflux Drum D-1554 Inventory Isolation

Initiators:
3 XZSM-744 410 70% limit switch of the debutanizer OVHD pumps suction
valve XV-744 active
4 XZS0-744 410 OPEN limit switch of the debutanizer OVHD pumps suction
valve XV-744 active
5 LXALL-744 410 Low low level in the Debutanizer Reflux Drum D-1554
Actions:
initiator No:
1a MXS-722 1, 2, 3, 5 410 TRIP the debutanizer OVHD pump P-1556A
1b MXS-722 4 410 ALLOW debutanizer OVHD pump P-1556A
to be restarted:
XV is fully open.
2a MXS-723 1, 2, 3, 5 410 TRIP the debutanizer OVHD pump P-1556B
2b MXS-723 4 410 ALLOW the debutanizer OVHD pump P-
1556B to be restarted:
XV is fully open.
Page 209 of 323

REV: A DATE: 06/12/07
CRACKER (RFCC)

initiator No:
3 XSY-744 1, 2, 6, 7 410 CLOSE XV-744 in the debutanizer OVHD
pumps suction line
5 LIC-739 1, 2, 3, 4, 5 410 LIC-739 switch to manual and output 0% to
close LV-739
Reset:
XHSR-744
4.2.43. Logic UX-715: T-1556 Interface Isolation

Initiators:
1 LXALL-748 411 Low low interface level in LPG Amine Absorber T-1556
Actions:
initiator No:
off from T-1556 back to the ARU.
0% to close LV-746.
Reset:
UHSR-715.
4.2.44. Logic UX-716: LPG amine coalescer D-1555 Interface Isolation

Initiators:
1 LXALL-751 411 Low low interface level in LPG Amine Coalescer D-1555
Actions:
Page 210 of 323

REV: A DATE: 06/12/07
CRACKER (RFCC)

initiator No:
off from D-1555.
0% to close LV-749 on the rich amine draw-
off line.
Reset:
UHSR-716.
4.2.45. Logic UX-717: LPG amine absorber T-1556 depressurization

Initiators:
Actions:
initiator No:
1 XSY-752 1 411 OPEN XV-752 to depressurize to flare.
2 FSY-723 1 411 CLOSE FV-723 to stop the feed flow to T-
1556
Reset:
• DCS software UHSR-716;
XHSR-752.
4.2.46. Logic UX-718: Fuel Gas Absorber Outlet KO Drum D-1559 Interface Isolation
Initiators:
1 LXALL-735 408 Low low interface level in Fuel Gas Absorber Outlet KO
Drum D-1559
Page 211 of 323

REV: A DATE: 06/12/07
CRACKER (RFCC)
Actions:
initiator No:
off from D-1559.
0% to close LV-733 on the rich amine draw-
off line.
Reset:
UHSR-719.
4.2.47. Logic UX-719: D-1553 depressurization

Initiators:
Actions:
initiator No:
1 XSY-733 1 408 OPEN XV-733 to depressurize to flare.
Reset:
• DCS software UHSR-719;
XHSR-733.
4.2.48. Logic UX-861 Wet Gas Compressor C-1551 Protection

Initiators:
1 XS-862 092 C-1551 Process conditions
2 PAL-867 037 Low pressure of the lube oil supply to C-1551
3 HS-868 092 C-1551 Local/Remote Switch
Page 212 of 323

REV: A DATE: 06/12/07
CRACKER (RFCC)

4 LAH-861 037 High level in the rundown tank of C-1551
5 PAL-868 092 C-1551 control oil supply pressure low
6 ZAC-865 092 C-1551 T&T valve full close limit switch
7 PDAL-585 037 C-1551 buffer gas supply differential pressure low
8 UXHS-863 092 C-1551 Emergency Stop
9 UXHS-705 AB 092 C-1551 trip signal from ESD console
10 PALL-866 037 C-1551 lube oil supply pressure low low
11 PDAHH-863A 037 C-1551 Primary Seal Vent Pressure (FE) High High
12 PDAHH-863B 037 C-1551 Primary Seal Vent Pressure (DE) High High
13 SAHH-862 092 C-1551 overspeed trip active
14 XS-871 092 Governor fault
15 UXS-865A/B 037 Compressor Axial Disp. High high
16 UXS-866A/B 092 Turbine axial disp. High high
17 SSLL-861 092 C-1551 turbine speed low
18 PAL-861 037 C-1551 Separation gas supply pressure low
19 PAL-599 037 C-1551 secondary gas supply pressure low
20 LAL-862 038 C-1551 oil reservoir level low
21 PAL-862 038 C-1551 Lube/control oil header pressure low
22 LAL-863 039 C-1551 Surface condenser Level low
23 LALL-863/866 039 C-1551 Surface condenser Level low low
24 LAH-863 039 C-1551 Surface condenser Level high
Actions:
initiator No:
1 YL-861 1, 2, 3, 4, 5, - ALLOW the wet gas compressor C-1551 to
6, 7 be restarted
2 UXA-861 1, 8, 9, 10, - TRIP the wet gas compressor C-1551 and
11, 12, 13, generate a common trip alarm
14, 15, 16
3 UXA-861 1, 8, 9, 10, - C-1551 common trip alarm (first out)
11, 12, 13,
14, 15, 16
4 - 17 - CLOSE the process MOV
5 YL-876, 877 18, 19, 20 - ALLOW the oil pump to be started
Page 213 of 323

REV: A DATE: 06/12/07
CRACKER (RFCC)

initiator No:
6 21 - AUTO START the standby pump
7 YL-876, 877 22 - ALLOW the condensate pump to be started
8 MGL-876, 877 23 - TRIP the condensate pump
9 - 24 - AUTO START the condensate pump
4.3. Safeguarding Equipment
4.3.1. Pressure Safety Devices

Over pressuring of the equipment occurs in many ways. The basic cause of power
pressure is imbalance in heat and material flow in the equipment or piping.
Pressure safety devices have been installed to protect and/or section against over
pressure.
Here is the list of the pressure safety valves found in the RFCC:
Setting
TAG No. Description Type Location PID:
(kg/cm2g)
015-PSV Breather MC RECYCLE PUMP P-
RV 637
-570 Valve 1512A
015-PSV Breather MC RECYCLE PUMP P-
RV 637
-571 Valve 1512B
015-RO Breather INTER STAGE DRUM
RV 637
-732 Valve PUMP P-1551B
015-PSV Relief Valve PG FROM INTERSTAGE
RV 403
-701-A (Pilot) KO DRUM D-1552
015-PSV Relief Valve PG FROM INTERSTAGE
RV 403
-701-B (Pilot) KO DRUM D-1552
015-PSV Relief Valve HP SEP D-1553 VAPOR
RV 404
-705-B (Pilot) TO T-1551
015-PSV Relief Valve HP SEP D-1553 VAPOR
RV 404
-705-A (Pilot) TO T-1551
015-PSV Relief Valve BLOWER AIR TO
RV 132
-008-A (Spring) CATALYST LINES
RV 132
-008-B (Spring) CATALYST LINES
RV 132
-008-C (Spring) CATALYST LINES
RV 132
-008-D (Spring) CATALYST LINES
RV 132
-008-E (Spring) CATALYST LINES
RV 132
-008-F (Spring) CATALYST LINES
Page 214 of 323

REV: A DATE: 06/12/07
CRACKER (RFCC)
Setting
(kg/cm2g)
RV 132
-008-G (Spring) CATALYST LINES
015-PSV Relief Valve SPENT CATALYST
RV 135
-006 (Spring) HOPPER D-1506
015-PSV Relief Valve AUXILIARY CATALYST
RV 136
015-PSV Relief Valve FRESH CATALYST
RV 137
015-PSV Relief Valve
RV FUEL GAS DRUM D-1509 138
-007-A (Spring)
RV FUEL GAS DRUM D-1509 138
-007-B (Spring)
015-PSV Relief Valve AIR HEATER FG KO
RV 206
-362-A (Spring) DRUM D-1525
015-PSV Relief Valve AIR HEATER FG KO
RV 206
-362-B (Spring) DRUM D-1525
015-PSV Relief Valve CO BOILER FG KO DRUM
RV 206
-359 (Spring) D-1526
015-PSV Relief Valve FEED SURGE DRUM D-
RV 301
-401-A (Spring) 1513
015-PSV Relief Valve FEED SURGE DRUM D-
RV 301
-401-B (Spring) 1513
015-PSV Relief Valve DISCHARGE TO PSV-
RV 303
-406-A (Spring) 408A/B
RV 303
-406-B (Spring) 408A/B
RV 303
-406-C (Spring) 408A/B
015-PSV Relief Valve DISCHARGE FROM PSV-
RV 304
-408-A (Spring) 406A/B/C
015-PSV Relief Valve DISCHARGE FROM PSV-
RV 304
-408-B (Spring) 406A/B/C
015-PSV Relief Valve HCO RECYCLE MP
RV 306
-409-A (Spring) STEAM GEN E-1508
RV 306
-409-B (Spring) STEAM GEN E-1508
015-PSV Relief Valve HCO PMPAROUND MP
RV 308
-412-A (Spring) STEAM GEN E-1523
RV 308
-412-B (Spring) STEAM GEN E-1523
015-PSV Relief Valve SL FROM LP BLOWDOWN
RV 452
015-PSV Relief Valve SL FROM LP BLOWDOWN
RV 452
015-PSV Relief Valve STRIPPER OVHD TO
RV 405
-704-A (Spring) COND E-1554A/B
015-PSV Relief Valve STRIPPER OVHD TO
RV 405
-704-B (Spring) COND E-1554A/B
Page 215 of 323

REV: A DATE: 06/12/07
CRACKER (RFCC)
Setting
(kg/cm2g)
015-PSV Relief Valve TOP SECONDARY
RV 407
-709-A (Spring) ABSORBER T-1553
015-PSV Relief Valve TOP SECONDARY
RV 407
-709-B (Spring) ABSORBER T-1553
015-PSV Relief Valve PL FROM LEAN OIL
RV 407
-710-A (Spring) COALESCER D-1556
015-PSV Relief Valve PL FROM LEAN OIL
RV 407
-710-B (Spring) COALESCER D-1556
015-PSV Relief Valve PG FROM FG ABS
RV 408
-712-A (Spring) OUTLET DRUM D-1559
015-PSV Relief Valve PG FROM FG ABS
RV 408
-712-B (Spring) OUTLET DRUM D-1559
015-PSV Relief Valve PG FROM TOP
RV 409
-714-A (Spring) DEBUTANIZER TK T-1554
015-PSV Relief Valve PG FROM TOP
RV 409
-714-B (Spring) DEBUTANIZER TK T-1554
015-PSV Relief Valve PG FROM LPG AMINE
RV 411
-719-A (Spring) ABS TANK T-1556
015-PSV Relief Valve PG FROM LPG AMINE
RV 411
-719-B (Spring) ABS TANK T-1556
015-PSV Relief Valve ANTIFOAMING PUMP P-
RV 411
-721 (Spring) 1557
015-PSV Relief Valve ANTIFOAMING PUMP P-
RV 411
-722 (Spring) 1558
015-PSV Relief Valve DEBUTANIZER REFLUX
RV 410
015-PSV Relief Valve DEBUTANIZER REFLUX
RV 410
015-PSV Relief Valve PA TO FIRST
RV 128
-003 (Spring) REGENERATOR D-1502
015-PSV Relief Valve SLURRY PUMP AROUND
RV 311
-416 (Spring) PUMP P-1519C
015-PSV Relief Valve PL TO FEED SURGE
RV 301
-456 (Spring) DRUM D-1513
015-PSV Relief Valve FEED FRM LCO PREHT
RV 302
-402 (Spring) EXCHNG E-1512B
015-PSV Relief Valve SLURRY PUMPAROUND
RV 311
-415 (Spring) PUMP P-1519B
015-PSV Relief Valve SLURRY PUMPAROUND
RV 311
-414 (Spring) PUMP P-1519A
015-PSV Relief Valve SLURRY TO SUPPLY PA
RV 312
-417-A (Spring) RETURN LINE
015-PSV Relief Valve FEED FRM LCO PREHT
RV 302
-403 (Spring) EXCHNG E-1512D
015-PSV Relief Valve SLURRY TO SUPPLY PA
RV 312
-419-A (Spring) RETURN LINE
015-PSV Relief Valve SLURRY HP STEAM
RV 312
-420-A (Spring) GENERATOR E-1503A
Page 216 of 323

REV: A DATE: 06/12/07
CRACKER (RFCC)
Setting
(kg/cm2g)
015-PSV Relief Valve PL FROM MP STEAM HTR
RV 302
-404 (Spring) E-1522
RV 312
-420-B (Spring) GENERATOR E-1503B
015-PSV Relief Valve PL FROM MP STEAM HTR
RV 302
-405 (Spring) E-1524
015-PSV Relief Valve SLURRY HP STEAM GEN
RV 312
-418-B (Spring) E-1503A
RV 306
-410 (Spring) STEAM GEN E-1508
015-PSV Relief Valve SLURRY HP STEAM GEN
RV 312
-418-A (Spring) E-1503A
RV 308
-411 (Spring) STEAM GEN E-1523
015-PSV Relief Valve SLURRY FRM PSV-
RV 313
-421-A (Spring) 417&419
015-PSV Relief Valve SLURRY HP STEAM GEN.
RV 313
-422-A (Spring) E-1503 C
015-PSV Relief Valve SLURRY HP STEAM GEN.
RV 313
-422-B (Spring) E-1503 C
RV 314
RV 314
-424-B (Spring) GENERATOR E-1505A
015-PSV Relief Valve SLURRY MP STEAM
RV 314
RV 314
RV 315
-423-A (Spring) GENERATOR E-1504B
RV 315
RV 315
RV 315
015-PSV Relief Valve HCO LP STEAM
RV 316
-429-A (Spring) GENERATOR E-1510
015-PSV Relief Valve HCO LP STEAM
RV 316
-429-B (Spring) GENERATOR E-1510
015-PSV Relief Valve FRACTIONATOR OVHD
RV 319
-432-A (Spring) FRM T-1501
RV 319
-432-B (Spring) FRM T-1501
RV 319
-432-C (Spring) FRM T-1501
RV 319
-432-D (Spring) FRM T-1501
Page 217 of 323

REV: A DATE: 06/12/07
CRACKER (RFCC)
Setting
(kg/cm2g)
RV 319
-432-E (Spring) FRM T-1501
RV 319
-432-F (Spring) FRM T-1501
RV 319
-432-G (Spring) FRM T-1501
RV 319
-432-H (Spring) FRM T-1501
015-PSV Relief Valve CORROSION INHABITOR
RV 319
015-PSV Relief Valve TOP SLRY DRAWOFF
RV 321
015-PSV Relief Valve TOP SLRY DRAWOFF
RV 321
RV 322
RV 322
RV 322
RV 322
015-PSV Relief Valve PS FROM SLRY LP
RV 322
-439 (Spring) STMGEN E-1506A/B
015-PSV Relief Valve PS FROM SLRY LP
RV 322
-438 (Spring) STMGEN E-1506A/B
015-PSV Relief Valve PL TO SLRY CLF COOLER
RV 323
-440 (Spring) E-1507B
015-PSV Relief Valve PL TO SLRY CLF COOLER
RV 323
-441 (Spring) E-1507D
015-PSV Relief Valve TOP BACK FLSH OIL
RV 324
-444-A (Spring) RECV DRM D-1517
015-PSV Relief Valve TOP BACK FLSH OIL
RV 324
-444-B (Spring) RECV DRM D-1517
015-PSV Relief Valve TOP FLSH OIL DRAWOFF
RV 325
-445-A (Spring) DRM D-1517
015-PSV Relief Valve TOP FLSH OIL DRAWOFF
RV 325
-445-B (Spring) DRM D-1517
015-PSV Relief Valve TOP HCO FLSHOIL DRUM
RV 326
-446-A (Spring) D-1518
015-PSV Relief Valve TOP HCO FLSHOIL DRUM
RV 326
-446-B (Spring) D-1518
015-PSV Relief Valve SL FRM HCO FLSHOIL
RV 326
015-PSV Relief Valve TOP LCO FLUSH OIL
RV 327
015-PSV Relief Valve TOP LCO FLUSH OIL
RV 327
Page 218 of 323

REV: A DATE: 06/12/07
CRACKER (RFCC)
Setting
(kg/cm2g)
015-PSV Relief Valve LCO PRODUCT LP STEAM
RV 328
-454-A (Spring) GENTR E-1513
015-PSV Relief Valve LCO PRODUCT LP STEAM
RV 328
-454-B (Spring) GENTR E-1513
015-PSV Relief Valve LIGHT SLOPS DRUM D-
RV 329
-457-A (Spring) 1522
015-PSV Relief Valve LIGHT SLOPS DRUM D-
RV 329
-457-B (Spring) 1522
015-PSV Relief Valve HEAVY SLOPS DRUM D-
RV 330
-458-A (Spring) 1523
015-PSV Relief Valve HEAVY SLOPS DRUM D-
RV 330
-458-B (Spring) 1523
015-PSV Relief Valve TPW FROM TPW SURGE
RV 331
015-PSV Relief Valve TPW FROM TPW SURGE
RV 331
015-PSV Relief Valve METAL PASSVTR PUMP
RV 121
-001-A (Spring) DISCH P-1502A
015-PSV Relief Valve METAL PASSVTR PUMP
RV 121
-001-B (Spring) DISCH P-1502B
015-PSV Relief Valve CLARIFIED OIL TO
RV 323
-494-A (Spring) STORAGE
015-PSV Relief Valve CLARIFIED OIL TO
RV 323
-494-B (Spring) STORAGE
015-PSV Relief Valve MP STEAM FRM STM
RV 123
-002 (Spring) INJECTION POINTS
015-PSV Relief Valve HCO FLUSH OIL TO LP
RV 326
-538-A (Spring) FLH HDR
015-PSV Relief Valve LCO PUMPAROUND
RV 637
RV 637
RV 637
RV 637
RV 637
RV 637
RV 637
RV 637
015-PSV Relief Valve LCO STROPPER PUMP P-
RV 637
-537 (Spring) 1511A
RV 637
-566 (Spring) 1511A
Page 219 of 323

REV: A DATE: 06/12/07
CRACKER (RFCC)
Setting
(kg/cm2g)
RV 637
-567 (Spring) 1511B
RV 637
-568 (Spring) 1511B
015-PSV Relief Valve MC RECYCLE PUMP P-
RV 637
-569 (Spring) 1512A
015-PSV Relief Valve MC RECYCLE PUMP P-
RV 637
-572 (Spring) 1512B
RV LEAN OIL PUMP P-1513A 637
-573 (Spring)
-574 (Spring)
-575 (Spring)
-576 (Spring)
015-PSV Relief Valve FRACTIONATOR REFLUX
RV 637
RV LEAN OIL PUMP P-1513B 637
-602 (Spring)
-603 (Spring)
-605 (Spring)
-606 (Spring)
015-PSV Relief Valve NAPHTHA PUMP AROUND
RV 637
RV 637
RV 637
RV 637
RV 637
RV 637
RV 637
RV 637
015-PSV Relief Valve HVN PRODUCT PUMP P-
RV 637
-620 (Spring) 1515A
RV 637
-621 (Spring) 1515A
RV 637
-623 (Spring) 1515B
Page 220 of 323

REV: A DATE: 06/12/07
CRACKER (RFCC)
Setting
(kg/cm2g)
RV 637
-625 (Spring) 1515B
015-PSV Relief Valve HCO FLUSHING OIL
RV 637
RV 637
RV 637
RV 637
015-PSV Relief Valve LCO FLUSHING OIL PUMP
RV 637
-633 (Spring) P-1522A
015-PSV Relief Valve LCO FLUSHING OIL PUMP
RV 637
-634 (Spring) P-1522B
015-PSV Relief Valve HEAVY SLOPS PUMP P-
RV 637
-635 (Spring) 1527A
015-PSV Relief Valve HEAVY SLOPS PUMP P-
RV 637
-636 (Spring) 1527B
015-PSV Relief Valve FRACTIONATOR REFLUX
RV 637
015-PSV Relief Valve OVERHEAD SOUR
RV 637
-640 (Spring) WATER PUMP P-1517A
015-PSV Relief Valve OVERHEAD SOUR
RV 637
-641 (Spring) WATER PUMP P-1517B
015-PSV Relief Valve OVERHEAD LIQUID PUMP
RV 637
-642 (Spring) P-1518A
RV 637
-643 (Spring) P-1518A
RV 637
-644 (Spring) P-1518B
RV 637
-649 (Spring) P-1518B
DEBUTANIZER
RV OVERHEAD PUMP P- 637
-752 (Spring)
1556A
DEBUTANIZER
RV OVERHEAD PUMP P- 637
-754 (Spring)
1556B
015-PSV Relief Valve INTER STAGE DRUM
RV 637
015-PSV Relief Valve INTER STAGE DRUM
RV 637
015-PSV Relief Valve KO DRUM LIQUID PUMP
RV 637
-766 (Spring) P-1552A
015-PSV Relief Valve KO DRUM LIQUID PUMP
RV 637
-767 (Spring) P-1552B
015-PSV Relief Valve STRIPPER FEED PUMP P-
RV 637
-768 (Spring) 1553A
Page 221 of 323

REV: A DATE: 06/12/07
CRACKER (RFCC)
Setting
(kg/cm2g)
015-PSV Relief Valve STRIPPER FEED PUMP P-
RV 637
-771 (Spring) 1553B
015-PSV Relief Valve GASOLINE RECYCLE
RV 637
015-PSV Relief Valve GASOLINE RECYCLE
RV 637
015-PSV Relief Valve P-1603B DISCHARGE
RV 411
-720-A (Spring) LINE
015-PSV Relief Valve P-1604A DISCHARGE
RV 411
-720-B (Spring) LINE
015-PSV Relief Valve PS FRM STMGEN E-1504B
RV 315
-425-A (Spring) AND E-1505B
015-PSV Relief Valve PS FRM STMGEN E-1504B
RV 315
-425-B (Spring) AND E-1505B
015-PSV Relief Valve PS FRM STMGEN E-1504A
RV 314
-427-A (Spring) AND E-1505A
015-PSV Relief Valve PS FRM STMGEN E-1504A
RV 314
-427-B (Spring) AND E-1505A
RV 126
-011-A (Spring)
RV 126
-011-B (Spring)
RV 307
-390-A (Spring)
RV 307
-390-B (Spring)
RV 317
-391-A (Spring)
RV 317
-391-B (Spring)
RV 312
-417-B (Spring)
RV 312
-419-B (Spring)
RV 326
-538-B (Spring)
RV 313
-421-B (Spring)
RV 123
-004-A (Spring)
RV 123
-004-B (Spring)
8474L-015-
RV PID-0041-
-783 (Spring)
653
8474L-015-
RV PID-0041-
-784 (Spring)
653
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Setting
(kg/cm2g)
RV
-869 (Spring)
RV 654
-313 (Spring)
RV 654
-314 (Spring)
RV 654
-801 (Spring)
RV 136
-005-S (Spring)
015-PSV Relief Valve CWS TO BLOWDOWN
RV 452
-639 (Thermal) COOLER E-1532
015-PSV Relief Valve CWS TO WET GAS COMP
RV 403
-702 (Thermal) CLR E-1552A/B
015-PSV Relief Valve CWS TO STRIPPER
RV 404
-706 (Thermal) CONDNSR E-1554A-D
015-PSV Relief Valve CWS TO GASOLINE
RV 406
015-PSV Relief Valve CWS TO LEAN OIL
RV 407
-713 (Thermal) COOELR E-1564
015-PSV Relief Valve CWS TO FUEL GAS
RV 408
015-PSV Relief Valve CWS TO DBTR CONDNSR
RV 410
-716 (Thermal) E-1561A/B
015-PSV Relief Valve CWS TO LPG COOELR E-
RV 411
-717 (Thermal) 1562
015-PSV Relief Valve CWS TO LEAN AMINE
RV 411
015-PSV Relief Valve CWS TO HVN TRIM
RV 328
015-PSV Relief Valve BFB FROM LCO PA BFW
RV 307
-413 (Thermal) HTR E-1511
015-PSV Relief Valve BFB FROM HVN BFW
RV 317
-430 (Thermal) HEATER E-1516
015-PSV Relief Valve CWS TO OVRHD TRM
RV 319
-433 (Thermal) CONDSR E-1520A-H
015-PSV Relief Valve TPW FROM SLRY CLF
RV 323
-442 (Thermal) COOLER E-1507B
015-PSV Relief Valve TPW FROM SLRY CLF
RV 323
-443 (Thermal) COOLER E-1507D
For further details, refer to the Flare Discharge Summary of the RFCC: Doc. No. 8474L-
015-NM-0006-701.
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CRACKER (RFCC)
TRAINING MODULE
UNIT: 15
Course Content:

X
Section 9 - HSE
Page 224 of 323

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CRACKER (RFCC)
SECTION 5 : FIRE & GAS SYSTEMS
5.1. Fire & Gas detection

Refer to the following documents:
8474L-015-DW-1950-021 Fire & Gas Detector Layout RFCC/LTU/NTU units
8474L-015-DW-1960-001 Escape Route Layout RFCC/LTU/NTU units
8474L-015-DW-1514-610 Fire and gas Cause and Effect Chart Area 3
5.2. Fire Protection

8474L-015-DW-1933-001 Fire Protection Layout RFCC/LTU/NTU units
8474L-015-DW-1933-011 Safety Equipment Layout RFCC/LTU/NTU units
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CRACKER (RFCC)
TRAINING MODULE
UNIT: 15
Course Content:

X
Section 9 - HSE
Page 226 of 323

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CRACKER (RFCC)
SECTION 6 : QUALITY CONTROL
This section outlines the sampling schedule and analytical methods that the licensor
suggests for monitoring the feed and product quality. The feed must be analyzed to be
certain that it conforms to the quality of the feed that was used for the design. This is
important for setting the operating severity level and for monitoring the catalyst activity.
The products must be analyzed to ensure that the unit is producing on grade materials.
The analytical results will often determine whether the material has to be "off-graded", or
whether the material is acceptable for the next processing step. Therefore, it is obvious
that ever precaution should be taken to make the sample representative of the original
material. That is, it must be like all the rest of the material being processed or the
material collected in the vessel.
The analytical results reported by the laboratory can be no better than the sample
submitted. An analysis or test however, efficiently carried out, will be rendered valueless
if the sample has been improperly taken.
Absolute verification of out-of-specification batches of material must be made by re-
sampling and repeating the analysis before the material is off-graded.
6.1. Sampling Analysis

For proper control of the unit it is essential to run laboratory tests on a regular basis. The
following tests are recommended as a minimum.
6.1.1. Feed Oil

Analysis Method Frequency
Gravity ASTM D 1298/D 4052 Daily
ASTM Distillation ASTM D 1160 Daily
Viscosity ASTM D 445 Daily
Sulfur ASTM D 4294 Daily
Nitrogen ASTM D 4629 Daily
Conradson carbon residue (CCR) ASTM D 189 Daily
Metals ASTM D 5863 / D 5708 /D 5185 Weekly
Aniline point ASTM D 611 Weekly
6.1.2. Catalyst
Spent Catalyst Carbon Element Analyser Daily
1st regenerator catalyst Carbon ASTM D 3178 or equivalent Daily
2nd regenerator catalyst Carbon ASTM D 3178 or equivalent Daily
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Fresh Catalyst Particle Size
MAT Activity
By catalyst vendor
Surface Area
By catalyst vendor
Pore Volume
By catalyst vendor
Bulk Density
By catalyst vendor
Metals
Rare Earths
6.1.3. Light Cycle Oil

Specific Gravity ASTM D 1298 / D 4052 Daily
Distillation ASTM D 86 Daily
Nitrogen ASTM D 4629 Daily
Color ASTM D 1500 Daily
Flash Point ASTM D 93 Daily
Cloud Point ASTM D 2500 Daily
Water ASTM D 4377 / E 0203 Daily
Viscosity at 50°C ASTM D 445 Daily
Pour Point ASTM D 97 Daily
6.1.4. Heavy Cycle Oil

Specific Gravity ASTM D 1298 / D 4052 At Request
Distillation ASTM D 86 / D 1160 At Request
Viscosity ASTM D 445 At Request
Sulfur ASTM D 4294 At Request
6.1.5. Clarified Oil

Distillation ASTM D 1160 At Request
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Viscosity at 100°C ASTM D 445 At request
Pour Point ASTM D 97 Daily
Flash Point ASTM D 93 At Request
Water & Sediment ASTM D 1796 Daily
Catalyst Loading (Ash) ASTM D 482 Daily
6.1.6. Slurry
Catalyst Loading ASTM D 482 Daily
6.1.7. Absorber Gas

Composition Gas Chromatograph Daily
H2S Draeger Tube Daily
6.1.8. Heavy Naphta

Distillation ASTM D 86 Daily
RON ASTM D 2699 Daily
MON ASTM D 323 Daily
6.1.9. LPG
Composition Gas Chromatograph Daily
C5 (mol%) ASTM D 2163 Daily
C2 (mol%) ASTM D 2163 Daily
Specific Gravity ASTM D 1657 As required
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6.1.10. Sour Water

pH ASTM D 1293 At request
Copper ASTM D 1688 At request
Iron ASTM D 1068 At request
Phenols ASTM D 1783 At request
Cyanides ASTM D 4282 At request
Sulfides ASTM D 4658 At request
Ammonia ASTM D 4658 At request
Hydrocarbons ASTM D 3921 At request
6.1.11. Sampling Connections

For the sampling connections details per type (as listed below), refer to the
following P&ID’s:
• 8474L-015-PID-0021-611 Sampler Details (1/3)
Connection Type Tag Service PID

Type 1A:
Low temperature liquid sample and
low pour point products (gasoline, Sour water from T-1501 overhead
diesel) SC-413 sour water pumps P-1517A/B to 320
SWS (unit 18)
Operating Temperature ≤ 50°C
Operating Pressure ≤ 8.16 kg/cm2g
Type 1B: Heavy naphta from heavy naphta
SC-412 trim cooler E-1518 to gasoline 328
Low temperature liquid sample
treating
Gasoline from gasoline cooler E-
Operating Pressure > 8.16 kg/cm2g SC-706 406
1559 to gasoline treating
Type 2: Sour water from HP separator
SC-704 404
Low temperature gas and flashing drum D-1553 to SWS
liquid sample service Rich Sponge Oil from Secondary
Operating Temperature ≤ 50°C SC-709 Absorber T-1553 to lean oil/rich 407
oil cooler E-1563
Sour water from lean oil coalescer
SC-710 407
D-1556 to SWS
SC-712 Rich amine from fuel gas 408

Page 230 of 323
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CRACKER (RFCC)

absorber T-1555 to ARU (unit 19)
Off gas from fuel gas absorber
SC-713 outlet KO drum D-1559 to fuel gas 408
system
Sour water from Debutanizer
SC-715 410
Reflux Drum D-1554 to SWS
LPG from LPG cooler E-1562 to
SC-716 411
LPG amine absorber T-1556
Rich amine from LPG amine
SC-717 411
absorber T-1556 to ARU (unit 19)
Type 3A:
Low temperature liquid sample LCO product from LCO air cooler
SC-419 328
Operating Temperature ≤ 50°C E-1514 to storage
Operating Pressure ≤ 8.16 kg/cm2g
Type 3A: LCO Product at the outlet of LCO
SC-418 328
Low temperature liquid sample air cooler E-1514
Operating Temperature ≤ 50°C LCO product from LCO air cooler

SC-421 328
Operating Pressure > 8.16 kg/cm2g E-1514 to LCO HDT
Wet gas from 1st stage KO drum

SC-701 outlet to wet gas compressor C- 401
1551 (1st stage)
Wet gas from interstage KO drum
SC-702 403
outlet to C-1551 (2nd Stage)
Stripper overhead from T-1552 to
SC-703 404
stripper condensers E-1554 A-D
Type 4A: HP separator vapour from D-1553

SC-705 405
to primary absorber T-1551
Low temperature gas and flashing
liquid sample service Primary absorber overhead from
SC-707 407
T-1551 to secondary absorber
Fuel gas from secondary
SC-711 absorber T-1553 to fuel gas 408
cooler E-1565
Fuel gas from fuel gas inlet
SC-714 absorber KO drum D-1557 to fuel 408
gas absorber inlet
LPG from LPG amine coalescer
SC-718 411
to LPG treating unit
Type 5A: Residue feed from feed surge

SCC-401 drum D-1513 to feed pumps P- 301
High temperature liquid sample and 1501 A/B suction
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low pour point products Continuous blowdown from LCO
SCC-411 316
Operating Temperature > 50°C LP steam generator E-1510
Operating Pressure ≤ 8.16 kg/cm2g Continuous blowdown from slurry
SCC-415 322
LP steam generator E-1506 B
Continuous blowdown from slurry
SCC-416 322
LP steam generator E-1506 A
Clarified Oil from the slurry
SCC-417 clarified oil coolers E-1507 A-D to 323
storage
HCO from the HCO LP steam
SCC-422 generator E-1510 to the HCO 316
flushing oil drum D-1518
Continuous blowdown from HCO
SCC-402 recycle MP steam generator E- 306
1508
Continuous blowdown from HCO
SCC-403 pumparound MP steam generator 308
E-1523
Continuous blowdown from the
SCC-404 Slurry HP steam generator E- 312
1503A
Type 5B: SCC-405 Slurry HP steam generator E- 312
1503B
High Temperature Liquid Sample
and low pour point products with Continuous blowdown from the
jacketed cooler SCC-406 Slurry HP steam generator E- 313
Operating Temperature > 50°C 1503C
Operating Pressure > 8.16 kg/cm2g Continuous blowdown from slurry

SCC-407 315
HP steam generator E-1504B
SCC-408 314
HP steam generator E-1504A
SCC-409 315
MP steam generator E-1505B
SCC-410 314
MP steam generator E-1505A
SCC-420 LCO product LP steam generator 328
E-1513
Type 7: Slurry product from the slurry
High Temperature Liquid Sample SC-414 draw-off drum to the slurry MP 321
and high pour point products steam generators E-1506 A/B
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Operating Temperature > 50°C
Type 8:
High Temperature gas & flashing Stripper T-1552 bottoms to
SCC-708 405
liquid sample service Debutanizer T-1554
Operating Temperature > 50°C
Type 15: Cold condensate leaving the
Low temperature liquid sample SC-101 turbine ST-1501 of the air blower 132
C-1501
Operating Temperature < 50°C
6.2. On-line analyzers

All the on-line analysers of the RFCC are dedicated to the control of the flue gas
composition, to ensure the environmental specifications are satisfied prior to discharging
to atmosphere.
The main components of the regenerator flue gases are as follow:
Parameter Value Range
O2 (vol%) 0 to 5
CO (vol%) 0.01 to 8
CO2 (vol%) 5 to 20
N2 (vol%) 60 to 80
H2O (vol%) 5 to 20
SOx (vol ppm) 50 to 1000
NOx (vol ppm) 20 to 400
Catalyst fines (mg/Nm3) 200 to 3000
Temperature (°C) 620 to 840
Pressure (kg/cm2g) 0.05 to 3.7
Measures of O2, CO and CO2 content are necessary for operating the unit. They are
made continuously. Dry and particle-free samples are required for both types of
analysers.
Measures of SOx and NOx content are necessary for pollution control. They can be made
continuously or from time to time.
The regenerator flue gas sampling sets 2 problems:

• Elimination of catalyst fines which concentration can reach 3000 mg/Nm3
• Elimination of water which concentration can reach 20 vol%
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To overcome this, the sampling system comprises of the following steps:

• Primary filtration in which the solid particles are eliminated at a temperature over
the flue gas dew point (250°C (min.) to 840°C(max.)) in order to avoid plugging
and mud build up. So the filtration chamber is equipped with superheated MP
steam tracing and heat conservation.
• Carrying system: the sample is carried in stainless steel or monel tube traced with
MP steam from the filtration chamber to the conditioning system. The sample is
carried at temperature over the dew point in order to avoid acid condensation in
the pipe due to SOx.
• Conditioning system, where the sample is cooled down. It goes through a
separator from condensates extraction. The condensates are drawn off by a
peristaltic pump in the bottom of the conditioning device. In case of flue gas at
atmospheric pressure the sample is compressed by a diaphragm pump prior to
being dried. In case of flue gas under pressure, the sample is expanded after
drying.
• Analysers:
o O2 content is measured by paramagnetic type analyser
o CO and CO2 content is measured by infrared photometric type analyser
o SOx content is measured by infrared photometry
o NOx is measured by chemiluminescence
Physical Design Value

Analyzer
Description Service property CO Norm CO PID:
tag
analyzed Min. al Max.
1st
Paramagnetic type 0.0 0.0 0.0
AI-004 regenerator O2 content -
O2 analyzer Mol% Mol% Mol%
flue gas
1st
Infrared photometric 11.57 9.94 8.0
AI-005 regenerator CO2 content -
type CO2 analyzer Mol% Mol% Mol%
flue gas
1st
Infrared photometric 4.63 6.26 8.00
AI-006 regenerator CO content -
type CO analyzer Mol% Mol% Mol%
flue gas
2nd
Infrared photometric 0.00
AI-007 regenerator CO content
type CO analyzer Mol%
flue gas
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Design Value
2nd
Infrared photometric 16.98
AI-008 regenerator CO2 content -
type CO2 analyzer Mol%
flue gas
2nd
Paramagnetic type 1.85
AI-009 regenerator O2 content -
O2 analyzer Mol%
flue gas
<300 <300
Infrared photometric CO Boiler
AI-011 CO content ppm ppm -
type CO analyzer Flue Gas
vol vol
Infrared photometric CO Boiler 13.56 14.17

AI-012 CO2 content -
type CO2 analyzer Flue Gas Mol% Mol%
Paramagnetic type CO Boiler 1.78 1.78

AI-013 O2 content -
O2 analyzer Flue Gas Mol% Mol%
Flue gas
Paramagnetic type 1.78 1.78
AI-018 inlet to O2 content 205
O2 analyzer Mol% Mol%
stack
Flue gas
Infrared 0.05 0.06
AI-019 inlet to SOx content 205
Spectrophotometer Mol% Mol%
stack
Flue gas <1000 <1000

Chemiluminescence
AI-020 inlet to NOx content ppm ppm 205
type analyzer
stack vol vol
For further details refer to the process data sheet of the RFCC analyzers, doc. No.
8474L-015-PDS-AE-001.
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CRACKER (RFCC)
TRAINING MODULE
UNIT: 15
Course Content:

X
Section 9 - HSE
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CRACKER (RFCC)
SECTION 7 : CAUSES AND EFFECT
7.1. Cause & Effect Matrix:

• Cause and Effect Chart, Doc. No. 8474L-015-DW-1514-602
• Fire & gas Cause and Effect Chart for Area 3, Doc. No. 8474L-015-DW-1514-610
Note:
The cause & effect matrix Doc. No. 8474L-015-DW-1514-602 details the safety trips and
protection evoked in the safeguards narrative in section 4 of this document.
The fire & gas cause and effect chart deals with all the fire & gas detection system in the
area 3 (units 015, 016 and 017).
7.1.1. Example from Cause and Effect Chart

To better understand how the Cause & Effect Matrix can be interpreted, an
example is given, which details the information that can be extracted from a sheet
of the Cause & Effect Diagram. It shall be read in conjunction with the
corresponding sheet of the Cause & Effect Diagram.
7.1.1.1. Sheet 18: UX-426: T-1501 & P-1519 inventory isolation

The following table describes all the causes activating the logic UX-426:

7 XZSM-415 311 70% limit switch of P-1519C suction valve XV-415 active
8 XZSO-415 311 OPEN limit switch of P-1519C suction valve XV-415 active
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18 UXHS-426C 311 LOCAL hardwire switch active
19 UXHS-426D 311 LOCAL hardwire switch active
20 UXHS-426E 311 LOCAL hardwire switch active
21 UXHS-426F 311 LOCAL hardwire switch active
22 UXHS-426G 311 LOCAL hardwire switch active
Depending on which initiators are active, the logic UX-0426 may generate
the effects detailed in the following table. For each effect, the
corresponding initiators are indicated by a letter at the junction between
the cause and the effect. The letter tells which can of action is taken.
For example “A” indicates the activation of a device/system, “C” and “O”
indicate the closing and opening of a valve respectively.

initiator No:
1a XSY-419 1, 2, 3, 9, 11, 311 CLOSE the slurry pumparound pump P-
18, 19, 20, 1519A turbine HP steam valve XV-419
21, 22
1519A turbine HP steam valve XV-419
pumparound pump P-1519A turbine HP
steam valve XV-419:
14, 18, 19, 1519B turbine HP steam valve XV-421
20, 21, 22
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initiator No:
1519B turbine HP steam valve XV-421
steam valve XV-421:
17, 18, 19, 1519C turbine HP steam valve XV-423
20, 21, 22
1519C turbine HP steam valve XV-423
steam valve XV-423:
4 XSY-413 1, 2, 18, 19, 311 CLOSE P-1519A suction motor operated
20, 21, 22 valve XV-413
5 XSY-414 1, 2, 18, 19, 311 CLOSE P-1519B suction motor operated
20, 21, 22 valve XV-414
6 XSY-415 1, 2, 18, 19, 311 CLOSE P-1519C suction motor operated
20, 21, 22 valve XV-415
7 XSY-416 1, 2, 18, 19, 311 CLOSE P-1519A discharge motor operated
20, 21, 22 valve XV-416
8 XSY-417 1, 2, 18, 19, 311 CLOSE P-1519B discharge motor operated
20, 21, 22 valve XV-417
9 XSY-418 1, 2, 18, 19, 311 CLOSE P-1519C discharge motor operated
20, 21, 22 valve XV-418
20, 21, 22
20, 21, 22
20, 21, 22
20, 21, 22
20, 21, 22
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initiator No:
20, 21, 22
• The motor operated valves must be reset locally: XV-
413/414/415/416/417/ 418 are reset by XHSR-
413/414/415/416/417/418 respectively.
The C&E chart also indicates the Maintenance Override Switches (MOS)
and Operation Override Switches (OOS) associated with the instrument
triggering the logic and allowing the operator to bypass the conditions
tripping the system:
Instrument OOS MOS

UXHS-426A N/A N/A
UXHS-426B N/A N/A
XZSM-413 N/A XZHS-413-A
XZSO-413 N/A XZHS-413-B
HS-419 N/A N/A
XHSO-419B N/A N/A
XHSC-419B N/A N/A
HS-421 N/A N/A
XHSO-421B N/A N/A
XHSC-421B N/A N/A
HS-423 N/A N/A
XHSO-423B N/A N/A
XHSC-423B N/A N/A
UXHS-426C N/A N/A
UXHS-426D N/A N/A
UXHS-426E N/A N/A
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UXHS-426F N/A N/A

UXHS-426G N/A N/A
When no OOS or MOS are available, then the condition leading to the
activation of the logic cannot be bypassed.
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TRAINING MODULE
UNIT: 15
Course Content:

X
Section 9 - HSE
Page 242 of 323

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CRACKER (RFCC)
SECTION 8 : OPERATING PRACTICES
8.1. Normal Operation
8.1.1. Operating conditions

The following is a narrative of the main process conditions of the RFCC unit in
steady state and FOR THE BACH HO MAX DISTILLATE CASE ONLY. It also
details the line up during normal operation.
For a complete description of the Heat and material Balance & Operating
Conditions of the unit 015, refer to the following process flow diagrams:
Normal operation Narrative
Feed Section
Figure 54: Feed Preheat Section
Refer to P&ID’s: 8474L-015-PID-0021-301 / 302 / 303 / 304 / 121
407,000 kg/hr of long residue is fed directly to the feed surge drum D-1513 from
the Crude Unit (CDU) through XV-404, at 115°C and 4.5 kg/cm2g. The feed surge
drum pressure is maintained at 1.0 kg/cm2g by either admitting Fuel Gas via PV-
403A or venting excess off gas to the Flare header via PV-403B. From D-1513,
the feed flows to the suction of the Feed Pump on duty P-1501A via TI-403. P-
1501A pumps the feed to the LCO pumparound feed preheat exchangers E-1512
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A-D, through FIC-403. A slip stream of the feed is recycled back to the feed surge
drum via FV-403. The total duty of E-1512A-D is 14.79 MW.
The LCO PA feed preheat exchangers are constituted of 2 branches, in which the
feed flows in parallel:
• 1st Branch: Part of the feed is heated against LCO PA in the shell side of E-
1512A before flowing to the shell side of E-1512B via TW-404. The
preheated feed then exits the shell side of E-1512B via TZ-405.
• 2nd Branch: The remaining part of the feed flows through the shell side of
the E-1512C. The feed leaving the shell side of E-1512C flows through TW-
406 to the shell side of E-1512D and exits via TW-407.
The preheated feed leaving the shell side of E-1512B and E-1512D is recombined
and flows through TI-408 and PI-408 to the shell side of the MP steam feed heater
E-1522. MP steam is supplied to the tube side of E-1522 via FV-410. The duty of
E-1522 is 3.77 MW. Then the feed flows to the shell side of the HP steam feed
heater E-1524 via TI-409. HP steam is fed to the tube side of the exchanger via
FV-411.
The heated residue feed leaving E-1524 then flows to the 1st feed preheat slurry
exchangers E-1502 A/B/C, via TI-410, TIC-411, PI-409 and PV-410. The feed
flows through the shell side of these exchangers according to the following
sequence: E-1502A (shell side), TW-412, E-1502B (shell side), TW-533, E-1502C
(shell side). The total duty of E-1502 A-C is 19.95 MW.
Upstream of E-1502A, a slip stream flows through the bypass line of the slurry
feed preheat exchangers via TV-002.
The heated feed leaving the shell side of E-1502C then flows to the 2nd feed
preheat slurry exchangers E-1501 A/B via TI-421. Upstream of E-1501 A/B, the
feed is equally split into 2 streams flowing in parallel to the shell side E-1501A and
E-1501B. The total duty of the 2nd feed preheat slurry exchangers is 6.75 MW.
The feed leaving E-1501A and E-1501B flows through TW-534 and TW-535
respectively before being recombined and mixed with the feed bypass from E-
1524. The total preheated feed then flows towards the reactor riser via PIC-410,
TI-414, FIC-001, TI-001.
Downstream of TI-001, HCO recycle from E-1508 flows into the preheated feed
line via FIC-002 and FV-002. The temperature of the total feed is 290°C. The total
feed flows to the feed line static mixer M-1501 via FXA-405 and XV-002.
Metal passivator, from the metal passivator drum D-1508, is NOT injected into the
feed line at the inlet of M-1510, since it is required for the Mixed Crude Case Only.
Reaction Section
Figure 55: Reaction Section – Bach Ho Maximum Distillate Case
Refer to P&ID’s: 8474L-015-PID-0021-121 / 122 / 138

Downstream of the static mixer M-1501, the feed mixture flows to each feed
injectors I-1501 A-F via TI-003, FIC-003A-F, FV-003A-F and PG-003A-F.
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The feed should be split evenly between the feed nozzles as observed by
individual flow indicators. Pressures PG-003A-F on each feed nozzle should be
monitored as a verification of flow and indication of nozzle condition.
162,000 kg/hr of Dispersion steam is supplied to each of the six feed nozzles to
promote atomization and vaporization of the feed. MP steam at 250°C flows to
each of the six feed nozzles via TI-004, PI-004, FIC-005 A-F, FV-005 A-F and PG-
005A.
2,790 kg/hr of stabilization steam is supplied to the stabilization injectors I-1503 A
to D at the bottom of the riser. The MP steam at 250°C is supplied from the MP
steam header to each of the 4 injectors via TI-007, FIC-007 A to D, FV-007 A to D
and PG-007 A to D.
MTC is NOT required for Bach Ho crude operation and is only used when on
mixed crudes and in high gasoline make modes. In such a case, MTC recycle is
pumped from the tray #19 of the main fractionator T-1501 by means of the duty
MTC recycle pump P-1512A to the MTC injectors I-1502 A to D. These injectors
are located downstream of the feed injectors. The pressure at the pump discharge
can be checked locally via PG-413. From the pump discharge, the MTC recycle
flows to each of the 4 MTC injectors I-1502 A to D via FI-009, PI-009, XV-003, TI-
031, FIC-010 A to D, FV-010 A to D and PG-010 A to D. the flow is evenly split
between each of the 4 MTC injectors.
Even though MTC is not required for the Bach Ho Crude operation, a total of 660
kg/hr of MTC dispersion steam is injected to the 4 MTC injectors I-1502 A to D.
The MP steam at 250°C flows from the MP steam header to the each of the
injectors via TI-010, FIC-011 A to D, FV-011 A to D and PG-011 A to D.
Finally, 6,875 kg/hr of backflush oil at 170°C is pumped by P-1506A from the
backflush oil receiver D-1517 to the riser, downstream of the MTC injectors.
Backflush oil flows from P-1506A discharge to the unique backflush oil injector I-
1504 through XV-004, TI-039, FIC-012, FV-012 and PG-009. The pressure at the
pump discharge can be monitored locally by means of PG-477.
200 kg/hr of MP dispersion steam is also injected into the backflush oil injector:
The MP steam at 250°C flows to the injector via FIC-013, FV-013, TI-006 and PG-
012.
Riser/Reactor
The sensible heat, heat of vaporization and heat of reaction required by the feed is
supplied by the hot regenerated catalyst. From the withdrawal well, 35.77 Ton/min
of hot regenerated catalyst flows to the riser wye via the Regenerated Catalyst
Slide Valve SV-1501. The riser outlet temperature (TIC-020) is controlled by the
amount of regenerated catalyst admitted to the riser through SV-1501. The
catalyst flowing from the withdrawal well is fluidized by the injection of fuel gas
from the fuel gas drum D-1509 and thru PCV-013, downstream of SV-1501. Fuel
gas is injected at several locations from SV-1501 to the riser wye.
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In the wye section at the base of the riser, 500 kg/hr of steam are injected via a
steam ring to keep the regenerated catalyst in a fluid state at all times: the MP
steam flows from the header to the ring via TI-011, FT/FI-006, and PG-006.
The small droplets of feed contact hot regenerated catalyst in a counter current
way and vaporize immediately. The vaporized oil intimately mixes with the catalyst
particles and cracks into lighter, more valuable products along with slurry oil, coke
and gas.
The cracking reactions take place during the 2 seconds residence time in the riser
as the reaction mixture (composed of the products and the catalyst) accelerates
toward the Riser Outlet Separator System (ROSS) at the top of the riser.
The catalyst is quickly separated from the hydrocarbon/steam vapors in the ROSS
separator located at the end of the riser.
After exiting the ROSS separator, the vapours pass through the 6 Disengager
Cyclones CY-1501 A/B/C/D/E/F to complete the separation of catalyst from
vapours. The ROSS separator and disengager cyclones CY-1501A-F separate the
product vapors from spent catalyst and return the catalyst to the stripper bed.
544,699 kg/hr reactor product vapours at 505°C, containing a small amount of
inerts, catalyst and steam, flow to the bottom of the main fractionator T-1501, via
TI-022 and MOV-011.
The reactor pressure "floats on" the main fractionator pressure and as such is not
directly controlled at the main fractionator reflux drum D-1514.
The reactor temperatures are monitored by means of TI-005 (downstream of the
stabilization injectors), TI-008 (downstream of the feed injectors) and TI-009
(downstream of the MTC injectors). The riser outlet temperature indicated by TI-
021 and controlled by TIC-020 is 505°C.
300 kg/hr of anti-coking steam is provided at the top of the disengager/stripper

cyclones. The MP steam at 250°C is supplied from the MP steam header to the
ring via FIC-033, FV-033 and PG-041.
Stripper
Refer to P&ID’s: 8474L-015-PID-0021- 123 / 138
Catalyst exiting the ROSS separator is pre-stripped with 900 kg/hr of MP steam
from a steam ring located immediately at the exit of the separator diplegs. This is
an important feature for reducing coke yield. MP steam at 250°C is supplied from
the header via FIC-032, FV-032 and PG-040.
The catalyst is further stripped by 7000 kg/hr of steam at 250°C from the main
steam ring as the catalyst flows down the Disengager/stripper D-1501. MP steam
at 250°C is supplied from the header to the main ring via FIC-030, FV-030 and
PG-038. 2 additional rings are also provided in addition to the main ring:
• The upper ring, above the main ring, achieves a second stage of pre-
stripping. For this, 3400 kg/hr of MP steam at 250°C are supplied from the
steam header to the upper ring via FIC-031, FV-031 and PG-039.
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• The lower ring is located in the bottom head of the stripper to achieve a
stable fluidization at the inlet of the spent catalyst standpipe. For this, 2700
kg/hr of MP steam at 250°C are supplied from the steam header to the
fluffing ring via FIC-029, FV-029 and PG-037.
The steam rate for this ring is part of the total steam required for good
stripping but its prime function is to aerate the catalyst entering the spent
catalyst standpipe. This is important for adequate head build-up to maintain
an adequate slide valve differential pressure for controlling the stripper
level.
The total steam flow is designed to provide about 6 kg of steam per ton of catalyst
circulated.
The contact between catalyst and steam is enhanced by the presence of fluidized
bed packing permitting cross and counter current flow of steam and catalyst. The
fluidized bed packing is located between the main ring and the lower ring.
It allows efficient contact between the catalyst and steam to displace the volatile
hydrocarbons contained on and in the catalyst particles before they enter the 1st
stage regenerator D-1502, where coke will be burnt off.
The temperature in the stripper is monitored via (from top to bottom): TI-018, TI-
019, TI-016, TI-017, TI-014 and TI-013.
Spent Catalyst Transfer

Refer to P&ID’s: 8474L-015-PID-0021-125 / 138
Downstream of the main ring, stripped catalyst flows down the spent catalyst
standpipe. The spent catalyst is aerated by means of fuel gas flowing through
PCV-071 and PG-072 from the fuel gas drum D-1509. This fuel gas drum is
supplied with fuel gas from the fuel gas header. D-1509 is also supplied in fuel gas
from D-1559 in the gas recovery section, on pressure control with PIC-367 acting
on PV-367A. The fuel gas pressure in D-1509 can be monitored locally with PG-
368. The total flow of FG leaving the drum D-1509 to various locations in the
reaction section (for fluidization or aeration purpose) is monitored by FI-203.
Nitrogen is also supplied via PCV-089, PG-090 and FI-021 for catalyst aeration.
This aeration help maintain proper density and fluid characteristics of the spent
catalyst. Fuel gas aeration injectors are distributed all along the spent catalyst
stand pipe upstream of the spent catalyst slide valve SV-1502, while 4 Nitrogen
aeration injectors are evenly distributed across SV-1502.
While aerated, the catalyst flows down through the spent catalyst line expansion
joint EX-1501 and then the spent catalyst slide valve SV-1502, which regulates the
level of the stripper by regulating the flow of catalyst leaving it.
Then the spent catalyst flows into the 1st stage regenerator D-1502 through a
distributor which ensures that the entering coke-laden catalyst is spread across
the regenerator bed.
Catalyst Regeneration Section
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The first stage regenerator D-1502 burns 50 to 80% of the coke and the remainder
is burned in the second stage regenerator D-1503.
Air blower and air heaters

Refer to P&ID’s: 8474L-015-PID-0021-128 / 130 / 134 / 132 / 133 / 138 / 206
The combustion air required for the combustion reactions in the 1st and 2nd
catalyst regenerators D-1502 and D-1503 is supplied by the steam turbine driven
air blower C-1501.
Atmospheric air is introduced to the air blower C-1501 through an intake filter and
silencer F-1501. At C-1501 discharge, the blower air at 238°C is distributed, via
PT-834, PG-356 and PIC-311, to a header system providing combustion air to the
downstream equipment as follow:
• 166,001 kg/hr of combustion air at 238°C is supplied to the first regenerator
air heater H-1501 via FIC-161, PV-311 and the first regenerator air ring
assisted check valve CV-1501.
In H-1501 bower air is heated up by fuel gas combustion. The air heater is
supplied with fuel gas from the air heater fuel gas KO drum D-1525 via XV-
016 and XV-017. The air heater fuel gas KO drum D-1525 is supplied with
pilot fuel gas from the battery limits via PV-371B in normal operation.
Preheated air leaves the 1st regenerator heater and is supplied to the inner
air rings and outer air rings at the bottom of the 1st Catalyst Regenerator D-
1502 via PG-314, TI-067, TIC-068 and TXA-069.
The outer air ring and inner air ring are designed to handle about 70% and
30% of the combustion air to the first stage regenerator D-1502
respectively.
• 31,685 kg/hr of combustion air at 238°C is supplied to the 2nd regenerator
air heater H-1502 via FIC-164, FV-164 and the 2nd regenerator air ring
assisted check valve CV-1502. In H-1502, air is heated up by fuel gas
combustion. The air heater is supplied with fuel gas from the air heater fuel
gas KO drum D-1525 via XV-014 and XV-015. The air heater fuel gas KO
drum D-1525 is supplied with pilot fuel gas from the battery limits via PV-
371B in normal operation.
Preheated air is then supplied to the unique air ring located at the bottom of
the 2nd regenerator D-1503 via PG-317, TI-070, TIC-071 and TXA-072.
• 47,832 kg/hr of blower air at 238°C is also used as lift air and is supplied to
the bottom of the lift line of the 1st regenerator in order to transfer partly
regenerated catalyst from D-1502 to D-1503. Air is supplied from the
discharge header of the air blower C-1501 via FIC-166, FV-166 and the air
lift assisted check valve CV-1503. Air is injected through the hollow stem of
the plug valve PV-1501 which regulates the amount of catalyst transferred
to the 2nd stage regenerator.
• 514 kg/hr of blower at 238°C is also injected in the catalyst loading line at
the bottom of the 1st regenerator D-1502 as fluidizing medium. Air is
supplied from the discharge header of the air blower C-1501 via FT/FI-071
and PG-114.
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• 1029 kg/hr of blower at 238°C is also injected in the catalyst loading line at
the bottom of the 2nd regenerator D-1503 as fluidizing medium. Air is
supplied from the discharge header of the air blower C-1501 via FT/FI-097
and PG-166.
• Finally 336 kg/hr of blower air at 2238°C is supplied in the withdrawal ring
of the withdrawal well downstream of the point where the hot regenerated
catalyst is discharged to the well, also as fluidizing medium. Air is supplied
from the discharge header of the air blower C-1501 via FIC-169, FV-169
and PG-239.
First stage regenerator

Refer to P&ID’s: 8474L-015-PID-0021-126 / 127 / 128 / 201/ 203
Spent catalyst containing roughly 1 to 1.5 wt % coke flows from the spent catalyst
distributor and is spread across the bed in the first stage regenerator D-1502.
Plant air (primary) is provided along the outlet of the spent catalyst standpipe to
help for the catalyst transfer. Plant is supplied from the PA header via PCV-142
and PG-143 to several nozzles disturbed along the outlet of the standpipe.
Part of the coke is burned by combustion air supplied from the outer and inner air
rings. This regenerator operates in a counter current (air inlet at bottom and spent
catalyst inlet at top) to prevent catalyst overheating.
In order to limit hydrothermal deactivation of the catalyst, the regeneration
conditions are mild: 1st stage regenerator total combustion air is controlled to limit
the temperature in this 1st stage to maximum 730°C. For this operating case, the
1st regenerator is operated at 2.28 kg/cm2g. The normal operating temperatures of
the 1st stage regenerator are: 636°C (bottom) & 631°C (top).
The partially regenerated catalyst flows down through the first stage regenerator
bed to the entrance of the air lift. Aeration by a fluffing ring is supplied in the
vicinity of the air lift to ensure smooth flow of catalyst to the lift. 574 kg/hr of plant
air (primary) is supplied to the fluffing ring via PCV-138, PG-139, FT/FI-070 nad
PG-113. The hollow stem plug valve PV-1501 regulates the flow of catalyst to the
lift line and is controlled by the level in the first stage regenerator D-1502 via LIC-
004. 47832 kg/hr of blower air injected through the hollow stem of the plug valve
into the air lift to lift the catalyst in a dilute phase up to the second stage
regenerator D-1503.
2 stage cyclones (CY-1502A-F / CY-1503A-F) separate entrained catalyst from
the flue gas. 178544 kg/hr of flue gas exits the 1st stage regenerator D-1502
towards the CO boiler H-1503 at 631°C via TI-030, analysers AI-004/005/006, the
first regenerator flue gas slide valve SV-1503 and the first regenerator flue gas
block valve BV-1501A.
The temperature in the 1st stage regenerator is monitored with 6 temperature
indicators TI-032/033/034/035/036/037 and is averaged by TI-038.
Second stage regenerator

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The partially regenerated catalyst flows up the lift line through the expansion joint
EX-1502 between the regenerators and enters the 2nd stage regenerator D-1503
below the combustion air ring. A distributor at the end of the lift provides for
efficient distribution of catalyst and air from the lift.
Catalyst is then completely regenerated to less than about 0.05% carbon through
combustion at more severe conditions than in the first stage regenerator D-1502.
The following are the normal operating conditions of the 2nd regenerator D-1503
for this operating case:
• Pressure: 1.30 kg/cm2g
• Bottom temperature: 695°C
• Top temperature: 720°C
4 external refractory lined cyclones CY-1504A-D are used on the 2nd stage flue
gas outlet to remove entrained catalyst. The cyclone dip legs are external to the
Aeration with PA is supplied to the diplegs to maintain a smooth fluidized catalyst
flow and the diplegs outlets are equipped with flapper (trickle) valves to prevent
catalyst and gas backflow into the cyclones. Plant Air (Primary) is supplied to the
each dipleg via PCV-164 A to D.
86,941 kg/hr of flue gas leave the 2nd stage regenerator at 720°C and flows to the
Waste Heat Boiler H-1503 through TI-064, the flue gas analysers AI-007/008/009,
the 2nd Regenerator Flue gas Slide Valve SV-1504, TI-078 and the 2nd
Regenerator Flue gas Block Valve BV-1502 A.
The temperature in the 2nd stage regenerator is monitored with 4 temperature
indicators TI-050/052/058/060 and is averaged by TI-063.
Note:
The pressure drop across the ring is kept above 0.07 bar at turndown to maintain
adequate distribution and prevent intrusion of catalyst into the ring and avoid
associated erosion.
Regenerated catalyst transfer

Refer to P&ID’s: 8474L-015-PID-0021-122 / 129 / 131 /
The hot regenerated catalyst flows from the 2nd stage regenerator D-1503 through
a lateral into the withdrawal well. In the withdrawal well a stable bed is established
at proper standpipe density by introduction of 336 kg/hr of fluidizing air from the
withdrawal well ring.
A smooth stable flow of catalyst down the standpipe is provided by injection of
aeration Plant Air at several elevations on the regenerated catalyst standpipe: PA
(primary) is supplied to 2 aeration nozzles on the lateral via PCV-214. PA
(primary) is also supplied to 9 aeration nozzles in the upper part of the withdrawal
well via PCV-212. Finally, PA (primary) is supplied to 9 aeration nozzles on the
lower part of the withdrawal well, upstream of the regenerated catalyst slide valve
SV-1501, via PCV-210.
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At the bottom of the withdrawal well, the catalyst flows through the regenerated
catalyst slide valve SV-1501 to the riser wye at the base of the riser where a
steam ring fluidizes the catalyst. The wye steam and fluidization points in the wye
section ensure that the catalyst flow to the feed injection point is stable and
smooth in order for the feed injection system to perform at its optimum.
Catalyst handling
The catalyst handling system includes hoppers for storage of fresh catalyst and
spent catalyst, loading devices for catalyst addition and a draw-off device for
continuous equilibrium catalyst withdrawal.
Three hoppers are installed:
• The fresh catalyst hopper D-1505,
• The spent catalyst hopper D-1506
• The auxiliary catalyst hopper D-1507, which provides flexibility in the
operation for different options:
o Storage of imported equilibrium catalyst reused as part of the make-
up catalyst,
o Storage of excess spent catalyst,
o Storage of a 2nd grade of fresh catalyst for make-up.
The spent and fresh catalyst hoppers are sized to contain the entire unit inventory.
Each hopper is provided with one cyclone and with aerations in the bottom cone to
assist the catalyst circulation to the transfer lines.
Catalyst addition
Continuous addition of fresh catalyst to the RFCC is essential for at least three
reasons:
• To maintain an optimum catalyst activity and selectivity,
• To keep metals on equilibrium catalyst at an acceptable level,
• To make up the inventory of circulating catalyst, compensating for catalyst
losses.
Two hoppers have been provided for catalyst addition. This allows the addition
simultaneously two different types of catalyst. It allows also to load one hopper
from a truck using the ejector system while the other hopper can remain
pressurized for the normal catalyst addition operation.
A catalyst feeder is used to automatically add fresh catalyst at the desired rate.
The feeder can be adjusted for batch size and frequency of additions.
The catalyst feeders are directly located below the catalyst hoppers. The amount
of catalyst introduced to the catalyst feeder is controlled by a weight cell and a
diaphragm valve at the catalyst feeder inlet. When the desired weight is in the
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loader, the diaphragm valve closes. A switch is then activated which opens
fluidizing and pressuring air to the feeder. The feeder pressures up to about 3.5
kg/cm2 g and another diaphragm valve opens which loads the catalyst into the
first stage regenerator via TI-024.
It is possible to bypass the catalyst make-up feeders during operation for repairs.
Catalyst withdrawal
As catalyst addition is higher than the catalyst losses from the unit, catalyst must
be withdrawn in order to keep the unit inventory. This operation is achieved by a
specific continuous draw-off system, X-1501, provided on the first regenerator D-
1501. Hot catalyst is withdrawn by an ON/OFF valve UV-021 actuated by timer,
cooled down through a finned tube and sent to the spent catalyst hopper at a
temperature below 400°C.
The amount of withdrawn catalyst is controlled by a restriction orifice RO-090.
For catalyst conveying and line cleaning, plant air is injected into the catalyst at
line downstream of the restriction orifice by another ON/OFF valve UV-022
actuated by timer.
The plant air is set in order to limit the catalyst velocity in the draw-off line (10
m/s), to limit the erosion.
The total daily amount of catalyst withdrawal is adjusted by timer setting taking
into account the operation requirements for the overall catalyst balance.
Flue gas treatment

Figure 55: Flue Gas Treatment Section (Bach Ho MD case)
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Figure 56: COB/WHB Package Flow Scheme
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Refer to P&ID’s: 8474L-015-PID-0021-201 / 202 / 203 / 204 / 205 / 206 / 306 / 308
/ 307 / 312 / 313 / 314 / 315 / 317.
For H-1503, refer to Vendor P&ID’s: 8474L-015-A0103-0160-001-029 / 030 / 031 /
032 / 033 / 034 / 035 / 142 / 143 / 144.
For X-1507, refer to Vendor P&ID’s: 8474L-015-A0103-4240-002-128 / 129 / 130 /
131 / 133.
194,650 kg/hr of flue gas at 631°C coming from the first regenerator are sent to
the CO incinerator H-1503 at 0.085 kg/cm2g, via flue gas slide valve SV-1503, TI-
084 and the flue gas block valve BV-1501A for combustion completion.
The incinerator burner is supplied with 172,701 kg/hr of combustion air via the
forced draft air fans C-1502 A/B, through XV-914 A/B. Combustion air is sent to
the CO air ports of the CO combustor via FV-901 and to the auxiliary burners via
FV-902.
The flue gas from the CO Boiler is routed to the Waste Heat Boiler H-1503 for HP
steam regeneration.
86,941 kg/hr of flue gas at 720°C coming from the second regenerator D-1503 are
sent straight to the waste heat boiler H-1503 at 0.085 kg/cm2g, via the second
regenerator flue gas slide valve and SV-1504 and the COB/WHB 2nd regenerator
flue gas block valve BV-1502 A.
526,133 kg/hr of flue gas exiting the waste heat boiler H-1503 at 314°C are sent to
the electrostatic precipitator X-1507 before flowing through the economizer E-1525
section of the COB/WHB package, and then to the stack SK-1501 at 236°C.
Heat released in WHB H-1503 is used for HP steam generation:

229,892 kg/hr of HP boiler feed water at 112°C is fed from the battery limits to the
heavy naphta boiler feed water heater E-1516 where HP BFW is heated to
114.9°C in the tube side against heavy naphta product.
The heated BFW is then sent to the tube side of the LCO Pumparound BFW
heater E-1511 via TI-484. There the BFW is heated to 121.4°C against LCO
pumparound (shell side) drawn off from the main fractionator.
The preheated HP BFW leaving E-1511 via TI-434 is then split into 2 streams:
• 18,092 kg/hr of the preheated BFW is fed to the slurry HP Steam
Generators E-1504 A/B, via FV-443 and FV-441 respectively. In E-1504
A/B HP steam is generated against slurry pumparound pumped by P-1519
A/B/C from the bottom of the main fractionator.
The HP steam leaves E-1504 A & B at 200.9°C via FI-444 and FI-442
respectively. It is then recombined before being fed to the HP steam
superheater of the waste heat boiler.
• 211,500 kg/hr of the preheated BFW at 121.4°C is sent to the economiser
section of the COB/WHB Package H-1503. The preheated BFW first flows
through FV-930 to the tube side of the BFW Preheater E-1534 where it is
heated up to 165°C against 19,800 kg/hr of MP steam from the MP steam
de-superheater. Then preheated BFW flows through TIC-923A and PP-943
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to the Economizer E-1525. In the economizer, the flue gas coming from the
electrostatic precipitator X-1507 is used as heating medium. The steam
leaving the economizer is then fed to the Steam Drum D-1512, via PP-942
and TI-924.
Phosphate is also injected into the Steam Drum D-1512 by means of the
Phosphate injection Pump on duty A-1502-P-01-A from the Phosphate Tank A-
1502-TK-01. The pressure at the pump discharge is monitored locally with PG-
940.
Boiler water then exits the bottom of the steam drum via 3 lines, the inlet of each
being equipped with a vortex breaker, and flows to the 4 Evaporator Coil Banks of
the WHB H-1503. In each of the Evaporator Coil Banks, steam is generated (tube
side) by means of the flue gas exiting the HP superheater of the WHB H-1503.
The mixture of steam and boiler water at the outlet of each evaporator coil bank is
then routed back to the steam drum via 4 dedicated lines.
Boiler water from the steam drum is also fed to the Screen Steam Generator
upstream the HP steam Superheater in the Waste Heat Boiler. The steam/boiler
water stream generated by the flue gas exiting the CO Combustion exits the
Screen Steam Generator and is routed back to the Steam Drum D-1512.
Saturated steam from D-1512 is sent to the HP Steam Superheater after being
mixed with 18,092 kg/hr of HP steam from E-1504 A/B. In the Superheater, flue
gas exiting the Screen Steam Generator generates Superheated HP steam (tube
side). The superheated HP steam generated is then de-superheated by means of
HP BFW prior to being sent to the Superheated HP steam header via FI-911B.
A continuous blowdown from the steam drum is sent to the continous blowdown
drum D-1531. The LP steam recovered in D-1531 is sent to the LP steam header
while the water collected is sent to the intermittent blowdown drum D-1532 via LV-
906. The water in D-1532 is cooled down against cooling water in the Blowdown
Cooler E-1533 before being sent to the oily water sewer via TG-926 and TI-925.
Superheated MP steam is also generated in the WHB:

LP Boiler Feed Water is fed to the following MP steam generators in parallel:
• 6,498 kg/hr of LP BFW are fed to the HCO recycle MP steam generator E-
1508, via FV-415, where LP BFW is heated (shell side) against HCO
recycle drawn-off from the main fractionator. MP steam leaves E-1508 via
FI-416.
• 7,300 kg/hr of LP BFW is fed to the HCO Pumparound MP steam generator
E-1523, via FV-421, where LP BFW is heated (shell side) against HCO
pumparound drawn off from the main fractionator. MP steam then leaves E-
1523 towards the MP steam superheater via FT-422A/B.
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• 13,868 kg/hr of LP BFW are fed to the Slurry MP steam generators E-1505
A/B, via FV-447 and FV-445 respectively. In E-1505 A/B LP Boiler Feed
Water is heated (shell side) against slurry from the HP steam generators E-
1504 A/B. MP steam then leaves E-1505 A and B towards the MP steam
superheater via FT-448 and FI-446 respectively.
The MP steam streams leaving in the above exchangers are then recombined and
27,666 kg/hr of MP steam at200.9°C are fed to the MP steam superheater
downstream of the 4th Evaporator Coil Bank. There, the MP steam is superheated
against the flue gas leaving the evaporator. Superheated MP steam is then de-
superheated against LP BFW prior to being discharged to the MP steam header.
526,133 kg/hr of flue gas leaving the WHB H-1503 at 314°C is then routed to the
Electrostatic Precipitator X-1507, via PG-382, MOV-003, TT-085, TT-086 and TT-
092. In X-1507, the content of catalyst dust contained in the flue gas leaving the
COB/WHB package is decreased to meet the environmental specification: The
dust fine content at precipitator outlet shall not exceed 50 mg/Nm3 dry basis.
The flue gas leaving the electrostatic precipitator is then sent to the economizer E-
1525 through PT-389, ROV-001 and TT-093. The flue leaves the economizer at
236°C and is finally sent to the stack via TT-098A/B, and the analyzers AI-018, AI-
019, AI-020 and AI-021.
Steam Generation Blow-down Operation

The following steam blow down is recommended for MPS and HPS steam
generator to maintain the quality of the generated steam, which are used for
turbine:
- Continuous blow down: 3.0 % of BFW feed
- Intermittent blow down: 10 % of BFW feed
For LPS Generator, the facilities are provided to cover continuous and intermittent
operation, but blow down operation is normally not required, since LPS is not used
for the turbine. Most of LPS is used for stripping steam or heating steam.
Phospate chemical injection is required in case steam generators are operated
with blowdown. It intended the dosage of phosphate is to maintain 10-20 wt ppm,
referring conductivity of BFW in the generator.
Phosphate solution is prepared by injection package X-1510.
For COB/WHB package, the operation concept is as same as steam generation of
the process heat exchanger that injection of phosphate should be adjusted,
referring sampling data of BFW in the steam drum of WHB, and continuous blow
down flow rate.
Phosphate injection
Refer to P&ID’s: 8474L-015-PID-0021-332.
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CRACKER (RFCC)
Phosphate solution, from the tank TK-1510 in the phosphate injection package X-
1510, is injected to the BFW fed to the following steam generators:
• Slurry HP steam generators E-1504 A/B by means of the phosphate
injection pumps P-1531 D/E respectively. The pressure at the pumps
discharge can be monitored locally with PG-638 D/E respectively.
• Slurry MP steam generators E-1505 A/B by means of the phosphate
injection pumps P-1532 A/B respectively. The pressure at the pumps
discharge can be monitored locally with PG-639 A/B respectively.
• HCO LP steam generator E-1510, also from the discharge of the phosphate
injection pump P-1532B. The pressure at the pumps discharge can be
monitored locally with PG-639 B.
• HCO pump pumparound MP steam generator E-1523, Slurry LP steam
generators E-1506 A/B and LCO product LP steam generator E-1513 by
means of the phosphate injection pump P-1532C. The pressure at the
pumps discharge can be monitored locally with PG-639 C.
• HCO recycle MP steam generator E-1508 by means of the phosphate
injection pump P-1532D. The pressure at the pumps discharge can be
monitored locally with PG-639 D.
Fractionation Section
Figure 57: Fractionation Section – Bach Ho Maximum Distillate Case
The operating conditions in the main fractionator T-1501 are:
Top Pressure: 0.85 kg/cm2g Top Temperature: 96°C
Bottom Pressure: 1.15 kg/cm2g Bottom Temperature: 340°C
Fractionator bottom section

/ 321 / 322 / 323 / 325 /
544,699 kg/hr of reactor effluent at 505°C from the disengager of the reaction
section is sent to the bottom of the main fractionator T-1501 below the Bed #5.
1,040,949 kg/hr of bottom slurry pumparound at 340°C flow to the suction of the
Slurry Pumparound Pumps on duty P-1519A/B via TIC-439, TI-438, XV-413 and
PG521 for P-1519A, XV-414 and PG-522 for P-1519B. At the discharge of the
pumps, the slurry PA flows through PG-431 & XV-416 for P-1519A, PG-432 & XV-
417 for P-1519B, and FI-423 (on the common discharge header) before being
delivered to the following downstream equipment at 339.9°C:
In the case of Bach Ho feed, a large proportion of the bottom pumparound duty is
used to preheat the feed in the 1st & 2nd Feed Preheat Slurry Exchangers E-1502
A/B/C and E-1501 A/B:
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CRACKER (RFCC)
• 290,000 kg/hr of Slurry PA are pumped by P-1519 A/B to the shell side of
the 2nd feed preheat slurry exchangers E-1501 A & B in parallel. The slurry
leaving the shell side of E-1501A flows through TW-529, FIC-406 and FV-
406, before being mixed with the slurry PA leaving the shell side of E-
1501B through TW-530, FIC-501 and FV-501. The recombined slurry PA
leaving E-1501 A&B then flows to the slurry PA return header, thru TI-422
indicating a normal operating temperature of 309.9°C.
The total duty of the 2nd feed preheat slurry exchangers is 6.75 MW.
• 310,000 kg/hr of Slurry PA flow from the discharge of P-1519 A/B to the 1st
feed preheat slurry exchangers E-1502 C, B and A in series as follow: the
slurry PA flows thru E-1502C (shell side), TW-413, E-1502B (shell side),
TW-532, E-1502A (shell side). Downstream of E-1502A, the slurry PA flows
through TW-531, and TI-423 indicating a normal operating temperature of
254.4°C before being split into 2 streams:
o 220,000 kg/hr of slurry PA flow thru FIC-407 and FV-407 to the slurry
quenching header and are returned to the quench zone of the main
fractionator T-1501.
o 90,000 kg/hr of slurry PA flow thru FIC-408 and FV-408 to the slurry
PA return header and are returned to T-1501 above the Bed #5.
The total duty of the 1st feed preheat slurry exchangers is 19.95 MW.
The remaining slurry PA, that is 440,949 kg/hr of slurry is supplied to the Slurry HP
steam generators E-1504 A/B and the MP steam generators E-1505 A/B divided in
2 branches (A & B) as follow:
• Part of the slurry PA flows through the tube side of E-1504A, exits via TI-
468, flows through the tube side of E-1505A. Downstream of E-1505A the
slurry flows thru TI-469, FIC-438 and FV-438 before being recombined with
the Slurry PA leaving the branch B.
• An equal amount of slurry PA flows through the tube side of E-1504B, exits
via TI-466, flows through the tube side of E-1505B. Downstream of E-
1505B the slurry flows thru TI-467, FIC-437 and FV-437 before being
recombined with the Slurry PA leaving the branch A.
The total duty of the Slurry HP steam generators E-1504 A/B is 11.67 MW and the
total duty of the MP steam generators E-1505 A/B is 9.22 MW.
Once recombined the slurry PA leaving E-1505 A&B flows thru TI-470 indicating a
normal operating temperature of 220°C before being split into 2 streams:
• 193,021 kg/hr of slurry PA flow thru FIC-439 and FV-439 to the slurry
quenching header and are returned to the quench zone of the main
fractionator T-1501.
• 17,321 kg/hr of slurry PA flow thru FIC-440 and FV-440 to the slurry PA
return header and are returned to T-1501 above the Bed #5.
At the discharge of the slurry PA pumps P-1519 A&B, 204,685 kg/hr of slurry PA
bypass is directly returned to the Bed #5 of the main fractionator thru FT-426A/B
and FV-426.
The total amount of slurry PA return to T-1501, that is 602,006 kg/hr of slurry PA
return, is returned to the bed #5 of the main fractionator T-1501 via TI-441.
Page 258 of 323

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CRACKER (RFCC)
The total amount of slurry quenching, that is 413,021 kg/hr of slurry, is returned to
the quench zone of the main fractionator via TI-440.
Note:
The slurry HP steam generators E-1503 A-C are bypassed in the Bach Ho
operation.
25,930 kg/hr of slurry product at 220°C is taken from the discharge of the MP
steam generators E-1505 A/B, downstream of TI-470, and flow to slurry draw-off
drum D-1515 via FIC-462, FV-462 and XV-451. D-1515 is operated at 220°C and
1.0 kg/cm2g. The pressure in D-1515 is maintained at 1.0 kg/cm2g by admitting
fuel gas thru PV-468A or venting excess off gas thru PV-468B.
The slurry product flows to the suction of the Slurry Product Pump on duty P-
1504A, via TI494 and PG-526, which pumps it to the Slurry LP Steam Generator
on duty E-1506 A via PG-469. The duty of E-1506A is 0.879 MW.
Downstream of E-1506 A, the cooled slurry flows, via TI-495, TIC-496 and PG-
574, to the slurry oil pre-filter on duty F-1503A before entering the Slurry
Separator X-1504 where catalyst fines are removed. The differential pressure
across the filter is monitored with PDI-398 and PDG-395.
27,930 kg/hr of clarified oil leave the slurry separator X-1504 and flow to the
tempered water coolers E-1507 B & A in series (C & D are bypassed) before going
to storage at 90°C and 8.0 kg/cm2g thru TI-499, FIC-464 and FV-464. The total
duty of E-1507 A&B is 1.32 MW.
The slurry separator X-1504 consists of 10 modules. These are automatically and
sequentially taken out of service for back-flushing while the others remain in
service. The modules are back-flushed with Backflush Oil (HCO) from the
Backflush Oil Draw Off Drum D-1516. Backflush oil flows from the bottom of D-
1516 to the suction of P-1505A via TI-503. The backflush oil is pumped by means
of the backflush oil pump on duty P-1505A to the slurry separator X-1504 via PG-
481, FIC-468, FV-468 and UV-460.
The flush oil from the separator, containing a high concentration of catalyst fines,
goes to back-flush oil receiver D-1517 via XV-459 after being mixed with HCO
flowing from E-1510 via FIC-460 and FV-460. The pressure in D-1517 is
maintained at 1.0 kg/cm2g by either admitting fuel gas inside the vessel via PV-
475A or venting excess off gas to the flare via PV-475B.
From D-1517, 6,875 kg/hr of backflush oil is returned to the reactor riser by means
of the backflush oil recycle pump on duty P-1506A and thru PG-477 and FIC-491.
The flow of backflush oil recycle to the backflush oil injectors of the riser is kept
constant by controlling the flow of backflush oil sent back to D-1517 via FV-491
from the discharge of P-1506A. The temperature of the recycle oil leaving the
bottom of D-1517 is monitored via TI-502.
HCO section
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CRACKER (RFCC)
HCO products, pumparound and HCO recycle are taken from the draw off tray
above the Bed #4 of the main fractionator T-1501.
364,913 kg/hr of HCO pumparound at 337°C flow to the suction of the HCO
Pumparound Pump on duty P-1508A via TI-444 and XV-409. HCO PA is pumped
via PG-425, XV-411 and FIC-419 to the following equipment in parallel:
• 199,500 kg/hr of HCO PA at 337°C are pumped to the tube side of the
Debutanizer reboilers E-1560 A & B (equal amount to each exchanger).
HCO PA leaves E-1560A via TW-759 and E-1560B via TW-760 before
being recombined and sent to the HCO PA return header via FV-722 and
TI-761. The duty of the debutanizer reboilers is 18.17 MW.
• 32,842 kg/hr of HCO PA at 337°C are pumped to the shell side of the
Heavy Naphtha Stripper Reboiler E-1509 via FIC-454 and FV-454. The
HCO PA leaves E-1509 via TI-483 to the PA return header. The duty of E-
1509 is 2.00 MW.
• 55,121 kg/hr of HCO PA at 337°C are pumped to the tube side of MP
Steam Generator E-1523. The HCO PA leaves E-1523 at 220.1°C and
flows thru TI-435, FT-420A/B and FV-420 to the HCO PA return header.
The duty of E-1523 is 4.83 MW.
• 77,450 kg/hr of HCO bypass is sent directly to the HCO PA return header
via FV-419 from the discharge of the HCO PA pump on duty.
HCO PA is then returned to the main fractionator, above the Bed #3, via TIC-446
and TI-445.
HCO for flushing oil is also taken from the draw off tray above the Bed #4 of the
main fractionator T-1501 and flows thru LV-431 to the HCO stripper T-1504 where
it is stripped by means of 788 kg/hr of LP steam at 160°C. LP steam flows from
the LP steam header to T-1504 via FIC-449 and FV-449. The stripper vapour
leaving T-1504 via TI-471 and PG-443 is returned to T-1501 just below the tray
#30.
26257 kg/hr of stripped HCO at 324.2°C flow from the bottom of T-1504 to the
suction of HCO product pump on duty P-1509 A, via TI-472 and XV-430. HCO
product is pumped thru FIC-474 to the tube side of the LP Steam Generator E-
1510. Cooled HCO leaves the tube side of E-1510 at 170°C and is split into 2
streams:
• 3479 kg/hr of HCO are sent to the backflush oil draw off drum D-1516 (for
use in the slurry separator as described above) via FV-467. D-1516 is
operated at 170°C and 1.0 kg/cm2 by either admitting fuel gas into the
drum via PV-479A or venting excess off-gas to the flare via PV-479B.
• 22,278 kg/hr of HCO product at 170°C are set to the HCO flushing oil drum
D-1518 via FIC-469 and FV-469. The pressure in the HCO flushing oil is
maintained constant by either admitting fuel gas thru PV-483A or venting
excess off-gas to flare via PV-483B.
HCO flushing oil flows from the bottom of D-1518 to the suction of the HCO
flushing oil pump on duty P-1521A via TI-504. HCO flushing oil is pumped
to the HCO flushing oil filter on duty F-1502A via FIC-461, PIA-487 and
PG-520. Downstream of FIC-461, a slip stream of the HCO flushing oil is
recycled back to D-1518 via FV-461.
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REV: A DATE: 06/12/07
CRACKER (RFCC)
Filtered HCO flushing oil then flows thru FI-470 to the HP flush oil header.
Part of the HCO flushing oil is sent to the LP Flush Header on pressure
control via PV-496.
For maximum distillate mode operation, HCO is recycled to the reactor feed.
117,100 kg/hr of HCO recycle is taken from the draw off tray above the Bed #4
and flows to the suction of the HCO recycle pump on duty P-1507A via XV-406.
HCO recycle is pumped to the tube side of the HCO recycle MP steam generator
E-1508 via PG-411 and XV-408. HCO recycle leaves E-1508 thru TW-424 and
PDV-420. Part of the HCO recycle bypasses E-1508 thru TV-425 and is mixed
with the HCO leaving E-1508 downstream of PDV-420. The recombined HCO
flows at 290°C thru TIC-426, TI-426, FIC-002 and FV-002 to the reaction section
where is mixed with the preheated feed upstream of the feed line static mixer M-
1501.
LCO section
Refer to P&ID’s: 8474L-015-PID-0021-302 / 307 / 309 / 318 / 328 / 405
LCO product and LCO pumparound are drawn off thru TI-449 from the
pumparound draw-off tray below the bed#2 of the main fractionator.
733,664 kg/hr of LCO pumparound at 230.3°C flow to the suction of the LCO
Pumparound Pump on duty P-1510A. LCO PA is pumped via PG-422 and FIC-
417 to the following equipment in parallel:
• 91,555 kg/hr of LCO PA at 230.3°C are pumped to the shell side of the
LCO PA BFW heater E-1511. LCO PA leaves E-1511 at 194.9°C and flows
via TI-432, FT-418 A/B and FV-418 to the LCO PA return header. The duty
of E-1511 is 2.24 MW.
• 400,000 kg/hr of LCO PA at 230.3°C are pumped to the 2 branches of the
LCO pumparound feed preheat exchangers E-1512 A/B/C/D as follow:
o 200,000 kg/hr of LCO PA flows to E-1512B (tube side), TW-416, E-
1512A (tube side) and TW-418 before being recombined with the
LCO PA leaving the other branch.
o 200,000 kg/hr of LCO PA flows to E-1512D (tube side), TW-417, E-
1512C (tube side) and TW-419 before being recombined with the
LCO PA leaving the other branch.
LCO leaving E-1502A and E-1502C is recombined and 400,000 kg/hr of
LCO at 176°C flows to the LCO PA return header via FIC-409, TI-420 and
FV-409. The total duty of E-1512 A-D is 14.79 MW.
• 168,743 kg/hr of LCO PA at 230.3°C are sent to the tube side of the 2nd
stripper reboiler E-1557 via FIC-710. The LCO PA leaves E-1557 and flows
to the LCO PA return header via TI-730 and FV-710. The duty of E-1557 is
8.97 MW.
• 73,366 kg/hr of LCO bypass is sent directly to the LCO PA return header
via FV-417 from the discharge of the LCO PA pump on duty.
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CRACKER (RFCC)
HCO PA is then returned to the main fractionator above the Bed #2, via TIC-452
and TI-451.
LCO product is taken as a slip stream at the suction of the LCO pumparound
pumps P-1510 A/B and is sent to the tray #1 the LCO stripper T-1503, via LV-436,
where the LCO is stripped with 300 kg/hr of LP steam. The LP steam flows from
the LP steam header to the LCO stripper T-1503 via FIC-452 and FV-452.
The stripper vapour leaving T-1503 via TI-475 and PG-448 is returned to T-1501
just below the tray #24. Stripped LCO flows to the suction of the LCO Stripper
Pump on duty P-1511 A via TI-476. LCO product is pumped to the tube side of the
LCO product LP steam generator E-1513 (duty = 5.65 MW) via PG-449.
Downstream of P-1511 A/B, a slip stream of the LCO product is recycled back to
the LCO stripper via FT-478. LCO product leaving the tube side of E-1513 at
158°C flows through TI-505 to the LCO air cooler E-1514 (duty = 8.66 MW) and
exits via TI-512 before being split into 2 streams:
• 139,198 kg/hr of LCO are sent to the storage at 50°C and 6.0 kg/cm2g via
FIC-472, FV-472, TI-513, FI-473 and TI-514. For maximum LCO operation
(maximum distillate operation), heavy naphtha from the Heavy Naphta Trim
Cooler E-1516 is mixed with this stream before it is sent to storage
• 165160 kg/hr of LCO are sent to the LCO HDT at 48.7°C and 6.0 kg/cm2g
via FIC-479 and FV-479. For maximum LCO operation (maximum distillate
operation), heavy naphtha from the Heavy Naphta Trim Cooler E-1516 is
also mixed with this stream before it is sent to the LCO Hydrotreater unit.
MTC and heavy naphtha section

MTC is NOT drawn off from tray #19 of the main fractionator in the Bach Ho Crude
operation.
Heavy naphtha pumparound and heavy naphta product are drawn off from the
draw-off tray below the bed #1 of the main fractionator.
508,243 kg/hr of heavy naphta (HVN) pumparound at 161.6°C flow to the suction
of the heavy naphta PA pump on duty P-1514A. HVN PA is pumped via PG-415
and FIC-412 to the following equipment in parallel:
• 149,489 kg/hr of HVN PA are pumped to the HVN PA Cooler E-1521 where
it is cooled down to 54.9°C. HVN PA leaving E-1521 flows through TI-427,
FT-414 A/B and FV-414 to the HVN PA return header. The duty of E-1521
is 9.52 MW.
• 50,824 kg/hr of heavy naphta PA are pumped to the stripper feed preheater
E-1555 in the gas recovery section via FI-726. The heavy naphta PA
leaving E-1555 flows back to the Heavy Naphta PA return header via TI-
725 and TV-723. The duty of E-1555 is 1.48 MW.
Page 262 of 323

REV: A DATE: 06/12/07
CRACKER (RFCC)
• 200,000 kg/hr of heavy naphta PA are pumped to the Propylene Recovery

Unit (PRU, unit 21) via TI-413. Heavy naphta PA is returned from the PRU
thru TI-428 to the heavy naphta PA return header.
Heavy Naphta PA is then returned thru TIC-430 and TI-429 to the main
fractionator T-1501 on top of the bed #1.
Heavy naphta product is taken as a slip stream of the pumparound draw-off at the
suction of the P-1514 A/B and is sent to the tray #1 of the heavy naphta stripper T-
1502 via LV-439. T-1502 bottoms flow to the tube side of the reboiler E-1509 via
TI-478 where it is heated against HCO PA. Re-boiled heavy naphta is returned t T-
1502, below the tray #8 via TI-482. The duty of the HVN reboiler E-1509 is 2.00
MW.
The stripper vapour leaving T-1502 via TI-477 and PG-451 is returned to the main
fractionator above the pumparound bed, Bed #1.
25,962 kg/hr of stripped heavy naphtha flow from the bottom of T-1502 to the
suction of the HVN product pump on duty P-1515A. HVN product is pumped to the
shell side of the HVN BFW Heater E-1516 via PG-452. In E-1516, HVN is used as
heating medium to preheat BFW (tube side) which is then sent to E-1511. The
duty of E-1516 is 0.985 MW.
Heavy naphta leaving the shell side of E-1516 is then sent to the heavy naphta air
cooler E-1517 (duty = 1.69 MW) via TI-479. The heavy naphta leaving E-1517 is
then sent thru TI-480 to the HVN Trim Cooler E-1518. The duty of the HVN trim
cooler E-1518 is 0.135 MW.
25,962 kg/hr of heavy naphta leaving the trim cooler E-1518 at 40°C flow through
FIC-435, FV-433 and TI-485 before being mixed with the LCO product sent to the
LCO HDT and storage downstream of the LCO air cooler E-1514.
Heavy naphtha is also drawn off at the suction of the HVN PA pumps P-1514 A/B
as lean oil for the secondary absorber in the Gas recovery Section. The lean oil is
pumped by P-1513A at 9.5 kg/cm2g to the tube side of the Lean Oil / Rich Oil
Exchanger E-1563, in the gas recovery section.
Top section
Rich oil from the bottom of the secondary absorber in the Gas Recovery Section is
fed to tray #9 of the main fractionator. Water accumulated in the partial draw-off
accumulator tray, provided below the top tray, is continuously drawn off and flows
by gravity to the inlet of overhead condenser E-1519 via TI-458, LV-416.
Fractionator overhead section

Page 263 of 323

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CRACKER (RFCC)
The overhead vapor from T-1501 flows thru TI-460 and TIC-461 at 96°C and 0.85
kg/cm2g to the overhead condenser E-1519 (total duty = 47.31 MW), comprising
of 16 bundles. It is mixed with the water draw-off from the tray #9 of the main
fractionator. Corrosion inhibitor is also supplied to the overhead vapour at the inlet
of E-1519: 2.5 kg/hr of corrosion inhibitor is supplied from the corrosion inhibitor
tank TK-1501 to the inlet of E-1519 by means of the corrosion inhibitor pump on
duty P-1520A. Pressure at the pump discharge can be checked locally by means
of PG-467. Downstream of the overhead air condenser E-1519, the overhead
vapour from T-1501 flows thru TI-536 to the 8 overhead trim condensers E-1520 A
to H in parallel (total duty = 16.12 MW). Partly condensed overheads leaving the
trim condensers E-1520 A-H flow thru TI-489 to the fractionator reflux drum D-
1514.
The following off-gases are also fed to the reflux drum:
• 291kg/hr of off gas from the CDU at 50°C and 0.7 kg/cm2g are also fed to
D-1514 via FI-458 and TI-492.
• 243 kg/hr of off gas from the NHT at 40°C and 0.6 kg/cm2g are also fed to
D-1514 via FI-457 and TI-491.
The liquid hydrocarbon separated in D-1514 is separated into 2 streams:
• 201,987 kg/hr of liquid hydrocarbon flow from the main fractionator reflux
drum thru XV-444 and TI-490 to the suction of the fractionator reflux pump
on duty P-1516A: Liquid reflux is pumped back to the tray #1 of the main
fractionator at 42.2°C via PG-463, FIC-427 and FV-427.
• 84,726 kg/hr of net overhead liquid product flow from the main fractionator
reflux drum thru XV-444 and TI-490 to the suction of the overhead liquid
pump on duty P-1518A. Net overhead liquid is pumped at 42.5°C, thru FIC-
455 and FV-455, to the top tray of the primary absorber T-1551.
Liquid sent to the primary absorber T-1551 is flow controlled by FIC-455
with FV-455. Excess liquid pumped by P-1518A is sent back to the main
fractionator reflux drum D-1514 via FT-477.
The sour water collected in the boot of the fractionator reflux flows to the suction of
the overhead sour water pump on duty P-1517A via XV-445. Downstream of P-
1517 A/B discharge, the flow of sour water is spit into 3 streams:
• 30,000 kg/hr of overhead sour water are pumped back to the overhead
condenser E-1519, via FIC-459, FV-459 and thru a restriction orifice.
• 28,000 kg/hr of overhead sour water are pumped to the inlet of E-1551,
via FIC-703, FV-703 and RO-715A, for mixing with the wet gas from the
first stage of C-1551.
• 5252 kg/hr of sour overhead water are pumped to the SWS (unit 18), via
FIC-456, FV-456 and TI-736, after being mixed with the sour water
collected in the boot of the HP separator drum D-1553.
Finally, 118,909 kg/hr of overhead vapour from D-1514 flows to the first stage KO
drum of the wet gas compressor D-1551 at 41.9°C via PIC-458, PG-457, and TI-
703.
Page 264 of 323

REV: A DATE: 06/12/07
CRACKER (RFCC)
The main fractionator reflux drum is operated at 42°C and 0.4 kg/cm2g. The
pressure in the gas outlet of D-1514 is controlled by PIC-458 by venting excess
off-gas thru PV-458 to the flare.
Gas Recovery section

Figure 58: Gas Recovery Section – Bach Ho Max. Distillate Case
Wet gas compressor and HP condenser
Refer to P&ID’s: 8474L-015-PID-0021-401 / 402 / 403 / 404
118,909 kg/hr of wet gas from the Main Fractionator Reflux Drum D-1514 flows to
the wet gas compressor first stage knock-out drum D-1551 via PIC-458, PG-457,
and TI-703. In D-1551 entrained and condensed liquids are separated. The liquid
collected in D-1551 is pumped by either of the KO drum liquid pumps P-1552 A/B
back to the fractionator reflux drum D-1514. The first stage KO drum D-1555 is
operated at 0.3 kg/cm2g and 42°C.
The gas from D-1551 flows to the 1st stage of the compressor C-1551 via FT-701,
MOV-703 PG-704, and PT-703. The wet gas exits the first compression stage at
4.1 kg/cm2g and 102°C and flows through PG-706, PT-705, TT-702 and MOV-704
before being split into 2 streams:
• A spill back stream is returned back to E-1519 via FI-704 and UV-701
• The majority of the wet gas is sent for cooling in the wet gas compressor
intercooler E-1551. Before entering the intercooler E-1551, the wet gas is
mixed with 28,000 kg/hr of sour water pumped by P-1517A from the boot of
the main fractionator reflux drum D-1514. The duty of E-1551 is 8.32 MW.
Downstream of E-1551, the wet gas flow thru TW-720A and TI-704 to each of the
two wet gas compressors trim-coolers E-1552 A&B in parallel. The total duty of E-
1552 A/B is 2.08 MW. Downstream of E-1552 A/B, the wet gas is sent to the inter-
stage KO drum D-1552 via TI-709 indicating a normal operating temperature of
42°C. The inter-stage KO drum D-1552 is operated at 3.4 kg/cm2g.
63,712 kg/hr of wet gas leaving D-1552 at 3.4 kg/cm2g flow to the second stage
compressor C-1551 via PG-708, PIC-707, FT-702, MOV-705, TT-710, PG-710
and PT-709. The wet gas leaving the 2nd stage is compressed to 15.9 kg/cm2g.
Downstream of the second stage compressor, the majority of the wet gas flows at
114°C and 15.9 kg/cm2g to the HP condenser E-1553, via PG-712, TXA-632, PT-
711, TT/TI-711 and MOV-706. A slip stream of the compressed wet gas is
recycled back to the inlet of E-1551 via FI-705 and UV-702.
Before entering the HP condenser, the compressed wet gas is mixed with 83,197
kg/hr of interstage liquid at 42.3°C. The interstage liquid is pumped from the
bottom of the interstage KO drum D-1552 to the inlet of the HP condenser E-1553
by means of the interstage pump P-1551A, thru FI-727 and LV-705. The duty of
the HP steam condenser E-1553 is 5.59 MW.
The partly condensed wet gas stream leaving the HP condenser E-1553 is fed to
the stripper condensers E-1554 A/B/C/D via TI-713.
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Stripper condenser and high pressure separator drum

The following streams are combined before being fed to the stripper condensers
E-1554 A/B/C/D:
• 127,834 kg/hr of liquid at 56.8°C from the bottom of the primary absorber T-
1551 via TI-721, FI-708 and LV-710.
• 2071 kg/hr of LPG at 52°C and 20.0 kg/cm2g from the CDU (unit 11) via FI-
741 and TI-714.
• 22,703 kg/hr of stripper overhead at 59.8°C from the stripper T-1552 via TI-
722, FIC-709 and PG-717.
The combined stream flows through TI-715 before being split into 2 equal streams,
each flowing in one of the 2 parallel branches constituting the stripper condensers
E-1554A-D (duty = 4.51 MW): One half of the combined stream flows through the
shell side of E-1554B and then E-1554A (shell side) before exiting this branch of
the stripper condensers thru TW-716. The other half of the combined stream flows
through the shell side of E-1554D and then E-1554C (shell side) before exiting this
branch of the stripper condensers thru TW-717. The mixed phase streams leaving
E-1554Aand E-1554C are recombined before entering the HP separator drum D-
1553 via TI-720. The HP separator D-1554 is operated at 15.1 kg/cm2g and 40°C.
30,572 kg/hr of water collected in the boot of the HP separator is sent to the SWS
at 40°C and 3.5 kg/cm2g via XV-716, LV-714, FI-712 and TI-736, after mixing with
5252 kg/hr of sour water pumped from the main fractionator reflux drum D-1514 by
P-1517A.
243,294 kg/hr of LPG and gasoline mixture at 40°C flow from D-1554, thru XV-719
and TI-726, to the suction of the stripper feed pump on duty P-1553A. This
hydrocarbon mix constitutes the feed of the stripper T-1552; It is first pumped to
the stripper feed preheater E-1555 via PG-721, FIC-711 and FV-711. The flow of
feed to E-1555 is controlled by FIC-711 acting on FV-711. The excess liquid at the
pump discharge is recycled to the separator drum D-1554 via FT/FI-728. The duty
of the stripper feed preheater is 1.48 MW. Preheated stripper feed leaving E-1555
flows thru TIC-723 and TI-724 to the first tray of the stripper.
25,634 kg/hr of vapour phase from D-1553 is flow thru PG-719, PIC-718 and FI-
707 to the primary absorber T-1551 (below the last tray).
Primary absorber T-1551

Normal operating parameters of the primary absorber for the Bach Ho MD Case:
Top Pressure: 14.8 kg/cm2g Top temperature: 48°C
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84,726 kg/hr of net overhead liquid product at 42.5°C from the main fractionator
reflux drum is pumped by P-1518A, thru FIC-455 and FV-455, to the top tray of the
primary absorber T-1551.
Downstream of the Gasoline Cooler E-1559, 30,000 kg/hr of gasoline (from the
bottom of the debutanizer T-1554) are also recycled to the inlet of the primary
absorber T-1551 by means of the duty gasoline recycle pump P-1554A: Gasoline
flows to the suction of the pump via PG-728 and is pumped to the inlet of T-1551
for mixing with the net overhead liquid product, via PG-729, FIC-713 and FV-713.
This flow of gasoline recycle enables required recovery of C3 and C4.
127,834 kg/hr of bottom rich oil from leaves the bottom of the primary absorber T-
1551 and flows through TI-721, FI-708 and LV-710, back to the inlet of the stripper
condensers E-1554 A-D.
12,519 kg/hr of overheads leave the top of the primary absorber T-1551 at 14.8
kg/cm2g and 48°C and flow thru PG-726, FI-717 and TI-738 to the secondary
absorber T-1553, below the tray #20.
Stripper
The purpose of the stripper is to remove H2S, C2 and lighter from The LPG and
gasoline mixture.
Normal operating parameters of the stripper for the Bach Ho MD Case:
Bottom Pressure: 16.0 kg/cm2g Bottom temperature: 122°C
243,294 kg/hr of preheated LPG and gasoline mixture feed leaving E-1555 flows
thru TIC-723 and TI-724 to the first tray of the stripper.
The necessary heat to perform the stripping operation is supplied by two reboilers
in series: The stripper bottoms flow thru TI-727 to the shell side of the first reboiler
E-1556 (duty = 4.62) where it is heated up against gasoline form the bottom of the
debutanizer T-1554.
Stripper bottoms then flow to the shell side of the second reboiler E-1557 (duty =
8.97) where it is heated against 168,743 kg/hr of LCO PA from the main
fractionator. The heat input to E-1557 is controlled by the stripper overhead vapor
rate FIC-709. This rate, and hence the reboiler duty, is set to meet the C2
specification in the debutanizer overheads.
22,703 kg/hr of overhead vapour leaving the stripper at 59.8°C is returned to and
condensed in E-1554 A-D via TI-722, FIC-709 and PG-717.
220,591 kg/hr of stripped LPG and Gasoline leave the bottom of the stripper T-
1552 at 126°C and flow to the tray #22 of the debutanizer via TI-728, FIC-714 and
FV-714
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Secondary absorber T-1553

The secondary absorber T-1553 recovers gasoline light fractions contained in the
overhead gas from primary absorber T-1551.
12,519 kg/hr of overheads leave the top of the primary absorber T-1551 at 14.8
kg/cm2g and 48°C and flow thru PG-726, FI-717 and TI-738 to the secondary
absorber T-1553, below the tray #20.
The lean oil used for the absorption is a heavy naphtha stream draw-off from the
main fractionator T-1501 (draw-off tray below the bed #1) and pumped by P-1513
A to the tube side of the lean oil/rich oil exchanger E-1563 (duty = 1.14 MW). Lean
oil then flows thru TI-749 to the shell side of the lean oil cooler E-1564 where it is
cooled against cooling water. The duty of E-1564 is 1.36 MW.
Cooled lean oil leaving E-1564 then flows through TI-751 and PG-734 to the lean
oil coalescer D-1556 where water is separated from the hydrocarbon phase. The
sour water collected in the boot of D-1556 is then sent to the SWS via XV-725, LV-
723, FI-712 and TI-736, after mixing with sour water from the fractionation section,
D-1553 and D-1554.
34,990 kg/hr of lean oil at 40.2°C flow from D-1556 to the top tray of the
secondary absorber T-1553 via PG-736, FIC-718 and FV-718.
Normal operating parameters of the secondary absorber for Bach Ho MD Case:
The rich oil at 59°C from the bottom of the secondary absorber T-1553 flows thru
TI-739 and LV-720 to the lean oil/rich oil exchanger E-1563 where it recovers heat
before being recycled to the tray #9 of the Main Fractionator T-1501, via TI-740
and TI-787.
The stripped overhead gas leaving T-1553 flows thru TI-741, PIC-733 and PG-766
to the shell side of the fuel gas water cooler E-1565 (duty = 0.042 MW). Cooled
fuel gas then flows thru TI-743 to the Fuel Gas Absorber Feed KO Drum D-1557.
Fuel gas absorber
Refer to P&ID’s: 8474L-015-PID-0021-408
The small amount of liquid in the effluent from E-1565 is separated in the K.O.
drum D-1557. The liquid is sent to mixing with rich oil at the inlet of the lean oil/rich
oil exchanger E-1563 via LV-726. The FG Absorber Feed KO Drum D-1557 is
operated at 40°C and 14.1 kg/cm2g.
The overhead gas of the FG absorber feed KO drum is fed to the bottom of the
Fuel Gas Absorber T-1555 via TI-744. 18,127 kg/hr of lean amine at 55°C and
22,6 kg/cm2g flow from the ARU (unit 19) thru FIC-719, FV-719 and TI-745 to the
top of the fuel gas absorber T-1555.
Normal operating parameters of the Fuel Gas Absorber for Bach Ho MD Case:
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Once treated by the lean amine, the overhead gas is sent to the Fuel Gas
Absorber Outlet K.O. drum D-1559, where entrained and condensed liquid are
separated. 8661 kg/hr of treated fuel gas leave the top of the FG Absorber Outlet
KO Drum D-1559 and flow to the fuel gas system at 4.5 kg/cm2g and 54°C via
PG-741, TI-747, FI-720 and PV-733.
A total of 18127 kg/hr of rich amine is sent back to the ARU at 64°C and 7.0
kg/cm2g. This stream is composed of:
• Mainly rich amine leaving the bottom of the FG Absorber T-1555 via XV-
732, LV-730 and TI748;
• Rich amine separated in the KO drum D-1559 and flowing thru XV-735 and
LV-733 to mixing with the rich amine from T-1555 downstream of TI-748.
Debutanizer
220,591 kg/hr of stripped LPG and Gasoline leave the bottom of the stripper T-
1552 at 126°C and flow to the tray #22 of the debutanizer via TI-728, FIC-714 and
FV-714
Normal operating parameters of the secondary absorber for Bach Ho MD Case:
The heat required to perform the separation is provided by the debutanizer

reboilers E-1560 A&B: An equal amount of debutanizer bottoms flow to the shell
side of each reboiler where it is heated against HCO PA from the main
fractionator. Re-boiled bottoms then leave E-1560 A and B and flow thru TI-770
and TI-758 respectively, back to the debutanizer below the bottom tray.
The reboilers duty (18.17 MW) is set to ensure that the C4 specification in the
gasoline is met.
The overhead vapour leaves the debutanizer at 68°C and 11.7 kg/cm2g and flows
thru TI-762, PG-744 and PIC-745 to the debutanizer condensers E-1561 A & B in
parallel, where the overhead vapour are totally condensed. Condensed overheads
are then fed to the debutanizer feed surge drum D-1554.
The pressure in T-1554 is controlled with PIC-745 by bypassing part of the
overhead vapour around E-1561 A/B to the reflux drum D-1554, via PV-745.
The duty of the debutanizer condensers is 16.08 MW.
The sour water collected in the reflux drum D-1554 is sent to the SWS via XV-741,
LV-739, FI-712 and TI-736, after mixing with sour water from the fractionation
section, D-1553 and D-1556.
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The hydrocarbon liquid of the debutanizer reflux drum flows thru XV-744 to the
suction of the debutanizer overhead pump on duty P-1556A. Downstream of P-
1556A the hydrocarbon is split into 2 streams:
• 106,325 kg/hr of HC are sent to the tray #1 of the debutanizer as a reflux
via FIC-721 and FV-721. The reflux rate is flow controlled by FIC-721 reset
by the temperature controller TIC-754 on the sensitive tray (tray #8) in the
top section of the column. This control loop determines the C5 specification
in the overhead product.
• 57,044 kg/hr of overhead liquid, the LPG product, flow to the shell side of
the LPG water cooler E-1562 (duty = 0.342 MW). Cooled LPG leaving the
shell side of E-1562 at 40°C then flow thru TI-768, FIC-723, FV-723 and
PG-755 to the bottom of the LPG Amine Absorber T-1556.
The gasoline product leaving the bottom of the debutanizer T-1554 at 171°C then
flows thru XV-738, TI-755 to the tube side of the stripper first reboiler E-1556.
Downstream of E-1556, the gasoline product flows thru TI-731 to the gasoline air
cooler E-1558 (duty = 9.00 MW). Gasoline then flows thru TI-732 to the gasoline
water cooler E-1559 (duty = 0.957 MW). Downstream of E-1559, the gasoline
stream is split in 2:
• 30,000 kg/hr of gasoline are recycled by means of the gasoline recycle
pump P-1554A to the inlet of T-1551.
• 133,547 kg/hr of gasoline, the gasoline product, flow thru FIC-715, FV-715,
FI-716 and TI-735 to the gasoline treating unit at 8.5 kg/cm2g and 40°C.
LPG amine absorber T-1556

Cooled LPG leaves the shell side of E-1562 at 40°C and flows thru TI-768, FIC-
723, FV-723 and PG-755 to the bottom of the LPG Amine Absorber T-1556.
23,331 kg/hr of lean amine at 55°C and 22.6 kg/cm2g flow from the ARU thru the
shell side of the lean amine water cooler E-1566, TI-772, FIC-724 and FV-724 to
the LPG Amine Absorber above the top packing bed.
The overhead LPG liquid flows thru PG-757, TI-795, and PDI-761 to the LPG
amine coalescer D-1555. The LPG Amine Coalescer is operated at 18.4 kg/cm2g
and 40°C.
57,023 kg/hr of LPG overheads from D-1555, the LPG product, is sent to the LPG
Treater Unit (LTU, unit 16) at 40°C and 18 kg/cm2g.
A total of 23,352 kg/hr of rich amine is returned to the ARU at 7.0 kg/cm2 and
41°C. This stream is composed of:
• Mainly rich amine leaving the bottom of the LPG Amine Absorber thru XV-
748, LV-746 and TI-771;
• Rich amine leaving the boot of the LPG amine coalescer D-1555 thru XV-
751, LV-749 and sent to mixing with the rich amine from T-1556,
downstream of TI-771.
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8.1.2. Operating Parameters

For guidelines on the operating parameters of the RFCC and how to adjust the
operating conditions, refer to the chapters 7.3, 7.4, 7.5, 7.6 and 7.7 of the licensor
operating manual, doc. No. 8474L-015-ML-001.
8.2. Start-up Procedure

The following will present the main steps of the start-up procedure without detailing the
procedure to perform each action. For a detailed description of the start-up procedures,
refer to specific procedures into the RFCC Operating Manual doc. No. 8474L-015-ML-
001.
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8.2.1. Pre-commissioning Activities

These are the necessary pre-commissioning activities:
1. Vessel and other Major Equipment Inspection
2. Line Cleaning
3. Servicing and Calibration of Instruments
4. Run-in of Rotary machineries
5. Chemical Cleaning
6. Refractory Drying
7. System Drying
8. Loading of Chemicals, Catalysts, and Other Materials
9. Operational Tightness Test
10. Air Freeing
11. Commissioning of Additional Plant Services
8.2.2. Initial Start-up
8.2.2.1. Status of the Unit prior to first start-up

The status of the unit prior to its initial start-up is as follows:
• Tightness test and nitrogen purges have been completed (O2 <
0.5% volume) on the feed preparation section.
• Free water trapped has been drained at low points.
• All necessary utilities are in service: blinds on the headers have
been swing open and valves opened on all users.
• All instrumentation has been checked and is in service.
• The emergency shutdown systems have been tested and are
ready for operation.
• On disengager and first regenerator cyclones, set blocks to open
the trickle valves on the diplegs (if it not planned to re-enter the
vessel use a material that will incinerate or melt at the
temperatures expected).
• Verify that the disengager and the regenerators manways are
closed.
• Verify isolation and blinding of the fuel gas system.
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8.2.2.2. Chronology of first Start-up
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8.2.3. Initial & Normal Start-Up
8.2.3.1. Start-up summary of the Reaction Section

See Next Page
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8.2.3.2. Start-up summary of the Fractionation & Gas Recovery Sections

See Next Page
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8.3. Shutdown Procedures

The following presents the main steps of the shutdown procedure only. For a detailed
description of the normal shutdown procedure, refer to specific procedures into the RFCC
Operating Manual 8474L-015-ML-001.
There are three types of shutdown. The normal shutdown scheduled for a turnaround,
the shutdown due to short duration problem in part of the unit, and the emergency
shutdown.
The normal scheduled shutdown requires the catalyst unloading while, for a short time
shutdown, one will try to keep the catalyst circulation by all means in order to restart the
unit as quickly as possible.
8.3.1. Normal Shutdown
8.3.1.1. Normal Shutdown Summary of Reactor & Regenerator

Normal scheduled shutdown should be made in orderly sequences
because there is no issue of emergency.
The main points to observe are:
• Keep catalyst circulation during the shutdown as long as possible.
• Make sure all circuits are flushed to avoid problems during the
inspection and the next start-up.
• Keep products on specification as long as possible.
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8.3.1.2. Normal Shutdown Summary of Fractionation and Gas Recovery Section
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8.4. Emergency Shutdown
8.4.1. General emergency shutdown

Emergencies, which occur in the RFCC unit, must be recognized and acted upon
immediately. The operators and supervisory personnel should carefully study in
advance, and become thoroughly familiar with the proper steps to be taken in such
situations. The emergency conditions described here could lead to serious
damage to equipment if the situation is not handled properly.
It is strongly recommended that the emergency procedures and the automatic
shutdown systems be understood by all persons involved in the operation. In
general, the objective of the emergency procedures is to avoid damage to
equipment, to the unit and to the personnel.
The most common causes of emergency shutdowns are described below,

together with their effects and the actions to be undertaken. In several cases, a
number of actions are carried out by the emergency sequences. But operators
must always check the satisfactory completion of the sequence and complement it
as described. In addition they must be able to perform the safety sequence in
manual mode, if needed.
A few actions (through hand-switches) are left to operators judgement.
The sequences must be reviewed before start-up
In most of failure cases, it is recommended or required to stop the feed to the unit.
This can be done by activating the emergency system UX-001. Each time the
following operations must be achieved:
• Check that feed has been bypassed back to the feed surge drum
• Check that all recycles to the riser have been stopped.
• Check that passivator injection has been stopped.
• Close the control valves on feed and recycle lines.
• Check that dispersion steams, stabilization steam and riser bottom steam
are effective.
• If the duration of the failure exceeds a couple of hours, the fuel gas purges
on the reaction section should be switched to nitrogen purges.
8.4.2. Power failure

A failure of electrical power will result in an emergency shutdown of the unit.
Steam pressure will generally be kept for a short time. However, refinery wide
power failure results in steam failure, subsequent to power failure, as sea water
and BFW will stop with a refinery wide power failure.
Instrument indications and controls should not be affected as the UPS system will
give back up for quite some time.
The consequences and emergency sequences to be followed will depend on
whether it is a localized power failure or refinery wide power failure.
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Note that Air Blower and Wet Gas Compressor will also stop with a power failure,
since sea water to the turbine’s surface condensers will be stopped during power
failure as most of the sea water pumps are driven by motor. Refer to the
corresponding equipment failure described hereafter.
The object is to get the unit into a safe condition while battery power or alternate
power is available to the instruments. The following will occur:
• Feed oil will stop
• Disengager will depressurize rapidly
• SV-1502 differential pressure will fall
• Cooling water supply will stop.
The following actions should be taken immediately:
a) Activate UX-001, block in all oil feed to riser. Place SV-1501, SV-1502, and
plug valve on manual and close. Shutdown passivator injection.
b) Adjust fresh feed dispersion steam and all other oil injectors dispersion steam
to minimum.
c) Adjust pressures as required to control differential pressures. Reduce
combustion air rates to 50% operating conditions if possible.
d) Due to lack of sufficient cooling in the main fractionator overhead system, any
steam usage in the riser should be minimized.
e) Stop heating steam to E-1522 and E-1524.
f) Stop stripping steam to T-1503 & T-1504
Specific note for steam demand management between RFCC and PRU.
Though, PRU is not part of RFCC, but complex of RFCC group. PRU should be
also brought into emergency mode operation, during upset of RFCC. Since PRU
compressor C-2101 consumes substantial HPS (30-35 ton/hr), stop C-2101 for
proper management of HPS demand, during emergency of RFCC.
When electrical supply is re-established check operation of pumps and air coolers.
Restart the unit following normal start-up procedures.
8.4.3. Instrument air failure

Usually instrument air failure is of short duration and the unit can be started-up
immediately after return to normal conditions.
However, loss of instrument air will require an emergency shutdown of the unit.
Supervision should set a standard for minimum instrument air pressure for
continued operation referring the minimum IA pressure where the actuators on
CVs have been designed (4.0 kg/cm2g). Although control elements will drift
toward their fail-safe positions, operator intervention is required to manage the
shutdown. If falling air pressure reaches the minimum pressure, the emergency
shutdown sequence should be enacted.
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a) Activate UX-001 to recycle feed from the riser to feed surge drum, block in oil
to the riser, and continue dispersion and stabilization steam to clear the riser.
b) Place the regenerated catalyst slide valve on manual and close.
c) When the stripper level begins to fall, place the spent catalyst slide valve on
manual and close.
d) Set the dispersion steam to about 50% flow rate and reduce the stripping
steam to 50% of the operating conditions.
e) Close the plug valve but be careful not to overfill first regenerator.
f) Adjust the air rates to about 50% flow rate but be careful not to lose air lift flow.
g) When feed is cut out of from the riser, the disengager pressure will fall rapidly.
Adjust pressures as required to maintain the spent catalyst slide valve
differential.
h) Start torch oil and on through bypass valve and keep the temperature near
600°C in the regenerators. Due to loss of purge air or instrument supply air,
instruments and level indicators may begin to give false signals. Look for
correlating variables, especially temperatures to help understand the status of
the process. For this reason, extreme care should be taken in making any
moves on the levels when there is no instrument air pressure. Continuous
operator attention is required where the process is on hand valve control.
i) Determine the expected duration of the outage. If less than 24 hours the
catalyst can be maintained hot with torch oil. The disengager pressure should
be maintained at least 0.1 kg/cm2 higher than the regenerator pressure to
keep air out of the disengager.
j) When instrument air is re-established return to control on the various hand
valves that are being used. Check all instrument purges to ensure they are not
plugged and see that instruments are reading correctly.
k) Check all nozzle points to see that they are not plugged and place them in
service.
l) When this has been accomplished the unit may be started using the normal
start-up procedure.
Note:
The major problem will come from the air blower which can surge or choke during
transient operations. Snort valves, UV-822/823/824 will fail open and valve
controlling air to the air lift will fail in position. This is important to avoid return of
catalyst from second regenerator into first regenerator.
8.4.4. Fluidization / Aeration / Purge Air and FG failure

Loss of fluidization, aeration, or purge air flow will require the unit to be shutdown.
Erroneous instrument readings and or catalyst circulation instability make the unit
uncontrollable without operator action.
a) Activate UX-001 to cut feed to the riser, to go to bypass and to block in the oil
feed and adjust the dispersion steam at the rate of 50% operating conditions.
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b) Shutdown passivator injection.

c) Put the regenerated catalyst slide valve on manual and close.
d) When the stripper level begins to drop out the spent catalyst slide valve on
manual and close. Close the plug valve but be careful not to overfill first
regenerator.
e) When feed is cut out from the riser, the disengager pressure will drop rapidly.
f) Adjust pressures as required to maintain a positive spent catalyst slide valve
differential.
g) Be aware that instruments taps on the regeneration and reaction section may
plug up and give false readings. Therefore exercise extreme caution in making
any moves on the regenerators.
By closely monitoring the regenerators temperature profile the unit may be kept
hot with torch oil. All instrument taps should be checked for plugging after
aeration is re-established.
When assured that all taps are free, the unit may be re-started as for a normal
start-up.
Note:
In disengager side only, fluidization, aeration and purge are supplied with fuel gas
in normal operation, but nitrogen take place for start-up and FG failure.
8.4.5. Steam failure

Loss of steam will require a complete shutdown of the unit due to loss of the Air
blower and wet gas compressor, and loss of dispersion, stabilization and stripping
steam.
a) Actuate UX-001, to stop feed and bypass the riser, block in all oil feeds to the
riser, and shut down the passivator injection system if it is in operation.
b) Close the SV-1501 on manual control. Maintain dispersion steam as long as
possible to clear the riser of catalyst.
c) When the stripper catalyst level begins to drop, close the SV-1502)\ on manual
control. Close the plug valve being careful not to allow the first stage
regenerator to overfill.
d) When oil feed is cut out of the riser, the system pressure will drop rapidly. As
necessary, adjust system pressure to maintain the adequate differential on the
SV-1502
e) Transfer as much as possible of the catalyst retained in the stripper to the first
regenerator by carefully opening the spent catalyst slide valve. Avoid pressure
differential to go below 0.1 kg/cm2.
f) Since the air blower is steam driven the regenerator catalyst beds will slump.
Torch oil cannot be used to maintain regenerator temperatures without proper
catalyst fluidization. Ensure that the plug valve does not open as that would
cause the catalyst in the second stage regenerator to flow into the first stage
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regenerator. Block in steam headers to the process before steam header

pressure falls below regenerators pressures.
g) The wet gas compressor is also steam turbine driven and will shut down. It will
be necessary to depressure the main fractionator to prevent the potential of
hydrocarbons backing into the regenerators. The depressurizing control valve
PIC-458 at the outlet of D-1514 should be set to open at a pressure of around
0.15 kg/cm2 above the normal operating pressure to prevent the disengager
from slumping.
h) The slurry circuit should be flushed to prevent any plugging problems as the
slurry system cools down.
i) Determine the expected duration of the outage. If the expected start-up will be
within 48 hours, the unit can remain hot on torch oil control after getting the air
blower back in operation. If the outage is expected to extend beyond 48 hours
the catalyst should be emptied from the unit.
When steam supply is re-established, first ensure that steam headers are dry
all the way up to the process and then start stripping, dispersion and
stabilization steam. When this is done, the unit may be restarted using the
normal start-up procedure.
j) If no operator intervention is taken upon loss of steam pressure, the catalyst
circulation will stop due to loss of riser lift. When feed is cut off due the
temperature increases, the riser will slump. This can lead to extended
shutdown and plugged equipment which is difficult and costly to clear.
Exceedingly high temperatures in the regenerator can be experienced upon
the loss of dispersion, stabilization, and stripping steam if feed is not cut off
immediately.
k) When steam is available begin circulation of the slurry system and, if
necessary, use torch oil as in the normal start-up. Confirm that the steam is dry
and then establish both stripping and main fractionator steam. Control pressure
on the main fractionator as required to maintain differentials between the
disengager regenerators. At this point the unit can be restarted following the
normal start-up guidelines.
8.4.6. Boiler feed water failure

Loss of boiler feed water (BFW) will require a shutdown of the RFCC unit.
Actuate UX-001.
Additionally, the loss of steam production may lead to a steam failure. If this
happens, the procedure for steam failure should be followed. A BFW failure will
require bypassing the flue gas equipments (CO Boiler and waste heat boiler),
maintain water circulation through the tubes as long as possible to maintain
cooling on the tubes. The wet gas compressor and all steam generation
equipment should be shut down.
As liquid levels require, other pumps should be shut down.
When BFW is available establish levels in the steam generators and restart the
unit following normal start-up procedures.
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8.4.7. Cooling water failure

Loss of cooling to the fractionation and Gas Recovery section will require the
shutdown of the RFCC unit.
Loss of lube oil cooler of the air blower and wet gas compressor also require to trip
Air Blower and wet gas compressor.
Actuate UX-001, to stop feed to the riser, block in all oil injectors feeds, and adjust
the fresh feed dispersion steam rate for 50% operating condition. Place the SV-
1501, SV-1502, and plug valve on manual and close. Since the lube oil system for
the air blower and wet gas compressor require cooling water for continued
operation, shut down the wet gas compressor and air blower.
Due to reduced cooling capacity in the main fractionator system, any steam usage
in the reaction and regeneration sections should be minimized. Since the air
blower is shut down, it will be necessary to depressurize the main fractionator to
minimize disengager regenerator differential pressure and prevent to potential flow
of hydrocarbons from the disengager into the regenerators. Disengager pressure
should be held around 0.15 kg/cm2 above the first stage regenerator pressure.
When cooling water is re-established the unit may be restarted following normal
start-up procedures.
The effect of cooling water loss should be studied by refinery personnel to develop
a detailed plan of action.
8.4.8. Sea water failure

Sea water is used for coolant of the surface condenser of the air blower and wet
gas compressor.
Therefore, failure of sea water will automatically trip of air blower and wet gas
compressor, as turbine is not work properly. Follow operation procedure of Air
Blower failure and Wet Gas Compressor failure.
8.4.9. Air blower failure

In case of air blower failure, the unit will be shut down by UX-005, which will
actuate UX-002 and UX-001 systems. The pressure in the regenerators will fall
rapidly resulting in possible flow reversal at SV-1501 if the operator does not act
immediately.
Reduce the main fractionator pressure to flare to minimize the disengager /
regenerator differential pressure. Bypass the fresh oil feed to the feed surge drum,
block in all oil feeds to the riser, while reducing all other injector steam and
stripping steam to about 50% of operating conditions. Shut down passivator
injection if it is in operation. Place the SV-1501 and SV-1502 on manual and close.
Place the plug valve on manual and close. Disengager pressure should be held at
about 0.15 kg/cm2 above regenerator pressure.
Catalyst may have backed into air lines so extreme care should be taken when re-
establishing air flow.
Normally the following actions are required to re-established air flow to the unit
when restarting the blower:
a) Close the control valves on the line to the first stage regenerator air rings.
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b) Open the plant air into the catalyst lift line between the first regenerator and
second regenerator. The uppermost blast point should be started first, and
then open the lower blast points stepwise down the lift line.
c) Before starting the blower it must be checked that all air lines are free of
catalyst upstream the assisted check valves. Ensure that the check valves are
in closed position.
d) Plant air connections have been provided upstream the regenerators air rings.
These connections must be put in operation to clear the air rings from the
accumulated catalyst.
e) The amount of catalyst back flow into the air heaters must be checked by
visual inspection. In case of significant catalyst amount in the heaters, the blast
connections provided on the air lines must be put in operation to clear the
lines. The connections must be put in operation one by one, starting with the
connection located close to the regenerator.
f) With all blast points open, slowly begin lift air from the air blower and then
reduce plant air to minimum purge rates.
g) After clearing of the air lines, the air blower can be restarted
h) Open the control valves on the line to the R-1 rings. This should be done
slowly so as not to lose lift air flow.
i) When all air flows are re-established, the unit may be started as in the normal
start-up procedure.
Notes:
The unit can be restarted if the catalyst temperatures are not too low (above
400°C).
Loss of the blower by serious mechanical failure due to long duration problem will
necessitate the normal shutdown of the RFCC unit with catalyst unloading.
The loss of the blower causes the fluidized bed to slump. As a result, not all
catalyst is regenerated and fully cooled.
The critical items regarding the catalyst unloading without blower are:
• To be able to maintain enough pressure in the regenerators to transfer the
catalyst to the hopper (a delta pressure about 0.7 kg/cm2 – by plant air
injections – should be sufficient).
• To cool down the catalyst in the regenerators to a temperature below
300°C. This is essential to avoid any coke combustion either in the catalyst
transfer lines or in the spent catalyst hopper.
During catalyst unloading, a careful survey of the temperatures in the regenerators
disengager stripper, and at the top of the spent catalyst hopper should be
performed.
Before catalyst unloading following plant safety rules, install blinds to allow the
final vacuum truck removal of the remaining catalyst as necessary.
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8.4.10. Feed pump failure

Loss of feed will activate emergency shutdown system, activate UX-001 to stop
feed and recycles to the riser and bypass the riser.
If the spare feed pump can be quickly started, the unit may be brought back on
line in a short period of time. If unable to start a fresh feed pump, maintain the unit
in a hot condition.
a) Adjust the dispersion steam at the maximum rate of operating conditions.
b) Take the regenerated catalyst slide valve on manual control to monitor the
catalyst circulation. Place the feed control on manual and close.
c) When the feed is taken out of the unit the disengager pressure will fall. Adjust
the pressure balance to maintain a positive pressure differential between the
disengager and the regenerators (higher than 0.15kg/cm2).
d) Start torch oil injection immediately in the regenerators to keep the catalyst
about 600°C.
e) When feed is available, re-establish the operating conditions as required
before the normal oil-in (riser outlet temperature around 530°C, pressure
balance,...) and restart the unit following normal start-up procedures.
8.4.11. Other pump failure

Loss of any other pump will not require a shut down of the RFCC unless the spare
pump cannot be started. In cases where the spare pump is unavailable, it may be
possible to continue operation by adjusting unit operations. Each system should
be studied to determine how to continue operation is case of pump failure.
8.4.12. Fuel gas failure

Typically, fuel gas failure will not require a shutdown of the RFCC. Fuel gas is
used in the CO Boiler.
Switch main fuel source from fuel gas to fuel oil so that COB operation can be
continue as far as possible.
Loss of the CO Incinerator may require a shutdown of the RFCC since the carbon
monoxide rich flue gas from first regenerator is released to the atmosphere.
Violations of the environmental permits may force reduction of the RFCC feed.
Provision is made that fuel oil can be also used for COB combustion burner. Use
fuel oil firing, maximum extent at failure of fuel gas, and maintain COB operation
as far as possible.
If feed is cut off from the unit, the reaction / regeneration sections can be
maintained in a hot condition using torch oil for 24 hours. If the outage is expected
to extend beyond 24 hours, the catalyst should be emptied as for a normal
shutdown.
As the CO Incinerator is off-line, the heat load to the Waste Heat Boiler will be
reduced and therefore steam production will diminish. A shut-down of the COB will
have a serious impact on the overall steam balance of the refinery, including Air
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Blower and WGC in RFCC. Steam from the utility boilers will be used for back-up
of steam demand. Reduce RFCC throughput, and reduce Air Blower and WGC
load to reduce steam demand, if insufficient steam can be supplied from utility
boilers. If steam availability is critical, then cut-off heating steam of HPS and MPS
to E-1522 and E-1524.
When fuel gas is available, re-establish the unit following the normal start-up
procedures.
8.4.13. Wet gas compressor failure

Loss of the WGC will require a reduction in fresh feed rate or possibly a shut down
of the RFCC. Follow any emergency procedures from the WGC vendor to
safeguard the WGC.
If this shutdown is for a short period of time, reduce feed flow rate to about 60% of
the operating condition and flare the gas at the overhead receiver.
If it not possible to flare the gas or if pressure is uncontrollable:
a) Activate UX-001 to stop feed and recycles to the riser.
b) Place slide valves and plug valve on manual control.
c) Control the disengager pressure higher than the regenerators pressures. Inject
fuel gas in the overhead receiver as necessary. The catalyst circulation can be
maintained as long as the pressure differential through the spent catalyst slide
valve is kept above 0.15 kg/cm2 and as long as the steam flow in riser is
sufficient to lift the catalyst (minimum velocity: 5 m/s).
d) If catalyst circulation is maintained, check the flue gas treatment equipments
(steam drum levels), check the main fractionator level and check the
temperatures in the regenerators; use torch oil to maintain the catalyst about
600°C.
1. If catalyst circulation is difficult to maintain at adequate conditions (eg
unsteady pressure balance, high or low temperatures in regenerators),
actuate UX-002 to shut-down the unit.
2. In addition, instrument purge systems on the disengager side use
treated gas from the Gas Recovery as the primary media. Automatic
back-up by nitrogen will be made when supply of treated off gas is
stopped as consequence of the failure of the wet gas compressor.
Operations should carefully monitor the back-up nitrogen system is
working (eg PV-367B is opened).
When the WGC is ready for restarting follow vendor’s procedures and restart the
unit following normal start-up procedure.
Notes:
Loss of the WGC by serious mechanical failure due to long duration problem will
require the normal shutdown of the RFCC unit with catalyst unloading.
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Loss of the WGC will reduce production of RFCC off gas to the refinery fuel gas
system. Since RFCC off gas is the prime source of fuel gas, proper management
of fuel gas and fuel oil is required to avoid loss of fuel gas in the refinery. Maximize
fuel oil firing in the major users of fuel gas (Utility Boilers, CDU and COB) and
vaporize LPG, if required.
8.4.14. Catalyst slide valve / plug valve failure

For a failure of catalyst slide / plug valves, the unit may remain in operation
depending upon the type of failure and which valve fails. It may be possible to
continue operation with manual local control of the valve position. If this is
attempted, it is very important to have continuous monitoring of the control
variable and good communications between the control room and the operator at
the valve. If the plug valve fails, the unit may continue to operate by controlling the
first regenerator catalyst level with the first/ second regenerator differential
pressure. Is stable control cannot be obtained quickly, the unit should be
shutdown.
a) If stable control cannot be achieved activate UX-001 to stop feed and recycles
to the riser, block in all oil feeds, and shutdown passivator injection if it is in
operation.
b) Close the SV-1501 on manual or with the handwheel. If the SV-1502 cannot be
closed, reduce the dispersion, stabilization steam and riser bottom ring
injection to about 20-30% let the riser slump.
c) Adjust pressures to hold a positive SCSV differential. The RCSV differential
may go to zero if the riser is slumped.
d) Hold the disengager pressure 0.15 kg/cm2 above the regenerator pressure.
Notes:
If catalyst slide valve is blocked in closed position, check that UX-001 and UX-002
have been activated.
If either catalyst slide valve is blocked in open position activate UX-001 and try to
take the other catalyst valves on manual control and adjust the valves opening to
obtain a stable and constant catalyst circulation through the unit. The circulation
rate will be dictated by the opening of the failed valve.
Loss of catalyst slide valve by serious mechanical failure due to long duration
problem will necessitate the normal shutdown of the RFCC unit with catalyst
unloading.
8.4.15. Loss of regenerators pressure control (flue gas slide valve failure)
For a failure of flue gas slide valves, the unit may remain in operation depending
upon the type of failure and which valve fails. It may be possible to continue
operation with manual local control of the valve position. If this is attempted, it is
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very important to have continuous monitoring of the control variable and good
communications between the control room and the operator at the valve.
If stable control cannot be achieved, activate UX-001 to stop feed and recycles to
the riser, block in all oil feeds, and shutdown passivator injection if it is in
operation. Hold the disengager pressure 0.15 kg/cm2 above the regenerator
pressure.
Note:
Loss of flue gas slide valve by serious mechanical failure due to long duration
problem, will necessitate the normal shut down of the RFCC unit with catalyst
unloading.
8.4.16. Control system failure

For a failure of control system, the unit may remain in operation for a short time
typically 10 to 15 min. Otherwise the unit is shut down by activating UX-001 and
UX-002.
8.4.17. Oil reversal

This situation can occur when oil injected in the riser flows back into the second
regenerator instead of being lifted up in the riser. This is the consequence of a
sudden increase of disengager pressure or sudden decrease of second
regenerator pressure. It is detected by a sudden rise of the second regenerator
temperatures which can exceed the limit of the design and can be very dangerous.
a) Immediately actuate UX-002 and UX-001 and check that catalyst slide valves
are all closed. Check that oil is effectively bypassed from riser, block all oil feeds.
b) Decrease air rates if the temperatures continue to rise.
c) Establish a pressure higher in the disengager than in the regenerators. Inject
fuel gas in the fractionator overhead receiver.
d) Restart the unit as soon as the reason for the oil reversal is explained and
corrected.
Note:
Catalyst is withdrawn into an external withdrawal stand pipe. This proven system
ensures an efficient seal against oil reversal.
8.4.18. Low riser outlet temperature (ROT)

In case of too low Riser Outlet temperature (< 480°C), the feed is not cracked and
the catalyst will be socked with hydrocarbons. These hydrocarbons will be carried
into the first regenerator where they will burn, causing unacceptable temperature
run away.
Loss of ROT will require a reduction in fresh feed rate or possibly a shut down of
the RFCC by activating UX-001. The catalyst circulation can continue on
automatic control, however, the operator may have to temporarily intervene to
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manually reduce the catalyst circulation rates. Feed-in can be achieved when an
acceptable Riser Outlet Temperature for start-up (510-530°C) is obtained.
8.4.19. Plugged catalyst circulation

It can happen that the catalyst is plugged in the lift or standpipes, especially during
the start-up periods.
In that case feed and recycles must be stopped to the riser (actuate UX-001)
before attempting to unplugging the catalyst.
a) In case of plugging in the air lift, blast connections are provided along the air lift
to help to re-fluidize the catalyst. Put the blast connections in operation one by
one, starting with the upper connection. Lift air flow rate and pressure can be
increased to help to de-plug the air lift.
b) In case of catalyst plugging in a standpipe, the circulation can be restored by
increasing the differential pressure through the line: decrease the first
regenerator pressure in case of spent catalyst line plugging and increase the
second regenerator pressure in case of regenerated catalyst line plugging (if
increasing the aeration and fluidization rates is not sufficient). During the
deplugging operation, do not maintain the catalyst slide valve continuously fully
open; proceed with quick close/open valve operations.
8.4.20. Downstream unit failure

Depending upon the nature of the downstream equipment failure, the RFCC may
operate at reduced throughput. If unable to operate in a stable, controlled manner
the unit should be shutdown following the normal shutdown procedure. Follow as
close as possible the normal shutdown procedure. If the outage is expected to be
less than about 48 hours, the unit can be kept hot with torch oil. If the outage is
expected to extend beyond 48 hours, plan for unloading catalyst as per the normal
shutdown procedure.
In the case of continued stand-by operation, reduce the disengager pressure to
0.15 kg/cm2 above the first stage regenerator pressure and reduce stripper
catalyst level to minimum.
Once the downstream failure is repaired, the unit may be restarted following the
normal start-up procedure.
8.4.21. Fire emergency

In case of a fire emergency, it should be determined what effect the emergency
will have on the RFCC.
If shut down of the unit is required, the normal shutdown procedure should be
followed as closely as possible (activate UX-001). If the emergency requires
immediate action, it may not be possible to completely utilize the normal shutdown
procedure. In those cases, oil hydrocarbon feeds should be isolated from the
reactor section and the unit should be maintained in a hot condition using torch oil.
As required the catalyst circulation may be shut down (activate UX-002) until the
emergency situation is under control.
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8.4.22. Emergency shutdown of Fractionator and Gas Recovery Section - General

In an emergency, steps must be taken to bring the unit to a safe shutdown
condition. An emergency may be caused due to failure of a utility or failure of
equipment. Emergency shutdown of the reaction section will also necessitate
shutdown of the fractionation and gas recovery sections.
Initially, the unit should be shutdown and maintained in a hot condition by
switching the slurry steam generators to heating. Admit fuel gas to the main
fractionator overheads to maintain the pressure balance in the reactor. It may be
necessary to shut down the wet gas compressor because of steam balance
requirements or because of compressor surging.
If the emergency is anticipated to be for long duration, shutdown should proceed
as for a normal shutdown, as far as equipment is available to do so.
8.4.23. Steam failure for the Fractionation/Gas Recovery Section

On loss of steam, the air blower in the reaction section and the wet gas
compressor will be lost.
This will require a shutdown of the unit. The slurry pumparound pumps are all
steam turbine driven and these also will be lost. Depressurize the main
fractionator to prevent the possibility of flow of hydrocarbon back to the
regenerators. Flush the slurry circuit to prevent plugging problems as the slurry
circuits cool down. Shut off stripping steam to the HCO and LCO strippers.
When steam becomes available, start the slurry pumps and start slurry circulation.
Confirm the liquid level of T-1501 with LI-411A and B prior start slurry pumparound
pumps. If necessary, heat the slurry circuits as for normal start-up. Admit fuel gas
to the main fractionator overhead and start the wet gas compressor. Continue
start-up of the unit following the procedure for normal start-up.
8.4.24. Instrument air failure for the Fractionation/Gas Recovery Section

Instrument air failure will require shutdown of the unit. The control valves will go to
the failure position.
The operators should be familiar with these positions. If the wet gas compressor
has not shut down on instrument failure, it should be shut down following the
normal shutdown procedure. Maintain slurry circulation. It will be necessary to
manually control boiler feed water to the slurry pumparound steam generators,
using the control valve by-passes. Other pumps should be shut down as liquid
levels decrease.
Stop stripping steam to the strippers. As steam flow may continue to the reactor,
the main fractionator reflux drum water level will require manual control.
If necessary, heat the slurry circuit in the steam generators to maintain the main
fractionator hot. When instrument air is available, check all control valves for
proper operation. Any control valves being by-passed should be placed back in
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service and by-pass valves closed. Restart the unit following the normal start-up
procedure.
8.4.25. Boiler feed water failure for the Fractionation/Gas Recovery Section
Loss of boiler feed water will require shutdown of the unit. Loss of boiler feed
water can lead to loss of steam, depending on the duration. In this case, follow the
procedure for steam failure.
When boiler feed water is available, establish levels in the steam generators and
restart the unit following the normal start-up procedure.
8.4.26. Fuel gas failure for the Fractionation/Gas Recovery Section

Fuel gas failure will not normally require a shutdown of the fractionator section.
Fuel gas is used for pressure control on the feed surge drum. Loss of pressure
control should not result in any operating difficulty as any loss of pressure will be
gradual. Fuel gas is also used as pressure control on the surge drums associated
with the slurry separator. Loss of this control should not result in any operating
difficulty.
8.4.27. Electrical power failure for the Fractionation/Gas Recovery Section

Electrical power failure will require a shutdown of the unit. There is a possibility
that steam failure will also occur, soon after refinery wide power failure as no sea
water and cooling water.
Wet gas compressor will be shut-down, automatically, as sea water is not
available in the event of refinery wide power failure.
Try to maintain operation of the following pumps at power failure, and subsequent
steam failure:
• Main fractionator bottom pump P-1519ABC
• HCO flushing pump P-1521A for supplying flushing oil to P-1519ABC. In
case HCO is not available from the main fractionator, try to introduce LCO
from the tankage, if available.
In case shut-down duration is to be longer, maintain the main fractionator hot by
switching the slurry steam generators to heating.
For prolong steam available to the essential part of RFCC, i.e. steam to riser and
reactor stripping, cut off the steam to the following users, manually:
• MP steam to E-1522
• HP steam to E-1524
• HPS to COB FD fan CT-1502B, subject to availability of HPBFW and fuel
oil and or fuel gas.
• LP steam to T-1503
• LP steam to T-1504
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As the fractionator overhead air condenser and overhead sour water pumps will
be lost, the use of steam to the reactor should be minimized.
When power is available restart the unit following the normal start-up procedure.
8.4.28. Cooling water failure for the Fractionation/Gas Recovery Section

Cooling water failure will require a shutdown of the unit. Cooling water is used for
main fractionator trim condenser, and trim condensers of the wet gas compressor.
Cooling water is also used for pump auxiliary coolers, and lube oil cooler of the
Wet Gas Compressor. Shut down the wet gas compressor and maintain the main
fractionator hot by switching the slurry steam generators to heating.
8.4.29. Sea water failure for the Fractionation/Gas Recovery Section

Sea water is used for coolant of the surface condenser of the wet gas compressor.
Therefore, failure of sea water will automatically trip of WGC, as turbine is not
work properly. Follow operation procedure of wet gas compressor failure.
8.4.30. Wet gas compressor failure for the Fractionation/Gas Recovery Section
On loss of the wet gas compressor, divert the fractionator overhead gas to flare
and start to reduce feed to the unit. If the wet gas compressor cannot be re-started
quickly, this will require shutdown of the unit.
Follow any emergency procedures from the vendor to safeguard the compressor.
Maintain the main fractionator hot by switching the slurry steam generators to
heating. When the wet gas compressor is ready to start, follow the normal start-up
procedure to re-start the unit.
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TRAINING MODULE
UNIT: 15
Course Content:
Section 9 - HSE
X
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SECTION 9 : HSE
9.1. Hazardous Areas

Refer to the following attached documents:
• 8474L-015-DW-0051-001 Plot Plan – RFCC/LTU/NTU units
• 8474L-015-DW-1920-001 Hazardous Area Classification diagram –
RFCC/LTU/NTU units
9.2. Safety Equipment
Refer to the following attached document:
• 8474L-015-DW-1933-011 Safety Equipment Layout RFCC/LTU/NTU units
9.3. Specific PPE

For the description of the PPE required for the chemicals used in the RFCC, refer to the
specific MSDS which must be supplied by the material vendor. All personnel involved in
chemical handling related work in the RFCC unit must wear the specific PPE required.
The substances used in the RFCC include:
• Catalyst and additives,
• Flue gases,
• Cracked Hydrocarbons,
• Hydrogen Sulfide
The following advice is valid for any chemical handling:

• Use good work and personal hygiene practices to avoid exposure.
• Keep an eye wash fountain available.
• Keep a safety shower available.
• If clothing is contaminated, remove clothing and thoroughly wash the affected
area.
• Do not eat or drink while handling chemicals
9.3.1. Catalyst
RFCC catalyst is able to cause eyes and lungs irritations. When working with
catalyst (taking samples, catalyst containers loading and unloading…) face
shields or goggles and a dust mask must be worn.
Hot catalyst will burn skin. During catalyst sampling the whole body must be
protected by adequate clothing. One should be careful with pile of hot
catalyst spillage which can be cold externally but very hot inside.
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9.3.2. Flue gas

In the RFCC process there are two different flue gases. The flue gas coming from
the first regenerator contains CO and is a very dangerous gas.
9.3.2.1. Carbon Monoxide

The following details the Personal Protection Equipment required when
entering a zone susceptible to contain CO:
Eye/Face Protection: Safety Goggles or Glasses

Skin Protection: Any material protective gloves
Respiratory Protection: Positive pressure air line with full-face mask and escape bottle or
self-contained breathing apparatus should be available for
emergency use.
Always wear a self contained air mask when entering in an area
or vessel suspected to contain CO.
Other: Safety Shoes
9.3.3. H2S
The best method for prevention of H2S poisoning is to stay out of areas known or
suspected to contain it. The sense of smell is not an infallible guide as to the
presence of H2S, for although the compound has a distinct and unpleasant odor
(rotten eggs), it will frequently paralyze the olfactory nerves to the extent that
the victim does not realize that he is breathing it. This is particularly true of
higher concentrations of the gas.
Fresh air masks or gas masks suitable for use with hydrogen sulfide must
be used in all work where exposure is likely to occur. Such masks must be
checked frequently to make sure that they are not exhausted. People who must
work on or in equipment containing appreciable concentrations of H2S, must wear
fresh air masks and should work in pairs so that one may effect a rescue or call for
help should the other be overcome.
As mentioned above, the atmosphere in which people work should be checked
from time to time for appreciable concentrations of H2S.
REMEMBER - JUST BECAUSE YOUR NOSE SAYS IT'S NOT THERE, DOESN'T
MEAN THAT IT IS NOT.
PPE recommendation for protection against H2S:
Ventilation Use adequate ventilation to control exposure below recommended levels

For concentrations exceeding the recommended exposure level, use
Respiratory NIOSH/MSHA approved air purifying respirator.
Protection If conditions immediately dangerous to life or health (IDLH) exist, use
NIOSH/MSHA approved self-contained breathing apparatus (SCBA)
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equipment.
Eye
For splash protection use chemical goggles and face shield
Protection
Skin Gloves and coveralls of rubber or neoprene construction if liquid contact could
Protection occur. Avoid unnecessary skin contamination with material
9.3.4. Nickel passivator – NALCO NICKEL PASSIVATION PLUS EC9192

The following table details the PPE required when handling this chemical:
The use and choice of personal protection equipment is related to the hazard
of the product, the workplace and the way the product is handled.
General In general, we recommend as a minimum precaution that safety glasses with
Advice side-shields and workclothes protecting arms, legs and body be used.
In addition any person visiting an area where this product is handled should at
least wear safety glasses with side-shields.
Where concentrations in air may exceed the limits given in this section, the use
of a half face filter mask or air supplied breathing apparatus is recommended.
A suitable filter material depends on the amount and type of chemicals being
handled.
Respiratory
Consider the use of filter type: A-B-E-K-P In event of emergency or planned
Protection
entry into unknown concentrations a positive pressure, full-facepiece SCBA
should be used.
If respiratory protection is required, institute a complete respiratory protection
program including selection, fit testing, training, maintenance and inspection.
When handling this product, the use of chemical gauntlets is recommended.
Hand PVC gloves are recommended.
Protection
Gloves should be replaced immediately if signs of degradation are observed.
Skin When handling this product, the use of overalls is recommended. A full slicker
Protection suit is recommended if gross exposure is possible.
Eye
Wear chemical splash goggles
Protection
9.3.5. Corrosion Inhibitor - CHIMEC 1430

Respiratory
A localized aspiration is necessary if the warmed product forms vapours
protection
protective gloves in neoprene or latex, approved for protection against
Skin protection
chemical substances
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Eye protection goggles or face shield with safety glasses

Others appropriated protective clothing
9.3.6. Antifoam CHIMEC 8045

A localized aspiration is necessary if the warmed product forms vapours.

Respiratory Ensure good ventilation.
protection In closed areas or in case of insufficient ventilation, use protective mask with
filter for organic vapours.
Protective gloves made of nitrile or PVA, approved for protection against
Skin Protection
chemical substances
Eye Protection Goggles or face shield with safety glasses
9.3.7. Phosphate NALCO 7208

Where concentrations in air may exceed the limits given in this section, the
use of a half face filter mask or air supplied breathing apparatus is
recommended.
Respiratory A suitable filter material depends on the amount and type of chemicals being
protection handled.
Consider the use of filter type: Particulate filter - HEPA (Purple) If respiratory
protection is required, institute a complete respiratory protection program
including selection, fit testing, training, maintenance and inspection.
Hand
Neoprene gloves, Nitrile gloves, Butyl gloves, PVC gloves
Protection
Skin Protection Neoprene gloves, Nitrile gloves, Butyl gloves, PVC gloves
Eye Protection Wear chemical splash goggles
9.4. Chemical Hazards

The material safety datasheet for chemicals used in the RFCC will be provided by vendor
and serves as reference. These datasheets clearly explains what are the health hazards
specific to each chemical.
It is of the utmost importance that all employees involved in this unit read and understand
the MSDS of the chemical they will handle before proceeding to work. No work or
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operation should be allowed to commence before all employees involved in chemical

handling related work have demonstrated knowledge of the health hazards they my face.
The substances used in the RFCC include:
• Catalyst and additives,
• Flue gases,
• Cracked Hydrocarbons,
• Hydrogen Sulfide
9.4.1. Hazardous Properties of Catalyst

RFCC catalyst is able to cause eyes and lungs irritations. Hot catalyst will burn
skin. One should be careful with pile of hot catalyst spillage which can be cold
externally but very hot inside.
9.4.2. Flue gas

In the RFCC process there are two different flue gases. The flue gas coming from
the first regenerator contains CO and is a very dangerous gas. Exposure to a
concentration as low as 0.4 % vol. can be fatal in a short period of time. The
flue gas contains no or very little oxygen and is a dense gas which can
accumulate in low parts of equipments. Therefore it can cause asphyxiation
or poisoning if not sufficiently purged off.
First aid consists of taking the victim out of the dangerous area and then to use
artificial respiration.
9.4.2.1. Hazardous properties of carbon monoxide (CO)

Carbon monoxide has the ability to replace oxygen in the blood; too
high concentration in the body may cause death in a short period of
time.
CO also acts to keep the oxygen in the blood from reaching the tissues
causing a type of suffocation. Maximum allowable concentration in the air
is 100 ppm.
CO burns readily and is dangerous when exposed to heat or flames.
Its explosive limits range from 12.5% to 74% volume.
Auto ignition temperature: 650°C.
Mixtures of CO and air in certain proportions are flammable.
The following table summarizes the health hazards of CO:
Eye Effects: None reported

Skin Effects: None Reported
Ingestion Effects: None Reported
Inhalation Effects: Inhaled carbon monoxide binds with blood hemoglobin to form
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carboxyhemoglobin. Carboxyhemoglobin can not take part in normal

oxygen transport, greatly reducing the blood’s ability to transport oxygen.
Too high concentration in the body may cause death in a short
period of time.
Depending on levels and duration of exposure, symptoms may include
headache, dizziness, heart palpitations, weakness, confusion, nausea,
and even convulsions, eventual unconsciousness and death.
9.4.3. Hazardous Properties of Cracked hydrocarbons

Cracked hydrocarbons are skin irritants. Precautions should be taken during
maintenance operations or products sampling to avoid contact with skin and eyes.
It also contains aromatics which are poisons. In case of exposure, skin should be
washed with soap and eyes thoroughly cleaned with water. Contaminated clothes
should be removed.
9.4.4. Hazardous Properties of Hydrogen Sulfide Toxicity

Classification:
Hydrogen sulfide is both an irritant and an extremely poisonous gas. it is extremely

toxic (almost as toxic as hydrogen cyanide) and highly corrosive to certain metals.
Breathing even low concentrations of hydrogen sulfide (H2S) gas can cause
poisoning.
Hydrogen sulphide at concentrations greater than 500 ppm is highly toxic and can
cause immediate death. The unit must be completely gas tight and leaks repaired
immediately when occur. It can be lethal to under-estimate an H2S leak.
It is highly soluble in both water and oil. H2S is colorless, and heavier than air. It
will therefore accumulate in low places, in dangerous concentrations. It is
however, readily dispersed 'by the wind' movement, so areas where there is a risk
of H2S emission should be well ventilated.
H2S is explosive in air in the range of 4.3% to 45% by volume, and has an
automatic ignition temperature of 292OC. It burns with a blue flame producing
Sulphur Dioxide (SO2), which is also a toxic gas.
Human tolerance of exposure varies greatly between individuals at lower
concentrations. As concentrations increase, tolerance variations decrease rapidly.
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A feature of H2S poisoning is that the H2S immobilizes or paralyses that part of
the central nervous system, which controls the body's automatic breathing system.
H2S acts by deadening nerve endings including those associated with smell. H2S
can usually be detected by its 'bad egg' smell, but the sense of smell is quickly lost
in concentrations over 1000 ppm, even at 50 ppm the sense of smell is unreliable.
WARNING: YOU CANNOT RELY ON YOUR NOSE TO TELL YOU HOW MUCH
H2S IS PRESENT.
At concentration greater than 20 ppm it is no longer possible to smell the gas, thus
greatly increasing its hazard.
No work should be undertaken on the unit where there is danger of

breathing H2S, and one should never enter or remain in an area containing it
without wearing a suitable fresh air mask.
9.4.4.1. Acute Hydrogen Sulfide Poisoning

Breathing air or gas containing more than 500 mol-ppm H2S can cause
acute poisoning and possibly be fatal.
Symptoms of Acute Poisoning
The symptoms of acute H2S poisoning are muscular spasms, irregular
breathing, lowered pulse, odor to the breath and nausea. Loss of
consciousness and suspension of respiration quickly follow.
Even after the victim recovers, there is still the risk of edema (excess
accumulation of fluid) of the lungs which may cause severe illness or
death in 8 to 48 hours.
First Aid Treatment of Acute Poisoning
Move the victim at once to fresh air. If breathing has not stopped, keep
the victim in fresh air and keep him quiet. If possible, put him to bed.
Secure a physician and keep the patient quiet and under close
observation for about 48 hours for possible edema of the lungs.
In cases where the victim has become unconscious and breathing has
stopped, artificial respiration must be started at once. If a Pulmotor or
other mechanical equipment is available, it may be used by a trained
person; if not, artificial respiration by mouth-to-mouth resuscitation must
be started as soon as possible. Speed in beginning the artificial
respiration is essential. Do not give up. Men have been revived after more
than four hours of artificial respiration.
If other persons are present send one of them for a physician. Others
should rub the patient's arms and legs and apply hot water bottles,
blankets or other sources of warmth to keep him warm. After the patient is
revived, he should be kept quiet and warm, and remain under observation
for 48 hours for the appearance of edema of the lungs.
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9.4.4.2. Subacute Hydrogen sulfide Poisoning

Breathing air or gas containing H2S anywhere between 10 to 500 mol-
ppm for an hour or more may cause subacute or chronic hydrogen sulfide
poisoning.
Symptoms of Subacute Poisoning
The symptoms of subacute H2S poisoning are headache, inflammation of
the eyes and throat, dizziness, indigestion, excessive saliva, and
weakness. These can be the result of continued exposure to H2S in low
concentrations. Edema of the lungs may also occur.
First Aid Treatment of Subacute Poisoning
Keep the patient in the dark to reduce eyestrain and have a physician
treat the inflamed eyes and throat. Watch for possible edema.
Where subacute poisoning has been suspected, the atmosphere should
be checked repeatedly for the presence of H2S by such methods as
testing by odor, with moist lead acetate paper, and by Tutweiler H2S
determination to make sure that the condition does not continue.
9.4.5. Hazardous Properties of NALCO NICKEL PASSIVATION PLUS EC9192

Hazard Classification:
The following table summarizes the health hazards of this chemical:
Inhalation Repeated or prolonged exposure may irritate the respiratory tract.

Product mist or vapors may cause headache, nausea, vomiting,
drowsiness, stupor or unconsciousness.
Methyl alcohol may cause central nervous system effects which may
result in permanent visual changes including blindness.
Skin Contact Can cause moderate irritation. Harmful if absorbed through skin.
Methanol may be absorbed through the skin and cause central nervous
system effects which may result in permanent visual changes including
blindness.
Eye Contact Can cause moderate irritation
Ingestion Not a likely route of exposure. There may be irritation to the gastro-
intestinal tract. Harmful if swallowed. Can cause blindness.
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Note:
Keep out of waterways: Toxic to aquatic organisms.
9.4.6. Hazardous Properties of Corrosion Inhibitor - CHIMEC 1430

Inhalation Vapours or fog inhalation at high temperature may produce irritation of

respiratory tract.
Skin Contact Corrosive, may produce dermatitis and burns
Eye Contact Corrosive
Ingestion burning effects in mouth, throat and stomach with abdominal
cramps
9.4.7. Hazardous Properties of Antifoam CHIMEC 8045

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Inhalation Slight exposure: irritation of eyes and primary respiratory tract, with
temporary reduction of smelling capacity.
Exposure to high vapour concentration: depressant effect on the central
nervous system with headaches, drowsiness, derangement, serious
damage to visual faculties, nausea, vomiting, drunkenness.
May cause anesthetic and/or narcotic effects.
Skin Contact Prolonged and repeated contact may produce dermatitis and irritation
Eye Contact Vapours may cause irritation
Ingestion Ingestion causes severe irritation of the mouth, throat and stomach, with
nausea, vomiting, dizziness, faintness, drowsiness and lack of
coordination.
Ingestion creates a high risk of aspiration and subsequent chemical
pneumonia.
9.4.8. Hazardous Properties of Phosphate NALCO 7208

Inhalation Not a likely route of exposure. No adverse effects expected

Skin Contact Can cause moderate to severe irritation
Eye Contact Can cause moderate to severe irritation
Ingestion Can cause moderate to severe irritation
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TRAINING MODULE
UNIT: 15
Course Content:
Section 9 - HSE

X
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SECTION 10 : REFERENCE DOCUMENTS INDEX
10.1. Operating Manual/ Licensor Documentation

8474L-015-ML-001 RFCC Operating Manual
10.2. Arrangement Drawings, Layouts and Plot Plans

8474L-015-DW-0051-001 Plot Plan – RFCC / LTU / NTU
8474L-015-DW-1960-001 Escape Route Layout for RFCC / LTU / NTU
10.3. Process Flow Diagrams

10.4. Piping and Instrumentation Diagrams

Interconnections:
8474L-015-PID-0021-101 Interconnecting Process Lines to RFCC
8474L-015-PID-0021-102 Interconnecting Process Lines from RFCC
8474L-015-PID-0021-103 Interconnecting Process Lines to/from LTU
8474L-015-PID-0021-104 Interconnecting Process Lines to/from NTU
8474L-015-PID-0021-105 Interconnecting Process Lines to/from PRU
8474L-015-PID-0021-106 Interconnecting Utilities
8474L-015-PID-0021-107 Interconnecting Utilities
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Specific Details:
8474L-015-PID-0021-111 Specific Details (1/4)
Reactor/Regenerator Section:
8474L-015-PID-0021-121 Riser: Feed injectors
8474L-015-PID-0021-122 Riser: MTC & Backflush oil injectors
8474L-015-PID-0021-123 Disengager/Stripper: Stripping
8474L-015-PID-0021-124 Disengager/Stripper: Purging
8474L-015-PID-0021-125 Spent Catalyst Line
8474L-015-PID-0021-126 1st Regenerator Dense Phase-Upper
8474L-015-PID-0021-127 1st Regenerator Dense Phase-Lower
8474L-015-PID-0021-128 1st Regenerator Dilute Phase
8474L-015-PID-0021-129 2nd Regenerator Upper
8474L-015-PID-0021-130 2nd Regenerator Lower
8474L-015-PID-0021-131 Withdrawal Well
8474L-015-PID-0021-132 Air Blower
8474L-015-PID-0021-133 1st Regenerator Air Heater
8474L-015-PID-0021-134 2nd Regenerator Air Heater
8474L-015-PID-0021-135 Spent Catalyst Hopper
8474L-015-PID-0021-136 Auxiliary Catalyst Hopper
8474L-015-PID-0021-137 Fresh Catalyst Hopper
8474L-015-PID-0021-138 Steam Injection & Fuel Gas Inst. Purging
Flue Gas Treatment Section:

8474L-015-PID-0021-201 1st Regenerator Flue Gas
8474L-015-PID-0021-202 2nd Regenerator Flue Gas
8474L-015-PID-0021-203 CO Boiler Package
8474L-015-PID-0021-204 Electrostatic Precipitator
8474L-015-PID-0021-205 Economizer
8474L-015-PID-0021-206 Flue Gas KO Drum
Fractionation Section:
8474L-015-PID-0021-301 Feed Surge Drum and Pumps
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8474L-015-PID-0021-302 LCO PA/MPS/HPS Feed Heaters

8474L-015-PID-0021-303 1st Slurry preheat exchangers
8474L-015-PID-0021-304 2nd Slurry preheat exchangers
8474L-015-PID-0021-305 MTC Recycle and Heavy Naphta PA
8474L-015-PID-0021-306 HCO recycle
8474L-015-PID-0021-307 LCO PA Pumps
8474L-015-PID-0021-308 HCO PA Pumps & HCO PA MPS Generator
8474L-015-PID-0021-309 Main Fractionator Upper Section
8474L-015-PID-0021-310 Main Fractionator Lower Section
8474L-015-PID-0021-311 Slurry PA Pumps
8474L-015-PID-0021-312 Slurry PA HP steam generators A&B
8474L-015-PID-0021-313 Slurry PA HP steam generators C
8474L-015-PID-0021-314 Slurry PA HP/MP steam generators A
8474L-015-PID-0021-315 Slurry PA HP/MP steam generators B
8474L-015-PID-0021-316 HCO Stripper
8474L-015-PID-0021-317 Heavy Naphta Stripper
8474L-015-PID-0021-318 LCO Stripper
8474L-015-PID-0021-319 Fractionator Overhead
8474L-015-PID-0021-320 Fractionator Reflux Drum
8474L-015-PID-0021-321 Slurry Draw Off Drum
8474L-015-PID-0021-322 Slurry LP Steam Generators
8474L-015-PID-0021-323 Clarified Oil Cooler and Slurry Separator
8474L-015-PID-0021-324 Slurry Separator Backflushing (1/2)
8474L-015-PID-0021-325 Slurry Separator Backflushing (2/2)
8474L-015-PID-0021-326 HCO Flushing Oil
8474L-015-PID-0021-327 HCO Flushing Oil
8474L-015-PID-0021-328 LCO Product Cooling
8474L-015-PID-0021-329 Light Slops Drum
8474L-015-PID-0021-330 Heavy Slops Drum
8474L-015-PID-0021-331 Tempered Water System
8474L-015-PID-0021-332 Phosphate Injection Package
Gas Recovery Section:

8474L-015-PID-0021-401 Wet gas compressor 1st stage KO Drum
8474L-015-PID-0021-402 Wet gas compressor
8474L-015-PID-0021-403 Wet gas compressor Inter/Trim Cooler
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8474L-015-PID-0021-404 HP Separator
8474L-015-PID-0021-405 Primary Absorber and Stripper
8474L-015-PID-0021-406 Gasoline Cooldown
8474L-015-PID-0021-407 Secondary Absorber
8474L-015-PID-0021-408 Fuel Gas Absorber
8474L-015-PID-0021-409 Debutanizer
8474L-015-PID-0021-410 Debutanizer Condenser and Reflux Drum
8474L-015-PID-0021-411 LPG Amine Absorber
8474L-015-PID-0021-451 Closed Drain Recovery

8474L-015-PID-0021-452 Blowdown System
8474L-015-PID-0021-453 Amine Closed Drain Recovery
8474L-015-PID-0021-454 Oily Water Lift Station
10.5. Equipment list

Refer to the attached equipment list of unit 015:
Unit 015 Extracted Equipment List
10.6. Main Equipment Data Sheet

8474L-015-PDS-AE-401 Process Data Sheet of RFCC Analysers
8474L-015-PDS-BV-1501-719 Process Data Sheet of BV-1501
8474L-015-PDS-BV-1502-720 Process Data Sheet of BV-1502
8474L-015-PDS-D-1501-101 Process Data Sheet of D-1501
8474L-015-PDS-D-1501-210 Process Data Sheet of D-1501 (Packing)
8474L-015-PDS-H-1501-501 Process Data Sheet of H-1501
8474L-015-PDS-PV-1501-721 Process Data Sheet of PV-1501
8474L-015-PDS-SV-1501-711 Process Data Sheet of SV-1501
8474L-015-PDS-T-1501-211 Process Data Sheet of T-1501
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8474L-015-PDS-T-1501-212 Process Data Sheet of T-1501 (Trays)

8474L-015-PDS-T-1501-213 Process Data Sheet of T-1501 (Packing)
8474L-015-PDS-T-1551-222 Process Data Sheet of T-1551 (Tray)
8474L-015-PDS-T-1556-232 Process Data Sheet of T-1556 (Packing)
8474L-015-PDS-X-1504-604 Process Data Sheet of X-1504
8474L-015-PDS-X-1507-607 Process Data Sheet of X-1507
10.7. Instrument List

Refer to attached extracted instrument list of unit 012:
Unit 012 Extracted Instrument List.xls
10.8. Cause & Effect Matrix

8474L-015-DW-1514-602
10.9. Safety Logic diagram

8474L-XX-XXXX-XXX
10.10. Fire & Gas Cause & Effect Chart

8474L-015-DW-1514-610
10.11. Fire & Gas Detectors Layout

8474L-015-DW-1950-001 Fire & Gas Detector Layout RFCC/LTU/NTU
10.12. Fire Protection Layout

8474L-015-DW-1933-001 Fire Protection Layout RFCC/LTU/NTU
8474L-015-DW-1933-011 Safety Equipment Layout RFCC/LTU/NTU
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10.13. Hazardous Area Classification

8474L-015-DW-1920-001 Hazardous Area Classification Plan – RFCC/LTU/NTU
10.14. MSDS
For the MSDS of the following chemicals, refer to the attachments of the licensor
operating manual:
• Nickel Passivator EC9192
• Corrosion Inhibitor CHIMEC 1430
• Anti foam Chemical CHIMEC 8045
• Phosphate NALCO 7208
10.15. Vendors Documentation

COB/WHB Package:
8474L-015-A0103-0160-001-029 P&ID Combustion air system
8474L-015-A0103-0160-001-030 P&ID CO Combustor
8474L-015-A0103-0160-001-031 P&ID CO Combustor
8474L-015-A0103-0160-001-032 P&ID Fuel Skid
8474L-015-A0103-0160-001-033 P&ID Waste Heat Recovery Section
8474L-015-A0103-0160-001-034 P&ID Steam Drum
8474L-015-A0103-0160-001-035 P&ID Blowdown System
8474L-015-A0103-0160-001-142 P&ID Economizer
8474L-015-A0103-0160-001-143 P&ID Ancillaries
8474L-015-A0103-0160-001-144 P&ID Economizer Sootblower
8474L-015-A1001-0160-001-098 H-1503 Package Datasheet
Electrostatic Precipitator:
8474L-015-A0103-4240-002-005 P&ID ESP
8474L-015-A0103-4240-002-009 P&ID ESP
8474L-015-A0103-4240-002-128 P&ID ESP
8474L-015-A0103-4240-002-129 P&ID ESP
8474L-015-A0103-4240-002-130 P&ID ESP
8474L-015-A0103-4240-002-131 P&ID ESP
8474L-015-A0103-4240-002-133 P&ID ESP
8474L-015-A1001-4240-001-011 Data Sheet X-1507
8474L-015-A3501-4240-002-122 X-1507 Operational Procedure
8474L-015-A3501-4240-002-135 Ash Handling Control Flowchart
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8474L-015-A3505-4240-001-023 Logic Sequence Diagram
Wet Gas Compressor:

8474L-015-A1001-1010-001-007 Data Sheet of C-1551
8474L-015-A3501-1010-001-108 Control System Description
8474L-015-A3505-1010-001-041 Cause & Effect Diagram
Air Blower:
8474L-015-A1001-1040-001-226 Blower Data Sheet
8474L-015-A3505-1040-001-063 Blower Cause & Effect Diagram
Page 323 of 323

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Vendor Document No. Rev.

RESIDUE FLUID CATALYTIC CRACKER (RFCC)

VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM)

Requisition Number: 8474L-000-CFB-XXXX-0001 Stamp

Purchase Order Number: 8474L-000-CS01-17061

Equipment / Item Tag: Not Applicable

Equipment / Item Description: Not Applicable

TPC Document Number: 8474L-015-A5016-0000-001-005

A 06-DEC-07 Issue for review Benoit Rabaud Paul Walsh JB Guillemin

Pages changed in this revision:

RESIDUE FLUID CATALYTIC CRACKER (RFCC)

A 06/12/07 Benoit Rabaud Paul Walsh JB Guillemin

THIS MODULE MUST BE RECOGNIZED AS A TOOL AND GUIDE ONLY. IT WOULD BE

IT IS IMPERATIVE THAT THE READER ALWAYS AS CERTAIN THAT REFERENCE

SECTION 1 : GENERAL description ........................................................................................... 14

2.3.2. First stage regenerator ............................................................................... 57

3.1.12. Feed Pumps Automatic Start-up............................................................... 98

3.3.5. Special Valves .......................................................................................... 138

4.2.21. Logic UX-432: D-1515 overfilling protection ........................................... 197

6.1.1. Feed Oil .................................................................................................... 227

8.4.2. Power failure ............................................................................................. 290

9.3.2. Flue gas .................................................................................................... 307

RESIDUE FLUID CATALYTIC CRACKER (RFCC)

Section 3 - Process Control

Section 4 - Safeguarding Devices

Section 5 - Fire & Gas Systems

Section 6 - Quality Control

Section 7 - Cause & Effects

Section 8 - Operating Procedures

Section 10 - Reference Document Index

SECTION 1 : GENERAL DESCRIPTION

Figure 1: 2D Refinery Plot Plan

Figure 2: 3D Refinery Plot Plan

1.1. Purpose of the Unit

Figure 3: Refinery Plot Plan

North East View

North West View

1.2. Basis of Design

1.2.1. Duty of Plant

1.2.2. Feed Characteristics

1.2.2.1. Atmospheric Residue Properties

Crude (Sour) 100% (Sweet) ASTM Test

1.2.2.2. CDU Stabilizer Off Gas

Property Crude (Sour) Blend [1] 100% (Sweet) Bach Ho

1.2.2.3. NHT Stripper off gas to RFCC

1.2.2.4. CDU LPG Rich Stream

Property Crude (Sour) Blend [1] 100% (Sweet) Bach Ho

1.2.2.5. Slops feed to RFCC

1.2.3. Product Specifications

1.2.3.1. Distillation Specifications

Product Property Max. Gasoline Max. Distillate

1.2.3.2. Gas Recovery Targets

1.2.3.3. Flue Gas Specifications

1.2.3.4. Fuel Gas Specification

1.2.3.5. Decant Oil Specification (after Slurry Separation)

1.2.3.6. Estimated Product Properties

Mixed Bach Ho Mixed Bach Ho

Mixed Bach Ho Mixed Bach Ho

Mixed Bach Ho Mixed Bach Ho

1.2.3.7. LPG Composition

Mixed MG Bach Ho MG Mixed MD Bach Ho MD

Component LPG (kmol/h) LPG (kmol/h) LPG (kmol/h) LPG (kmol/h)

Mixed MG Bach Ho MG Mixed MD Bach Ho MD