Reliance Industries Limited Cracker Plant Process Description and Utilities Manual

SECTION MODULE NO.
RELIANCE INDUSTRIES LIMITED

CKR-PR-P-001
PROCESS DESCRIPTION
AND
UTILITIES
CKR-PR-P-011
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Preface
This operating manual gives general guidelines for the
understanding and operation of the Cracker Plant. It provides
basic information on the process , utilities, efuent treatment
and emergencies. This shall be read with other Standard
Operating Procedures to understand precisely the operation
and control methodology of the plant.
It is recognised that several improvements can be made to this
manual for more efcient operation of the plant. ny such
changes shall be communicated to the !anager in charge for
proper updating and revision.
Autor
".!.#rishna
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CONTENTS!
1 N"L # NAP$T$A CRACKER PLANT AT RIL% $A&IRA
$.$ Introduction
$.% &eed 'tock
$.( )ther Products
$.* Chemicals, dditives nd Catalysts
$.+ Products 'peci,cation
' Process Description
%.-$ Cracking &urnaces
%.-% .'C main furnace and recycle furnace /uench ,ttings
%.-( 0uench )il Tower
%.-* 1&) 'tripper
%.-+ 2&) 'tripper
%.-3 0uench 4ater Tower
%.-5 6ilution 'team generation system
%.-7 6istillate stripper
%.-8 0uench 4ater Circulation Circuit
%.$- 0uench )il Circulation Circuit
%.$$ Pan )il Circulation Circuit
%.$% Cracked gas compression ,cid gas removal,
6ehydration
%.$( 6emethaniser system
%.$* P' .nit
%.$+ 6eethaniser
%.$3 C% cetylene hydrogenation system
%.$5 9thylene fractionation
%.$7 6epropaniser
%.$8 C( !P6 hydrogenation system
%.%- 'econdary and tertiary deethanisers
%.%$ Propylene fractionation
%.%% 6ebutaniser
%.%( C* hydrogenation and u:. C* hydrogenation
%.%* 9thylene refrigeration system
%.%+ Propylene ;efrigeration 'ystem
%.%3 <asoline 1ydrogenation .nit
%.%5 'pent Caustic ):idation .nit
( .tilities
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(.$ C4 'ystem
(.% 'team 'ystem
(.( Condensate and "oiler feed water system
(.* &uel gas system
(.+ =itrogen, plant air, instrument air system
(.3 'ervice 4ater system
(.5 6! 4ater system
(.7 &ire water system
(.8 9lectrical Power systems
*.- Plant 9fuents and disposal !ethods
*.$ 2i/uid efuents
*.% 'olid efuents
*.( <aseous efuents
+ 9mergencies
+.$ Power failure >I'"2 )=2?@
+.% 'team failure
+.( I failure
+.* C4 failure
+.+ 04 failure
+.3 0) failure
3 9/uipment 2ist
5
5.$ ;elief and blowdown system
5.% &lare system at )'"2
7.- &ire and <as 6etection 'ystem
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1(1 INTRODUCTION
The =<2 A =aphtha Cracker plant is designed to product
+,--,--- metric tonnes per annum of polymer grade ethylene
from cracking =aphtha and =<2. 'ubse/uently, the plant was
engineered to increase the capacity from +,--,--- !T to
5,--,--- !T.
It is designed to crack =aphtha, =<2, <) and C%AC( recycle
and fresh streams. 1owever, the 5,--,--- !T capacity of
ethylene is produced by cracking of low aromatics naphtha
only. lso, the recycle streams like C%,C(,C+, C3BC7 rafnate
from aromatics plant and hydrogenated mi: C* are cocracked
with =aphtha in the furnaces.
The minimum propylene production capacity is (,%-,--- !T
for an optimum cracking severity of (.$$ #'& for the designed
on stream time of 7--- hours per year.
The plant is able to produce 1P ethylene vapour at
+7kgAcm%g ,2P vapour ethylene at %5 kgAcm%g. and ethylene as
li/uid at B87
-
C for storage in atmospheric tank.
The plant also includes two I&P units C* hydrogenation unit for
processing mi:ed C* and <1. unit for the treatment of
gasoline generated during cracking. &or the production of high
purity hydrogen, one P' unit is installed supplied by .)P,
.'.
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1(' )EED STOCKS
The cracker plant is designed on the basis of single light
naphtha feed stock as de,ned below C
'< C -.5
6istribution Curve C
-
C
$"P C *+
$-D C 37
+-D C $--
8-D C $(-
&"P C $+-
PONA ! *T
Parafns 5*D !in.
=aphthalenes "alance
romatic $-D
)le,ns Eol. !a:. $.-D
1ydrogen, 4TD $+.%
'ulphur PP! wtAwt 7-- ma:.
;EP kgAcm%a -.8* ma:.
1owever, plant is capable in using other feed stacks
=<2A<),C%AC(, recycle hydrogenated C* mi:, C+ from <1.
and C3BC7 rafnates from aromatics.
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DESI"N SPECI)ICATION O) N"L )EEDSTOCK!
Particu+ars Unit Design
'peci,c <ravity B -.5(
'T! distillationC
I"P C *+
+-D C 8+
&"P C $+-
P)= analysisC
Parafns vol. D +8
=aphthenes vol. D %3
romatic vol. $+
)le,ns vol. nil
'ulphur ppm wtAwt 7--
;eid Eapour
pressure
kgAcm
%
a -.+
2ead ppm wtAwt -.-5+
Chloride ppm wtAwt %
Colour 'aybolt
Note !
The iBParafns may be present up to +-D by wt. of total
Parafns
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DESI"N SPECI)ICATION O) C'#C, )EEDSTOCK!
Co-ponents
Co+our
Units Design
!ethane D mol -.5
9thane D mol 5+.+*
Propane D mol %$.83
"utanes D mol $.+
DESI"N SPECI)ICATION O) C,#C. )EEDSTOCK!
Co-ponents Units Design
9thane D mol -.87D
Propane D mol *8.-%D
nB"utane D mol (*.($D
iB"utane D mol $*.5$D
Pentane D mol -.87D
1(, Oter Products!
4hile main products form cracker plant are ethylene and
propylene, there are a number of lesser products. These are
listed below C
/etane!
The plant is able to produce +-- kgAhr of methane vapour at %5
kgAcm%g and ambient temperature. It is intended to be used as
ballast gas !9< plants
$0drogen!
The high purity hydrogen produced form P' unit is intended
for captive use for cetylene, !P6 , C* mi: and gasoline
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hydrogenations. The e:cess hydrogen is e:ported to )'"2 for
use in aromatics, PT F P9 Plants.
)ue+ Oi+!
The fuel oil component product during li/uid feed stocks are
rich in carbon inde:. This can be used as feestock for carbon
block manufacture.
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Etane 1 Propane!
The ethane and propane produced form ethylene and propylene
fractionation system is cracked in recycle furnaces or along
with =aphtha in four main furnaces. 9:cess of ethane and
propane after vaporisation can be dumped in to fuel gas. lso
provision for e:port of ethane Apropane mi: is also provided.
1owever, li/uid propane from propylene fractionation system is
preferentially e:ported to )'"2 for storage to act as back up
fuel during emergency >or@ during startBup of the plant.
C2 /i3(!
C+ !i:ture reported from gasoline in depentaniser unit after
hydrogenation of diole,ns impurities is recycled to furnace for
cracking along with =aphtha.
C4-C5 Cut !
C3BC7 after treatment in gasoline hydrogenation unit for the
improvement of stability, octane no. "romine number and
sulphur is fed as feedstock for aromatics plant for the
separation of benGene, toluene and :ylene.
)ue+ "as !
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&uel <as which is a mi: of primarily methane and hydrogen is
fed to furnaces for providing heat for cracking. The e:cess of
the re/uirement is sent to )'"2 for use in fuel in gas turbines,
dowtherm heaters, EC! furnaces etc.
$0drogenated C. /i3 !
"utadiene rich C* mi: from li/uid cracking is hydrogenated in
main and au:. C* hydrogenation units to remove butadiene to
e:tinction is sent to )'"2 to the sold as industrial 2P< >or@
e:cess of the maker is cracked in main furnaces along with
=aphtha.
1(. Ce-ica+s% Cata+0sts and additi6es!
1(.(1 Ce-ica+s!
!any chemicals are used at diHerent parts of the plant for the
smooth and efcient of the plant. They are listed as below C
$@ mmonia
i@ 6eaerator >E8--@
ii@ 04 Tower )A1 >CB%%-@
%@ Caustic >%-D@
i@ 6ilution steam stripper >not used@
ii@ Condensate polishing unit for regeneration
iii@ Caustic tower
(@ 1C2 >%-D@
i@ Condensate polishing unit for regeneration
ii@ 'C) efuent neutralisation
*@ 6!6'
i@ .'C main furnaces with =aphtha
ii@ .'C recycle furnaces with 6ilution steam
+@ 1ydraGine
i@ 6eaerator
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3@ Trisodium Phosphate
i@ !ain F ;ecycle furnace steam drums
5@ !ethanol
i@ s re/uired in cold sections
7@ Corrosion inhibitor 6P $7--
i@ Process water stripper B C%3-
8@ ntifoulant 6);& 8*(3%
I@ 6epropaniser CB+$-
$-@ 9mulsion "reaker 6);& 9" *-%*
i@ CB%%- /uench water tower
$$@ =eutralising mine 6P $85
i@ CB%%- 0uench water tower
$%@ ntio:idant 6);& *$-
i@ ;aw pyrolysis gasoline feed
ii@ C+ product
iii@ C8 product
iv@ ;aw C3BC7 cut
$(@ Corrosion Inhibitor 6);& %--% CI
i@ <1. 'tripper
$*@ ntipolymerant >Trial on@
i@ Caustic tower
1(.(' Cata+0sts and Desiccants!
Unit Item No. T!e So"#$e
1 C#%$&e' G%(
De)'#%to#
V *+0 A,B Mo-e$"-%# (ie.e
EPG 11/0 %n'
A-"min% B%--(
UOP
1 Se$on'%#
'e)'#%to#
V 23* A,B Mo-e$"-%# (ie.e
EPG 1,/ 4 %n'
A-"min% B%--(
UOP
* C1 A$et-ene
)'#o5en%tion
R-231 A,B,C R-
231 A,B
G 3/ E C%t%-(t(
%n' A-"min% B%--(
SUD CHEMIE
UCIL
2 C* MAPD
H'#o5en%tion
R-3*1 A,B,C LD 1+* $%t%-(t
%n' A-"min% B%--(
P#o$%t%-(e
3 C2 M%in %n'
%"6i-i%#
)'#o5en%tion
7IRST (t%5e
R-/018 R-/0* LD 193 :
A-"min% B%--(
P#o$%t%-(e
9 C2 M%in :
A"6i-i%#
R-/018 R-/02 LD 1+1 :
A-"min% B%--(
P#o$%t%-(e
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)'#o5en%tion II
(t%5e
+ G%(o-ine
)'#o5en%tion I
(t%5e
R-+10 A,B LD 193 :
A-"min% B%--(
P#o$%t%-(e
/ G%(o-ine
)'#o5en%tion II
(t%5e
R-+20 LD 123 ;o# "!!e#
<e' %n'
ALUMINA <%--(
1=R *09C %n'
%-"min% <%--( ;o#
-o>e# <e'
P#o$%t%-(e
1.5 Prod#ct speci$ications%
SPECI)ICATION O) POL7/ER "RADE ET$7LENE
PRODUCT!
Co-ponents Units "uaranteed
8a+ues
E3pected
9thylene D mol 88.8+ min
!ethane I 9thane ppm molAmol +-- ma: *- ma:
C( and 1eavier ppm molAmol $- ma:
)ther )le,ns ppm molAmol $- ma:
cetylene ppm molAmol + ma:
Propadiene ppm molAmol + ma:
1ydrogen ppm molAmol $- ma:
C) ppm molAmol -.% ma:
C)% ppm molAmol + ma:
):ygen ppm molAmol + ma:
=itrogen ppm molAmol +- ma:
=) ppm molAmol + ma:
mmonia ppm molAmol + ma:
Carbon ):ysulphide ppm molAmol -.-% ma:
'ulphur ppm wtAwt $ ma:
4ater ppm wtAwt $ ma:
!ethanol ppm molAmol + ma:
Chlorides ppm molAmol % ma:
cetone ppm molAmol % ma:
!ethylacetylene ppm molAmol + ma:
rsine ppm wtAwt -.-( ma:
Carbonyl ppm molAmol + ma:
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SP&'()('A*(+N +) P+,-M&. /.AD& P.+P-,&N& P.+DU'*%
Co-ponents Units "uaranteed 8a+ues
Propylene D mol 88.7 min
9thane ppm molAmol (- ma:
9thylene ppm molAmol $- ma:
Propane ppm molAmol "alance
C* and 1eavier ppm molAmol % ma: >as C*s@
cetylene ppm molAmol $ ma:
"utenes ppm molAmol % ma:
"utadiene ppm molAmol % ma:
!ethyl acetylene plus
Propadiene ppm molAmol $- ma:
1ydrogen ppm molAmol %- ma:
C) ppm molAmol -.-+ ma:
):ygen ppm molAmol % ma:
mmonia ppm wtAwt + ma:
Carbon ):ysulphide ppm molAmol -.-% ma:
)ther =on condensibles ppm molAmol (-- ma:
'ulphur ppm wtAwt $ ma:
4ater ppm wtAwt % ma:
!ethanol ppm molAmol + ma:
<reen )il ppm molAmol
rsine ppm wtAwt -.-( ma:
Phosphine ppm wtAwt -.-( ma:
Isopropanol ppm molAmol (+ ma:
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SPECI)ICATION O) $7DRO"EN PRODUCT!
1ydrogen D mol 88.8 min
C) ppm molAmol + ma:
mmonia ppm molAmol $ ma:
!ercury mgAm( $ ma:
):ygen ppm molAmol + ma:
Total 'ulphur ppm wtAwt -.+ ma:
4ater mgAm( + ma:
C1*s, C%13s 1%
rgon
"alance
cetylene ppm molAmol $- ma:
SPECI)ICATION O) /ET$ANE PRODUCT!
!ethane D mol 8+.- min
9thylene D mol $.- ma:
1ydrogen D mol (.- ma:
Carbon !ono:ide D mol $.- ma:
cetylene ppm
molAmol
+- >$@ ma:
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SPECI)ICATION O) C. STREA/S!
A( /i3ed C. Strea- 9:e;ore 0drogenation<!
9:pected Ealue
C(s and 2igher -.$+D wt ma:
C8s -.*D wt ma:
$, (B"utadiene +%D wt min and +3D wt ma:
=( $0drogenated C. Strea-
"utadiene $- ppm wt ma:
6imer >C7@ contentC +-- ppm ma:
Trimer ><reen )il@ contentC none
SPECI)ICATION O) C2 PRODUCT 9PARTIALL7
$7DRO"ENATED@C
Components .nits Ealues
6istillate ;esidue D wt $.+
C8s and lighter D mol "alance
C3s D mol $.%D ma:
"enGene D mol -.(D ma:
6iene value % ma:
Copper 'trip Corrosion $"
9:isting <um mgA$--ml after
heptane wash
* ma:
SP&'()('A*(+N +) 0-D.+/&NA*&D '6/'! 'U*%
Co-ponents Units 8a+ues
C8s D mol
C8sB%--
-
C D mol
C3BC7 "alance
Total 'ulphur ppm wt $.- ma:
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"romine number grA$-- gr -.$
Thiophene J'K ppm wt -.+ ma:
Copper 'trip Corrosion I
6iene Ealve =il
9:isting <um mgA$-- ml after
heptane wash
6istillate ;esidue D $.+ ma: >'T! 6B
3%@
):idation 'tability !inutes 83- min with +
ppm antio:idant
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SPECI)ICATION O) P7ROL7SIS )UEL OIL!
PARTICULARS UNITS
L)O $)O P)O
sphaltene D wt L-.% (-B+- $+B%-
;amsbottom
Carbon
D wt L-.+ %-B+- $-B$+>$@
sh D wt L-.-+ L-.-+ L-.-+
'ulfur D wt L-.-8 L-.-8 L-.-8
'odium ppm wt L$- L$- L$->%@
"!CI $%+ M$%+ M$%+
&lash Pt deg C 8-B$-- M$-- M$--
Pour Pt deg C L-.- M+-.- M$+.-
=)T9' C
$. Typical values are /uoted
%. "ased on no sodium being present in the plant feeds.
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PROCESS DESCRIPTION
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'(00 PROCESS DESCRIPTION!
This section contains a description of the process Now during
normal operation with the ;I2 O9:pansion CaseP &996'T)C#.
The description should be read in conQunction with process Now
diagrams -(%--$+B5+6B-$ to $-.
'(01 CRACKIN" )URNACES
total of $+ cracking furnaces are provided to achieve the
re/uired annual ethylene and propylene production.
Twelve of these furnaces, 1B$$- t- 1B$8- and 1B$8%, $8* and
$83, described as .'C >ultra selective conversion@ furnaces are
utilised to crack li/uid naphtha fresh feed and 1B$$- to 1B$8-
for =aphtha and <) both and the li/uid recycle streams
generated within the plant or from the aromatics unit i.e.
hydrogenated C*s, hydrogenated C+s and C3BC7 rafnate.
The remaining three furnaces, 1B$$$, 1B$%$ and 1B$($
described as .'C recycle furnaces are installed to crack
gaseous ethane and propane feedstocks which are recovered
and recycled from the recovery section. &our of the .'C
furnaces 1B$$-, $%-,$(- and $*-, can be utilised for ethane A
propane coBcracking with naphtha while one of the .'C recycle
furnaces is being decocked.
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The naphtha feedstock is stored in )'"2, tanks and pumped to
the battery limit at $-.+ kgAcm%g. 1ydrogenated C+Ks and C3B
C7 rafnate for recycle cracking can also be supplied from
)'"2 storage as C+BC75 ma: naphtha fresh feed line. The total
Now of C+BC7Ks blended into the =aphtha is regulated. The
naphtha li/uid blend is preheated by e:change with circulating
/uench water in the =aphtha feed 1eater, 9B-*$. 1ydrogenated
C*Ks for recycle cracking can be obtained from storage or
directly from the hydrogenation units. separate hydrogenated
C*Ks header is provided and the Now to each fresh feed furnace
can be independently controlled. The hydrogenated C*Ks are
blended with the =aphtha upstream of the furnace convection
section. The combined =aphtha li/uid blend is fed through the
.'C furnace convection section and partly vaporised. 6ilution
steam is added downstream to the hydrocarbon feed stream to
complete vaporisation. weight ratio of -.+ steam to
hydrocarbon is utilised.
The li/uid hydrocarbon feed is divided e/ually into si: streams
before being fed to the .'C furnace convection section. the
hydrocarbon fed is preheated by the furnace Nue gas in the ,fth
from bottom bank of the si:Bbank convection section.
'lightly superheated dilution steam form the 6ilution 'team
'tripper, CB%5-, overhead and from the au:iliary dilution steam
stripper, CB7- overhead is split into si: streams and fed to the
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dilution steam superheating coils located in the second from
bottom bank of convection section.
Three streams from each of the hydrocarbon and dilution steam
coils are combined into one and mi:ed in a sparger to complete
the vaporisation of hydrocarbon. There are two spargers per
furnace. )ne outlet is taken from each sparger and split into
three streams. The si: streams of hydrocarbon and dilution
steam mi:ture are further heated in the fourth and then ,rst
bank of the convection section. Three streams of heated
hydrocarbon and dilution steam mi:ture at the outlet of the
,rst bank are combined into one mi:ing ,tting. There are tow
mi:ing ,ttings per furnace. &our outlets are taken from each
mi:ing ,tting, and each outlet is split into eight radiant coils.
9ach radiant coil is ,tted with a critical Now venturi noGGle.
The boiler feed water from the 6eaerator is preheated in the
si:th >top@ bank of the .'C &urnace convection section and fed
to the steam drums, EB$$- to $8-, $8%, $8* and $83. The
saturated steam generated in .'R and T2R e:changers is
superheated in the third bank of the convection section.
The recycle ethane feed to the .'C ;ecycle &urnaces is
vaporised by heat e:change against demethaniGer feed, in 9B
*3$, and heated against propylene refrigerant, in 9B*$$, while
recycle propane feed is vaporised against circulating /uench
water in 9B+*%. The ethane and propane is mi:ed and further
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heated against circulating /uench water, in 9B-$$, before being
fed to the .'C recycle furnaces. 6ilution steam is added in a
weight ratio of -.( steamAhydrocarbon.
The ethane and propane mi:ed feed is split into four streams
before being fed to the .'C ;ecycle &urnace Convection
section. The mi:ed hydrocarbon feed is preheated by the
furnace Nue gas in the fourth >top@ bank of the fourBbank
convection section.
'lightly superheated steam from the dilution steam generator
is inQected into each hydrocarbon stream at the outlet of the
fourth bank. The four mi:ed streams are further heated in the
,rst >hottest@ bank of the convection section. Two streams of
the heated hydrocarbon and dilution steam mi:ture are
combined at the outlet of the ,rst bank into one mi:ing ,tting.
There are two mi:ing ,ttings per recycle furnace. Two outlets
are taken from each mi:ing ,tting, and each feeds a separate
radiant coil. 9ach radiant coil is ,tted with a critical Now venturi
=oGGle.
The boiler feedwater form the deaerator is preheated in the
third bank of the .'C ;ecycle &urnace convection section and
fed to the steam 6rums, EB$$$,$%$ and $($. The saturated
steam generated in .'R e:changers is superheated in the
second bank of the convection section.
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"oth types of furnaces are vertical radiant tube typeS the .'C
&urnace employs 3* O.P coils with inlet and outlet at the top of
the radiant bo:. The .'C recycle furnace employs four O!P
type radiant coils with inlet and outlet also at the top of the
radiant bo:.
The .'C &urnaces each have (% Noor ,red burners. The burners
are designed for gas ,ring only.
The .'C ;ecycle &urnaces have both wall and Noor burners.
"oth Noor and wall burners are gas ,red. There are $3 Noor
,red burners and (% wall burners per furnace.
The feedstocks are thermally cracked in the furnaces where
dilution steam to feed ratios and furnace efuent temperature
are carefully controlled to achieve the desired ole,n distribution
and yield. The furnace efuents are cooled rapidly by heat
e:change against boiler feed water in steam generating .'R
e:changers, 9B$$- to $8-, $8%,$8* and $83 B1 F TB0, and 9B
$$+A$%+A$(+ B6, and T2R 9:changers, 9B$$$ to $8$, $8(,$8+
and $85. ;apid /uenching of the furnace efuent is necessary
to prevent degradation of ole,ns into undesirable components.
The high pressure steam generated in .'R and T2R e:changers
is superheated in the convection section before being used,
mainly for compressor turbine drivers.
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'(0' USC )res ;eed and Rec0c+e )urnace >uenc
)ittings
The 0uench &ittings, UB$$- to $8- and UB$8%, $8* and $83, on
the .'C fresh feed furnaces and UB$$$A$%$ on the .'C ;ecycle
&urnaces are provided to reduce the temperature of the furnace
efuent before entering the /uench oil tower, CB%$- and 1eavy
&uel )il 'tripper, CB%(-, respectively. 1B$($ efuent enters CB
%$- board on material balm to re/uirement . The temperature
reduction, or /uenching, is achieved by contacting individual
furnace efuent streams with /uench oil in specially designed
,ttings.
'(0, >uenc Oi+ To?er
The 0uench )il Tower, CB%$- condenses the fuel oil
components and recovers higher level heat by cooling furnace
efuent from the discharge of the /uench ,ttings to
appro:imately $-(
-
C. It is divided into the following three
sections, each of which has a speci,c operating purpose
0uench )il Circulating 'ection
Pan )il Circulating 'ection
;ectifying 'ection
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CKR-PR-P-001
'(0,(1 >uenc Oi+ Circu+ating 9Scru::ing Section<
The efuents from the .'C &urnace and .'C ;ecycle &urnace
0uench &ittings Now to the 0uench )il Tower. The efuent from
all of the .'C 0uench &ittings and the new .'C ;ecycle
&urnace 0uench &itting, UB$($ are routed via the top section of
the 1eavy &uel )il 'tripper CB%(-.
The vapour and li/uid portions of the efuent stream are
separated in the bottom of the 0uench )il Tower and 1eavy
&uel )il 'tripper. The combined vapours rise through the
bottom section of the 0) tower contains four trays and a
distributor. The 0uench oil distributor is positioned below the
chimneys of the pan oil collection pan.
The 0uench )il Circulating Pumps, PB%$- A"AC, discharge
through the 0uench )il &ilters, UB%$- A"AC which remove any
coke particles, before heat is recovered from the oil. slip
stream of hot /uench oil is fed to the three .'C recycle furnace
0uench ,ttings to better control the outlet temperature from
the three 0uench ,ttings.
1eat is recovered from the /uench oil in the 6ilution 'team
<enerator A 0uench )il ;eboilers, 9B%5$ A1. The cooled
/uench oil then Nows to the all of the .'C &urnace 0uench
&ittings and the scrubbing section of the 0uench oil tower.
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CKR-PR-P-001
'(0,(' Pan Oi+ Circu+ation Section
The pan oil >P)@ circulating section of the 0uench )il Tower
condenses a portion fuel oil together with any vaporised
/uench oil and also cools the cracked gas. The circulating
section contains ten trays, the pan oil collector pan, and the
pan oil distributor.
Eapour, cracked gas, and steam enter the bottom of this
section through the chimneys in the pan oil collector pan. The
pan oil from the collector pan Nows to the Pan )il Circulating
Pump, PB%$$ A" from where it is pumped and circulated to
obtain heat recovery. portion of the uncooled pan oil is sent
to the distributor spray in the 0uench )il Tower scrubbing
section. nother uncooled portion of the pan oil is fed to the
light fuel oil stripper, CB%*- on Now control and the balance is
cooled in the pan oil user e:changers. The cooled pan oil is
reintroduced into the 0uench )il Tower pan oil circulating
section via the pan oil distributor.
'(0,(, Recti;0ing Section
2ight &uel )il components contained in the vapours entering
the rectifying section are condensed in this section to prevent
their transfer to the 04 tower and thereby maintain the end
point of the raw P?;)2?'I' gasoline. The re/uired fractionation
in this particular section is accomplished by using gasoline
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CKR-PR-P-001
reNu: from the base of the 0uench 4ater Tower, CB%%- on a
Now control. The light fuel oil components are collected on the
draw B oH tray and Now controlled to the light fuel oil stripper,
CB%*-. )verhead vapour from the stripper returns to the
rectifying section. The 0uench )il Tower overhead, at
appro:imately $-(
-
C, is sent to the 0uench 4ater Tower, CB
%%-.
'(0. $ea60 )ue+ Oi+ Stripper
The 1eavy &uel )il 'tripper, CB%(- strips the light ends from
the heavy &uel )il and returns to the 0uench )il Tower.
The stripping eHect is achieved by contacting /uench oil with
the .'C recycle furnaces vapour efuent in the 0uench &ittings,
UB$$$ and UB$%$, and passing the combined mi:ture into the
1eavy &uel )il 'tripper, CB%(-, where separation into vapour
and li/uid is achieved.
The separation of light and heavy ends in the 1eavy &uel )il
'tripper results in a return of light ends into the 0uench )il
Tower and buildBup of a large middle boiling range /uench oil
inventory as re/uired for circulation and optimum heat
recovery. The heavy fraction separated out in the 1eavy &uel
)il 'tripper bottom contains all the asphaltenes and tar which
are formed in the cracking operation.
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CKR-PR-P-001
The heavy fuel oil stripper bottoms li/uid is pumped by 1eavy
&uel )il Product Pumps, PB%(- A" to product blending, cooling
and delivery to plant battery limits.
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SECTION MODULE NO.
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CKR-PR-P-001
'(02 Ligt )ue+ Oi+ Stripper
The 2ight &uel )il 'tripper, CB%*- regulates the /uench oil
/uality and optimises the heat recovery in the 0uench )il
Tower.
The light &uel )il 'tripper is fed from two sources. The main
source is the draw oH tray in the /uench oil tower recti,cation
section, the second source is the recycle stream form the pan
oil circuit. 'tripping of the light components is eHected by
dilution steam inQection, which enters below the bottom tray.
The stripped vapour returns to the recti,cation section of the
0uench )il Tower. The light fuel oil product passes from the
bottoms to the 2ight &uel )il Product Pumps, PB%*- A", which
discharge it to the fuel oil blending, cooling and delivery
system.
'(04 >uenc *ater To?er
The cracked gas from the recti,cation section of the 0uench )il
Tower passes into the 0uench 4ater Tower, CB%%-. In this
tower, the gas is further cooled to *-.3
-
C, by direct contact with
circulating /uench water. 9Hective contact and cooling of the
gas with /uench water are attained by returning the circulating
/uench water through distributors in the tower middle and top
sections. &or this service, two packed beds are provided for
contacting the gas and /uench water.
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CKR-PR-P-001
The Now and distribution of /uench water into the middle and
top sections is regulated by Now controllers reset by the
temperature of middle section overhead and top section
overhead, respectively, to attain cooling of the cracked gas and
to provide a hot /uench water supply for process reboiling and
heating.
In this tower, dilution steam and the gasoline fraction of the
cracked gas are condensed. The condensed hydrocarbon and
water are separated in the bottom section, which contains a
series of chevronBtype plate bafes for the settling out of the
water and hydrocarbon phases. Part of the separated gasoline
is used as reNu: to the 0uench )il Tower and the balance feeds
the distillate 'tripper, CB%+-.
!ost of the hot water from the base of this tower is circulated
through various process heaters and reboilers before returning
to the /uench water tower, while the balance is fed to the
dilution steam generation system.
'(0@ Di+ution Stea- "eneration S0ste-
!ost of the dilution steam contained in the furnace efuent is
condensed in the 0uench 4ater Tower. The reuse of steam
condensate collected form both the condensation of dilution
steam in the 0uench 4ater Tower and in the cracked gas
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SECTION MODULE NO.
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CKR-PR-P-001
compression system minimises the demineraliGed water
makeup re/uirements and reduces the load on the waste water
efuent treatment system.
4ater is circulated by the 0uench 4ater Circulating Pumps, PB
%%- A"AC, to the dilution steam generation system. The water
is ,rst delivered to the water stripper feed ,lter, UB%3$ Ab,
which removes trace solids such s pipe scale and coke that
impair the eHectiveness of the downstream coalescer.
The ,ltered water enters the water stripper feed coalescer, EB
%3% A", where free hydrocarbon droplets are separated from
the water. These hydrocarbons are returned to the 0uench
4ater Tower from the top of the coalescer.
The water from the coalescer is heated by e:change against
dilution steam blowdown in the 6ilution 'team 'tripper
blowdown cooler A stripper feed heater, 9B%+8. The water then
passes through the water stripper feed heater, 9B%+7, where it
is heated against pan oil. It then enters the water stripper CB
%3-, where it is stripped of dissolved hydrocarbons, acid gases,
and ammonia. 'tripping steam is provided from the 6ilution
steam 'tripper overhead. The overhead vapours Now to the
/uench water tower.
The dilution steam stripper feed pumps, PB%3- A", deliver the
water stripper bottoms to the two dilution steam strippers. The
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CKR-PR-P-001
main portion of the process water is routed to the 6'' tower, CB
%5-, and enBroute is heated by e:change against (.+ kgAcm%g
level steam in 9B%38. The water then passes through the
6ilution 'team 'tripper &eed 1eater =o.$, 9B%37, where it is
heated against pan oil. The preheated condensate enters the
6ilution 'team 'tripper, CB%5-, above the top tray.
The 6'' tower, CB%5- bottoms are reboiled against /uench oil
in the 6ilution 'team 'tripper A 0uench )il ;eboiler, 9B%5$ A1,
and against $% kgAcm%g level steam in 6ilution 'team
'tripper A 'team ;eboiler, 9B%5- A6.
The remaining portion of the process water stream is routed to
the au:iliary 6'' tower, CB%7- and enBroute is preheated
against steam condenste in the au:iliary dilution steam stripper
feed heater, 9B%58. The preheated process water enters the
au:iliary 6ilution steam stripper CB%7- above the top tray. CB
%7-, bottoms are reboiled against $% kgAcm%g steam in the
au:iliary dilution steam stripper reboiler, 9B%7- AC.
!ost of the generated dilution steam Nows to the cracking
furnaces, where it is used for dilution of hydrocarbon feed,
decoking of furnace tubes, or operating a furnace on hot
standby without hydrocarbon feed. small portion is used for
stripping in the light fuel oil stripper and 2P 4ater 'tripper.
ppro:imately + percent of the steam produced is returned to
the 4ater 'tripper for use as stripping steam.
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SECTION MODULE NO.
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CKR-PR-P-001
2!P steam inQection into the dilution steam header maintains
sufcient superheat to avoid condensation in the piping to the
furnaces. 2!P steam can also be used directly to supplement
the dilution steam to the furnaces. The blowdown, the net
bottoms stream from CB%5-, is cooled ,rst in the 6ilution
'team <enerator "lowdown A 4ater 'tripper &eed 1eater, then
against cooling water in the 6ilution 'team <enerator
"lowdown Cooler, 9B%5(, before being discharged to the oily
water sewer. The blowdown from CB%7- is cooled against
cooling water before being discharged to the oily water sewer.
'(05 Disti++ate Stripper
The 6istillate 'tripper, CB%+-, debutaniGes the gasoline
collected in the bottom section of the 0uench 4ater Tower and
,rst three stages of cracked gas compression, before it is fed to
the gasoline hydrotreating unit.
<asoline from the 0uench 4ater Tower is fed to the stripper by
a slip stream from the /uench oil tower reNu: pump, PB%$$ A"
while the feed from the cracked gas second stage suction drum
is pumped by distillate stripper feed pump, PB%(- A".
C*Ks and light ends from the 6istillate stripper are returned to
the cracked gas compressor via the 0uench 4ater Tower.
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CKR-PR-P-001
The 6istillate 'tripper is reboiled by pan oil in the 6istillate
'tripper ;eboiler, 9B%+-. The gasoline product from the bottom
is pumped via the 6istillate 'tripper "ottoms Pump, PB%+- A".
!ost of the gasoline from this pump goes to the <1.. portion
is recycled back to the 0uench )il Tower to provide additional
reNu: inventory. The stream is sent to the 0uench )il Tower Pan
)il section >rather than to the top of the tower@ to ensure that
any heavy components are fractionated out.
'(0A >uenc *ater and Pan Oi+ circuits
0uench water is circulated to the following users from the
0uench 4ater tower, CB%%-, via the /uench water circulation
pumps, PB%%- AC, at a temperature of appro:. 7%
-
C C
9:changer =o. C 6escription
9B-$$ 9thane A Propane recycle heater
9B-*$ =aphtha feed heater
9B-+$ A" <) feed heater no.$
9B%$- &uel oil cooler
9B%$+ 0uench water steam heater
9B(*- 4eak caustic heater
9B(+8 Condensate stripper feed heater
9B(3- A" Condensate stripper reboiler
9B*$- 6emethaniGer prestripper reboiler
9B*(8 6emetahniGer prestripper bottoms heater
9B**- AC 6eethaniGer ;eboiler
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CKR-PR-P-001
9B+(- 'econdary deethaniGer reboiler
9B+(+ Tertiary deethaniser reboiler
9B+*- A6 Propylene tower au:iliary reboiler
9B+*% Propane recycle vaporiser
9B5($ 4ash oil condenser
Two of the e:changers, 9B5($ and 9B%$-, provide an additional
heat input to the /uench water and a third e:changer, 9B%$+,
utilises steam to adQust the /uench water temperature. The
remaining users accept the waster heat from the /uench water
system.
fter interchanging heat with the 04 users, all of the /uench
water is cooled in the primary /uench water cooler, 9B%%- Ag,
down to a temperature of +*.*
-
C. The bulk of this water is fed
to the lower packed section of the 04 tower. The remainder is
further cooled in the secondary /uench water cooler, 9B%(-
A1, down to a temperature of (5.7
-
C before being fed to the
upper packed section of the 04 tower.
Pan oil is circulated to the following users from the /uench oil
tower via pan oil circulation pumps, PB%$$ aA" CB
E3canger No( Description
9B%37 6ilution 'team 'tripper &eed 1eater =o.$
9B%+7 4ater 'tripper feed 1eater
9B%+- 6istillate 'tripper ;eboiler
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CKR-PR-P-001
9B+$- 6epropaniGer ;eboiler
The ,nal Pan )il temperature of $%$-C is controlled by
diverting pan oil Now to the pan oil trim cooler, 9B%$8, before
the pan oil is recirculated back to the middle section of the
/uench oil tower.
'(10 Co-pression#Acid "as Re-o6a+#De0dration
The water saturated hydrocarbon overhead form the /uench
water tower is fed to the cracked gas >C <@ ,rst stage suction
drum, EB($-. The C.<. ,rst stage condensate Pump, PB($- A",
discharges the li/uid transferred from drum EB(%- and any
slugs of li/uid carryover in the cracked gas back to the /uench
water tower. The vapour from this drum Nows to the ,rst stage
of the cracked gas compressor, "B(--.
4ash oil is inQected into the suction line of each compression
stage by the wash oil InQection Pump, PB(-- A". 4ash oil is
inQected to keep the impeller blade tip wet, thus preventing
polymer accumulation. The ,rst three stages of compression
are each followed by an aftercooler and a discharge drum used
to separate water A hydrocarbon condensate from vapour. 1eat
is reQected to cooling water in each aftercooler. The ,rst stage
aftercooler, 9B($-, efuent is combined with gasoline
hydrogenation unit vents in the %nd stage suction drum, EB(%-
before entering the %nd stage of compression. The condensate
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CKR-PR-P-001
stripper overhead Qoins the second stage aftercooler, 9B(%-,
into the (rd stage suction drum, EB((-.
The li/uid form the C.<. Third stage 6ischarge 6rum, EB((+, is
successively cascaded to the C<. Third stage suction drum and
then to C.<. second stage suction drum, which is designed to
separate the hydrocarbon condensate from the water. The
hydrocarbon condensate from the C< second stage suction
drum is sent to the 6istillate stripper, while the water is routed
to the C< $st stage suction drum. The oily water is pumped via
PB($- A" to the /uench 4ater Tower, CB%%-.
To prevent C.<. compressor surging, two minimum Now
bypasses are provided. The ,rst bypass protects the ,rst three
stages of compression, and the second bypass protects the
fourth stage.
The ,rst minimum Now bypass is provided form the third stage
discharge drum to the ,rst stage suction drum. The recycle
automatically protects the compressor by keeping the Now
above surge point during reduced capacity operation.
The third stage discharge gas is passed through a caustic wash
followed by a water wash in the caustic tower, CB(*-. The acid
free tower efuent is combined with the vents from the
ethylene recti,er and secondary demethaniser reNu: drums
and fed to the C < &ourth 'tage 6rum, EB(*-. The drum
CHECKED BY PAGE 3!
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SECTION MODULE NO.
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CKR-PR-P-001
overhead feeds the &ourth Compression 'tage. The discharge
efuent is cooled in the C < &ourth 'tage ftercooler, 9B(*+, by
cooling water and passed to the Cracked <as ;ecti,er, CB(+-,
which fractionates the heavy ends and reduces the gas Now to
the demethaniser system. ;eNu: for the recti,er is provided by
hydrocarbon condensed in the C < ;ecti,er )verhead
Condenser, 9B(++, using propylene refrigerant. The C <
;ecti,er ;eNu: 6rum, EB(*3, is designed to separate the
hydrocarbon condensate from water. The water from the C <
&ourth 'tage 'uction 6rum and C < ;ecti,er ;eNu: 6rum is
sent to the Third 'tage 'uction 6rum. "ottoms from the C <
;ecti,er are discharged to the &ourth 'tage 'uction 6rum.
The &ourth 'tage 'uction 6rum condensate is routed to the
Condensate 'tripper &eed Coalescer, EB(+8, for the removal of
free water. The water is collected in a boot and sent to the Third
'tage 'uction 6rum. The hydrocarbon stream is heated against
/uench water in the Condensate 'tripper &eed 1eater, 9B(+8,
to prevent hydrate formation and then fed to the Condensate
'tripper, CB(3-.
In the 'tripper, c%s and lighter are recovered overhead and
sent to the C. < . Third 'tage 'uction 6rum. The Condensate
'tripper "ottoms Pump, PB(3- A", delivers the remaining
hydrocarbons to the 6epropaniGer, CB+$-. 'tripping vapour is
produced by /uench water in the Condensate 'tripper ;eboiler,
9B(3- A".
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SECTION MODULE NO.
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CKR-PR-P-001
The second minimum Now bypass line, taken from the C.<.
;ecti,er overhead, is recycled to the C.<. &ourth 'tage 'uction
6rum. small stream taken from upstream of the C.<. &ourth
'tage ftercooler is used to heat this gas to avoid hydrate
formation across the kickBback minimum Now control valve. In
addition, a bypass stream to the third stage discharge is
provided to ensure ade/uate vapour loading on the ;ipple trays
of the Caustic Tower during reduced capacity operation.
'(10(1 Acid "as Re-o6a+
The caustic wash operation is installed to remove hydrogen
sulphide and carbon dio:ide from the cracked gas in order to
meet product /uality re/uirements on the ethylene and
propylene products. lso, the removal of these acid gases
protects downstream catalytic operations, since some acid gas
components are known to be catalyst poisons. cid gases are
also removed to avoid corrosion and the possible formation of
C)% ice within the cold process systems.
These acid gases, which are produced in the cracking furnaces,
are removed by scrubbing the gas from the C. <. third 'tage
6ischarge 6rum with circulating caustic solutions in the Caustic
Tower, CB(*-. The tower is divided into four sections. The three
bottom sections provide for caustic scrubbing of the cracked
gas. The bottom section uses weak caustic, the middle uses
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CKR-PR-P-001
medium caustic, and the top circulates strong caustic. The
fourth section, at the top of the tower, is the water wash
section, which prevents caustic carryover into the cracked gas
&ourth 'tage 'uction 6rum.
The acidic cracked gas enters the caustic tower below the
bottom section where it is contacted with weak caustic solution.
The weak caustic is circulated by the weak caustic circulating
pump, PB(*% A", then heated against /uench water in the
weak caustic 1eater, 9B(*-, prior to making contact with the
acidic cracked gas. This ensures that the cracked gas does not
fall below its dew point, which would cause hydrocarbon
condensation.
The cracked gas Nows upward, contacting the medium caustic,
and then the strong caustic solution. These streams are
recirculated by the !edium Caustic Circulating Pump, PB(*(
A", and strong caustic circulating Pump, PB(** A",
respectively.
'pent caustic solution is contained in the caustic tower bottoms
section, where by any hydrocarbon condensate A polymer oils
are separated out via an overNow weir into a separate holdBup
compartment. The spent caustic is mi:ed with aromatic
gasoline from the discharge line of the ;ecirculating <asoline
Pump, V(*5 A", via the spent caustic Aaromatic gasoline mi:er,
UB(*( and is then fed to the spent caustic deoiling drum, EB(*%.
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CKR-PR-P-001
'eparation of entrained oil from the spent caustic, and some
hydrocarbon degassing, is achieved in the deoiling drum. The
recovered li/uid hydrocarbons are discharged on level control
to /uench water tower. The drum pressure Noats on the C< %nd
stage suction 6rum pressure. The deoiled spent caustic is then
discharged to the spent caustic 6egassing 6rum, EB(*(, which
operates at neatBatmospheric pressure. The residual
hydrocarbon gas is Nashed to the Nare system, and the spent
caustic is ,nally pumped to the steam stripper, CB$$-$ via the
steam stripper feed preheater 9B$$-$.
In the steam stripper benGene and other entrained aromatics
are stripped with live 2P steam which is inQected below the
bottom tray. The overhead vapour from the tower is recycled
back to the 04 tower, via the water #.). 6rum, EB$$-%, which
collects any slugs of water that may be carried over. The
aromatics free spent caustic bottoms stream is pumped by the
steam stripper bottoms pump, PB$$-* A" to the spent caustic
o:idation unit for further treatment.
In the event that the steam stripper is out of commission the
raw spent caustic li/uor can be sent to the spent caustic
holding tank, TB$$-$ A", and subse/uently recycled to the
steam stripper utilising the spent caustic feed recycle pump, PB
$$-$ A".
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SECTION MODULE NO.
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CKR-PR-P-001
&resh caustic is delivered from oHsite as a %- wt. percent
solution to the concentrated caustic tank, TB(*-. !akeup
caustic is drawn from the tank by the concentrated caustic
pump, PB(*$ A", and charged to the caustic tower via the
caustic diluent mi:er, UB(*$, where it is mi:ed with spent wash
water to produce a $- percent caustic solution. The wash water
is supplied from the caustic tower wash water loop. The
consumption of caustic depends on the /uantity of C)% and
1%' in the feed to the tower and on the residual concentration
of =a)1 in the spent caustic solution.
The Caustic Pump, PB(*$ A", supplies the re/uired makeup
caustic to the Caustic Tower and is used for p1 control in the
dilution steam generation system.
The makeBup caustic to the caustic tower is combined with the
return circulating strong caustic, whereby the strong caustic
circulating pump provides mi:ing of the two streams. 9:cess
strong caustic overNows from the caustic strong section to the
medium section via an e:ternal downNow pipe on the strong
caustic chimney tray. In turn, the e:cess medium caustic
solution overNows to the weak caustic section via an internal
dowNow pipe on the medium caustic chimney tray.
!eans for aromatic gasoline >C3BC7 cut@ inQection is provided
into the top of each of the caustic scrubbing sections. InQection
of gasoline into the suction of the strong caustic circulating
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CKR-PR-P-001
pump is on a continuous basis. The aromatic gasoline acts as a
solvent for any polymers being accumulated on the trays and
passes down with the spent caustic to the 6eoiling 6rum, EB(*%
where it is separated and discharged to the 0uench 4ater
tower.
The neutralised cracked gas passes to the wash water section
where it is cooled by reQecting heat to the circulating wash
water stream. 6eaerated boiler feedwater is used as a makeup
supply to the wash water section. The wash water is circulated
by the wash water circulating pump, PB(*+ A", which directs
the water through the wash water cooler, 9B(*$, where it is
cooled against cooling water. The cooled wash water Nows to
the top tray of the Caustic Tower.
In the event of a cracked gas compressor shutdown, li/uid in
each section of the tower will fall from the ;ipple trays towards
the bottom of each section. &or the top section, the e:cess
wash water will accumulate in the wash water chimney tray.
The strong caustic chimney tray is capable of holding the
maQority of the dumping li/uid from the strong caustic section,
following the provision of a control valve provided on the
e:ternal downNow pipe to the medium caustic section which is
to close when the cracked gas compressor trips. The bottoms
compartment below the C < &eed noGGle provides e:cess li/uid
holding capacity for the e:cess strong caustic solution, and all
of the li/uid from the medium and weak caustic sections.
CHECKED BY PAGE 44
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CKR-PR-P-001
'(10(' C " De0dration
The cracked efuent from the overhead of the C < ;ecti,er
;eNu: 6rum is fed to one of two cracked gas dehydrators, EB
(5- A". These ,:edBbed dehydrators are each composed of a
main bed and a guard bed. "oth beds are ,lled with molecular
sieve. 4hile one dehydrator is operating the second is either
being reactivated or is in a standby position.
The desiccant in the main bed is designed for a %* hour
operating cycle at the end of bed life. The desiccant in the
guard section provides additional protection time before water
breakthrough. t the end of each cycle, the standby dehydrator
is put into service and the operating dehydrator is switched
over to reactivation.
;eactivation of the desiccant is accomplished with reactivation
gas >a methaneAhydrogen mi:ture@ by upward Now through the
beds. &resh reactivation gas is supplied from the 6emethaniGer
'ystem. It is ,rst heated against reactivation gas efuent in the
;eactivation <as &eed A 9fuent 9:changer, 9B(5$, and is then
further heated by 1P steam in the ;eactivation <as 1eater, 9B
(5%. The hot gas passes upward through the dehydrator,
heating the bed and desorbing the water from the molecular
CHECKED BY PAGE 45
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SECTION MODULE NO.
2

CKR-PR-P-001
sieve. The efuent passes to the ;eactivation <as &eedA9fuent
9:changer where heat is released to cooling water. The cooled
efuent enters the ;eactivation <as 'eparator, EB(5$, where
water and hydrocarbon li/uids, removed from the desiccant,
are separated from the reactivation gas. The gas is then
returned to the fuel gas system, and the oily water gas is then
returned to the fuel gas system and the oily water is discharged
to the 0uench 4ater Tower. The hot reactivated is discharged
to the 0uench 4ater Tower. The hot reactivated desiccant is
then cooled to the normal temperature with cold residue gas
which is cooled and chilled in the ;eactivation <as &eed Cooler,
9B(5(, and in the ;eactivation <as &eed Chiller, 9B(5*,
respectively.
'(11 De-etaniBer S0ste-
The 6emethaniGer system consists of two parallel feed chilling
trains and three stages of fractionation C the 6emethaniGer
Prestripper, CB*$-, the 6emethaniGer, CB*%-, and the ;esidue
<as ;ecti,er, CB*(-.
There are two parallel sets of precoolers. 9ach set consists of
three heat e:changers, through which the total cracked gas
feed from the dehydrators is cooled and partially condensed
prior to the ,rst li/uid fraction being separated in the
6emethaniGer Prestripper &eed 6rum, EB*$-, and the
6emethaniGer Prestripper Parallel &eed 6rum, EB*$*. The ,rst
CHECKED BY PAGE 46
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2

CKR-PR-P-001
parallel set of precoolers are the 6emethaniGer Precooler =o.$,
9B*-$, and 6emethaniGer Parallel Precooler =o.$, 9B*-5, which
useB3.5 C propylene refrigerant as coolant.
&urther cooling of the cracked gas occurs in the 6emethaniGer
"ottoms ;eheater, 9B*(7, and its parallel reheater, 9B*-7,
which utilise the 6emethaniGer net bottoms stream as coolant.
In 6emethaniGer Precooler =o.%, 9B*-%, and its parallel
precooler, 9B*-8, the cracked gas mi:ture is cooled by B%(.( C
propylene refrigerant. The li/uid condensed at this point
contains some methane and C%s and the maQor portion of the
C( and heavier componentsS it is separated from the vapour in
the 6emethaniGer Prestripper feed drum, EB*$-, and its parallel
drum, EB*$*. The li/uid streams from these drums are
combined and fed to the demethaniGer Prestripper, CB*$-, as
the bottom feed for removal of methane.
The vapour from the 6emethaniGer Prestripper &eed 6rum, EB
*$- is cooled and partially condensed in the 9thane ;ecycle
Eaporiser, 9B*3$, where recycle ethane from the 9thylene
'tripper bottoms is vaporised. The partially condensed stream
is further cooled by using B*-C propylene refrigerant in the
6emethaniGer precooler =o.(, 9B*-(. This partially condensed
stream is fed to the 6emethaniGer feed drum no. $, EB*$$, for
separation of the vapour A li/uid streams. The vapour from the
6emethaniGer Prestripper Parallel feed drum is also cooled by
usingB*-C propylene refrigerant in the 6emethaniGer Parallel
CHECKED BY PAGE 4
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CKR-PR-P-001
Precooler no.( This partially condensed stream is fed to the
demethaniGer parallel feed drum no.$, EB*$+ for separation of
the vapour A li/uid streams.
The li/uid streams from EB*$$ and EB*$+ contain methane and
C%s, along with much of the remaining C( and heavier
components. They are combined and fed to the 6emethaniGer
Prestripper as the top feed. The vapour phase from EB*$$ is
divided into two parallel streams, after which it is cooled further
and partially condensed. The larger portion of this vapour
stream is cooled by using the B+$.$C and B5(.( C levels of
ethylene refrigerant in the reminder is cooled by heat e:change
with residue gas in demethaniGer core e:changer no.%, 9B*$%.
"oth partially condensed streams are recombined and fed to
the demethaniGer feed drum no.%, EB*$%, where vapour and
li/uid streams re separated. The vapour phase from EB*$+ is
also cooled using two levels of ethylene refrigerant >B+$.$ C and
B5(.( C@ in the 6emethaniGer parallel precooler no.*, 9B*%%. The
partially condensed stream is then fed to demethaniGer parallel
feed drum no.%, EB*$3, where vapour and li/uid streams are
separated.
The li/uid streams from EB*$% and EB*$3 are combined and fed
to the 6emethaniser, CB*%-. The vapour streams from these
drums >mainly hydrogen, methane, and ethylene@ are further
cooled and partially condensed in an e:changer arrangement
identical to that of the previous stage, e:cept for the use of
CHECKED BY PAGE 4!
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SECTION MODULE NO.
2

CKR-PR-P-001
B$--.3 C ethylene refrigerant in the 6emethaniGer Precooler
=o.3, 9B*-3, and 6emethaniGer Parallel Precooler =o.3, 9B*%*,
respectively. The split stream from EB*$% is cooled by heat
e:change with residue gas in 6emethaniGer Core 9:changer
=o.(, 9B*$(. vapour A li/uid separation is repeated in the
6emethaniGer &eed 6rum =o.(, EB*$(, and 6emethaniGer
Parallel &eed 6rum =o.(, EB*$5. The li/uid streams, consisting
of ethylene , ethane, and methane, are combined and fed to
the 6emethaniGer, CB*%-. The vapour streams are combined
and cooled further and partially condensed in the
6emethaniGer core e:changer =o.*, 9B*$*, prior to being fed
into the ;esidue <as ;ecti,er, CB*(-, where the ethylene loss
to fuel is minimised.
The li/uid streams from the 6emethaniGer Prestripper &eed
6rum and 6emethaniGer Prestripper Parallel &eed 6rum, are
combined and fed to the 6emethaniGer Prestripper, CB*$-.
second feed to the Prestripper tower comes form the
6emethaniGer feed drum no.$ and the demethaniGer parallel
feed rum no.$ The prestripper is reboiled with /uench water in
the demethaniGer prestripper reboiler, 9B*$-. The stripper
bottoms product is essentially methane free with roughly one
third of the C% components and goes directly to the
deethaniGer, CB**-, bypassing the demethaniGer, CB*%-. The
prestripper overhead vapour is fed to the demethaniGer.
CHECKED BY PAGE 4"
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2

CKR-PR-P-001
The purpose of the demethaniGer is to make a sharp separation
between methane and ethylene. 9ach feed enters the tower at
diHerent tray locations to gain the ma:imum bene,t from the
preBfractionation produced by the fractional condensation. The
heat input for the 6emethaniGer ;eboiler, 9B*%-, is supplied by
condensing 5.% C propylene refrigerant vapour. The
demethaniGer condenser, 9B*%+, is cooled by evaporating
ethylene refrigerant at B$--.3C. The overhead product vapour
stream is heated as it passes through the 6emethaniGer core
e:changer no.( and is then directed to the !ethane 9:pander,
"B*%$.
The ;esidue <as ;ecti,er recovers the ethylene contained in
6emethaniGer &eed 6rum =o.(, and 6emethaniGer Parallel &eed
6rum =o.(. The li/uid from the bottom of the ;esidue <as
;ecti,er is returned to the top of the 6emethaniGer, CB*%-. The
;esidue gas overhead is partially condensed in the
6emethaniGer core e:changer no.+, 9B*$+, by gas which has
been chilled by e:pansion in the cryogenic e:pansion turbine.
The residue gas from the ;esidue gas recti,er reNu: drum, EB
*(3, is cooled an partially condensed through the 1ydrogen
core e:changer, 9B*$8. The partially condensed stream is fed to
the hydrogen drum EB*($, where 8+ percent hydrogen vapour
is separated from the li/uid. The ma:imum amount of 8+
percent hydrogen vapour is sent to the pressure swing
dsorption .nit, UB*--, for the production of e:tra high purity
hydrogen. The hydrogen vapour is heated through the
CHECKED BY PAGE 50
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SECTION MODULE NO.
2

CKR-PR-P-001
demethaniGer core e:changer no.$ through * and through the
hydrogen core e:changer.
The remainder of the 1ydrogen 6rum vapour and the 1ydrogen
6rum "ottoms >fuel gas@ are Nashed down to $.*+ kgAcm
%
g and
are reheated in the following multiBpass e:changers. 1ydrogen
core e:changer, 9B*$8, 6emethaniGer core e:changers =os. $
through +. The fuel gas and the purge gas from the P' unit
are then directed to the &uel <as Compressor, "B8--, at a
temperature of about (%
-
C.
The 6emethaniGer net overhead vapour stream is heated
through 6emethaniGer core e:changer no.( and is then sent to
the !ethane 9:pander, "B*%$. The e:pander outlet
temperature is such that the re/uired amount of cooling is
supplied to the overhead recti,er condenser. The e:pander
efuent, which is at low pressure, is reheated in demethaniGer
core e:changers nos. $ through +. The heated gas regn. goes to
the !ethane ;ecompressor, "B*%-. The compressor is driven by
the e:pander, usually, an integral construction. The gas leaves
the compressor at a pressure of +.3 kgAcm
%
g, sufcient for
regeneration re/uirements.
The 6emethaniGer bottoms product goes to the 6eethaniGer
after being heated by e:changer with cracked gas from
precooler no.$
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2

CKR-PR-P-001
The !ethane produce stream is obtained by removing a portion
of the li/uid from the 6emethaniGer, ;eNu: 6rum, EB*%3, and
vaporising in an air vaporiser, 9B*%5, to about + C. The vapour
is then allowed to warmBup to ambient temperature by heat
gain from the atmosphere in the pipeline before transfer to
)'"2M
'(1' PSA Unit
The P' unit, UB*--, provided by .)P, consists of a
prefabricated valve and piping skid, adsorber vessels,
molecular sieve type adsorbent control panel, instrumentation,
and a tail gas surge tank. The unit is designed to permit
outdoor unattended operation. It employs a pressure swing
adosrpiton >P'@ process to purify the 8+ mol percent hydrogen
stream supplied from the 6emethaniGer system.
The P' process uses a series of adsorbent beds to provide a
continuous and constant hydrogen product Now. The adsorbers
operate on an alternating cycle of adsorption and regeneration.
)ne adsorber is always in operation while the remaining are in
various stages of regeneration.
The unit produces a high purity hydrogen stream which ful,ls
the e:port product stream re/uirement, as well as the C%, C(,
CHECKED BY PAGE 52
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SECTION MODULE NO.
2

CKR-PR-P-001
C* and <asoline hydrogenation unit needs. The hydrogen
stream has a minimum composition of 88.8 mol percent
hydrogen. The balance of the feed gas is purged to the fuel gas
system. Constant hydrogen recovery can be maintained at Now
rates as low as oneBthird of the design feed Now rate.
'(1, DeetaniBer
The dual feed deethaniGer , CB**- separates the 6emethaniGer
and 6emethaniGer Prestripper bottoms streams into a C%
stream and a C( and heavier stream. The demethaniGer net
bottoms is heated in the 6emethaniGer bottoms reheater, 9B
*(7, and its parallel reheater, 9B*-7, before entering the tower
as the top feed. The 6emethaniGer Prestripper "ottoms
;eheater, 9B*(8 A", and is the lower feed to the tower.
The 6eethaniGer gross overhead, consisting primarily of C%Ks, is
partially condensed in the 6eethaniGer condenser, 9B**+, using
B%(.(
-
C propylene refrigerant. The vapourBli/uid mi:ture is
separated in the 6eethaniGer reNu: drum, EB**3. The li/uid is
returned to the tower as reNu: by the deethaniGer reNu: pump,
PB**+ A", and the net overhead vapour is directed to the c%
acetylene hydrogenation system.
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SECTION MODULE NO.
2

CKR-PR-P-001
The reboil heat to the tower is supplied by the deethaniGer
reboiler, 9B**- A", using /uench water. The deethaniGer net
bottoms stream, which is composed of C(Ks and heavier
components, is fed to the 6epropaniGer.
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2

CKR-PR-P-001
'(1. C' Acet0+ene $0drogenation S0ste-
cetylene >C%1%@ is produced in the cracking operation and as
an impurity must be removed from the deethaniGer overhead
stream by catalytic hydrogenation >Palladium based catalyst@,
so that the ethylene product contains less than % ppm of
acetylene. cetyleneWs are hydrogenated into ethylene and
ethane, which are subse/uently separated in the ethylene
fractionation system.
The acetylene is removed in a three step hydrogenation
process. Three identical adiabatic reactors are employed
working in series. The ,rst step is performed by the primary C%
hydrogenation reactor, ;B*+% A" which has its own spare. The
second and third steps are performed by the C% hydrogenation
reactors, ;B*+$ A"AC, which share a common spare.
The deethaniGer net overhead vapour leaving the deethaniGer
reNu: drum, EB**3, is fed to the hydrogenation system on Now
control. 1ydrogen from the P' unit is inQected, on ratio Now
control, before it enters the C% hydrogenation feed A efuent
e:changer, 9B*+% A6, and is steam heated by C%
hydrogenation feed heater, 9B*+-, where the inlet temperature
to the &I;'T reactor is made in the ,rst reactor. The reaction is
controlled by adQusting the reaction temperature and by
bleeding in raw hydrogen containing C) into the pure hydrogen
stream from the P' unit.
CHECKED BY PAGE 55
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2

CKR-PR-P-001
The efuent from the ,rst reactor passes through the C%
hydrogenation adiabatic reactor Intercooler =o.$, 9B*+7, where
the inlet temperature to the second reactor is controlled. split
range Now control system is provided such that part of the Now
may be byBpassed across 9B*+7 for better temperature control.
1ydrogen is inQected on ratio Now control, upstream of 9B*+7.
ppro:imately (+D of the conversion of the acetylene is made
in the second reactor. The reaction is controlled by adQusting
the reaction temperature and by bleeding in raw hydrogen
containing C) into the pure hydrogen stream from the P'
unit.
The efuent from the second reactor is cooled in the C%
1ydrogenation diabatic ;eactor Intercooler =o.%, 9B*++,
before passing to the third reactor. 1ydrogen is again inQected
on ratio control. In this reactor, the remaining acetylene is
removed so that the reactor efuent contains less than $.5 ppm
acetylene. The reaction is controlled by adQusting the reaction
temperature and by bleeding in raw hydrogen containing C)
into the pure hydrogen stream from the P' unit.
9fuent leaving the third reactor is waterBcooled in C%
hydrogenation diabatic ;eactor fterooler, 9B*+3 A", prior to
preheating the feed to the ,rst reactor in the C% hydrogenation
feed A efuent e:changer, 9B*+% A6.
CHECKED BY PAGE 56
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2

CKR-PR-P-001
The reactor beds are periodically regenerated using
regeneration gas supplied from the reactor treatment furnace,
1B5$-, in the gasoline hydrogenation .nit. The three reactors,
;B*+$ A"AC are rotated such that the newly regenerated bed
assumes the third reactor position.
The efuent from 9B*+% A6 passes to the C% hydrogenation
efuent separator, EB*++, where condensed polymers are
knocked out prior to the efuent being dried in the secondary
dehydrators, EB*+( A". fter drying, the efuent passes to the
9thylene recti,er, CB*5-. The secondary dehydrators are
supplied for removal of any water formed in the acetylene
hydrogenation reaction any polymers not removed in the C%
1ydrogenation efuent separator. 4hile one dehydrator is
operating, the second is either being reactivated or is in a
standby operation. ;eactivation of the desiccant is
accomplished by upward Now of reactivation gas through the
beds. The reactivation gas is supplied from the same system
employed by the cracked gas dehydrators, EB(5- A".
'(12 Et0+ene )ractionation
The C% acetylene hydrogenation system feeds the twoBtower
ethylene fractionation system. The feed stream consists
essentially of ethylene and ethane with trace /uantities of
methane, hydrogen and propylene. This system fractionates
the feed into an ethylene product stream and an ethane stream
for recycle cracking in the furnaces.
CHECKED BY PAGE 5
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SECTION MODULE NO.
2

CKR-PR-P-001
pasteurising section is located at the top of the ethylene
recti,er, CB*5-, above the ethylene product drawoH, to
separate any lights from the ethylene product. The recti,er
gross overhead is condensed against B*-
-
C propylene
refrigeration in the ethylene recti,er condenser, 9B*5+. The
condensed li/uid is collected in the ethylene ;ecti,er ;eNu:
6rum, EB*53, then pumped back to the top pasteurising tray by
the ethylene recti,er reNu: pump, PB*5+ A". vent is
recycled from the drum to the C. <. &ourth 'tage 'uction 6rum.
"elow the pasteurising section, the ethylene product is
withdrawn as li/uid and fed under its own pressure to the
intermediate storage spheres.
The option also e:ists to either send the ethylene product to
atmospheric storage via the ethylene product coolers no.$,% F
(, 9B*7-, 9B*7$, 9B*7% respectively, or to vaporise the ethylene
product and deliver it as a low pressure vapour to the battery
limits via the ethylene product vaporiser, 9B*55, and ethylene
product superheater, 9B*57 Ab.
=ormally, the ethylene li/uid will be imported from the
intermediate storage spheres after /uality control and either
fed as a low pressure li/uid to the ethylene product vaporiser,
9B*55, and ethylene product superheater, 9B*57 A" to produce
a low pressure vapour for e:port or fed as a high pressure li/uid
to the 1P ethylene product heater no.$, 9B*-, and 1P ethylene
CHECKED BY PAGE 5!
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SECTION MODULE NO.
2

CKR-PR-P-001
product no.%, 9B*8$, to produce a high pressure vapour for
e:port.
"oth ethylene fractionation towers are e/uipped with reboilers.
6esuperheated ethylene refrigeration compressor discharge
vapour is the reboiling medium for the ethylene recti,er
reboiler, 9B*5-. Propylene refrigerant vapour at 5.%
-
C is the
reboiling medium for the ethylene stripper reboiler, 9B*3-.
The ethylene stripper, CB*3-, net bottoms supplies the ethane
recycle. The ethane recycle is routed to the ethane recycle
vaporiser, 9B*3$, superheated in the demethaniGer core
e:changer no.$, 9B*$$, and then delivered to the .'C recycle
furnace as feed for cracking.
'(14 Depropaniser
The dualBfeed 6epropaniGer, CB+$-, is fed by the 6eethaniGer
bottoms and condensate stripper bottoms. Propylene, propane,
and any lighter components make up the tower overhead. This
stream is totally condensed by vaporising 8.*
-
C propylene
refrigerant in the 6epropaniGer condenser, 9B+$+. The
condensed li/uid is collected in the 6epropaniser ;eNu: 6rum,
EB+$3. The li/uid is pumped to the tower as reNu: by the
6epropaniGer ;eNu: pump, PB+$+ A". The net overhead stream
is pumped by the C( hydrogenation feed pump, PB+$3 Ab, to
the C( 1ydrogenation system.
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SECTION MODULE NO.
2

CKR-PR-P-001
The 6epropaniGer gross bottoms is reboiled against pan oil in
the 6epropaniGer ;eboiler, 9B+$- A". The net bottoms stream,
composed mainly of C*Ks and heavier components, is sent to
the 6ebutaniGer.
'(1@ C, $0drogenation S0ste-
The C( 1ydrogenation system, designed by Institut &rancais du
Petrole >I&P@ is a one stage, li/uidBphase catalytic process.
There are three installed reactors, ;B+($ A"AC. Two are
normally operated in parallel while the third is on standBby.
!ethyl acetylene >! and propadiene >P6@ in the 6epropaniGer
net overhead are selectively converted to propylene and
propane in the reactors.
The condensed 6epropaniGer net overhead is pumped into the
system by the C( 1ydrogenation &eed Pump, PB+$3 A". This
stream ,rst Nows through the C( hydrogenation feed coalescer,
EB+$8, which eliminates any free water. The coalescer outlet is
split into two parallel passes, one for each operational reactor.
9ach pass is diluted with li/uid C( recycled from the C(
hydrogenation recycle pump, PB+%- A", and then mi:ed with
makeBup hydrogen from the P' unit. The purpose of the li/uid
recycle is to control inlet concentration of !IP6 in the reactor
feed. This avoids e:cessive vaporisation in the reactors due to
the highly e:othermic reactions.
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2

CKR-PR-P-001
In the reactors, ! and P6 are selectively hydrogenated to
propylene, propylene hydrogenation to propane is minimised.
The heat of reaction induces partial vaporisation of the
hydrocarbon stream.
Purge to the C.<. &ourth 'uction 6rum@. 6uring normal
operation, the efuent is subBcooled and no oHBgas is purged.
The drum bottoms are pumped out by the C( hydrogenation
recycle pump, PB+%- A", and divided into two streams C li/uid
recycle for reactor feed dilution and the product which feeds
the secondary deethaniGer, CB+(-.
The spare reactor allows catalyst reduction, reactivation or
regeneration operations with the C( 1ydrogenation unit
running.
&or catalyst reduction or reactivation operations, hydrogen
makeBup gas is combined with fuel gas of the methane type to
achieve mi:ed stream hydrogen content of %+ molD.
lternately, nitrogen may be used instead of fuel gas. The
mi:ed stream is then preheated to the re/uired temperature in
the C( hydrogenation catalyst treatment e:changer, 9B+%%. The
oHBgas, which is similar to the inlet gas, is sent to Nare for
disposal.
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CKR-PR-P-001
The reactors are regenerated, as re/uired, by regeneration gas
supplied from the <1. ,rst 'tage ;eactor Treatment &urnace,
1B5$-. 'pent regeneration gas is returned to the <1. decoking
drum, EB5$(, for disposal. The composition of the spent gas is
similar to the fresh regeneration gas e:cept that it contains
small amount of light hydrocarbons at the beginning of reactor
sweeping and C)AC)
%
, during combustion steps.
'(15 Secondar0 and Tertiar0 DeetaniBer
'econdary and Tertiary 6eethaniGer,C +(- F CB+(+, towers in
series are designed to remove water and C% and lighter
hydrocarbons from the propylene A propane stream prior to C(
fractionation.
The li/uid efuent from the C( hydrogenation system is fed to
the secondary deethaniGer at tray number %%. The overhead
vapour stream is condensed against cooling water in the
secondary 6eethaniGer condenser, 9B+(+. &ollowing the
separation of water in the secondary 6eethaniGer reNu: drum,
EB+(3, the total hydrocarbon condensate phase is pumped back
to the top of the tower by the secondary deethaniGer reNu:
pump, PB+(+ A". =oncondensables in the secondary
deethaniGer overhead are normally vented to the cracked gas
fourth stage suction drum. ny condensed water is removed
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2

CKR-PR-P-001
from the boot of the reNu: drum and is sent to the oilyBwater
sewer.
The secondary deethaniGer reboiler, 9B+(-, is heated by /uench
water. The tower bottom stream Nows to the Tertiary
6eethaniGer, CB+(+ via the secondary deethaniGer bottoms
pump, PB+(- A".
The Tertiary 6eethaniGer, CB+(+, tower has been added to the
system in series with the secondary deethaniGer to
accommodate the increased e:pansion loads. It is designed to
further remove water and C% and lighter hydrocarbons from the
propylene A propane stream prior to C( fractionation to meet
the re/uired product speci,cations.
The 'econdary 6eethaniGer "ottoms Pump efuent is fed to the
Tertiary 6eethaniGer, CB+(+, at tray number %%. The overhead
vapour stream is condensed against cooling water in the
Tertiary 6eethaniGer Condenser, 9B+(5. &ollowing the
separation of water in the Tertiary 6eethaniGer ;eNu: 6rum, EB
+(5, the total hydrocarbon condensate phase is pumped back
to the top of the tower by the Tertiary deethaniGer reNu: pump,
PB+(5 A". =oncondensables in the Tertiary 6eethaniGer
overhead are vented to the cracked gas &ourth 'tage 'uction
6rum. ny condensed water is removed from the boot of the
;eNu: 6rum and is sent to the oilyBwater sewer.
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CKR-PR-P-001
The Tertiary 6eethaniGer ;eboiler, 9B+(3, is heated by /uench
water. The tower bottom stream Nows to the Propylene
'tripper, cB+*-, via the Tertiary 6eethaniGer "ottoms Pump, PB
+(3 A".
'(1A Prop0+ene )ractionation
The net bottoms stream from the secondary deethaniGer,
containing propylene, propane, plus trace amounts of ethane
and C*Ks , is fed to the propylene stripper, CB+*-. "ecause of
the large number of trays re/uired to make the separation, two
towers are provided for the propylene A propane fractionation C
the Propylene 'tripper, CB+*-, and the Propylene ;ecti,er, CB
++-. ;eboil heat I supplied to the bottom of the stripper by
circulating /uench water in the Propylene Tower ;eboilers, 9B
+*- A6 and if necessary by the Propylene Tower u:iliary
;eboilers, 9B+*$ A". The 'tripper bottoms stream consists of
propane recycle which is vaporised in the Propane ;ecycle
Eaporiser, 9B+*%, and is sent to the .'C ;ecycle &urnaces for
cracking. <reen oil formed in the C( hydrogenation reactor is
continuously drained from 9B+*% and is sent back to the %nd
stage suction drum EB(%-.
Eapour from the top of the stripper Nows to the bottom of the
propylene recti,er. 2i/uid from the bottom of the recti,er is
pumped back to the top of the stripper via the propylene
transfer pump, PB++- A". )verhead vapour from the recti,er is
condensed using cooling water in the propylene tower
CHECKED BY PAGE 64
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B. DAS AUTHOR BMK
SECTION MODULE NO.
2

CKR-PR-P-001
condenser, 9B+++ A1, and passes to the Propylene tower reNu:
drum, EB++3. Condensate from the reNu: drum is pumped to
the top of the recti,er as reNu: and to oHsite propylene storage
and uses by the propylene tower reNu: A product pump, PB+++
A". slip stream, located oH the propylene product stream
provides make up to the propylene refrigeration system, as
needed.
'('0 De:utaniBer
The 6epropaniGer bottoms stream is fed to the debutaniGer, CB
+3-. The tower gross overhead is condensed against cooling
water in the debutaniGer condenser, 9B+3+. The mi:ed C*Ks
stream is pumped by the 6ebutaniGer ;eNu: A Product Pump, PB
+3+ Ab, from the 6ebutaniGer reNu: drum EB+33, to the C*
hydrogenation unit A intermediate storage and back to the
tower as reNu:.
The 6ebutaniGer bottoms stream is reboiled against 22P steam
in the 6ebutaniGer ;eboiler, 9B+3- A". The tower net bottoms,
consisting of C+s and heavier, are sent to the <asoline
1ydrogenation .nit.
'('1 C. $0drogenation S0ste- C
The raw C* cut is routed to the feed surge drum, EB7-$ and
then pumped under Now control by the feed pump, PB7-$ A".
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SECTION MODULE NO.
2

CKR-PR-P-001
The vessel pressure is regulated at *.+ kgAcm
%
g by a split range
control which regulates the =% make up and release to Nare.
The Now rate of hydrogen make up is regulated by Now ratio
control with the C* feed. This Now ratio set point is calculated
in proportion to the butadiene content at reactor inlet
>feedIrecycle@.
The C* cut feed is mi:ed with li/uid recycle and hydrogen make
up gas and Now to the top of the reactor ;B7-$. The
hydrogenation reaction is e:othermic and a cooled recycle
stream is re/uired to be mi:ed with the C* feed and hydrogen
in order to prevent e:cessive temperatures within the catalyst
bed and in order to ensure a good hydraulic distribution
through the catalyst bed.
s the mi:ture Nows down through the catalyst bed of the
reactor ;B7-$, the temperature rises due to the e:othermic
reaction. The inlet temperature of the reactor ;B7-$ is
minimised >in order to prolong the active life of the catalyst@
consistent with achieving the re/uired conversion rate of
diole,nic hydrocarbons. s the catalyst activity reduces, during
the run life, the feed temperature is increased form about *(
-
C
at start of run >');@, to about 3-
-
C at end of run >9);@. The
reactor outlet temperature should not e:ceed $--
-
C in order to
prevent e:cessive damage to the catalyst. "elow *-
-
C the
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SECTION MODULE NO.
2

CKR-PR-P-001
reaction rate is not sufcient to achieve the re/uired
conversion, even with fresh catalyst.
'team preheating through the heater 9B7-$ is necessary during
startBup to reach the inlet ;B7-$ temperature.
The volume of the gaseous phase in the mi:ture reduces as
hydrogen reacts with the diole,nic hydrocarbons but some of
the C* hydrocarbons are vaporised as the temperature rises.
The two phase mi:ture leaving the reactor ;B7-$ Nows directly
to the 1ot 'eparator, EB7-%. Eapour from the 1ot 'eparator EB
7-% is cooled in the postBcondenser, 9B7-(. The condensate
which is formed, is separated in the postBcondenser drum, EB
7-(, and is recycled to the separator EB7-% after mi:ing with
reactor ;B7-$ efuent. &irst reaction section pressure is
controlled by purging EB7-( gas to the cracked gas compressor
suction.
The li/uid collected in the 1ot 'eparator is pumped by the
;ecycle Pump, PB7-% A" and cooled in the ;ecycle Cooler, 9B
7-%. !ost of the cooled li/uid represents the ;B7-$ recycle and
the other part represents the ,rst stage efuent. separate
bypass control around the cooler 9B7-% enables the regulation
of ;B7-$ inlet temperature.
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SECTION MODULE NO.
2

CKR-PR-P-001
second separate 9B7-% byBpass control enables the regulation
of the ;B7-% inlet temperature. This stream is sent under Now
control to the second stage hydrogenation reactor ;B7-%.
The 1% make up to the ,nishing reactor ;B7-% is delivered
under Now ratio control. the set point of this Now ratio is
calculated in proportion to the butadiene content at ;B7-% inlet.
;B7-% efuent is cooled down to *(
-
C through the product
cooler, 9B7-*, and Nashed into the c* product Nash drum, EB7-*
at fuel gas network pressure to eliminate potential remains of
hydrogen or other light components. the li/uid product is
pumped to battery limit under level control by the C* product
pump.
n identical unit called as au:ilary hydrogenation is installed to
operate in parallel to main unit for additional loads .
'('' Et0+ene Re;rigeration S0ste-
The 9thylene ;efrigerant Compressor, "B3--, is a three stage
single casing machine. The machine is designed to supply
ethylene refrigerant at B$--.3
-
C, and B+$.$
-
C, respectively. The
compressor is driven by a steam turbine.
The compressor third stage discharge vapour is desuperheated
by using cooling water in the 9thylene ;efrigerant
6esuperheater =o.$, 9B3*+, then by using 5.% C and B3.5 C
CHECKED BY PAGE 6!
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B. DAS AUTHOR BMK
SECTION MODULE NO.
2

CKR-PR-P-001
propylene refrigerant in the 9thylene ;efrigerant
6esuperheaters =o.%, 9B3*3, and no.(, 9B3*5, respectively. The
refrigerant vapour then Nows through the ethylene refrigerant
oil ,lter, GB3$- A", for removal of compressor lube or seal oil.
The takeoH for the minimum Now bypass line is downstream of
the ,lter. =ormally, the desuperheated vapour is condensed in
the ethylene recti,er reboiler, 9B*5- A". &or startBup and upset
conditions, the au:iliary ethylene refrigerant condenser, 9B3*8
condensing the desuperheated ethylene vapour as re/uired.
The condensed ethylene refrigerant Nows to the ethylene
refrigerant surge drum, EB3*+.
The li/uid from the surge drum is sub cooled using B*-.-
-
C
propylene refrigerant in a plate B ,n e:changer, the ethylene
refrigerant subcooler, 9B3+-. The subcooled li/uid Nows into the
ethylene refrigerant third stage suction drum, EB3(-, via a level
control valve. slip stream of the subcooled li/uid Nows to the
ethylene product cooler no.$ refrigerant Nash pot, EB*7- and
demethaniGer parallel precooler no.* Nash pot , EB*%%, which
service ethylene product cooler no.$, 9B*7- >normally not in
service@ and demethaniGer parallel precooler no.*, 9B*%%,
respectively@.
The third stage suction drum pressure is maintained by the
compressor, resulting in a refrigerant temperature of B+$.$
-
C.
This drum serves as a thermossyphon drum for demethaniGer
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B. DAS AUTHOR BMK
SECTION MODULE NO.
2

CKR-PR-P-001
precooler no.*, 9B*-*. The Nash vapour generated in this drum
Now to the third stage suction noGGle of the compressor.
portion of the B+$.$
-
C li/uid Nows into the ethylene product
cooler no.% refrigerant Nash pot, EB*7$, servicing the ethylene
product cooler no.%, 9B*7$ and demethaniGer parallel precooler
no.* Nash pot ", EB*%(, servicing the demethaniGer parallel
precooler no.*, 9B*%%". The balance of the li/uid from EB3(-, is
fed into the ethylene refrigerant second stage suction drum, EB
3%-, via a level control valve.
The second stage suction drum pressure is maintained at a
corresponding li/uid temperature of B5(.(
-
C. This drum serves
as a thermosyphon drum for 6emethaniGer Precooler =o.+, 9B
*-+. The vapour generated in this drum Nows to the second
stage suction noGGle of the compressor.
maQority of the B5(.(
-
C li/uid satis,es four parallel process
usersC the 6emethaniGer Precooler =o.3, 9B*-3S 9thylene
Product Cooler no.(, 9B*7%S 6emethaniGer Condenser, 9B*%+S
and 6emethaniGer Parallel precooler =o.3, 9B*%*. The ethylene
vapour out of the associated Nash pots of these users is sent to
the ethylene ;efrigerant ,rst stage suction drum, EB3$8, at
B$--.3
-
C.
The entire ,rst stage suction drum vapour is sent to the
ethylene refrigerant compressor.
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B. DAS AUTHOR BMK
SECTION MODULE NO.
2

CKR-PR-P-001
ny accumulation of oil or li/uid in the ,rst stage suction drum
Nows into the ethylene refrigerant drain drum, EB3*3. This drum
is e/uipped with a propylene refrigerant heating coil, receiving
propylene vapour upstream of propylene refrigerant condenser,
9B388 A1, TA#, and discharging condensed propylene li/uid to
the propylene refrigerant fourth stage Nash drum, EB38-. ny
ethylene refrigerant li/uid in the drain drum is evaporated,
allowing the oil to accumulate and be periodically drained from
the drum.
Three minimum Now bypasses are provided into the
compressor suction drums to maintain the compressor in a
stable Now regime.
'(', Prop0+ene Re;rigeration S0ste-
The Propylene ;efrigerant Compressor, "B3+-, is a four stage
single B casing machine, which is designed to supply propylene
refrigeration at B*-
-
C, B%(.(
-
C, B3.5
-
C and 5.%
-
C, respectively.
The compressor is driven by an e:traction condensing steam
turbine.
The compressor discharge vapour is desuperheated and
condensed in the water cooled propylene refrigerant condenser
, 9B388 A1, TA#.
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SECTION MODULE NO.
2

CKR-PR-P-001
The minimum Now bypass is taken upstream of the propylene
refrigerant condenser. s re/uired , this vapour goes to the
propylene refrigerant ,rst stage suction, second stage suction,
third stage Nash, and fourth stage Nash drums.
The condensed propylene from 9B388 A1, TA#, Nows into the
propylene refrigerant surge drum, EB38+. The drum pressure is
maintained by saturated compressor discharge vapour. This is
necessary to prevent Ostonewall operationP.
The li/uid propylene at *-.3
-
C Nows from the surge drum and
divides into three separate streams. The propylene is subcooled
in all three streams, acting as the heating medium for process
streams. These services are C
6emethaniGer core e:changer no.$, 9B*$$. The subcooled
propylene Nows to propylene refrigerant second stage suction
drum, EB35-.
9thylene product superheater, 9B*57 A". The subcooled
propylene Nows to propylene refrigerant third stage Nash drum,
EB37-.
1P ethylene product heater no.%, 9B*8$. The subcooled
propylene is divided into three parallel process services.
;eactivation gas feed chiller, 9B(5*, 6epropaniGer condenser,
9B+$+ and cracked gas recti,er overhead condenser, 9B(++. The
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B. DAS AUTHOR BMK
SECTION MODULE NO.
2

CKR-PR-P-001
vapour generated in these services and the balance of li/uid
propylene refrigerant each Now to the propylene refrigerant
fourth stage Nash drum, EB38-.
The &ourth 'tage Nash drum vapour is used as the heat source
in the ethylene stripper reboiler, 9B*3-, and demethaniGer
reboiler, 9B*%-. The condensed propylene Nows through the
respective seal pots and is Nashed into the propylene
refrigerant third stage Nash drum, EB37-.
The fourth stage Nash drum operates at 5.%
-
C. This drum
serves as a thermosyphon drum for ethylene refrigerant
desuperheater no.%, 9B3*3. 'ome of the li/uid is vaporised in
the demethaniGer precooler no.$, 9B*-$, and demethaniGer
parallel precooler no.$, 9B*-5. The balance of the li/uid is
Nashed directly to the third stage Nash drum, EB37-.
The third stage Nash drum vapour, is condensed in the ethylene
product vaporiser, 9B*55, and the 1P 9thylene product heater
no.$, 9B*8-. The propylene condensed in these e:changer is
collected in the respective seal pot, EB*55 and EB*8-, then
Nashed to the propylene refrigerant second stage suction drum,
EB35-.
The third stage Nash drum operates at B3.5
-
C. This drum serves
as a thermosyphon drum for the ethylene refrigerant
desuperheater =o.(, 9B3*5. The li/uid propylene from the drum
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B. DAS AUTHOR BMK
SECTION MODULE NO.
2

CKR-PR-P-001
supplies the following four servicesC u:iliary ethylene
refrigerant condenser, 9B3*8 A"S 6eethaniGer condenser, 9B
**+ A6S 6emethaniGer precooler =o.%, 9B*-%, and
6emethaniGer Parallel precooler no.%, 9B*-8. The vaporised
propylene is sent to the propylene refrigerant second stage
suction drum, EB35-. dditionally, the third stage Nash drum
li/uid is Nashed into the second stage drum.
ll of the vapour from the second stage suction drum, at
B%(.(
-
C, is routed to the compressor. 'ome of the li/uid
satis,ed three parallel process users C 6emethaniser parallel
precooler no.(, 9B*%$S 6emethaniGer Precooler no.(, 9B*-( and
ethylene refrigerant subcooler, 9B+3-. The propylene vapour
out of these services is sent to the propylene refrigerant ,rst
stage suction drum, EB33-. The balance of the li/uid is Nashed
into the ,rst stage suction drum to satisfy the ethylene recti,er
condenser, 9B*5+, re/uirement.
The ,rst stage suction drum serves as a thermosyphon drum
for the ethylene recti,er condenser. The entire ,rst stage
suction drum vapour is sent to the refrigerant compressor. ny
e:cess li/uid in the ,rst stage suction drum may be sent to the
22P steamBtraced propylene refrigerant drain drum, EB383. The
vapour from the drain drum is returned to the ,rst stage
suction drum.
'('. "aso+ine $0drogenation Unit
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SECTION MODULE NO.
2

CKR-PR-P-001
The <1. consists of two stages. This process provided by
Institut &rancais du Petrole >I&P@ produces a feedstock for
downstream aromatic recovery by selectively hydrogenating
the diole,ns in the ,rst stage and the ole,ns in the second
stage.
'('.(1 )irst stage reaction section
The raw pyrolysis gasoline, mi:ed with the recycled wash oil, is
fed to the feed surge drum, EB5-$ under slight pressure, after
being ,ltered through the UB5-% A" package. The ,ltration
facility is mostly useful when some of the feed comes from the
storage tanks. &ree water, if any, can be purged from EB5-$
boot.
The ,rst stage feed pump, PB5-$ A" raises the feed pressure
up to the reaction selection pressure. Part of the PB5-$
discharge can be routed to storage under EB5-$ level control.
1% make up supply is introduced at the &irst stage feed pump
discharge under pressure control. The pressure of both reaction
sections, 16$ and 16%, is controlled from the same point, at
the top of the %nd stage separator drum, CB5*-.
The fresh feed and 1% make up are mi:ed with cooled reactor
efuent to dilute the feed. The role of the dilution is to lower
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B. DAS AUTHOR BMK
SECTION MODULE NO.
2

CKR-PR-P-001
the feed reactivity and thus obtain a smooth control of
temperature elevation in ;B5$- A" ,rst catalyst bed.
The mi:ed stream is charged to the reactor after heating
through 9B5-$, reactor feed efuent heat e:changer. ;B5$- A"
reactor inlet temperature is controlled by byBpassing part of the
reactor efuent around 9B5-$. 6uring startBup periods, the
temperature is controlled by means of the steam preheater 9B
5-%.
The reactions >diole,ns and alkenyl aromatics hydrogenation@
occur in mi:ed phase >mainly li/uid@ in a ,:ed bed type reactor
;B5$- A". The catalyst is divided into two beds. The overall
temperature pro,le through the reactor is controlled by dilution
of feed, as mentioned above, and by the inQection of /uench
under temperature Now control cascade >TC at the inlet of
second bed@.
;eactor ;B5$8 efuent, partly cooled through 9B5-$, is Nashed
into the 1ot 'eparator, EB5$-. Part of the li/uids is recycled as
/uench and dilution via the &irst stage /uench pump, PB5$- A"
and &irst stage /uench cooler, 9B5$$. The remainder is sent
under level Now control cascade etc. the depentaniGer, CB5%-.
EB5$- vapour phase is cooled down through the hot 'eparator
Eapour Condenser , 9B5$% and Nashed into cold separator EB
5$$. EB5$$ li/uid is fed to CB5%- under level control.
CHECKED BY PAGE 6
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SECTION MODULE NO.
2

CKR-PR-P-001
EB5$$ vapour feeds the second stage reaction section as
hydrogen rich makeBup.
6ecoking drum EB5$( collects the regeneration efuents of ,rst
and second stage reaction section, as well as C( and C*
hydrogenation units.
DepentaniserC
The ,rst purpose of the depentaniGer CB5%- is to stabilise the
,rst reactor product by eliminating the light components which
have been dissolved under high pressure in EB5$- and EB5$$.
The second purpose is to split the C+ cut from the C3I cut.
'tabilisation is performed in the uppermost trays. The overhead
vapours of CB5%- are condensed in the depentaniGer
condenser, 9B5%+ and the li/uid collected in reNu: drum, EB5%3.
;eNu: drum EB5%3 vapour phase is purged to Nare or to cracked
gas compressor under pressure control.
The EB5%3 li/uid is pumped by the depentaniGer reNu: pump, PB
5%+ A", as e:ternal reNu: under Now control reset by level
control.
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SECTION MODULE NO.
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CKR-PR-P-001
The C+ cut is withdrawn in li/uid phase under temperature Now
cascade control, and sent to battery limit after being water
cooled through the C+ product cooler, 9B5%3.
The depentaniGer reboiling is performed by the thermosyphon
reboiler 9B5%-. C3 I Cut is fed to the deoctaniGer, CB5(-, under
Now control reset by CB5%- bottom level control.
Deoctoniser!
The purpose of the 6eoctaniGer, CB5(- is to split the C3I cut
into C3BC7 cut and C8I cut, and also to withdraw a C8B%--
-
C
wash oil cut.
CB5(- is operated under slight vacuum in order to limit the
bottom temperature to $5+
-
c and to allow the reboiling with
saturated 2!P steam. Eacuum is maintained by means of
steam eQector UB5(3. The pressure is controlled at the top of CB
5(- by recycling !P steam at UB5(3 outlet into the eQector
together with the non condensable components issued from the
column through post condenser, 9B5(3.
The overhead vapours of CB5(- are condensed in the
deoctaniGer condenser, 9B5(+, and the li/uid is collected in
reNu: drum, EB5(3.
The 6eoctaniGer ;eNu: Pump, PB5(+ A", sends the e:ternal
reNu: to the column under Now control. The distillate feeds the
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SECTION MODULE NO.
2

CKR-PR-P-001
second stage reaction section via the %nd stage feed pump, PB
5(3 A", under Now control, reset by EB5(3 level control.
The 6eoctaniGer reboiling is performed by the thermosyphon
reboiler, 9B5(- A" which is controlled by temperature control
of the bottom section of the tower.
C8I cut is sent to battery limit via the deoctaniGer feed pump,
PB5(- A" and water cooler, 9B5(%.
The wash oil is withdrawn as a vapour phase ( trays above the
bottom of the column. It is condensed in water cooler, 9B5($,
and collected in the wash oil holding drum, EB5($. It is sent to
the battery limit via the wash oil transfer pump, PB5($ A" and
wash oil trim cooler, 9B5(5, under Now control.
'('.(, Second Stage Reaction Section
The feed to second stage reaction section is pumped via the
%nd stage feed pump, PB5(3 A" under Now control reset by EB
5(3 level control. &luctuation in EB5(3 level can also be
smoothed by the option of sending feed to storage.
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SECTION MODULE NO.
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CKR-PR-P-001
The feed is mi:ed with recycle and make up gas at the
compressor "B5*- A" discharge, before being heated up
through 9B5*- A"ACA6A9 feed efuent e:changer and feed
heater 1B5*-. The second stage reactor inlet temperature is
controlled by the furnace 1B5*-.
The reactions >hydrogenation of ole,ns and desulfuriGation@
occur in vapour phase on a ,:ed bed type reactor ;B5*- ,lled
with two types of catalysts C
26 $*+ C mainly hydrogenation
1;(-3C C mainly desulfurisation.
The temperature pro,le through the reactor is kept under
control by the inQection of /uench between the two catalyst
beds regulated by temperature control of the second bed.
The efuent of ;B5*- is Nashed in the second stage separator,
EB5*-, after consecutive cooling in 9B5*- A"ACA6A9 and 9B5*$
water cooler.
EB5*- vapour phase is partly released to Nare or to cracked gas
compressor under Now control. The overall pressure control is
ensured from EB5*- by action on 1% makeBup to the ,rst
reaction section. "oth reaction section pressures are controlled
through this pressure control.
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SECTION MODULE NO.
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CKR-PR-P-001
The remaining vapour phase is recycled to the %nd stage #.).
drum, EB5*$, where it is mi:ed with ,rst stage cold separator,
EB5$$, vapour, which is the h% rich make up to the second
stage reaction section.
"oth gases are sent under Now control back to the %nd stage
reaction section via the recycle and make up compressor, "B
5*- A".
The EB5*- net li/uid phase is fed to stripper section under level
Now cascade control, while some li/uid is recycled as /uench to
the reaction section via the %nd stage /uench pump, PB5*- A".
'('.(. Stripper Section
The purpose of the stripper, CB5+-, is to eliminate 1%' and light
components dissolved at high pressure in the C3BC7 cut.
"efore being fed to the stripper, the C3BC7 cut is heated up
against stripper bottom product through the feed A efuent
e:changer, 9B5*8 A".
The stripper overhead vapours are partially condensed in the
stripper Condenser, 9B5++ and collected in reNu: drum EB5+3.
The reNu: is returned to the column by the reNu: pump, PB5++
A", under Now control reset by EB5+3 level control.
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SECTION MODULE NO.
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CKR-PR-P-001
EB5+3 vapour phase is purged to Nare or to the cracked gas
compressor under column overhead pressure control.
The stripper reboiling is performed by the thermosyphon
reboiler, 9B5+-, using 2!P steam.
The bottom product is pumped under level control to battery
limit by the C3BC7 product pump, PB5+- A" through the feed A
efuent e:changer, 9B5*8 A" and water cooler 9B5+$.
the pump, PB5+% is provided for the inQection of corrosion
inhibitor into the stripper overhead.
The &irst stage reactor treatment furnace, 1B5$- is provided to
service the &irst stage reactor ;B5$- A", and the C%, C( and C*
reactors during catalyst treatments.
The purpose of the spent caustic o:idation unit is to o:idise the
sodium sulphide in the spent caustic as completely as
practicable to harmless sodium sulphate, to cool the resulting
efuent, and sent it to the efuent treatment plant.
'pent caustic is gasoline washed, deBoiled, stripped with steam,
cooled and sent to the 'C) feed surge drum, EB$$%$, which is
nitrogenBblanketed and vented to the wet Nare system.
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SECTION MODULE NO.
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CKR-PR-P-001
lternatively, the spent caustic feed is pumped from holding
tank TB$$-$ A" by PB$$-$ A", and sent to EB$$%$.
'pent caustic from EB$$%$ is pumped by reactor feed pump PB
$$%$ A" on Now control through feed A vent gas e:changer 9B
$$%% A", where it is heated on temperature control. The
heated spent caustic is sent to the bottom of ;B$$%%, the ,rst
reactor in a series of three.
The three reactors are fed with air from reactor feed air
compressor "B$$%$ A"AC, by way of air surge drum EB$$%(.
The air is sent under pressure control through feed air ,lter UB
$$%$ A"AC to two Now controllers on each reactor, supplying a
special distributor at the bottom of each reaction Gone. 9ach
distributor is also fed with desuperheated steam on Now
control.
9ach reactor operates nearly full of li/uid at $(-
-
C, and is
divided into two Gones by a valve tray. The spent caustic Nows
slowly upward in contact with a stream of ,ne air bubbles.
The reactor pressures are individually controlled to allow the
Now of spent caustic through each reactor, under level control.
)n the spent caustic stream from each reactor, a ,lter UB$$%(
A"AC is provided for removal of possible agglomerated
polymer.
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SECTION MODULE NO.
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CKR-PR-P-001
The residence time in each reactor is appro:imately * hours at
the ma:imum design rate.
The high reactor temperatures re/uired for good o:idation are
maintained by adQustment of the steam inQection rates. The
sulphide content is highest in ;B$$%%, which therefore re/uires
more air than the other reactors. 1eat from the o:idation
reactions is also highest in ;B$$%%, causing its steam inQection
rate to be the lowest.
):idised spent caustic from ;B$$%%C is ,ltered in UB$$%(C,
cooled in 9B$$%$ A", and released on level control to efuent
surge drum EB$$%%.
The vent gases from the reactors are released by their pressure
controls, and combined before Nowing through feed A vent gas
e:changer 9B$$%%A" and vent gas cooler 9B$$%(A" to EB$$%%.
Eent gas from EB$$%% is released on pressure control to
atmosphere at *-
-
C. It consists mainly of nitrogen and o:ygen,
with a small amount of water vapour. The o:idised spent
caustic from EB$$%% at *-
-
C is pumped by the efuent transfer
pump PB$$%% Ab on level control to the TB$$-$ product tank.
This spent caustic is further neutralised in CP. pit to p1 of 5.-
and pumped to efuent treatment plant.
CHECKED BY PAGE !4
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
UTILITIES
CHECKED BY PAGE !5
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
,(1 Coo+ing *ater S0ste-
The cooling water in supplied by a dedicated cooling water
tower at )'"2. The cooling water /uality supplied has the
following speci,cations C
p1 C 5.% to 5.7
Total 6issolved 'olids !a:. %+-- ppm as caco(.
Chlorides !a:. %-- ppm as cl.
'ilica !a:. $-- ppm as '$)%
&ree chlorine !a:. -.+ ppm
Turbidty !a:. $+ =TE
Total viable count !a:. -.( million colonies per ml.
Total hardness as Caco( +-- ma:.
-.P-* 3.+B8.- ppm
TBP)* 8B$*
Total &C (.- ma:.
Uinc as Un %.- ma:.
Corrosion monitoring system is provided at I'"2 at the inlet of
9B%(- e:changers.
Cooling water supply temperature is (*
-
C. In order to keep the
circumstances to an optimum low /uantity. a two level system
with some cooling services operating at an intermediate inlet
temperature of (8
-
C which is known as cooling water tempered
CHECKED BY PAGE !6
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
>C4T@. The ma:imum temperature rise through the entire
circuit is 8
-
C. The typical return temperature will be *(
-
C.
The cooling water supply pressure is +.- kgAcm%g with a return
pressure of %.+ kgAcm%g
The cooling tower contains $3 cells and 7 main pumps and two
stand by pumps which supply into the common C4' header of
+*P siGe. lso one more %-P parallel supply header
complements the cooling water supply to tertiary deethaniGer.
u:iliary C* hydrogenation and propylene fractionation
overhead condensers.
Total of +*--- m(Ahr cooling water supply re/uirement is met
by light pumps running continuously. The preselected three
standby pumps cut in on auto In case of drop in header
pressure to *.3 kg A cm%g.
There are Qumpover from C4 supply to C4 tempered and C4
supply to C4 return to balance the header re/uirements.
1owever, these Qump over valves are used only during startBup
and remained closed during normal plant running.
part from cooling water supply is provided to decoke pot
scrubbing , furnace decoke header inQection and pump seal A
hearing house cooling which are routed to )4' system. This is
provided to convert water by reducing service water
CHECKED BY PAGE !
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
re/uirement and accomplishing cooling tower blowdown which
otherwise it essential at holding tower to maintain circulating
water /uality.
CHECKED BY PAGE !!
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B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
Coo+ing *ater =a+ance
Coo+ing *ater
User
C*S $eader )+o? 9Cg#< C*T $eader )+o?
9Cg#<
C*R $eader )+o?
9Cg#<
In Out
9B(%- BC $.$+(.((* $.$+(.((*
9B((- BC $.$$8.58$ $.$$8.58$
9B(*+ B6 $.%$(.(%+ $.%$(.(%+
B$-$ =ote $ $+8,$%- $+8,$%-
"B*%-A*%$ %%,+88 %%,+88
"T<B8-- $-%,-3- $-%,-3-
9B8-- $35,8-5 $35,8-5
9B88- A" %+,8+5 %+,8+5
9B3*+ $38,$7- $38,$7-
"T<B3-- 3$,38- 3$,38-
9B83- (,58-,$%8 (,58-,$%8
9B87- $*5,3+* $*5,3+*
"T<B3+- $-%,-3- $-%,-3-
"B83+ $-,3((,7-% $-,3((,7-%
"T<B(-- 8%,877 8%,877
9B8(- $-,3((,7-% $-,3((,7-%
9B87$ $%+,+%7 $%+,+%7
9B87% (+,*+3 (+,*+3
9B388 B# $$,+3%,%%+ $$,+3%,%%+
9B+++ B1 7,33%,--- 7,33%,---
9B++3 $-,+-- $-,+--
9B+3+ 873,7-- 873,7--
9B5%+ 73*,+-- 73*,+--
9B5(3 *,--- *,---
9B5(5 7%,+-- 7%,+--
9B5(7 >=ote $@ 3(.3*7 3(,3*7
9B5+$ $+*,((( $+*,(((
9B5++ 3(,$35 3(,$35
9B8$- %%7,--- %%7,---
9B8%- *(3,8%3 *(3,8%3
9B5(+ $,875,*-- $,875,*--
9B%5( *3,--- *3,---
"B*+7 $,-((,3-- $,-((,3--
9B*++ $,-8-,3-- $,-8-,3--
9B*+3 A" $,$%-,%-- $,$%-,%--
9B+%$ **8,57( **8,57(
9B+(+ 3+-,--- 3+-,---
9B+33 +$(,*-- +$(,*--
9B5$$ +-5,335 +-5,335
9B5$% $(,--- $(,---
9B5%3 (-,335 (-,335
9B5(% 33,+-- 33,+--
9B5*$ *%-,((( *%-,(((
9B5*% +,--- +,---
9B7-% $,-%%,7%* $,-%%,7%*
9B7-( 3,3-- 3,3--
9B7-* 8*,83* 8*,83*
9B%(- B# *,$87,--- *,$87,---
9B(5( $%%,83- $%%,83-
9B%%- B< 7,*(3,5+- 7,*(3,5+-
9B(5+ (++,%$% (++,%$%
<B$--- >=)T9 $@ 35%,--- 35%,---
9B$$-% A" $55,--- $55,---
9B8%$ >=)T9 $@ %3(,+*( %3(,+*(
9B(*$ (++,%$% (++,%$%
PB8-- BC ((,3+* ((,3+*
CHECKED BY PAGE !"
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
PB8-$ A" 5$3 5$3
PB878 A" 5$3 5$3
9B($- B& $,38(,53( $,38(,53(
9B%5* (5,5-- (5,5--
9B+(5 5*5,+-- 5*5,+--
'." T)T2 *+,%%+,$%* (8,7+-,5-+ ((,7-(,$%$ (8,$55,+*-
"?P'' 3,-*5,+7* 3,-*5,+7*
T)T2 *+,%%+,$%* (8,7+-,5-+ (8,7+-,5-+ *+,%%+,$%*
CHECKED BY PAGE "0
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
Coo+ing *ater =a+ance )or @00 KTA E3pansion Case
ALL )LO*S ARE )RO/ LATEST ISSUE O) PROCESS DATA S$EETS D ,1 AU"(A.
9DESI"N )LO* i(e(NOR/AL OP"E DESI"N /AR"IN< PLUS A8AILA=LE 8ENDOR
DATA
Coo+ing *ater
User
C*S $eader )+o? 9Cg#< C*T $eader )+o?
9Cg#<
C*R $eader )+o?
9Cg#<
In Out
9B(%- BC $,%8$,(75 $,%8$,(75
9B((- BC $,%$8,%-( $,%$8,%-(
9B(*+ B6 $,((*,-35 $,((*,-35
B$-$ =ote $ $+8,$%- $+8,$%-
"B*%-A*%$ %%,+88 %%,+88
"T<B8-- $-%,-3- $-%,-3-
9B8-- $35,8-5 $35,8-5
9B88- A" %+,(5* %+,(5*
9B3*+ %-(,8(* %-(,8(*
"T<B3-- 3$,38- 3$,38-
9B83- (,58-,$%8 (,58-,$%8
9B87- $*5,3+* $*5,3+*
"T<B3+- $-%,-3- $-%,-3-
"B83+ $-,3((,7-% $-,3((,7-%
"T<B(-- 8%,877 8%,877
9B8(- $-,3((,7-% $-,3((,7-%
9B87$ $%+,+%7 $%+,+%7
9B87% (+,*+3 (+,*+3
9B388 B# $(,%5(,3%8 $(,%5(,3%8
9B+++ B1 8,83$,(-- 8,83$,(--
9B++3 $$,++- $$,++-
9B+3+ $,-7+,*7- $,-7+,*7-
9B5%+ $,-(5,*-- $,-(5,*--
9B5(3 *,*-- *,*--
9B5(5 8-,5+- 8-,5+-
9B5(7 >=ote $@ 3(,3*7 3(,3*7
9B5+$ $38,533 $38,533
9B5++ 5+,((* 5+,((*
9B8$- %%7,--- %%7,---
9B8%- *7-,3$8 *7-,3$8
9B5(+ %,%%+,777 %,%%+,777
9B%5( 7($,%33 7($,%33
9B*+7 $,$(3,83- $,$(3,83-
9B*++ $,$88,33- $,$88,33-
9B*+3 A" $,%(%,%%- $,%(%,%%-
9B+%$ *8*,53$ *8*,53$
9B+(+ 5*5,+-- 5*5,+--
9B+33 +3*,5*- +3*,5*-
9B5$$ 3-8,%-- 3-8,%--
9B5$% $*,(-- $*,(--
9B5%3 ((,5(* ((,5(*
9B5(% 5(,$+- 5(,$+-
9B5*$ *75,+73 *75,+73
9B5*% +,--- +,---
9B7-% $,%57,+(- $,%57,+(-
9B7-( $(,%-- $(,%--
9B7-* $(%,--- $(%,---
9B%(- B# *,$87,--- *,$87,---
9B(5( $*5,++% $*5,++%
9B%%- B< $-,3-%,--- $-,3-%,---
9B(5+ +73,$-- +73,$--
<B$--- >=)T9 $@ 35%,--- 35%,---
9B$$-% A" $55,--- $55,---
CHECKED BY PAGE "1
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
9B8%$ >=)T9 $@ %3(,+*( %3(,+*(
9B(*$ +3+,$37 +3+,$37
PB8-- BC ((,3+* ((,3+*
PB8-$ A" 5$3 5$3
PB878 A" 5$3 5$3
9B($- B& $,7(3,**% $,7(3,**%
9B%5* *$,*5- *$,*5-
9B+(5 5*5,+-- 5*5,+--
'." T)T2 +$,3$(,7%$ *+,5(7,+$3 (+,837,(5$ *$,7*(,353
"?P'' 8,55-,$*3 8,55-,$*3
T)T2 +$,3$(,7%$ *+,5(7,+$3 *+,5(7,+$3 +$,3$(,7%$
Notes ! 1( Coo+ing *ater Fo?s ;or E-@,5% "-1000% A-101 1 E-A'1 are :ased
on Re+iance data(
'( De+eted
,( Coo+ing *ater Fo?s to ana+0sers% ana+0ser ouse and pu-p pedesta+s
are not inc+uded 9-ini-a+% t0pica++0 1-4 +itres#-in<(
CHECKED BY PAGE "2
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
,(' Stea- S0ste-
The steam system is based on well established principles
developed by 'F4. The following sections shall be read with
reference to .tility Now diagram enclosed C
,('(1 Stea- Le6e+s
&ive steam levels are employed with the I'"2.
Pressure Cg#c-'g Te-perature
0
C
Stea-
Le6e+
Nor-a
+
/in /a3( Nor-a
+
/in( /a3(
'1P 'team $-+ $-% $-5 +$- *7- +$-
-
C
1P 'team *- (7 *% (5( (3- *--
!P 'team $5 $+ $7 %++ %(+ %7
2!P 'team $% $$.+ $( %3- %*- %5-
22P 'team (.+ (.- *.+ $75 $3+
S$P Stea- 9S$<
'1P 'team is generated in the main and cracking recycle
furnaces is utilised for driving C< Compressor and propylene
refrigeration compressor, along with import steam from )'"2.
'1P 1eader Noat with )'"2 $-+ kg level header. =ormally, '1P
to ! P let down remains closed and opens only during trip of
any one of the two machines to satisfy 1P steam demand. The
import header is siGed for %(+ TP1.
CHECKED BY PAGE "3
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
$P Stea- 9S/<
1P 'team is drawn as e:traction from propylene refrigeration
turbine for I'"2 re/uirements. =ormally, no import or e:port of
1P steam taken place. 1owever, the header that with )'"2
header. The header is siGed for 3- TP1. lso 1P to 2!P
letdown closed and opens only during trip of propylene
refrigeration compressor.
/P Stea- 9S/P<
!P 'team is generated as e:tractor from cracked gas
compressor turbine. This e:traction pressure is selected to Noat
with )'"2. e:isting pressure.A the header Nats with )'"2
header. =ormally, any e:cess of !P 'team letdown to 2!P
steam is e:ported to )'"2 network. 1owever, import of steam
takes place In case of C< Compressor trip beyond the
re/uirement of letdown from 1P to 2!P steam.
The import e:port header is siGed for $-- TP1.
/P Stea-L 9SL/<
2!P 'team steam generated from the letdown of !P steam
during normal operation >or@ from 1P steam during
emergencies A shutdown. There is nor 2!P pressure level )'"2.
There is import A e:port facility for this steam.
CHECKED BY PAGE "4
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
LLP Stea- 9SL<
This steam is imported by letdown of +.+ kgAcm%g pressure
level at )'"2. to e:tent of e:cess re/uirements of let down
from 2!P 2evel. The import header is siGed for +- TP1.
1owever, during startBup turndown and upsets two scenario is
diHerent depending on furnaces cracking and running of maQor
turbine drives.
,(, Condensate and =oi+er ;eed ?ater s0ste-
The cracker plant is self sufcient to handle and recycle all the
steam condenste into the "&4 system after treatment. The
facility for condensate, e:port to )'"2 is also provided. &or the
net /uantity of steam that is reported as there are no facilities
to import condensate, this loss is made up from the import of
6! water.
The "oiler feed water is generated in deaerator from recycling
of clean condensate and by polishing of contaminated
condensate in condensate polishing units. 6! water imported
form )'"2 is used to make up the loss of steam due to net
e:port or otherwise and loss of condensate. This steam is
heated and treated to meet boiler feed water for the generation
of steam in furnace steam drums.
Condensate Pressures C
1P Condensate C (5 kgAcm%
2!P Condensate C $- kgAcm%
CHECKED BY PAGE "5
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
22P Condensate C %.+ kgAcm%
Condensate system is divided into two subsystems as clean
condensate and support condensate. ll high pressure 1P, 2!P
from user e/uipment is condensate, Nashed in Nash drums to
generate steam and the condensate is returned to deaerator
directly as clean condensate.
22P condensate from user e/uipments where process side
pressure is higher than the steam pressure is routed to suspect
condensate vessel and subse/uently sent to CP. for polishing
or to deaerator through activated carbon ,lter.
ll surface condensate from C<C,C%,C(; turbines are sent to
deaerator after polishing in condensate polishing unit.
6uring startBup and upset conditions, surface condensate can
be e:ported to )'"2, before polishing core after polishing.
fter deaeration and p1 adQustment using ammonia, this is
termed as "oiler, feed water. This "&4 is pumped to furnace
steam drums for steam generation for make up in main and
au:iliary dilution steam generation systems and for
desuperheating in '1P to 1P letdown system. Two motor driven
and a turbine driven high pressure "&4 pumps ate provided out
of which two will be running normally and one motor driven
pump as stand by on auto. In case of pressure drop in 1P "&4
CHECKED BY PAGE "6
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
header, stand by pump takes auto start to maintain header
pressure.
)ne 2P boiler feed water pump is running to supply water to
desuperheating stations and nominal /uantity is e:ported to
aromatics plant.
,(. )ue+ "as S0ste-!
Cracker Plant is self sufcient of in fuel re/uirements. ll fuel
gas maQority methane from demethanise, residue gas from
chilling train and purge gas from P' unit is mi:ed in fuel gas
mi:ing drum and is consumed in main, recycle and <1.
furnaces at (.+ kgAcm%g pressure.
9:cess fuel gas during normal plant operation is e:ported at +.+
kgAcm% g pressure level from the discharge oH e:pander
compressor.
Provision of using C* rafnate from main and au:. C*
hydrogenation units >or@ form )'"2 storage is provided as back
up.
Provision of using propane A oH .spec propylene from )'"2
storage sphere. propane directly from propylene fracitonator is
also provided.
CHECKED BY PAGE "
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
2P< from )'"2 2P< bullets can also be routed to fuel gas
system through vaporisers in case of re/uirement.
6ue to various combination of full from methane during normal
operation to C* rafnate during emergencies, homogeniser
system is provided at the down stream of mi:ing drum to
adQust density of fuel to furnaces.
&uel gas is ,rst superheated with 22P steam and 2!P steam is
inQected superheated in the homogeniser based on the density
of the fuel gas entering the homogeniser.
&or initial startBup high pressure of fuel gas form )'"2 is
provided as make up into the fuel gas mi:ing drum.
6esign speci,cation of fuel gas
!oleD
C$ 8%.+D
C% $.37D
C( -.$D
C)% +.5D
1%) -.-$D
1%' * PP! molAmol
)perating pressure C %5 kgAcm%g
)perating temperature C $(-
-
C
6esign !4 C $5.8
CHECKED BY PAGE "!
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
,(2 Nitrogen Process Air% Instru-ent Air S0ste-
,(2(1 Nitrogen
=itrogen is supplied to cracker at two pressure levels as 1P
=itrogen and 2P =itrogen. This is supplied from air separation
unit.
,(2(1(1 $P Nitrogen
1P =itrogen is used during startBup as a sealing medium for
compressor during startBup air run. 6uring normal operations.
1P =itrogen is used in pump seals.
part from )'"2 import, battery of 1P nitrogen cylinders >two
sets@ is provided to maintain I'"2 header pressure to P!P seals
as back up in case of any drop in )'"2 header pressure.
,(2(1(' LP Nitrogen
2P =itrogen is used for various services as tank blanketing, seal
gas for ethylene refrigerator compressors and for hose stations
with =;E to cannot to any e/uipment for purging etc.
"oth 1P F 2P =itrogen shall be oil free, dew point of B$--
-
C at
atmospheric pressure and ma:. o:ygen gas content of $- ppm
molAmol.
CHECKED BY PAGE ""
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
Pressure
=ormal !in. !a:.
1P =itrogen (- %5 B
2P =itrogen 5 B 7
,(2(' Instru-ent Air
Instrument air is supplied form )'"2 by CPP which is
compressed, dried and free of oil. Two parallel headers one at
$-% = piperack and other at $-+ = pipe rack maintain the
re/uirement of I throughout the plant.
Pressure Cg#c-'g Te-perature 9
0
C< 9
0
C<
/in( Nor-a
+
/a3( /in( Nor-a
+
/a3
*.+ 5.- 5.+ (- *+ +- B*-
,(2(, P+ant Air
Plant air is supplied from )'"2 by CPP which is compressed,
saturated to moisture at the supply pressure. The oil content
shall be ma:. -.+ ppm wtAwt supply propane. The air is fed from
the hose points to e/uipments which re/uired deinertisation
etc.

Pressure Te-perature
/in( Nor-a+ /a3( /in( Nor-a+ /a3(
3.- 5.- 7.- (- *+ +-
CHECKED BY PAGE 100
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
,(4 Ser6ice *ater S0ste-
'ervice water which is treated raw water is supplied by CPP to
)'"2 which is used as service water at hose stations for
washing etc. and an drinking water at control room,
changerooms and yard toilet. lso this water is supplied to
laboratory for cleaning, washing etc.
SpeciGcations ;or Ser6ice *ater
p1 C 5.7
Thurbidity C % =TE
Chloride C (% ppm as cl.
'ulphate C (+ ppm as ')*
PBlkalinity C =il
!Blkalinity C $75 as Ca C)( ppm
Total nions C %38 as Ca C)( ppm
Total 1ardness C $(* as Ca C)( ppm
!agnesium 1ardness C 3% as Ca C)( ppm
'odium C $(+ as Ca C)( ppm
Total Cations C %38 as Ca C)( ppm
Total 'ilica C $- as 'i)% ppm
Collected silica C -.% as '$)% ppm
Total iron C -.+ as &9 ppm
Total 6issolved solids C $5- ppm
CHECKED BY PAGE 101
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
,(@ D/ *ater s0ste-
6! water is imported from CPP at a ma:imum peak Now rate of
%+- m(Ahr during startBup and upsets. 6! water is received in
6! water storage tank and pumped to deaerator as makeBups.
lso provision is provided for make up into /uench water tower
for make up. during upsets A startBup, 6! water consumption is
minimised by recycling the condensate from various system.
6! water from )'"2 has the following speci,cations C
p1 C 3.+ to 5.-
Total dissolved solids C -.+ ppm
Total hardness C =il
Chlorides C =il
Iron C .--+ ppm as &9
9lectricity conductivity C -.% msAcm
Total silica C -.-% as 'i)% ppm
'odium C =il
Colour C Colourless
CHECKED BY PAGE 102
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
,(5 )ire ?ater s0ste-
&ire water is received from the hydrant header surrounding the
plant I'"2 from )'"2 ,re water system. 9very area is provided
with divide headed ,re hydrant points with ,re hose bo:
adQacent to them. 9ach hydrant point has an isolation valve and
hydrant points >single@ on the structures has been provided
with common isolation valve at grade. part from hydrant
points, on line water monitors are provided at strategic
locations. 0uench ,ttings on main and recycle furnaces are
provided with manual deluge system to be care of any ,re
emergency at this locations.
1eaders in each area of the plant can be isolated by closing
slice valves provided at both the ends of the network. >;efer
enclosed singe line sketch@.
CHECKED BY PAGE 103
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
,(A ELECTRIC PO*ER S7STE/ !
9lectrical power at (( #E, +- 1G for startBup and normal operations shall
be available from the )'"2 central electrical power handling facility at the
battery limit.
The electrical power system is characterised as follows C
Particu+ars SpeciGcation Suggested Users
&re/uency of all C power supply +- 1U X (D
" 9lectrical Power <eneration C
9mergency <enerator C
Type
Eoltage 2evel
C ( phase
*$+ E X 3D
C Primary 6istribution in )'"2C
Type
Eoltage 2evel
C, ( phase
(( #E X +D
6 6C Power supply systemC
Eoltage 2evel a@
b@
c@
%%- E I $-D,
B%-D
$$- E I $-D,
B%-D
%* E 6C
Critical lighting control
supply for circuit
breakers, alarm
annunciators.
'hutdown system >all
solenoid valves@ in
e:isting plant area.
;elay logic, switches,
solenoid valves in I'"2.
9 )ther C Power 'upply 'ystem C
a@ Type
Eoltage 2evel
C ( phase
3.3 #E X 3D
!otor drives above $3-
#4
b Type
Eoltage 2evel
C, ( phase
*$+ E X 3D
!otor drives
>-.$7 #4 to $3- #4,
lighting, welding
machine, overhead crane.
c Type
Eoltage 2evel
C $ phase
%*- E X 3D
!otor drives below -.$7
#4 F control supply for
*$+ E motor contactor,
instrument cabinet
lighting, hand lamp
socket, portable tools,
motor panel A space
heater, plant
communication, ,re
alarm, level gauge
illumination.
d Type
Eoltage 2evel
.P' based
=on .P'
C, $ phase
$$- E X %D
$$- E X +D
ll instrument, 6C'
CHECKED BY PAGE 104
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
e Type
Eoltage 2evel
C, $ phase
%* E X 3D
&or handheld A portable
lighting
UTILIT7 CONDITIONS AT =ATTER7 LI/IT
22 'T;9! P;9''.;9 '122 "9 C)='I69;96 ' T <;69 29E92 C
S+( Particu+ars Unit Operating Conditions Design
/ini-u- Nor-a+ /a3i-u
-
'1P 'team
Pressure
Temperature
kgAcm%g
C
$-%
*7+
$-+
+--
$-5
+$-
$$% >*@
+$-
" 1P 'team C
Pressure
temperature
kgAcm%g
C
(7
(3-
*-
(5(
*%
*--
*5
*%-
C 1P 'team >Import@C
Pressure
Temperature
kgAcm%g
C
$+
%(+
$5
%*+
$7
%7-
%%
(+-
6 2!P 'team >9:port@C
Pressure
Temperature
kgAcm%g
C
$$.+
%*-
$%
%3-
$(
%5-
$+
(--
9 2P 'team >Import@C
Pressure
Temperature
kgAcm%g
C
*
$3-
*.+
$5-
+.+
%--
7.$
%5-
& 22P 'team >9:port@C
Pressure
Temperature
kgAcm%g
C
(.-
$3+
(.+
$75
*.+ >*@ 3.+
%+-
< 'team Condensate >9:port@C
Pressure >noteB(@
Temperature
kgAcm%g
C
(
!"
*.+
!"
$5.8
3+
1 Instrument ir C
Pressure
Temperature
kgAcm%g
C
*
(-
3.+
*+
5.+
+-
$-.+
3+
I Plant ir
Pressure
Temperature
kgAcm%g
C
*
(-
5.-
*+
5.+
+-
$-.+
3+
T 2P =itrogen <asC
Pressure
Temperature
kgAcm%g
C
5
mbient
7
mbient
8 $-.+
3+
# 1P =itrogen <asC
Pressure
Temperature
kgAcm%g
C
(-
mbient
(%
mbient
((
mbient
*-
3+
2 'ervice 4ater
Pressure
Temperature
kgAcm%g
C
*
mbient
+.+
mbient
5
mbient
$-
3+
! &ire 4aterC
Pressure
Temperature
kgAcm%g
C
$-
mbient
$%
3+
= Cooling 4ater
'upply Pressure kgAcm%g *.- + 3 7.-
CHECKED BY PAGE 105
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B. DAS AUTHOR BMK
SECTION MODULE NO.
3

CKR-PR-P-001
'upply Temperature
;eturn Pressure
;eturn Temperature
C
kgAcm%g
C
mbient (*
%.+
*(
(* 3+
7.-
3+
) 6emineraliGed >6!@ 4aterC
Pressure
Temperature
kgAcm%g
C
+
mbient
5.+
mbient
$-
3+
P 6rinking 4ater
Pressure
Temperature
kgAcm%g
C
-.+
mbient
$
mbient
(.- +.-
3+
0 2P "oiler &eed 4aterC
Pressure
Temperature
kgAcm%g
C
%$.%
$$+
((.+
$5.-
CHECKED BY PAGE 106
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SECTION MODULE NO.
4

CKR-PR-P-001
E))LUENTS
CHECKED BY PAGE 10
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4

CKR-PR-P-001
.(0 P+ant eHuents and Disposa+ /etods!
6ue to comple: nature of operations, a variety of solid,
gaseous and li/uid efuents are obtained form the gas cracker
plant. This is intended that all operating personnel shall take all
necessary measures to minimise efuents generation.
.(1 So+id eHuents!
CoCe!
Coke is the solid waste product obtained during decoking
operation from the decoke pots and during hydroQetting of .'R
and collection headers. This is being disposed oH to )'"2 as
land ,ll.
"y the addition of 6!6' to the feed of cracking main and
recycle furnaces, this coke formation is minimised.
.('"aseous eHuents !
)+ue "ases !
There are produced in cracking furnaces and in <1. furnaces
which are released to atmosphere continuous. The /uality of
this efuent from cracking furnace is continuously monitored by
one line C) and )% analysers. lso, complete emission
constituents are analysed by central environmental monitoring
cell to ensure adherence to local statutory re/uirements.
"ases $0drocar:ons
CHECKED BY PAGE 10!
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B. DAS AUTHOR BMK
SECTION MODULE NO.
4

CKR-PR-P-001
6uring normal operation, no gases efuents are produced as
most all of the vent gases are recycled into the process system
for recovery. &ew discharges as <1. stripper vent and spent
caustic o:idation stripper vents are routed into Nare system
where they are Nared at $$- ! high level. &or the completion of
combustion, steam is inQected into the Nare system. lso,
hydrocarbon vent during unit upset is routed to Nare stack for
complete combustion and safe disposal.
.(,LiIuid EHuents !
Stor- *ater !
4ater during rains is collected in the I'"2 by means of catch
pits and are routed to two storm water walls, located at north
and south side of the plants with slice gate to stop Now into the
storm water channel.
6uring normal season, the water collected into these walls from
,re water drain, boiler drum C"6, decoke pot drain and steam
condensate drains are pumped to efuent treatment plant for
suitable treatment and disposal.
6uring monsoon, water collected in these walls overNow into
the storm water channel and are disposed into Tapi ;iver entry.
Oi+0 ?ater se?er !
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B. DAS AUTHOR BMK
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4

CKR-PR-P-001
4ater containing traces are hydrocarbon, seal cooling li/uid
form pump seals, dil. steam generation blowdown, suspect
condensate drain, and other process a/ueous plant drain are
collected into )4' well via hubs connected to underground
closed piping system. This is pumped to efuent treatment
plant for suitable treatment and disposal.
Spent Caustic EHuent !
'pent Caustic from Caustic Tower after treatment with gasoline
and additives is pumped to spent caustic o:idation unit where
C)6 and sulfur content is reduced to the great e:tent. lso,
stripper provided at the upstream of spent caustic o:idation
unit removes aromatic components. Thus this efuent is
neutralised with hydrochloric acid to pit of 5.- and pumped to
efuent treatment plant for disposal.
CPU regeneration ?aste !
;egeneration water efuent from condensate polishing unit is
mi:ed along with 'C) efuent and neutralised to p1 5.- and
sent to 9TP for disposal.
>uenc oi+ se?er !
ll heavy oil drains in the prefractionation area is collected in a
hubs which are connected to double pipe underground network
to drain drum. &rom the drain drum it is recycle back into
/uench oil tower or can be sent to )'"2 storage tanks.
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5

CKR-PR-P-001
E/ER"ENCIES
CHECKED BY PAGE 111
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5

CKR-PR-P-001
2(0 E-ergenc0 Sutdo?n
In all cases of emergency, the )perator in charge shall e:ercise
his discretion regarding shutdown, bearing in mind C
a@ The safety of Personnel
b@ The safety of e/uipment
&ailure of an individual pumping unit, where a standby unit is
available for immediate serviceS individual instrument, failure,
where bypass or direct manual control >handQack@ is available,
and similar isolated or individual failures must not be treated as
re/uiring emergency shutdown. !omentary failure of any utility
should be treated as a temporary emergency and any tripped
e/uipment or its standby unit must be commissioned, as
/uickly as possible.
/uench oil failure must not be treated as re/uiring emergency
shutdown. 0uenching of the furnace efuent is automatically
continued by naphtha. Continue operation unit it is obvious that
oil circulation canWt be restored and a planned shutdown is then
carried out. 'hutdown of the furnaces should be undertaken if
the base li/uid level of the /uench oil tower, CB%$-, approaches
the transfer line inlet noGGle elevation and disposal of /uench
oil continues to be a problem. If /uenching of the furnace
efuent is insufcient for any reason, hydrocarbon feed should
be taken out of the furnaces. If a compressor should trip due to
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CKR-PR-P-001
an inBbuilt safety system, the fault should be cleared before
restartS trips must not be overridden. The e:tent to which the
furnaces are kept on line during such an emergency will depend
upon individual circumstances but there should be normally no
necessity to use an emergency trip on the furnaces.
The trip of any system, and in particular the reactor systems,
must be thoroughly investigated before attempting to bring
them back into operation. gain no emergency trip of any other
e/uipment should be necessary in this case.
9mergency shutdowns will be carried out for the following
events C
$. Total and sustained electric power failure
%. Total and sustained cooling water failure.
(. Total and sustained instrument air failure
*. 2oss of steam pressure
+. .ncomfortable leakage of hydrocarbons
3. 'erious and uncontrollable ,re.
The PFI diagrams show the maQor automatic alarm and
shutdown systems included in the plant. ')P must be
consulted as necessary for detailed operation.
E+ectric Po?er )ai+ure
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SECTION MODULE NO.
5

CKR-PR-P-001
sustained power failure is regarded as a remote possibility
but would however result in the shutdown of C
Bfurnaces, due to induced draft fan failure >'6B%
Bpumps and normal plant lighting
!otor driven compressors
ctions to be taken if Power is not Immediately ;estoredC
a@ "lock oH all hydrogen supply to the C% 1ydrogenation
;eactors, depressurise the reactors and nitrogen and
nitrogen purge. "lock in regeneration air Now if any is being
used. ;efer to the I&P )perating !anuals for information on
handling the C(,C* <asoline 1ydrogenation units.
b@ Close cracking furnace burner cocks, block in hydrocarbon
fuel supply, close dampers to reduce rate of refractory
cooling. Close decoking air if any was used. Try to maintain
dilution steam to furnaces as long as is necessary to purge
coils.
c@ If available, continue cooling water Nows to all units. ;elease
e:cessive pressures in e/uipments to the Nare, using safety
valve bypass valves, or depressuriGation control valves, in
preference to allowing the safety valves to lift and possibly
not reset.
d@ "lock in cracked gas dehydrators, take note of regeneration
status when blocking in regeneration lines.
e@ 'hut oH heating medium to fractionation tower reboilers at
control valves and A or block valves.
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SECTION MODULE NO.
5

CKR-PR-P-001
f@ Isolate the various refrigeration stages by block valves to
prevent pressure migration, if it is decided to shutdown the
compressors.
g@ ;educe li/uid levels in towers and drums to near normal, by
either pressuring to the ne:t process se/uence or to
blowdown drums, the choice being dependent upon
circumstances. In general, where a restart after an
emergency shutdown is anticipated fairly soon, levels should
be maintained at the optimum to facilitate the restart.
h@ 9/uipment should be shutdown and shut in as far as possible
by means of control room instruments, particular attention
being paid to e/uipment pressures.
Coo+ing *ater )ai+ure
Cooling 4ater failure will automatically trip all .'C and ;ecycle
furnaces to '6B%
BC< Compressor
BC% 1ydrogenation unit on oHspec.
ctions to be taken at a 'ustained 4ater &ailure
a@ "lock in furnaces as under 8.%.$>b@
b@ 'top electrically driven process compressors >"B5*- A"@ and
block in.
c@ 'top all heating media to reboilers.
d@ ;emove hydrogen from reactors and block in as under 8.%$.
>a@
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SECTION MODULE NO.
5

CKR-PR-P-001
e@ 'top charge pumps, stop reNu: pumps as reNu: drum levels
drop.
f@ )n a system by system basis release e:cessive pressures in
e/uipment to the Nare only when re/uired, using safety
valve bypass valves or drpressuriGation control valves, in
preference to allowing the safety valves to lift and possibly
not reset. <reat care must be taken not to overload the Nare
relief system by dumping large relief loads simultaneously.
g@ ;educe li/uid levels in towers and drums to near normal by
either pressuring to the ne:t process se/uence or to
blowdown drums, the choice being dependent upon
circumstances. In general, where a restart after an
emergency shutdown is anticipated fairly soon, levels should
be maintained at the optimum, to facilitate the restart.
h@ 9/uipment should be shutdown and shut in as far as
possible, by means of the control room instruments,
particular attention being paid to e/uipment pressures.
i@ 'top the pumping of fresh caustic solution to the caustic
wash tower.
Q@ 'top the inQection of 6!6' to the &urnaces and shutdown all
other process chemicals inQection systems.
k@ 'top all product withdrawal
Instru-ent Air )ai+ure
ir failure would be result in the failure of activating air to
control valves. the instrument design of the plant is such that
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SECTION MODULE NO.
5

CKR-PR-P-001
the valves move to put the plant in the safest possible
condition under the circumstances.
ction to be taken on a <eneral Instrument ir &ailure
ll automatic valves will have gone to the failBsafe position,
block valves on the following systems should also be closed to
make doubly sure of safe conditions.
a@ "lock oH hydrogen to all reactors, proceed as under 8.%.$>a@.
b@ 'hutdown furnaces as under 8.%.$>b@.
c@ block in compressors and refrigeration system.
d@ "lock in cracked gas dehydrators as under 8.%.$>d@.
e@ Isolate the various refrigeration stages to prevent pressure
migration.
f@ "lock oH heating medium to reboilers, preheaters, etc.
g@ ;educe li/uid levels in towers drums to normal working
levels by use of control valve bypasses pressuring to the
ne:t process se/uence or the blowdown drum, maintaining
ade/uate levels to facilitate the starting operation.
Loss o; stea- pressure
6ependent upon the steam main involved various emergencies
could occur and the senior operator will need to e:ercise his
discretion upon the appropriate action to be taken. I= all cases
every eHort must be made to continue dilution steam Nows to
the cracking furnaces until all hydrocarbon materials are
purged out.
CHECKED BY PAGE 11
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B. DAS AUTHOR BMK
SECTION MODULE NO.
5

CKR-PR-P-001
ction to be taken
a@ Conserve the dilution steam main pressure as long as
possible, reducing higher pressure steam consumption
wherever possible.
b@ ctivate shutdown $ on all furnaces. This will cut out furnace
feed, add dilution steam to the hydrocarbon coils and cut
3-D of the heat input to the furnaces.
c@ If dilution steam failure is imminent, activate shutdown % on
all furnaces. In addition to the '6B$ trips, this will cut out all
gas burners and after a short purge period, shut oH the
dilution steam Now.
It is possible that furnaces which suHer dilution steam failure
before the short purge period will re/uire decoking before the
ne:t startBup.
d@ If the 'B$-+ steam supply pressure falls, stop the cracked
gas compressor to maintain the ;efrigeration Compressors
in service if re/uired depending on the steam demand at low
levels.
NOTE C 4hen intending to shutdown furnaces or any other
e/uipment in an emergency situation, do not proceed by an
indirect route, i.e. making a process alteration which will in
normal se/uence lead to the desired shutdown action.
CHECKED BY PAGE 11!
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B. DAS AUTHOR BMK
SECTION MODULE NO.
5

CKR-PR-P-001
If shutdown $ or % on the furnaces is called, for, activate the
switches provided, checking that all furnace conditions proceed
thereby to the desired safe condition.
CHECKED BY PAGE 11"
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SECTION MODULE NO.
5

CKR-PR-P-001
Uncontro++a:+e LeaCage and )ire
ctions to be taken at the occurrence of a large leakage or ,re
will obviously depend upon the location of the ,re, the
pro:imity of other inNammable materials and numerous other
variables. Company standard ,re drill procedures should be
followed while the plant is being shutdown in as orderly a
manner as possible, e:tinguishing all furnace burners as /uickly
as possible, stopping fans and closing furnace stack dampers,
isolating the burning e/uipment and cutting oH supplies of
inNammable material to the source of the ,re.
!otor operated isolation valves are installed on the common
suction lines to all hydrocarbon pumps and are also installed on
the ,rst stage suction, third stage discharge, and the fourth
stage suction and discharge of the cracked gas compressor,
and the suction and discharge of all stages of the propylene
and ethylene refrigerant compressors, and also maQor product
streams. ll these valves are operable from the ,eld so that
easier isolation can be achieved. In the case of pumps, the
pump motor is tripped when the remote isolation switch is
activated. 'nufng steam purges to pump seals are provided
with remote ,eld valves.
6uring any plant emergency or normal shutdown, the
containment of gaseous and li/uid hydrocarbons with
controlled release to the Nare and blowdown must be enforced.
InNammable li/uids accidentally entering surface drainage
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SECTION MODULE NO.
5

CKR-PR-P-001
systems and hydrocarbon vapours can lead to haGardous
conditions or an increase in an e:isting conNagration.
CHECKED BY PAGE 121
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B. DAS AUTHOR BMK
SECTION MODULE NO.
6

CKR-PR-P-001
E>UIP/ENT LIST
CHECKED BY PAGE 122
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SECTION MODULE NO.
6

CKR-PR-P-001
4(0 EIuip-ent List
Section Tit+e
$ ".I26I=<'
% ;)TTI=< 90.IP!9=T'
( T)49;'
* 9RC1=<9;'
+ <9=9;2 90.IP!9=T
3 &.;=C9'
5 P.!P'
7 ;9CT);'
8 T=#'
$- 6;.!'
=UILDIN"S
ITE/
NO( DESCRIPTION
--( !echanical 4orkshopA6ining ;oom
--* 1EC Chilling .nit Compressor 1ouse
$-$ !CC F Control house
$-+ <as Turbine Control 1ouse
$$- &urnace nalyser 'helter =o.$
$%- &urnace nalyser 'helter =o.%
(-$ Cracker <as Compressor 'helter
*-$ !ethane Compressor 'helter
*$- Cold &ractionation nalyser 'helter =o.$
*+- Cold &ractionation nalyser =o.%
+$- 4arm &ractionation nalyser 'helter
3-$ ;efrigeration Compressor 'helter
5-$ <.1... Compressor 'helter
8-$ &uel <as Compressor 'helter
CHECKED BY PAGE 123
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B. DAS AUTHOR BMK
SECTION MODULE NO.
6

CKR-PR-P-001
ROTATIN" E>UIP/ENT
ITE/
NO(
>T7( DESCRIPTION
" $-- $ <as Turbine
" $-$ A" % &6 &an >!otor 6riven@
" $-% $ &6 &an >!otor 6riven@
" $-( $ <T &uel gas Compressor
" $$- $ I6 &an >.'C &urnace@
" $$$ $ I6 &an >.'C ;ecycle &urnace@
" $%- $ I6 &an >.'C &urnace@
" $%$ $ I6 &an >.'C ;ecycle &urnace@
" $(- $ I6 &an >.'C &urnace@
" $($ $ I6 &an >.'C ;ecycle &urnace@
" $*- $ I6 &an >.'C &urnace@
" $+- $ I6 &an >.'C &urnace@
" $3- $ I6 &an >.'C &urnace@
" $5- $ I6 &an >.'C &urnace@
" $7- $ I6 &an >.'C &urnace@
" $8- $ I6 &an >.'C &urnace@
" $8% $ I6 &an >.'C &urnace@
" $8* $ I6 &an >.'C &urnace@
" $83 $ I6 &an >.'C &urnace@
" (-- $ Cracked <as Compressor
" *%- $ !ethane ;ecompressor
" *%$ $ !ethane 9:pander
" 3-- $ 9thylene ;efrigerant Compressor
" 3+- $ Propylene ;efrigerant Compressor
" 5$- A" % $st 'tage !akeBup and ;ecycle Compressor
" 5*- A" % %nd 'tage !akeBup and ;ecycle Compressor
" 8-- $ &uel <as Compressor
" 8$+ $ Polisher ir "lower
" $$-$ A" % 1igh Pressure ir Compressors
" $$%$ A"AC ( 'C) ;eactor &eed ir Compressor
"T $-% $ &6 &an Turbine
"T (-- $ Cracked <as Compressor Turbine
"T 3-- $ 9thylene ;efrigerant Compressor Turbine
"T 3+- $ Propylene ;efrigerant Compressor Turbine
"T 8-- $ &uel <as Compressor Turbine
CHECKED BY PAGE 124
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SECTION MODULE NO.
6

CKR-PR-P-001
*+1&.S
ITE/
NO(
>T7( DESCRIPTION
C %$- $ 0uench )il Tower
C %%- $ 0uench 4ater Tower
C %(- $ 1eavy &uel )il 'tripper
C %*- $ 2ight &uel )il 'tripper
C %+- $ 6istillate 'tripper
C %3- $ 2P 4ater 'tripper
C %5- $ 6ilution 'team 'tripper
C %7- $ u:iliary 6ilution 'team 'tripper
C (*- $ Caustic Tower
C (+- $ Cracked <as ;ecti,er
C (3- $ Condensate 'tripper
C *$- $ 6emethaniGer Prestripper
C *%- $ 6emethaniGer
C *(- $ ;esidue <as ;ecti,er
C **- $ 6eethaniGer
C *3- $ 9thylene 'tripper
C *5- $ 9thylene ;ecti,er
C +$- $ 6epropaniGer
C +(- $ 'econdary 6eethaniGer
C +(+ $ Tertiary 6eethaniGer
C +*- $ Propylene 'tripper
C ++- $ Propylene ;ecti,er
C +3- $ 6ebutaniGer
C 5%- $ 6epentaniGer
C 5(- $ 6eoctaniGer
C 5+- $ 'tripper
C $$-$ $ 'team 'tripper
CHECKED BY PAGE 125
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SECTION MODULE NO.
6

CKR-PR-P-001
&2'0AN/&.S
ITE/
NO(
>T7( DESCRIPTION
9-$$ $ 9thaneAPropane ;ecycle 1eater
9 -*$ $ =aphtha &eed 1eater
9 -+$ A" % <) &eed 1eater
9 -+% $ <) &eed 1eater =o.%
9-+( $ <) &eed 1eater =o.(
9 $$- A1, TA0 $3 .'R 9:changer >.'C &resh &eed &urn.@
9 $$$ $ T2R 9:changer >.'C &resh &eed &urn.@
9 $$+ A6 * .'R 9:changer >.'C &resh &eed &urn.@
9 $%- A1, TA0 $3 .'R 9:changer >.'C &resh &eed &urn.@
9 $%$ $ T2R 9:changer >.'C &resh &eed &urn.@
9 $%+ A6 * .'R 9:changer >.'C &resh &eed &urn.@
9 $(- A1, TA0 $3 .'R 9:changer >.'C &resh &eed &urn.@
9 $($ $ T2R 9:changer >.'C &resh &eed &urn.@
9 $(+ A6 * .'R 9:changer >.'C &resh &eed &urn.@
9 $*- A1, TA0 $3 .'R 9:changer >.'C &resh &eed &urn.@
9 $*$ $ T2R 9:changer >.'C &resh &eed &urn.@
9 $+- A1, TA0 $3 .'R 9:changer >.'C &resh &eed &urn.@
9 $+$ $ T2R 9:changer >.'C &resh &eed &urn.@
9 $3-, A1, TA0 $3 .'R 9:changer >.'C &resh &eed &urn.@
9 $3$ $ T2R 9:changer >.'C &resh &eed &urn.@
9 $5- A1, TA0 $3 .'R 9:changer >.'C &resh &eed &urn.@
9$7$ $ T2R 9:changer >.'C &resh &eed &urn.@
9 $8% A1, TA0 $3 .'R 9:changer >.'C &resh &eed &urn.@
9 $8( $ T2R 9:changer >.'C &resh &eed &urn.@
9 $8* A1, TA0 $3 .'R 9:changer >.'C &resh &eed &urn.@
9 $8+ $ T2R 9:changer >.'C &resh &eed &urn.@
9 $83 A1, TA0 $3 .'R 9:changer >.'C &resh &eed &urn.@
9 $85 $ T2R 9:changer >.'C &resh &eed &urn.@
9 %$- AC ( &uel )il Product Cooler
9 %$+ A" % 0uench 4ater 'team 1eater
9 %$8 $ Pan )il Trim Cooler
9 %%- A< 5 Primary /uench water cooler
9 %(- A1, TA# $- 'econdary /uench water cooler
9 %(8 $ 2&) 'tripping 'team 'uperheater
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6

CKR-PR-P-001
ITE/
NO(
>T7( DESCRIPTION
9 %+- $ 6istillate 'tripper ;eboiler
9 %+7 $ 4ater 'tripper &eed 1eater
9 %+8 $ 6'' "d.A4ater 'tripper &eed 1eater
9 %3+ A" % 6'' &eed 1eater =o.$
9 %38 $ 6'' &eed 1eater =o.%
9 %5- A6 * 6'' 'team ;eboiler
9 %5$ A1 7 6'' 0.). ;eboiler
9 %5( $ 6'' "lowdown Cooler
9 %5* $ u:iliary 6ilution 'team 'tripper "lowdown Cooler
9 %58 $ u:. 6ilution 'team 'tripper &eed 1eater
9 %7- AC ( u:. 6ilution 'team 'tripper ;eboiler
9 ($- AC 3 C.<. &irst 'tage ftercooler
9 ($- A& ( C.<. 'econd 'tage ftercooler
9 (%- AC ( C,<. Third 'tage ftercooler
9 ((- AC $ 4eak Caustic 1eater
9 (*- $ 4ash 4ater Cooler
9 (*$ * C.<. &ourth 'tage ftercooler
9 (*+ A6 $ C.<. ;ecti,er )verhead Condenser
9 (++ $ Condensate 'tripper &eed 1eater
9 (+8 % Condensate 'tripper ;eboiler
9 (3- A" $ Condensate 'tripper ;eboiler
9 (5$ $ ;eact. <as &eed A 9fuent 9:changer
9 (5% $ ;eact. <as &eed 1eater
9 (5( $ ;eactivation <as &eed Cooler
9 (5* $ ;eactivation <as &eed Chiller
9 (5+ $ ;eactivation <as 9fuent Cooler
9 *-$ $ 6emethaniGer Precooler =o.$
9 *-% $ 6emethaniGer Precooler =o.%
9 *-( $ 6emethaniGer Precooler =o.(
9 *-* $ 6emethaniGer Precooler =o.*
9 *-+ $ 6emethaniGer Precooler =o.+
9 *-3 $ 6emethaniGer Precooler =o.3
9 *-5 $ 6emethaniGer Parallel Precooler =o.$
9 *-7 $ 6emethaniGer Parallel "T!' ;eheater
9 *-8 $ 6emethaniGer Parallel Precooler =o.%
9 *$- $ 6emethaniGer Prestripper ;eboiler
9 *$$ $ 6emethaniGer Core 9:changer =o.$
9 *$% $ 6emethaniGer Core 9:changer =o.%
9 *$( $ 6emethaniGer Core 9:changer =o.(
9 *$* $ 6emethaniGer Core 9:changer =o.*
9 *$+ $ 6emethaniGer Core 9:changer =o.+
9 *$8 $ 1ydrogen Core 9:changer
9 *%- $ 6emethaniGer ;eboiler
9 *%$ $ 6emethaniGer Parallel Precooler =o.(
9 *%% $ 6emethaniGer Parallel Precooler =o.*
CHECKED BY PAGE 12
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
6

CKR-PR-P-001
&2'0AN/&.S
ITE/
NO(
>T7( DESCRIPTION
9 *%* $ 6emethaniGer Precooler =o.3
9 *%+ $ 6emethaniGer Condenser
9 *%3 $ !ethane Product 1eater
9 *%5 $ !ethane Product 1eater
9 *(7 $ 6emethaniGer "ottoms ;eheater
9 *(8 A" % 6emethaniGer, Prestripper "tms ;eheater
9 **- AC ( 6eethaniGer ;eboiler
9 **+ A6 * 6eethaniGer Condenser
9 *+- $ C% 1ydrog. &eed 1eater
9 *+% A6 * C% 1ydrog. &eed A 9fuent 9:changer
9 *++ $ C% 1ydrog. dia. ;ct. Intercooler =o.%
9 *+3 A" % C% 1ydrog. dia. ;ct. ftercooler
9 *+7 $ C% 1ydrog. dia. ;ct. Intercooler =o.$
9 *3- $ 9thylene 'tripper ;eboiler
9 *3$ $ 9thylene ;ecycle Eaporiser
9 *5- A" % 9thylene ;ecti,er ;eboiler
9 *5+ A6 * 9thylene ;ecti,er Condenser
9 *55 $ 9thylene Product Eaporiser
9 *57 $ 9thylene Product 'uperheater
9 *7- $ 9thylene Product Cooler =o.$
9 *7$ $ 9thylene Product Cooler =o.%
9 *7% $ 9thylene Product Cooler =o.(
9 *8- $ 1P 9thylene Product 1eater =o.$
9 *8$ A" $ 1P 9thylene Product 1eater =o.%
9 +$- A" % 6epropaniGer ;eboiler
9 +$+ A" % 6epropaniGer Condenser
9 +%$ $ Interstage Cooler
9 +%% $ Catalyst Treatment
9 +(- $ 'econdary 6eethaniGer ;eboiler
9 +(+ $ 'econdary 6eethaniGer Condenser
9 +(3 $ Tertiary 6eethaniGer ;eboiler
9 +(5 $ Tertiary 6eethaniGer Condenser
9 +*- A6 * Propylene Tower ;eboiler
9 +*$ A" % Propylene Tower u:. ;eboiler
9 +*% $ Propane ;ecycle Eaporiser
9 +++ A1 7 Propylene Tower Condenser
9 ++3 $ Propylene Product Cooler
9 +3- A" % 6ebutaniGer ;eboiler
9 +3+ $ 6ebutaniGer Condenser
9 +33 $ Pyrolysis <asoline Product Cooler
9 3*+ $ C% ;efrigerant 6esuperheater =o.$
CHECKED BY PAGE 12!
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
6

CKR-PR-P-001
&2'0AN/&.S
ITE/
NO(
>T7( DESCRIPTION
9 3*3 $ C% ;efrigerant 6esuperheater =o.%
9 3*5 $ C% ;efrigerant 6esuperheater =o.(
9 3*8 A" % u:. C% ;efrigerant Condenser
9 3+- $ C% ;efrigerant 'ubcooler
9 38+ $ C( ;efrigerant 6esuperheater
9 388 A1, TA# $- C( ;efrigerant Condenser
9 5-$ $ $t 'tage ;eactor &eedA9f. 9:changer
9 5-% $ $st 'tage ;eactor 'tartBup 1eater
9 5$$ $ $st 'tage 0uench Cooler
9 5$% $ 1ot 'eparator Eapour Condenser
9 5$( $ $st 'tage Compressor "ypass Cooler
9 5%- $ 6epentaniGer Condenser
9 5%+ $ 6epentaniGer Condenser
9 5%3 $ C+ Product Cooler
9 5(- A" % 6eoctaniGer ;eboiler
9 5($ $ 4ash )il Condenser
9 5(% $ 6eoctaniGer "ottoms Cooler
9 5(+ $ 6eoctaniGer Condenser
9 5(3 $ 6ecoct Post Condenser Cooler
9 5(5 $ 4ash )il Trim Cooler
9 5(7 $ 9Qector Condenser
9 5*- A" + %nd stage &eed A 9fuent 9:changer
9 5*$ $ %nd stage ;eactor 9fuent Cooler
9 5*% $ %nd stage Compressor "ypass Cooler
9 5*8 A" % 'tripper &eed A 9fuent 9:changer
9 5+- $ 'tripper ;eboiler
9 5+$ $ C3BC7 Product Trim Cooler
9 5++ $ 'tripper Condenser
9 7-$ $ ;eactor startBup heater
9 7-% $ ;ecycle Cooler
9 7-( $ Post Condenser
9 7-* $ Product Cooler
9 7-+ $ C*1 'tartup 1eater >.nitB%@
9 7-3 $ C*1 ;ecycle Cooler >.nitB%@
9 7-5 $ C*1 Postcondensor >.nitB%@
9 7-7 $ C*1 Product Cooler >.nitB%@
9 8-- $ &uel <as Compressor ;ecycle Cooler
9 8-% $ Cold "lowdown Eaporiser
9 8-( $ C+ &uel Eaporiser
9 8-* $ 'uspect Cond. 6rum vent Condenser
9 8-+ $ C(AC* &uel Eaporiser
9 8-3 $ &uel gas 'uperheater
9 8-5 $ !ethanol Eaporiser
9 8-8 $ Cold &lare 'uperheater
CHECKED BY PAGE 12"
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
6

CKR-PR-P-001
&2'0AN/&.S
ITE/
NO(
>T7( DESCRIPTION
9 8$- $ #nockBout 6rum 'lops Cooler
9 8%- $ Contaminated Condensate Cooler
9 8%$ $ Condensate Polisher Inlet Cooler
9 8%% $ CP. 9fuent 1eat 9:changer
9 8(- $ C.<. Comp. 'team Turbine Condenser
9 8(7 $ 9Qector Condenser
9 83- $ C% ;efrig. Comp. 'team Turb Condenser
9 83$ $ UB83- 9Qector Condenser
9 83+ $ C( ;efrig. Comp. 'team Turb Condenser
9 833 $ UB83+ 9Qector Condenser
9 87- $ C%AC( ;efrig. Compressor 2ubeA'eal )il Cooler
9 87$ $ C< Compressor 2ube )il Cooler
9 87% $ Cg Compressor 'eal )il Cooler
9 88- A" % &uel <as Compressor 2ube A 'eal )il Cooler
9 $$-$ $ 'team 'tripper &eed PreBheater
9 $$-% A" $ 'team 'tripper 9fuent Cooler
9 $$-( $ InNuent A 9fuent 1eat 9:changer
9 $$-* $ ):idation ;eactor 9fuent Cooler
9 $$-+ $ 'C) Treated 9fuent Cooler
9 $$%$ $ 'C) 9fuent Cooler
9 $$%% $ 'C) &eed A Eent <as 9:changer
9 $$%( $ 'C) Eent <as Cooler
CHECKED BY PAGE 130
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
6

CKR-PR-P-001
GENERAL E?UIPMENT@
ITE/
NO(
>T7( DESCRIPTION
"< (-- $ Turning <ear !otor
"< 3+-
"2 (-- $ C< Compressor 2ube )il Console
"2 3+- $ 9 3+- F 9 3-- 2)A') Console
"2 8-- $ &< Compressor 2)A') Console
"' (-- $ C< Compressor 'eal )il Console
"T< (-- $ C< Compressor <land 'tm 9Qector Pkg
"T< 3-- $ C% ;efrig. Comp. <land 'tm. 9Qector Pkg
"T< 3+- $ C( ;efrig Comp <land 'tm. 9Qector Pkg
"T< 8-- $ &uel <as Comp <land 'tm 9Qector Pkg
< $-$ $ !ain Control ;oom 1EC Package
< 5$$ $ Polymerisation Inhibitor Package
Including : T-711, Z-711, P-711 A-D
< 5(3 $ 6eoctaniGer 9Qector 'ystem
< 5*% $ 6!6' InQection Package
Including: P-742
< 5+% $ Corrosion Inhibitor InQection Package
Including : T-752, Z-752, P-752
< 87$ $ Phosphate InQection Package
Including : T-981, Z-981, P-981 A/C
< 87% $ 1ydaGine InQection Package
Including: T-982, Z-982, P-982 A/B
< 873 $ 6!6' InQection Package
Including : T-986, P-986 A/B, P-995 A/D
< 875 $ Corrosion Inhibitor Package
Including: T-987. Z-987, P-987 A/B
< 877 $ 6efoaming C TB875, UB875, PB875 A"
Including : T-988, Z-988, P-988 A/B
< $--- $ 'pent Caustic ):idation .nit
U $$- $ 0uench &itting >.'C &urnace@
U $$$ $ 0uench &itting >.'C ;ecycle &urnace@
U $%- $ 0uench &itting >.'C &urnace@
U $%$ $ 0uench &itting >.'C ;ecycle &urnace@
U $(- $ 0uench &itting >.'C ;ecycle &urnace@
U $($ $ 0uench &itting >.'C &urnace@
U $*- $ 0uench &itting >.'C &urnace@
U $+- $ 0uench &itting >.'C &urnace@
U $3- $ 0uench &itting >.'C &urnace@
U $8% $ 0uench &itting >.'C &urnace@
U $8* $ 0uench &itting >.'C &urnace@
U $83 $ 0uench &itting >.'C &urnace@
U %$- A" $ 0uench )il &ilters
CHECKED BY PAGE 131
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
6

CKR-PR-P-001
/&N&.A, &3U(PM&N*
ITE/
NO(
>T7( DESCRIPTION
U %(- A" % 1eavy &uel )il &ilter
U %3$ A" % 4ater 'tripper feed &ilters
U (-- $ )il Puri,er
U (-$ $ Cracked <as Compressor 'ervice Crane
U (%- $ Eane 'eparator for %nd stage suction drum
U ((- $ Eane 'eparator for (rd stage 'uction 6rum
U ((+ $ Eane 'eparator for (rd stage suction drum
U (*- $ Eane separator for *th 'tage 'uction 6rum
U (*$ $ Caustic 6iluent !i:er
U (*% $ 4eek Caustic Circ. Pump 'uction 'trainer
U (*( $ 'pent Caustic A romatic <asoline !i:er
U (** $ Caustic rea 'ump
U *-- $ Pressure 'wing dsorption .nit
U *-$ $ !ethane Comp. 'ervice Crane
U 3-$ $ !ain Compressor 'ervice Crane
U 3-% $ 9thylene Compressor 'ervice Crane
U 3$- A" $ 9thylene ;efrigerant )il &ilters
U 3$$ $ Eane 'eparator for C%; $st 'tage 'uction 6rum
U 33- $ Eane 'eparator for C(; $st 'tage 'uction 6rum
U 38- $ Eane 'eparator for C(; *th 'tage &lash 6rum
U 5-$ $ <1. Compressor 'ervice Crane
U 5-% A" % ;P< &eed &ilters
U 5$$ $ Polymerisation Inhibitor !i:er
U 5(3 $ 6eoctaniGer 9Qector 'ystem
U 5*- $ %nd stage eQector
U 5+% $ Corrosion Inhibitor !i:er
U 8-- $ Condensate Polisher
U 8-$ A" % '*- 6esuperheater
U 8-% A" % '$% 6esuperheater
U 8-( A" % '(.+ 6esuperheater
U 8-* A" % 'uspect Condensate &ilters
U 8-+ $ <1. ;eboiler 'team 6esuperheater
U 8-3 $ '!P 9:traction 'team 6esuperheater
U 8$- $ &lare 'ystem >outside "attery 2imits of Cracker@
U 8$* $ Polisher cid Tank gitator
U 8(- $ C< Compressor Turbine 9Qector Package
U 83- $ C% refrig Compressor Turbine 9Qector Pkg
U 83+ $ C( refrig compressor Turbine 9Qector Pkg
U 87$ $ Phosphate tank gitator
U 87% $ 1ydraGine Tank gitator
U 875 $ Corrosion Inhibitor Tank gitator
U 877 $ 6efoaming gent Tank gitator
U 88- $ 9mergency Power generator
CHECKED BY PAGE 132
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
6

CKR-PR-P-001
/&N&.A, &3U(PM&N*
ITE/
NO(
>T7( DESCRIPTION
U 88+ A" % 'torm 'ewer Collection 'ump
U 883 $ )4' Collection 'ump
U $$-$ $ Eapour 'crubber
U $$-( $ 'C) 'team 6esuperheater
U $$-* % Carbon Canisters
U $$%$ $ 'C) &eed ir &ilter
U $$%% $ 'C) ;eactor &eed &ilter
U $$%( A"AC ( 'C) ;eactor 9fuent &ilters
U $$%* $ 'C) '2! 'team 6esuperheater
U $$%+ $ 'C) ;eactor 'parger Capsules >$ 2ot@
U $$%3 $ 'C) &eed 'team &ilter
U $$%5 $ 'C) Eent <as 'ilencer
)U.NA'&S
ITE/
NO(
>T7( DESCRIPTION
1 $$- $ .'C &resh &eed &urnace
1 $$$ $ .'C ;ecycle &urnace
1 $%- $ .'C &resh &eed &urnace
1 $%$ $ .'C ;ecycle &urnace
1 $(- $ .'C &resh &eed &urnace
1 $($ $ .'C ;ecycle &urnace
1 $*- $ .'C &resh &eed &urnace
1 $+- $ .'C &resh &eed &urnace
1 $3- $ .'C &resh &eed &urnace
1 $8% $ .'C &resh &eed &urnace
1 $8* $ .'C &resh &eed &urnace
1 $83 $ .'C &resh &eed &urnace
1 5$- $ $st 'tage ;eactor Treatment &urnace
1 5*- $ %nd 'tage ;eactor &eed 1eater A ;egeneration &urnace
CHECKED BY PAGE 133
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
6

CKR-PR-P-001
PUMPS
ITE/
NO(
>T7( DESCRIPTION
P %$- AC ( 0.). Circulating Pump
P %$$ A" % Pan )il Circulating Pump
P %%- AC ( 0uench 4ater Circulating Pump
P %%$ A" % 0uench )il Tower ;eNu: Pump
P %%+ AC ( 'econdary 0uench 4ater Circ. Pump
P %(- A" % 1eavy &uel )il Product Pump
P %*- A" % 2ight &uel )il Product Pump
P %+- A" % 6istillate 'tripper "ottoms Pump
P %3- A" % 6ilution 'team 'tripper &eed Pump
P %5- $ 0) 6rain 6rum Pump
P (-- A" % 4ash )il InQection Pump
P ($- A" % C.<. $st 'tage Condensate Pump
P (%- A" % 6istillate 'tripper &eed Pump
P (*$ A" % Concentrated Caustic Pump
P (*% A" % 4eak Caustic Circulating Pump
P (*( A" % !edium Caustic Circulating Pump
P (** A" % 'trong Caustic Circulating Pump
P (*+ A" % 4ash 4ater Circulating Pump
P (*3 A" % Caustic rea 'umYp Pump
P (*5 A" % romatic <asoline Circulating Pump
P (*7 A" % 'pent Caustic 6ischarge Pump
P (*8 $ romatic <asoline InQection Pump
P (++ A" % Cracked <as ;ecti,er ;eNu: Pump
P (3- A" % Condensate 'tripper "ottoms Pump
P *-- A" % !ethanol Pump
P *-$ $ !ethanol .nloading Pump
P *%+ A" % 6emethaniGer ;eNu: Pump
P **+ A" % 6eethaniGer ;eNu: Pump
P *+$ AC ( C* Coolant Circ. Pump
P *5- A" % 9thylene ;ecti,er "ottoms Pump
P *5+ A" % 9thylene ;ecti,er ;eNu: Pump
P +$+ A" % 6epropaniGer ;eNu: Pump
P +$3 A" % C( 1ydrogenation &eed Pump
P +%- A" % C( 1ydrogenation ;ecycle Pump
P +(- A" % 'econdary 6eethaniGer "ottoms Pump
P +(+ A" % 'econdary 6eethaniGer ;eNu: Pump
P +(3 A" % Tertiary 6eethaniGer "ottoms Pump
P +(5 A" % Tertiary 6eethaniGer ;eNu: Pump
P ++- A" % Propylene Transfer Pump
P +++ A" % Propylene Tower ;eNu:AProduct Pump
P +3+ A" % 6ebutaniGer ;eNu:AProduct Pump
P 5-$ A" % $st 'tage &eed Pump
P 5$- A" % $st 'tage 0uench Pump
CHECKED BY PAGE 134
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
6

CKR-PR-P-001
PUMPS
ITE/
NO(
>T7( DESCRIPTION
P 5$$ A" * Polymerisation Inhibitor Pump
P 5%+ Ab % 6epent aniGer ;eNu: Pump
P 5(- A" % 6eoctaniGer "ottoms pump
P 5($ A" % 4ash )il Transfer Pump
P 5(+ A" % 6eoctaniGer ;eNu: Pump
P 5(3 A" % %nd 'tage &eed Pump
P 5*- A" % %nd stage 0uench Pump
P 5*% $ 6!6' InQection Pump
P 5+- A" % C3BC7 Product Pump
P 5+% $ Corrosion Inhibitor Pump
P 5++ A" % 'tripper ;eNu: Pump
P 7-$ A" % &eed Pump
P 7-% A" % ;ecycle Pump
P 7-( A" % C* Product Pump
P 8-- AC ( "oiler &eed 4ater Pump
P 8-$ A" % 2P "oiler &eed 4ater Pump
P 8-% A" % knockBout 6rum 'lops Pump
P 8$- AC ( "oiler &eedwater !akeBup Pump
P 8$* $ CP. &eed Pump
P 8$+ A" % Polisher Caustic Pump
P 8$3 A" % Polisher cid Pump
P 8$5 $ Polisher 9fuent Pump
P 8(- A" % C< Compressor Turbine Condensate Pump
P 8($ A" % Cracked <as Compressor 'eal )il Pump
P 8(% A" % Cracked <as Compressor 2ube )il Pump
P 8*% A" % !ethane 9:pander A ;comp. Condensate Pump
P 8+3 A" % 6ebutaniGer ;eboiler Condensate Pump
P 83- A" % C%; Comp. Turbine Condensate Pump
P 83$ A" % C%AC( ;efrig Comp. 2ube A 'eal )il Pump
P 83+ A" % C(; Comp. Turbine Condensate Pump
P 85$ A" % 'A9 2) Pump "B5$- A"
P 85* A" % 'A9 2) Pump "B5*- A"
P 87$ AC ( Phosphate InQection Pump
P 87% A" % 1ydraGine InQection Pump
P 87( AC ( Polymerisation Inhibitor InQection Pump
P 87+ A6 * &resh &eed &urnaces 6!6' InQection Pumps
P 873 AC ( 6!6' InQection Pump
P 875 A" % Corrosion Inhibitor InQection Pump
P 877 A" % 6efoaming gent InQection Pump
P 878 A" % 'uspect Condensate Pump
P 88- A" % &uel <as Compressor 2ube A 'eal )il Pump
P 88$ AC ( "oiler &eedwater 2ube )il Pump
CHECKED BY PAGE 135
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
6

CKR-PR-P-001
PUMPS
ITE/
NO(
>T7( DESCRIPTION
P 88% A" % u:. Corrosion Inhibitor InQection Pumps
P 88+ A6 * 'torm 'ewer Transfer Pump
P 883 A" % )4' Transfer Pump
P 885 A" % Portable 6ewatering Pump
P $$-$ A" % 'pent Caustic &eed A ;ecycle Pump
P $$-% A" % 1igh Pressure &eed Pumps
P $$-( A" % 9fuent Transfer Pumps
P $$-* A" % 'team 'tripper "ottoms Pump
P $$%$ A" % 'C) ;eactor &eed Pump
P $$%% A" % 'C) 9fuent Transfer Pump
CHECKED BY PAGE 136
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
6

CKR-PR-P-001
.&A'*+.S
ITE/
NO(
>T7( DESCRIPTION
; *+$ AC ( C% 1ydrog. diabatic ;eactor
; *+% A" % Prim. C% 1ydrog. diabatic ;eactor
; +($ $ C( 1ydrog. ;eactor X $
; +($ " $ C( 1ydrog. ;eactor X %
; +($ C $ C( 1ydrog. ;eactor X (
; +(% $ C( 1ydrog. 'econd 'tage ;eactor
; 5$- A" % &irst 'tage ;eactor
; 5*- $ 'econd 'tage ;eactor
; 7-$ $ 1ydrogenation ;eactor
; 7-% $ &inal 1ydrogenation ;eactor
; 7-( $ C*1 ;eactor >.nitB%@
; 7-* $ C*1 &inal 1ydrog. ;eactor >.nitB%@
; $$-$ $ ):idation ;eactor
; $$%% A"AC ( 'C) ;eactor
*ANKS
ITE/
NO(
>T7( DESCRIPTION
T (-- $ 4ash )il Tank
T (*- $ Concentrated Caustic Tank
T *-- $ !ethanol Tank
T 5$$ $ Polymerisation Inhibitor Tank
T 5+% $ Corrosion Inhibitor Tank
T 8-- $ CP. &eed 'urge 6rum
T 8$- $ "&4 !akeBup 'torage Tank
T 8$* $ Polisher cid 'torage Tank
T 8$+ $ Polisher Caustic Tank
T 8$3 $ Polisher cid Tank
T 87$ $ Phosphate !i:ing Tank
T 87% $ 1ydraGine !i:ing Tank
T 87( $ Polymerisation Inhibitor Tank
T 873 $ 6!6' Tank
T 875 $ Corrosion Inhibitor !i:ing Tank
T 877 $ 6efoaming gent !i:ing Tank
T $$-$ A" $ 'pent Caustic 1olding Tank
CHECKED BY PAGE 13
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
6

CKR-PR-P-001
D.UMS
ITE/
NO(
>T7( DESCRIPTION
E -3$ $ 2P<AC* rafnate Eaporiser &eed 6rum
E $$- $ 'team 6rum >.'C &urnace@
E $$$ $ 'team 6rum >.'C ;ecycle &urnace@
E $%- $ 'team 6rum >.'C &urnace@
E $%$ $ 'team 6rum >.'C ;ecycle &urnace@
E $(- $ 'team 6rum >.'C &urnace@
E $($ $ 'team 6rum >.'C ;ecycle &urnace@
E $*- $ 'team 6rum >.'C ;ecycle &urnace@
E $+- $ 'team 6rum >.'C ;ecycle &urnace@
E $3- $ 'team 6rum >.'C ;ecycle &urnace@
E $8% $ 'team 6rum >.'C ;ecycle &urnace@
E $8* $ 'team 6rum >.'C ;ecycle &urnace@
E $83 $ 'team 6rum >.'C ;ecycle &urnace@
E $87 $ 6ecoke 6rum 'eparatorA'ilencer
E $88 $ 6ecoke 6rum 'eparatorA'ilencer
E %3% A" % 4ater 'tripper &eed Coalescer
E %5- $ 0uench )il 6rain 6rum
E ($- $ C< &irst 'tage 'uction 6rum
E (%- $ C< 'econd 'tage 'uction 6rum
E ((- $ C< Third 'tage 'uction 6rum
E ((+ $ C< Third 'tage 6ischarge 6rum
E (*- $ C< &ourth 'tage 'uction 6rum
E (*% $ 'pent Caustic 6eoiling 6rum
E (*( $ 'pent Caustic 6egassing 6rum
E (*3 $ Cracked <as ;ecti,er ;eNu: 6rum
E (+8 $ Condensate 'tripper &eed Coalescer
E (5- A" % Cracked <as 6ehydrators
E (5$ $ ;eactivation <as 'eparator
E *-( $ 6emethaniGer Preclr. =o.( ;efrig. &lash Pot
E *-3 $ 6emethaniGer Preclr. =o.3 &lash Pot
E *$- $ 6emethaniGer Prestripper &eed 6rum
E *$$ $ 6emethaniGer &eed 6rum =o.$
E *$% $ 6emethaniGer &eed 6rum =o.%
E *$( $ 6emethaniGer &eed 6rum =o.(
E *$* $ 6emethaniGer Prestripper Parallel &eed 6rum
E *$+ $ 6emethaniGer Parallel &eed 6rum =o.$
E *$3 $ 6emethaniGer Parallel &eed 6rum =o.%
E *$5 $ 6emethaniGer Parallel &eed 6rum =o.(
CHECKED BY PAGE 13!
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
6

CKR-PR-P-001
D.UMS
ITE/
NO(
>T7( DESCRIPTION
E *$7 $ !ethane 9:pander %nd 'tage 'uction 6rum
E *$8 $ 9B*$8 #nockout 6rum
E *%- $ 6emethaniGer ;eboiler ;efrig. 'eal Pot
E *%% $ 6emethaniGer Parallel Precooler X * &lash Pot
E *%( $ 6emethaniGer Parallel Precooler X * &lash Pot "
E *%* $ 6emethaniGer Parallel Precooler X 3 &lash Pot "
E *%+ $ 6emethaniGer Condenser ;efrig &lash Pot
E *%3 $ 6emethaniGer ;eNu: 6rum
E *($ $ 1ydrogen 6rum
E *(% $ P' .nit 'urge 6rum
E *(3 $ ;esidue <as ;ect. ;eNu: 6rum
E **+ $ 6eethaniGer Condenser ;efrig. &lash pot
E **3 $ 6eethaniGer ;eNu: 6rum
E *+( A" % 'econdary 6ehydrators
E *++ $ C% 1ydrogenation 9fuent 'eparator
E *3- $ 9thylene 'tripper ;efrig. 'eal Pot
E *53 $ 9thylene ;ecti,er ;eNu: 6rum
E *55 $ 9thylene Prod. Eaporiser ;efrig. 'eal Pot
E *7- $ 9thylene Product Cooler =o.$ ;efrig. &lash Pot
E *7$ $ 9thylene Product Cooler =o.% ;efrig. &lash Pot
E *7% $ 9thylene Product Cooler =o.( ;efrig. &lash Pot
E *8- $ 1P 9thylene Product 1eater =o.$ 'eal Pot
E +$3 $ 6epropaniGer ;eNu: 6rum
E +$8 $ C( 1ydrogenation &eed Coalescer
E +%+ $ C( 1ydrogenation 'eparator
E +(3 $ 'econdary 6eethaniGer ;eNu: 6rum
E +(5 $ Tertiary 6eethaniGer ;eNu: 6rum
E ++3 $ Propylene ;ecti,er ;eNu: 6rum
E +33 $ 6ebutaniGer ;eNu: 6rum
E 3$- $ 9thylene ;efrig. $st 'tage 'uction 6rum
E 3%- $ 9thylene ;efrig. %nd 'tage 'uction 6rum
E 3(- $ 9thylene ;efrig. (rd 'tage 'uction 6rum
E 3*+ $ 9thylene ;efrigerant 'urge drum
E 3*3 $ 9thylene ;efrigerant 6rain 6rum
E 3+- $ 9thylene ;efrigerant 'ubcooler &lash pot
E 33- $ Propylene ;efrig. $st 'tage 'uction 6rum
E 35- $ Propylene ;e,rg. %nd 'tage 'uction 6rum
E 37- $ Propylene ;efrig. (rd 'tage 'uction 6rum
E 38- $ Propylene ;efrig. *th 'tage 'uction 6rum
E 38+ $ Propylene ;efrigerant 'urge 6rum
E 383 $ Propylene ;efrigerant 6rain 6rum
E 5-$ $ &eed 'urge 6rum
E 5$- $ $st 'tage 1ot 'eparator
CHECKED BY PAGE 13"
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
6

CKR-PR-P-001
D.UMS
ITE/
NO(
>T7( DESCRIPTION
E 5$$ $ $st 'tage Cold 'eparator
E 5$% $ $st 'tage #nockBout 6rum
E 5$( $ 6ecoking 6rum
E 5%3 $ 6epentaniGer ;eNu: 6rum
E 5($ $ 4ash )il 1olding 6rum
E 5(3 $ 6eoctaniGer ;eNu: 6rum
E 5(5 $ UB5(3 )ily 4ater 'eparator
E 5*- $ %nd 'tage 'eparator 6rum
E 5*$ $ %nd 'tage #nockBout 6rum
E 5+3 $ 'tripper ;eNu: 6rum
E 7-$ $ &eed 'urge 6rum
E 7-% $ 1ot 'eparator
E 7-( $ Cold 'eparator
E 7-* $ C* Product &lash 6rum
E 7-+ $ C*1 &eed 'urge 6rum >.nitB%@
E 3-3 $ C*1 1ot 'eparator >.nitB%@
E 7-5 $ C*1 Cold 'eparator >.nitB%@
E 7-7 $ C* Product &lash 6rum >.nitB%@
E 8-- $ 6eaerator
E 8-$ $ Cold &lare #nockBout 6rum
E 8-% $ 1ot &lare #nockBout 6rum
E 8-* $ '(.+ 'uspect Condensate 6rum
E 8-+ $ <) &eed 1eater =o.( Condensate Pot
E 8-3 $ <) &eed 1eater =o.% Condensate Pot
E 8-5 $ !ethanol Eaporiser =o.$ Condensate Pot
E 8-7 $ Cold "lowdown Eaporiser Condnesate Pot
E 8$+ BC ( Polisher !i:ed "eds
v 8$3 $ Polisher ;egn Eessel
E 8$5 $ Polisher 9fuent Eessel
E 8%- $ '*- 'team Condensate &lash 6rum
E 8%3 $ 6'< &eed 1eater =o.% Condensate Pot
E 8%5 A" $ 6'< ;eboiler Condensate Pots
E 8%7 $ 0uench 4ater 'team 1eater Condensate Pot
E 8(- $ '$% 'team Condensate &lash 6rum
E 8($ $ Continuous "lowdown 6rum
E 8(% $ Intermittent "lowdown 6rum
E 8(5 $ ;eactivation <as 1eater Condensate Pot
E 8*- $ &uel <as !i:ing 6rum
E 8*+ $ C% 1ydrog. &eed 4ater Condensate Pot
E 8*3 $ C% 1ydrog. dia ;eactor &eed 1tr Cond. Pot
E 8+* $ Propylene Tower ;eboiler Condensate Pot
E 8+3 $ 6ebutaniGer ;eboiler Condensate Pot
E 83$ $ 2P<AC* ;afnate Eaporiser Cond Pot
E 85% $ 6epentaniGer ;eboiler Condensate Pot
CHECKED BY PAGE 140
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
6

CKR-PR-P-001
*a4le 1
ITE/
NO(
>T7( DESCRIPTION
E 85( $ 6eoctoniser ;eboiler Condensate Pot
E 85+ $ 'tripper ;eboiler Condensate Pot
E 87- $ C(AC* &uel Eaporiser Condensate Pot
E 87$ $ &uel <as 'uperheater Condensate Pot
E $$-$ $ 'team 'tripper &eed Preheater Condensate Pot
E $$-% $ 4ater #.). 6rum
E $$-( $ 'C) ;eactor &eed 'urge 6rum
E $$%$ $ 'C) &eed 'urge 6rum
E $$%% $ 'C) 9fuent 'urge 6rum
E $$%( $ 'C) ir 'urge 6rum
CHECKED BY PAGE 141
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.

CKR-PR-P-001
)LARE S7STE/
CHECKED BY PAGE 142
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.

CKR-PR-P-001
@(1 Pressure Re+ie;% =+o?do?n and Fare s0ste-
@(1(1 Pressure Re+ie; 8a+6e $eader S0ste-
4ithin Cracker Plant, a relief valve 1eader system is provided
to collect hydrocarbon discharges C
$. The C% F lighter efuents which below B*+
-
C are collected in
the cold Nare header made of autenitic steel subQected to
gravity separation in the cold Nare knockout drum and steam
superheated prior to being discharged to the hot Nare header.
%. Cold dry efuents >basically C(@ at temperatures from
-
C to
B*+
-
C are collected in the intermediate Nare header >I&@ which is
>2TC'@ subQected to gravity separation in the same knockBout
drum as the C% and lights efuents.
(. 1ot wet efuents above
-
C are collected in a carbon steel
header and subQected to gravity separation in the horNare
knockout drum. The gases from this drum Qoined by the
superheated efuent from the cold knockout drum and sent to
)'"2 Nare stack.
*. Cold Nare knock out drum vaporiser which vaporises any
li/uid lighters and the outlet superheater is provided, heated by
steam via an intermediate methanol loop as a heating medium.
@(1(' =+o?do?n S0ste-
CHECKED BY PAGE 143
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.

CKR-PR-P-001
"lowdown 'ystems are provided to remove residual
hydrocarbon only during unit shut down or ,re emergency. The
drains of all hydrocarbons that will vaporise when opened to
atmosphere are routed to the blowdown system. 1ot blowdown
is having C' piping >above
-
C@ and cold blown is provided with
'' headers. These drain are collected in a common headers
and terminate in their corresponding relief valve header #4
drums.
Provision is made for vaporising any coalesced li/uids. In cold
Nare knockout drum, a steam heated indirect e:changer is used
while in hot Nare knock out drum a steam coil is used.
ny accumulated li/uid from cold or hot Nare knock out drum
are pumped either to /uench oil tower or to )'"2.
@(' )+are s0ste- at OS=L
&lare from cracker I'"2, Tank farm, !9< F romatics gaseous
efuents are collected in the common header and are routed to
)'"2 Nea stack system.
&lare stack system, corrosion of knock out drum where any
li/uid is separated. Then gases are passed to li/uid drum where
these gases bubbled through water seal and reach the Nea
stack. Then there gases pass through molecular seal at the
stack top and are burnt at the Nare tip.
CHECKED BY PAGE 144
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.

CKR-PR-P-001
* =o.s of burners continuously burn at the tip which is supplied
by fuel gas separately. &lare front generator located at grade
provides necessary ignition for putting pilots on these are
designed remain on even during heavy wind with rain. 9ach
pilot is provided with a thermocouple which sends any loss of
Nare and connected to alarm. 'ystem both out the local panel
and in 6C'. lso, one thermocouple provided at the centre of
the tip gives warning incase of any burnback.,
Two stages of steam are provided one at the centre into the
Nare trip to cool the Nea provides steam for complete
combustion. Centre, steam is adQusted manually at controlled
rate and the 0' steam which is varied in accordance to the Now
to obtain smokeless Nare.
&lare stack design parameters
)+are "as!
&low ;ate C $,-+-,378 kgAhr
!ot. 4t. C ((.%3
Temp.C 7-
-
C
Pi+ot "as!
Type C &uel <as
CHECKED BY PAGE 145
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.

CKR-PR-P-001
Pressure C $--% kgAcm%g
!4 C $8.+5
Stea- !
Pressure C 5.-( kgAcm%g Z Nare trip.
&low ma:. C (%,3+8 kgAhr 0' manifold Z 5.-( kgAcm%g
&low C *(- kgAhr. Cooling rate for 0' manifold
&low !a:. C (7++ kgAhr. through centre tip Z 5.-( kgAcm%g
&low C %%+ kgAcm%g cooling rate for center tip Z 5.-( kgAcm%
OPERATIN" INSTRUCITONS C
Pre-Start Up CecC List
"efore starting up the Nare, checks should be made for the
following items C
$. Eerify that all the Nare components are installed in
accordance with the reference drawings.
%. If chromelBalumel Type # thermocouples are used, the blue
wire is negative >B@ and the brown wire is positive >I@.
(. ll system lines should be dry and free of dirt and foreign
material.
*. Check that all drain and vent valves are closed and that all
drain and vent plugs are tightly secured. drain plug or
valve is re/uired at each low point in each pilot ignition line.
+. ll manual valves in the pilot gas and waste gas systems
should be closed.
3. Check that all set points are properly adQusted.
CHECKED BY PAGE 146
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.

CKR-PR-P-001
5. The pilot ignition lines must be dry and unobstructed so that
the Name front is not /uenched or blocked.
Start-Up and Operation Procedures ;or S-oCe+ess )+are
S0ste- 9>S-C<!
The 99&B0'B3-A33C Nare uses * 9nergy 9fcient Pilots as an
ignition source. The Nare is e/uipped with a 7P 0' 'team
!anifold and steam inQectors capable of providing (%,3+8 kgAhr
of saturated steam Z 5.-( kgAcm%g. (P Centre 'team
'parger is included which is capable of providing (,7++ kgAhr of
saturated steam Z 5.-(kgAcm%g.
continuous steam Now of (5+ kgAhr should be maintained to
the 0' 'team !anifold for cooling and to prevent cracking of
the steam inQectors and manifold. The centre steam sparger
re/uires %%+ kgAhr of cooling steam.
1( Start up and operation!
Ligt te pi+ots!
The method of lighting the * pilots should be carried out using
the Name front generator panel. >refer to appendi: OP B
O)perating Instructions for &lame &ront <eneratorP B "ulletin
+*-$9 >% pages@.
c@ Introduce the cooling steam Now to the Centre 'team >%%+
kgAh@. The Centre 'team rate should be set manually.
CHECKED BY PAGE 14
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.

CKR-PR-P-001
d@ Introduce the cooling steam Now to the upper 0' 'team
;ing >(5+ kgAhr@.
e@ 'tart the waste gas Now at a nominal vent rate >+--B$---
kgAhr@
f@ 4ith the 0' 'team set at the cooling rate of (5+ kgAhr,
adQust the Centre 'team until smokeless operation is
achieved. It may be necessary to make this adQustment
several times with the Nea receiving gas at the nominal vent
rate.
4hen the re/uired Centre 'team rate is achieved, it should be
changed. It is suggested that the Centre 'team manual valve
handle be removed.
'ince one of the purposes of the Centre 'team is to prevent
burnBback inside the Nare tip, it is advisable to observe the Nare
tip at night for a glow >e:cessive heat@ below the Nare tip e:it.
The above procedure should be followed for initial startBup.
g@ 6uring a Naring event, the steam Now to the 0' 'team
!anifold should be adQusted to the point where smoke is not
visible and the Name is a yellow orange colour. The amount
of steam to achieve this is anticipated to be -.* kg steam
per $.-- kg. waste hydrocarbon.
h@ fter cessation of a Naring event, the 0' 'team !anifold
rate should be returned to a rate of (5+ kgAh for cooling. 6o
not readQust the centre steam rate as the Nare will still be
e:periencing a nominal vent rate of waste gas.
CHECKED BY PAGE 14!
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.

CKR-PR-P-001
'( Sut do?n
a@ Close the steam supply valves to the 0' 'team !anifold on
the Nare trip. Close the steam supply to the Centre 'team
'parger.
c@ 'hut 6own the purge gas Now C
d@ 9:tinguish the pilots by closing the pilot fuel gas block valve.
e@ Close all hand valves.
f@ Close all utility gas supply systems
OPERA TIN" INSTRUCITIONS )OR )LA/E )RONT "ENERATOR
Important C
. ll ignition lines must be one rich.
". ll low spots in ignition lines must be drained
=ote C 'agging between supports is sufcient to cause low
spots in the line which can hold li/uids and /uench ignition
Name.
C. Con,rm that all utilities are connected and operating
properly per the Qob drawing.
Ignition !
$. Purge Nare system with nitrogen or fuel gas until all o:ygen
has been replaced with purge gas.
"low down air and gas supply lines to Name front generator at
blow down valves to remove condensate. )pen all drains in the
low spots of ignition lines. "low down each ignition line, one at
CHECKED BY PAGE 14"
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.

CKR-PR-P-001
a time, through valves ,9 and C. Close all drains. Check each
ignition line for blockage by opening valve 6 and at a time.
4hen valve 6 is closed, pressure should fall oH rapidly on the
pressure gauges. If pressure does not fall oH rapidly, investigate
and correct the blockage in the ignition line.
(. Push switch J&P actuate !agiclite to check for spark at the
sight port.
*. )pen valve OK. Close valve O"P and OCP to ignite pilot =o.$
+. )pen valve O1P. This is the fuel for pilots.
3. )pen valve O9P and set pressure gauge at $- psig. >gas@.
5. )pen valve O6P and set pressure gauge at $( psig. >air@.
7. 4ait two to three minutes after opening valves 9 and 6.
8. Push and release /uickly, switch O&P. t the same time
observe through the sight port to see if airAgas mi:ture was
ignited.
>If same is not observed, change either the air or gas slightly
until Name is observed@. If the system uses !agiclite ignitor,
actuate as if you were using switch O&P.
$-. If pilot does not light, repeat steps 7 and 8.
$$. If repeating steps 7 and 8 two or three times does not ignite
the pilot, change air or gas pressure slightly using valve O6P or
valve O9P. ;epeat steps 7 and 8 until pilot is ignited.
$%. Close valve OP. )pen valve O"P to ignite Pilot =o.(. ;epeat
steps 7 and 8 until the pilot is ignited.
$*. 4hen all pilots are ignited, close valves J6P and O9P.
CHECKED BY PAGE 150
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.

CKR-PR-P-001
$+. )n light or sunny days, if is difcult to observe pilot Name
to verify ignition. To observe pilot Name, close valve O6P and
open valve O9P fully for two or three minutes. If ignited, pilot
Name will become luminous. This can be repeated for each pilot
by opening and closing valves ,", and C.
$3. fter all pilots are ignited and veri,ed, the Nea is ready for
operation. 4aste gas can now be Nared provided the remainder
of each system is operational.
$. If no spark is observed, check the electrical circuit and the
spark gap >$A$3B$A7 inch@.
If a blue Nash cannot be observed at the sight glass, check for
gas and air delivery as follows C
. 6isconnect the spark plug lead and remove sight glass.
". Check for air delivery by opening valve O6P and check for
gas delivery by opening valve O9P.
C. If a noticeable hiss does not occur, break the piping union
and check ori,ces at OIP >air@. and OTP >gas@.
(. If the pilot will not light and the above have been con,rmed.
. Check the piping between the Name front generator and the
pilot to ensue no low points in the piping have ,lled with
condensate.
". 9nsure that pilot gas pressures is per Qob drawing.
If a fuel gas other than that speci,ed on the Qob drawing used,
the ori,ces OIP and OTP must be resiGed. Please contact Tohn
Uink in Tulsa for speci,c recommendations.
CHECKED BY PAGE 151
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
!

CKR-PR-P-001
)(.& 5 /AS D&*&'*(+N S-S*&M
CHECKED BY PAGE 152
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
!

CKR-PR-P-001
1. (N*.+DU'*(+N
In'"(t#i%- !#o$e((e( in$#e%(in5- in.o-.e t)e "(e %n' m%n";%$t"#e o; )i5)- '%n5e#o"( ("<(t%n$e(8
!%#ti$"-%#- to6i$ %n' $om<"(ti<-e 5%(e(. Ine.it%<-8 o$$%(ion%- e($%!e( o; 5%(e( o$$"# $#e%tin5 %
!otenti%- )%A%#' to t)e in'"(t#i%- !-%nt8 it( em!-oee( %n' !eo!-e -i.in5 ne%#<. In mo(t in'"(t#ie(8
one o; t)e &e !%#t( o; %n (%;et !-%n ;o# #e'"$in5 t)e #i(&( to !e#(onne- %n' !-%nt i( t)e e%#--
>%#nin5 'e.i$e ("$) %( /as Detectors. T)e(e $%n )e-! to !#o.i'e mo#e time in >)i$) to t%&e
#eme'i%- o# !#ote$ti.e %$tion. T)e $%n %-(o <e "(e' %( !%#t o; tot%-8 inte5#%te' monito#in5 %n' (%;et
((tem ;o# %n in'"(t#i%- !-%nt.
T)i( #e!o#t i( inten'e' to o;;e# %n o.e#.ie> o; t)e 7i#e %n' G%( Dete$tion S(tem in N%!)t)% C#%$&e#
!-%nt in RIL8 H%Ai#%. It !#o.i'e( % <#ie; e6!-%n%tion o; t)e !#in$i!-e( in.o-.e' in ("$) ((tem( %n'
t)e in(t#"ment%tion nee'e' ;o# (%ti(;%$to# !#ote$tion o; !e#(onne- %n' en.i#onment.
Some o; t)e to!i$( #e-%te' to t)e 7i#e %n' G%( Dete$tion ((tem %#e %-(o 'i($"((e'.
2. '+MBUS*(B,& /AS&S
Com<"(tion i( <%(i$%-- % (im!-e $)emi$%- #e%$tion8 in >)i$) o65en $om<ine( #%!i'- >it) %not)e#
("<(t%n$e #e("-tin5 in t)e #e-e%(e o; ene#5. T)i( ene#5 %!!e%#( m%in- %( )e%t - (ometime( in t)e
;o#m o; ;-%me(. T)e i5nitin5 ("<(t%n$e i( no#m%--8 <"t not %->%(8 %n o#5%ni$ o# )'#o$%#<on
$om!o"n'( %n' $%n <e % (o-i'8 -iB"i'8 .%!o# o# 5%(.

)(.&
A(.
)U&,
0&A*
T)e !#o$e(( o; $om<"(tion $%n <e #e!#e(ente' < t)e >e---&no>n ;i#e t#i%n5-e. A( $%n <e (een8 t)#ee
;%$to#( %#e %->%( nee'e' i.e. % (o"#$e o; i5nition8 o65en %n' ;"e- in t)e ;o#m o; $om<"(ti<-e 5%( o#
.%!o#. In %n ;i#e !#e.ention ((tem8 t)e#e;o#e8 t)e %im i( %->%( to #emo.e %t -e%(t one o; t)e(e
!otenti%-- )%A%#'o"( item(.
3. *+2(' /AS&S
T)o"5) t)e#e i( % -%#5e 5#o"! o; 5%(e(8 >)i$) %#e <ot) $om<"(ti<-e %n' to6i$8 t)e )%A%#'( %n' t)e
#e5"-%tion( in.o-.e' %n' t)e t!e( o; (en(o# #eB"i#e' %#e 'i;;e#ent ;o# t)e t>o $%te5o#ie( o; t)e 5%(e(.
Cit) to6i$ ("<(t%n$e(8 D%!%#t ;#om t)e o<.io"( en.i#onment%- !#o<-em(E t)e m%in $on$e#n i( t)e e;;e$t
on >o#&e#( o; e6!o("#e to e.en .e# -o> $on$ent#%tion(8 >)i$) $o"-' <e in)%-e'8 in5e(te' o# %<(o#<e'
t)#o"5) t)e (&in. It i( im!o#t%nt not on- to me%("#e t)e $on$ent#%tion o; 5%(8 <"t %-(o t)e tot%- time
o; e6!o("#e8 (in$e %'.e#(e e;;e$t( $%n o;ten #e("-t ;#om %''iti.e8 -on5-te#m e6!o("#e. Sometime(
t)e(e ("<(t%n$e( $%n inte#%$t %n' !#o'"$e % ;%# >o#(e e;;e$t >)en to5et)e# t)%n t)e (e!%#%te e;;e$t o;
e%$) on it( o>n.
Con$e#n %<o"t $on$ent#%tion( o; to6i$ ("<(t%n$e( in t)e >o#&!-%$e ;o$"( on <ot) o#5%ni$ %n'
ino#5%ni$ $om!o"n'(8 in$-"'in5 t)e e;;e$t( t)e $o"-' )%.e on t)e )e%-t) %n' (%;et o; em!-oee(8 t)e
CHECKED BY PAGE 153
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
!

CKR-PR-P-001
!o((i<-e $ont%min%tion o; % m%n";%$t"#e' en' !#o'"$t Do# eB"i!ment "(e' in it( m%n";%$t"#eE %n'
%-(o t)e ("<(eB"ent 'i(#"!tion o; no#m%- >o#&in5 %$ti.itie(.
Con$ent#%tion( o; 5%( in %i# %#e e6!#e((e' %( !%#t( !e# mi--ion D!!mE8 >)i$) i( % me%("#e o; 5%(
$on$ent#%tion < it( .o-"me.

4. &2P,+S(6& ,(M(*S

T)e#e i( on- % -imite' <%n' o; 5%(,%i# $on$ent#%tion8 >)i$) >i-- !#o'"$e % $om<"(ti<-e mi6t"#e. T)i(
<%n' i( (!e$i;i$ ;o# e%$) 5%( %n' .%!o# %n' <o"n'e# < %n "!!e# -e.e-8 &no>n %( t)e Upper &7plosi8e
,i9it :U&,; %n' % -o>e# -e.e-8 $%--e' t)e ,o<er &7plosi8e ,i9it :,&,;.

*++
.('0
),AMMAB,&
.AN/&
*++
,&AN
100= air
0= >as
,&,
U&,
100= >as
0= air
At -e.e-( <e-o> t)e LEL8 t)e#e i( in(";;i$ient 5%( to !#o'"$e %n e6!-o(ion Di.e. t)e mi6t"#e i( too -e%nE8
>)i-(t %<o.e t)e UEL8 t)e mi6t"#e )%( in(";;i$ient o65en Di.e. t)e mi6t"#e i( too #i$)E. T)e
;-%mm%<-e #%n5e t)e#e;o#e ;%--( <et>een t)e -imit( o; t)e LEL %n' UEL ;o# e%$) in'i.i'"%- 5%( %#e
mi6t"#e o; 5%(e(. O"t(i'e t)e(e -imit(8 t)e mi6t"#e i( not $%!%<-e o; $om<"(tion.
5. 0A?A.D ?+N&S
Not %-- %#e%( o; %n in'"(t#i%- !-%nt o# (ite %#e $on(i'e#e' to <e eB"%-- )%A%#'o"(. 7o# in(t%n$e8 %n
"n'e#5#o"n' $o%- mine i( $on(i'e#e' %t %-- time( to <e %n %#e% o; m%6im"m #i(&8 <e$%"(e (ome
met)%ne 5%( $%n %->%( <e !#e(ent. On t)e ot)e# )%n'8 % ;%$to# >)e#e met)%ne i( o$$%(ion%-- &e!t
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o; t)e !-%nt.
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1. Con.e#(e-8 ;o# %n -i5)te#-t)%n-%i# 5%(e(8 ("$) %( )'#o5en8 met)%ne8 %mmoni%8 et$. T)e (en(o#
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Bot) t)e G%( %n' 7i#e 'ete$tion ((tem( )%.e t>o )i5)>%( e%$). Hi5)>%( one : t>o %#e "(e' ;o#
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)(/ % )(.& 5 /AS D&*&'*(+N S-S*&M B,+'K D(A/.AM
". D&*&'*+.S
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T)e 5%( 'ete$to#( $om!#i(e t>o m%in "nit( - % t#%n(mitte# %n' % (en(o#. A-- "nit( "(e % >e%t)e#
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LEL.
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)(/ % D(M&NS(+NS +) A '+MBUS*(B,& /AS D&*&'*+.
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)(/ % A *+2(' S&NS+.

)(/ % D(M&NS(+NS +) A *+2(' /AS D&*&'*+.
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%<o.e.
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Tot%- 1!0 co94#sti4le >as detectors %#e in t)e !-%nt. Sin$e t)e $om<"(ti<-e 5%(e( )%.e % ten'en$ to
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<"i-'in5 %#e%8 <ot) t)e t!e( o; 'ete$to#( )%.e <een $onne$te' (i'e < (i'e.
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)(/ % S&NS(*(6(*- +) *0& D&*&'*+.S *+1A.DS SM+K&
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-i5)t i( ($%tte#e' on <ot) t)e(e !"-(e( o; t)e !)oto-'io'e $%"(in5 t)e 'ete$to# to 5o to t)e %-%#m (t%te.
At t)e %-%#m (t%te8 % (i-i$on $ont#o--e' #e$ti;ie# on t)e !#inte' $i#$"it <o%#' i( (>it$)e' on %n' t)e
$"##ent '#%>n < t)e 'ete$to# i( in$#e%(e' ;#om %n %.e#%5e o; 20 mA to % m%6im"m o; 91mA. To
en("#e #e-i%<i-it8 t)e LED emit( -i5)t mo'"-%te' %t %<o"t * KHA %n' t)e !)oto-'io'e #e%$t( on- on
#e$ei.in5 -i5)t %t t)i( ;#eB"en$.
".2.2 (oniHation S9oGe Detectors %
An IoniA%tion Smo&e 'ete$to# )%( %n inne# %n' %n o"te# $)%m<e#. T)e inne# : o"te# $)%m<e#( %#e
$%--e' ioniA%tion Dinne# #e;e#en$e $)%m<e#E %n' (mo&e $)%m<e#( #e(!e$ti.e-. DT)e (mo&e $)%m<e#
)%( (mo&e in-et %!!%#%t"( ;itte' >it) %n in(e$t #e(i(t%nt me().E A #%'io%$ti.e (o"#$e )o-'e# %n' t)e
CHECKED BY PAGE 164
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
!

CKR-PR-P-001
(mo&e $)%m<e# %$t( %( !o(iti.e %n' ne5%ti.e e-e$t#o'e( #e(!e$ti.e-. T)e #%'io%$ti.e (o"#$e i( in(i'e
t)e ioniA%tion $)%m<e#. T)i( #%'io%$ti.e (o"#$e i##%'i%te( t)e %i# in <ot) t)e $)%m<e#( to !#o'"$e
!o(iti.e %n' ne5%ti.e ion(. On %!!-in5 % .o-t%5e %$#o(( t)e e-e$t#o'e(8 %n e-e$t#i$ ;ie-' i( ;o#me'.
T)e ion( %#e %tt#%$te' to t)e e-e$t#o'e( o; o!!o(ite (i5n(8 (ome ion( $o--i'e %n' #e$om<ine8 <"t % (m%--
net e-e$t#i$ $"##ent ;-o>( <et>een t)e e-e$t#o'e(. A (en(in5 e-e$t#o'e <et>een t)e t>o $)%m<e#(
$on.e#t( .%#i%tion( in t)e $)%m<e# $"##ent( into % .o-t%5e. C)en (mo&e !%#ti$-e( ente# t)e ioniA%tion
$)%m<e#8 ion( <e$ome %tt%$)e' to t)em %n' #e'"$e t)e $"##ent ;-o>in5 t)#o"5) t)e ioniA%tion
$)%m<e#. T)e $"##ent in t)e (mo&e $)%m<e# #e'"$e( ;%# mo#e t)%n t)%t o; ioniA%tion. T)i( im<%-%n$e
$%"(e( t)e (en(in5 e-e$t#o'e to 5o mo#e !o(iti.e. T)e (en(o# e-e$t#oni$( monito#( t)e .o-t%5e on t)e
(en(in5 e-e$t#o'e %n' !#o'"$e( % (i5n%- >)en % !#e(et t)#e()o-' -e.e- i( #e%$)e' %n' $%"(e( t)e
'ete$to# to 5o to t)e %-%#m (t%te.
T)e tot%- n"m<e# o; (mo&e 'ete$to#( "(e' in t)i( !-%nt i( 133 %n' t)e(e )%.e <een ("!!-ie' < A!o--o
7i#e Dete$to#( Limite'. T)e 'ete$to#( %#e "(e' in(i'e t)e $ont#o- #oom <"i-'in5 %#e%. T)e(e %#e
mo"nte' on t)e $ei-in58 %<o.e $ei-in5 %n' <e-o> ;%-(e ;-oo#in5. Remote in'i$%to#( %#e %-(o !#o.i'e'
;o# 5i.in5 in'i$%tion o; %n %$t"%tion %<o.e $ei-in5.
T)e IoniA%tion : O!ti$%- Smo&e 'ete$to#( %#e i'enti$%- in %!!e%#%n$e. T)e 'i;;e#en$e i( t)%t8 t)e
$o-o# o; t)e LED( on t)e IoniA%tion %n' O!ti$%- Smo&e 'ete$to#( %#e #e' %n' >)ite #e(!e$ti.e-. B"t
>)en t)e 5et %$t"%te'8 <ot) emit #e' -i5)t.
T)e tot%- n"m<e# o; s9oGe detectors "(e' in t)e $ont#o- #oom <"i-'in5 %#e% i( 155.
".3 Heat detectors %
He%t 'ete$to#( %#e <%(i$%-- tem!e#%t"#e-(en(in5 'e.i$e(. T)e m%in ;"n$tion o; t)e )e%t 'ete$to#( i( to
!#o.i'e ;i#e 'ete$tion >)e#e (!ee' o; #e(!on(e i( not (o $#iti$%-8 o# ;o# t)e %#e%( >)e#e "n>%nte'
t#i55e#in5 o; (mo&e 'ete$to#( i( -i&e- to o$$"#8 i.e. &it$)en %n' >o#&()o! %#e%(.
He%t 'ete$to#( %#e %.%i-%<-e in t)#ee <%(i$ ;o#m( --- 7i6e' Tem!e#%t"#e8 R%te o; Ri(e (en(o#( %n' R%te
Com!en(%te' (en(o#(. 7i6e' Tem!e#%t"#e t!e 'ete$to#( %#e "(e' in t)i( !-%nt. T)e(e )e%t 'ete$to#(
m% <e o; <i-met%- (>it$) 'e(i5n o# o; (in5-e ;i6e' e-e$t#oni$ t)e#m%- (en(o# 'e(i5n. T)e(e %#e
'e(i5ne' >it) % !#e-(et ;i6e' tem!e#%t"#e t#i! !oint e.5. 908 +3 o# K0
0
C.
I; t)e !#e(et tem!e#%t"#e .%-"e i( e6$ee'e'8 $ont%$t( o; t)e (>it$) $)%n5e( %n' 5ene#%te( %-%#m
(i5n%-. T)e 'ete$to# $ont%$t $-o(e( %t o!e#%tin5 tem!e#%t"#e. T)e $ont%$t i( (e-;-#e(ettin5.
T)e 'ete$to# tem!e#%t"#e (ettin5 i( t)e ("m o; %m<ient tem!e#%t"#e %n' 100
0
7. He#e8 %m<ient
tem!e#%t"#e )%( <een t%&en %( 20
0
7. T)e#e;o#e t)e (et !oint o; t)e )e%t 'ete$to#( i( 120
0
7 o# 90
0
C.
T)e 'ete$to# >i-- 5i.e % -o>--e.e- %-%#m i; t)e tem!e#%t"#e in$#e%(e( to 13J o; it( !#e(et .%-"e.
In $#%$&e# !-%nt on- 13 0eat detectors %#e in "(e. Mo(t o; t)em %#e "(e' in t)e t#%n(;o#me# %#'
%n' Die(e- Gene#%to# #oom.
".4 IR Flame Detectors %
T)e IR 7-%me Dete$to#( !#o.i'e e%#- >%#nin5 o; )'#o$%#<on ;-%me(. T)e 'ete$to#( %#e "(e' ;o# t)e
!#ote$tion o; )i5) #i(& %#e%( ;#om ;i#e D!#o'"$in5 CO1 E $%"(e' < t)e %$$i'ent%- <"#nin5 o; m%te#i%-(8
-i&e ;-%mm%<-e -iB"i'( : 5%(e(8 !%!e#8 >oo'8 !-%(ti$(8 et$. T)e 'ete$to# "(e( in;#%#e' (en(o#(8 ;i-te#(
%n' mi$#o!#o$e((o# t)%t !#o.i'e imm"nit to F<-%$& <o'G ;%-(e %-%#m (o"#$e(. T)e 'ete$to#( )%.e %
.e# ;%(t (!ee' o; #e(!on(e -- t!i$%-- 1 to * (e$on'(.
CHECKED BY PAGE 165
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
!

CKR-PR-P-001
T>o (i5n%-( D>%.e;o#m(E %#e 'e#i.e' ;#om t)e 2.* [m >%.e-en5t)8 >)i$) $o##e(!on'( to )ot CO1
emi((ion( o; % )'#o$%#<on ;i#e. T)e mi$#o!#o$e((o# %n%-(e( t)i( (i5n%- %n' %not)e# one t%&en ;#om
t)e *./[m >%.e-en5t) < me%n( o; % !%#ente' $o##e-%tion te$)niB"e to 'ete#mine t)e !#e(en$e o; ;i#e.
T)e 'ete$to#( $%n (ee )'#o$%#<on ;-%me( t)#o"5) (mo&e %n' )i5) 'en(itie( o; (o-.ent .%!o#(. T)e(e
%#e <-in' to>%#'( ("n#%(.
T)e#e %#e 16 (. )la9e Detectors in t)e !-%nt. T)e(e )%.e <een ("!!-ie' < T)o#n Se$"#it Limite'.
T)e 'ete$to#( %#e "(e' mo(t- in t)e C#%$& G%( Com!#e((o# DCGCE B"i-'in58 Re;#i5e#%tion
Com!#e((o#8 Met)%ne Com!#e((o# S)e-te#8 Re$$-e Com!#e((o# %n' 7"e- G%( Com!#e((o# %#e%.
".5 Manual Call Points %
T)e MAC i( t)e (im!-e(t o; %-- t)e ot)e# 'ete$to#( "(e' in t)e 7i#e %n' G%( 'ete$tion S(tem. T)i( i(
% m%n"%-- o!e#%te' 'e.i$e. T)e MAC "(e' in t)i( !-%nt i( o; FB#e%&-5-%((G t!e. T)e "nit i(
o!e#%te' < %!!-in5 t)"m< !#e(("#e to % !#e-($o#e' 5-%(( !-%te8 #e-e%(in5 % mi$#o-(>it$)8 >)i$) i(
no#m%-- )e-' o!en8 < t)e e'5e o; t)e 5-%(( !-%te %n' %-%#m i( 5ene#%te'. T)e 5-%(( i( $o.e#e' < %
$-e%# ;i-m to !#ote$t t)e o!e#%to# ;#om (";;e#in5 5-%(( $"t( o# (!-inte#( '"#in5 o!e#%tion. D"#in5
o!e#%tion8 t)e LED in t)e ;#ont (i'e %-(o 5-o>(.
T)e n"m<e# o; MAC( "(e' in t)e >)o-e !-%nt i( "0.

)(/ % '+NN&'*(+N D(A/.AM +) MA' 5 SD ).+M )(&,D *+ /AS
PAN&,
CHECKED BY PAGE 166
ISSUE 0
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SECTION MODULE NO.
!

CKR-PR-P-001
T)e#e %#e t>o -e.e- %-%#m( ;o# 5%( 'ete$tion ((tem @
7o# 0-100J LEL 'ete$to#(8 I(t D-o>e#E -e.e- %-%#m i( %t 10J LEL %n' 1n' D)i5)e#E -e.e- %-%#m i(
%t 90J LEL
7o# 0-300 !!m CO 'ete$to#(8 I(t -e.e- %-%#m i( %t 10J i.e. 30 !!m %n' 1n' -e.e- %-%#m i( %t 90J
i.e. *00 !!m.
7o# 0-30 !!m H1S 'ete$to#(8 I(t -e.e- %-%#m i( %t 10J i.e. 10 !!m %n' 1n' -e.e- %-%#m i( %t 30J
i.e. 13 !!m.
10. AUD(B,& AND 6(SUA, A,A.MS
7o# >%#nin5 t)e !e#(on( >o#&in5 in t)e !-%nt o; 5%( -e%&%5e o# ;i#e8 E-e$t#oni$ So"n'e#( %#e "(e'.
T)e tone o; t)e (o"n'e# i( .e# !ie#$in5 D300 - 1000 HAE. T)e (o"n' 5ene#%te' $%n <e mo'"-%te' in %
n"m<e# o; >%( D!"-(e8 >%#<-e8 m"-ti tone8 et$.E >)i$) m%&e( t)e (o"n' (t%n' o"t ;#om ot)e# %m<ient
noi(e(. In %#e%( >)e#e t)e %m<ient noi(e i( !%#ti$"-%#- )i5) to t)e !oint >)e#e t)e o$$"!%nt( %#e
#eB"i#e' to "(e e%# 'e;en'e#(8 F;-%()in5 -i5)tG %-%#m 'e.i$e( %#e %-(o "(e' %( % .i("%- <%$&"! >%#nin5
to t)e o$$"!%nt(.
11. S-S*&M D&S'.(P*(+N
11.1 Gas Control Cabinet %
T)e (i5n%-( ;#om %-- t)e 5%( 'ete$to#( $ome to t)i( $%<inet .i% t)e M%#()%--in5 $%<inet %n' %#e
te#min%te' in t)e ;o"# $)%nne- Sa$e Area 3#ad (np#t :SA3(; $%#'(. T)e(e (i5n%-( %$t %( t)e in!"t
to t)e 0i>A<aB 'ontrol 'ards :0'';. T)e G%( Cont#o- C%<inet )%( ;o"# !%i#( o; HCC(8
;"n$tionin5 in % m%in %n' (t%n'< $on;i5"#%tion. T)e#e %#e t>o Hi5)>%( in e%$) HCC @ P#im%#
%n' Se$on'%#. T)e P#im%# Hi5)>% i( no#m%-- %$ti.e. T)e Se$on'%# Hi5)>% i( %"tom%ti$%--
"(e' i; ;%i-"#e o; t)e P#im%# Hi5)>% i( 'ete$te' < t)e HCC. Comm"ni$%tion t%&e( !-%$e in one
Hi5)>% %t % time. E%$) !%i# o; HCCG( )%( <ot) % '"%- !o>e# ("!!- $%#' %n' % )i5)>% <"(
m%n%5e# mo'"-e. T)e <"( m%n%5e# mo'"-e $ont#o-( t)e (>it$)in5 ;#om t)e m%in to (t%n'< HCC
>)ene.e# t)e '"%- !o>e# ("!!- $%#' ;%i-(.
D"%- 0i>A<aB 6otin> 'ards :06'; %#e inte#;%$e' to e%$) o; t)e ;o"# )i5)>%( to !#o.i'e .ote'
%-%#m(. HVC t%&e( (i5n%-( ;#om t)e HCC %n' .ote( %( !e# "(e# -o5i$8 >)i$) i( $on;i5"#e' in HVC
%n' 5ene#%te( o"t!"t. T)e(e o"t!"t( %#e "(e' to in'i$%te %-%#m(8 (i#en(8 et$. T)e .otin5 o; t)e 7i#e
A#e% i( e6!-%ine' >it) t)e )e-! o; t)e .otin5 -o5i$ %n' t)e $%"(e %n' e;;e$t 'i%5#%m( in t)e ne6t !%5e.
CHECKED BY PAGE 16
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
!

CKR-PR-P-001

)(/ % 6+*(N/ ,+/(' )+. *0& D&*&'*+.S (N *0& )AD3

)A D 3 6+*(N/ MA(N '+N*.+, PAN&, /.AP0(' M(M(' PAN&,S
D G ROOM AUD. ALMS VISUAL ALMS
CAUSE EFFECTS 1 OUT
O7 1
1 OUT
O7 *
AUDIBLE
ALM
VISUAL
ALARM
7IRE GAS AUD ALMD7S
ONLYE
7IRE : GAS 7IRE,7LAME
GAS
DETECTION CCT
HEATDPOINTE 1ST H H H H H H
HEATDPOINTE 1ND H H H H H H H
GAS-7LAM 10J H H H
GAS-7LAM 90J 1ST H H H H
GAS-7LAM 90J 1ND H H H H H H H
MANUAL H H H H H H
)(/ % 'AUS& 5 &))&'* D(A/.AM )+. *0& )AD3
Hi5)>%( one %n' t>o )%.e t>ent-ei5)t SA?I $%#'( e%$). Tot%- (i6teen no o; 19 $)%nne- in!"t $%#'(
%#e "(e' in )i5)>%( t)#ee %n' ;o"#. A SA?I $%#' )%( ;o"# $)%nne-( >)i-(t % 19 $)%nne- I,P $%#' )%(
(i6teen $)%nne-( %( t)e n%me ("55e(t(.
T)e >)o-e !-%nt )%( <een 'i.i'e' into 'i;;e#ent ;i#e %#e%(. A-- t)e 5%(8 )e%t %n' IR ;-%me 'ete$to#(
)%.e "niB"e %''#e((e( %n' t)e %#e $onne$te' in'i.i'"%-- to t)e )i5)>%(. In (ome $%(e(8 MAC %n'
(mo&e 'ete$to#( o; (ome ;i#e %#e%( )%.e <een $onne$te' in -oo!( %n' t)e(e -oo!( )%.e <een %((i5ne'
"niB"e %''#e((e(. T)e ((tem <ein5 %n An%-o5"e A''#e((%<-e S(tem $%nnot $)e$& t)e (t%t"( o; e%$)
o; t)e 'ete$to#( in t)e -oo!.
CHECKED BY PAGE 16!
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
!

CKR-PR-P-001
T)e in$omin5 '%t% o; 5%( $on$ent#%tion %n' ;%"-t in;o#m%tion i( 5%t)e#e' on )i5)>%( one %n' t>o
%n' ;i#e %-%#m,;%"-t (>it$) in!"t( %#e 5%t)e#e' on )i5)>%( t)#ee %n' ;o"#. T)e 2-10 mA %n%-o5"e
-oo! (i5n%-( ;#om t)e 5%( 'ete$to#( $ome to t)e SA?I $%#'(8 >)i$) $on.e#t t)em to 'i5it%- ;o#m%t.
T)e o"t!"t( o; t)e SA?I $%#'( %#e t)e in!"t( to )i5)>% one %n' t>o. T)e (i5n%-( ;#om (mo&e8 )e%t8
IR ;-%me 'ete$to#( %n' MAC $ome to 19 $)%nne- I,P $%#'( D.i% 1 $)%nne- %n' 9 $)%nne- 7i#e $%#'(E.
T)e o"t!"t o; t)e(e $%#'( i( 5i.en to )i5)>%( t)#ee %n' ;o"#.
T)e m%in ;"n$tion o; HCC in !o--in5 mo'e i( to #eB"e(t '%t% ;#om e%$) %''#e(( -oo!. T)e '%t%
$o--e$te' i( $)e$&e' %5%in(t t)e $on;i5"#%tion '%t% in t)e EPROM in t)e HCC. T)e $on;i5"#%tion
'%t% $ont%in( %-%#m (ettin5( %n' #e-% '#i.e# $)%nne- %--o$%tion( ;o# e%$) Hi5)>% 'e.i$e %''#e((. I;
%n %-%#m -e.e-8 ;%"-t o# >%#nin5 $o'e i( !#e(ent in t)e #e$ei.e' me((%5e ;#om %n %''#e((e' 'e.i$e8 %
t#%n(i(to# #e-% '#i.e# $)%nne- m% <e %$ti.%te'.
In (ome (!e$i;i$ %#e%(8 (ome <"t not %-- 'ete$to#( %#e .ote' ;o# ;in%- o"t!"t8 e.5. T>o o"t o; t)#ee
'ete$to#( %#e .ote' i.e. i; %n t>o 'ete$to#( o"t o; t)e t)#ee 5et %$t"%te' t)en on- %n o"t!"t >i-- <e
5ene#%te'.
T)e Hi5)>%( o; %-- t)e ;o"# HCC( %#e $onne$te' to % Data 'oncentrator >)i$) %$t( %( %
m"-ti!-e6e#. T)e D%t% Con$ent#%to# $%n time 'i.i(ion m"-ti!-e6 "!to / HCC(. T)e D%t%
Con$ent#%to# $on.e#t( t)e RS 211 '%t% ;#om t)e HCC to RS 1*1 %n' 5i.e( it to t)e Protocol
'on8erter. T)e P#oto$o- Con.e#te# D<%(e' on Inte- /01/9 $om!%ti<-e (in5-e <o%#' $om!"te#E
inte#n%-- <"i-'( % t%<-e o; GDACS 5%( #e%'in5(8 (en(o# (t%t"(e(8 t!e( %n' #%n5e(. It t)en
$omm"ni$%te( t)e(e .%-"e( in % ("it%<-e ;o#m%t .i% % (e$on' (e#i%- !o#t to t)e DCS ((tem. T)e
P#oto$o- Con.e#te# $on.e#t( GDACS !#oto$o- to MODBUS !#oto$o-8 >)i$) i( %$$e!t%<-e ;o# ABB
DCS.
11.2 Fire control cabinet %
T)e (i5n%-( ;#om t)e 'ete$to#( "(e' ;o# ;i#e 'ete$tion $ome to t)i( $%<inet .i% t)e M%#()%--in5 $%<inet
%n' %#e te#min%te' in t)e 16 cAannel (/P cards. T)e (i5n%-( t)en 5o to t)e HCC( in t)e G%( $ont#o-
$%<inet.
T>o t!e( o; $%#'( %#e "(e' ;o# ;i#e 'ete$tion $ont#o-. *<in ?one )ire card monito#( t)e (mo&e
'ete$tion -oo!( %n' Si7 'Aannel S<itcA (np#t $%#'( monito#( t)e MAC -oo!(.
Be-o> t)e 7i#e C%#'(8 t)e#e i( % ("< !%ne- ;o# !#o.i'in5 %nn"n$i%tion %n' o!e#%tion ;"n$tion(. T)e(e
%#e %( ;o--o>( @
SBste9 AealtAB DG#een LEDE
SBste9 $a#lts DAm<e# LED(E
06A'/Plant Stat#s DAm<e# LED(E
Alar9 reset
Accept
,a9p *est
A#di4le alar9
T)e S(tem He%-t) in'i$%to# in t)e !%ne- 5oe( o;; >)ene.e# t)e#e i( %n ;%"-t in t)e ((tem.
T)e T>in Lone 7i#e Mo'"-e monito#( t)e 'ete$to# -oo! $"##ent ;o# o!en %n' ()o#t $i#$"it( %n' %-(o
!%((e( % nomin%- B"ie($ent $"##ent o; 2 mA t)#o"5) t)e -oo! ;o# monito#in5.
An HARDCARE e##o# $on'ition i( %nn"n$i%te' < .i("%- %n' %"'i<-e %-%#m( >it)in t)e $ont#o-
#oom ;o# initi%- %ttention (ee&in5. T)e %"'i<-e %-%#m )%( t>o tone(8 contin#o#s to 'e;ine ;i#e o# 5%(
%-%#m %n' inter9ittent to 'e;ine % ;%"-t $on'ition.
CHECKED BY PAGE 16"
ISSUE 0
B. DAS AUTHOR BMK
SECTION MODULE NO.
!

CKR-PR-P-001
11.3 Marshalling cabinet %
T)e '"%- <% m%#()%--in5 $%<inet !#o.i'e( t)e m%in te#min%tion ;%$i-it <et>een ;ie-' %n' $ont#o-
e-e$t#oni$(.
T)e !%ne- $ont%in( %-- int#in(i$ (%;et i(o-%tin5 mo'"-e( ;o# in!"t %n' o"t!"t -oo!(.
T!e,mo'e- %n' -oo! t!e@
MTL *021 G%( Dete$tion 2,10 mA -oo!(
MTL *02* 7i#e Dete$tion 1,20 mA -oo!(
Conne$tion( into t)e ot)e# ((tem !%ne-( %#e <ein5 te#min%te' in ELCO (o$&et(.
11.4 Control room mimic cabinet %
T)e $ont#o- #oom mimi$ !%ne- i( $on(i'e#e' t)e m%(te# mimi$. It )o"(e( LED 'i(!-%8 5#%!)i$%--
#e!#e(entin5 ;i#e %n' 5%( Aon%- %-%#m (t%t"(.
LED $o-o#(@ .ed D;i#e 'ete$tionE
A94er D$om<"(ti<-e 5%( 'ete$tionE
Bl#e DTo6i$ 5%( 'ete$tionE
M%(te#,;"n$tion,in'i$%tion(@ S#pplB on
SBste9 Alert DHVAC (t%t"( $)%n5eE
SBste9 $a#lt
,a9p test D(>it$)E
At t)e no#m%- $on'ition8 %-- t)e LED( %n' t)e -%m!( on t)e mimi$ !%ne- %#e o;;. T)e FS(tem A-e#tG
%n' FS(tem 7%"-tG 5-o> on- >)en t)e#e i( %n ;%"-t in t)e ((tem. T)e FL%m! Te(tG (>it$) i( "(e'
;o# $)e$&in5 t)e >o#&in5 $on'ition o; t)e LED( on t)e !%ne-. T)e LED( on % 7i#e A#e% 5-o> >)en
%n 5%( -e%&%5e o# ;i#e i( 'ete$te' in t)%t !%#ti$"-%# %#e%. A '#%;t o; t)e $%<inet i( 5i.en on t)e ne6t
!%5e.
11.5 Fire station mimic cabinet %
T)e ;i#e (t%tion mimi$ $%<inet i( (imi-%# to t)e $ont#o- #oom in #e(!e$t to t)e 'i(!-%.
12. S(&/&. 'A,(B.A*(+N 5 '+MMUN('A*(+N
S+)*1A.& PA'KA/&@ 'A,'+M
T)e o!e#%tion o; t)e G.D.A.C.S. i( ;"-- monito#e' %n' $ont#o--e' >it) t)e )e-! o; (o;t>%#e8 >)i$) i(
&no>n %( 'A,'+M. A PC )%.in5 CALCOM $%n <e $onne$te' to t)e RS 1*1C (e#i%- inte#;%$e on %
Bidico9. T)e Bi'i$om i( % <i-'i#e$tion%- $omm"ni$%to#8 >)i$) $%n $on.e#t <ot) RS 211 : RS
2/3 into RS 1*1 $omm"ni$%tion( ("it%<-e ;o# $onne$tion into % (e#i%- !o#t o; % $om!"te#.
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SECTION MODULE NO.
!

CKR-PR-P-001
C)ene.e# t)e#e i( no .i("%- in'i$%tion 'e;inin5 %n )%#'>%#e ;%i-"#e8 % (o;t>%#e 'i%5no(i( $%n <e
'one t)#o"5) CALCOM. T)e o!e#%to# $%n inte##o5%te % )i5)>% %n' it( #e(!e$ti.e 'e.i$e %''#e((
e-e$t#oni$( %(&in5 ;o# #e(!on(e( to t)e $ont#o- $omm%n'(. T)e #e(!on(e( $ont%in mo#e 'et%i-e' '%t%
on o$$"##en$e o; % ;%"-t. CALCOM i( %-(o "(e' ;o# $%-i<#%tin5 t)e 5%( 'ete$to#(.
13. 'A,(B.A*(+N P.+'&DU.& +) /AS
D&*&'*+.S
Sm%-- !%#ti$-e(8 $o##o(ion8 >%te# m% <-o$& t)e (inte# o; % $om<"(ti<-e (en(o# t)e#e< $%"(in5 it(
;%i-"#e. E6!o("#e to $e#t%in F!oi(on(G $%n %-(o 'e5#%'e t)e !e#;o#m%n$e o; % (en(o#. T)e#e;o#e it i(
e((enti%- t)%t %n 5%( monito#in5 ((tem ()o"-' <e $%-i<#%te' %t t)e time o; in(t%--%tion %( >e-- %(
$)e$&e' #e5"-%#- %n' #e-$%-i<#%te' %( ne$e((%#. An %$$"#%te- $%-i<#%te' standard 5%( mi6t"#e
()o"-' <e "(e' ;o# $)e$&in58 (o t)%t t)e FAe#oG %n' F(!%nG -e.e-( $%n <e (et $o##e$t- on t)e t#%n(mitte#.
He#e >e %#e "(in5 1.3J met)%ne in %i# %( t)e $%-i<#%tion 5%(.
To $%-i<#%te8 one )%( to e6!o(e t)e (en(o# to % ;-o> o; 5%( %n' t)e ot)e# to $)e$& t)e #e%'in5 ()o>n
on t)e ($%-e o; it( $ont#o- "nit DPCE. A'I"(tment( %#e t)en m%'e to t)e FAe#oG %n' F(!%nG
!otentiomete#( "nti- t)e #e%'in5 e6%$t- m%t$)e( t)%t o; t)e 5%( mi6t"#e $on$ent#%tion.
T)e $%-i<#%tion !#o$e'"#e ;o# <ot) t)e $om<"(ti<-e %n' to6i$ 5%( 'ete$to#( i( (%me. C%-i<#%tion $%n <e
'one in (it" o# #emote ;#om t)e t#%n(mitte#. Sen(o#( $%n <e !#e-$%-i<#%te' %n' t)en !-"55e' in. T)e
t#%n(mitte# i( ;%$to# (et %n' 'oe( not #eB"i#e $%-i<#%tion. I; #eB"i#e'8 t)e t#%n(mitte# $%n <e
$%-i<#%te' "(in5 % D#99B Sensor.
T)e (en(o#( %#e $%-i<#%te' #emote ;#om t)e t#%n(mitte# #sin> tAe 'ali4ration #nit %( ;o--o>( @
1. Po>e# i( %!!-ie' %n' >%ite' ;o# 3 min"te( ;o# (t%<i-iA%tion.
1. T)e $%-i<#%tion $o.e# %<o.e t)e %'I"(tment !otentiomete#( %#e -oo(en %n' (-i'e'
"!. T)e 'i(!-% on t)e $%-i<#%tion "nit >i-- ()o> FCALG.
*. Le#o !otentiomete# DMLE i( %'I"(te' to o<t%in Ae#o #e%'in5 on t)e 'i(!-%.
2. Te(t 5%( %t t)e #%te o; 1-1 -ite#(,min i( %!!-ie' %n' >%ite' ;o# 3 min"te( to
(t%<i-iAe.
3. S!%n !otentiomete# i( %'I"(te' "nti- 'i(!-% in'i$%te( 30J LEL o; t)e te(t 5%(.
9. Te(t 5%( i( #emo.e' %n' Ae#o i( #e-$)e$&e'.
+. T)e $%-i<#%tion $o.e# i( ti5)tene' D()o"-' not <e o.e# ti5)tene'E. T)e 'i(!-%
()o"-' #e%' Ae#o %n' t)e FCALG ;#om t)e 'i(!-% ()o"-' 'i(%!!e%#.
T)e %<o.e !#o$e'"#e i( #e!e%te' i; ne$e((%#.
T)e d#99B sensor i( "(e' to inIe$t eit)e# % Le#o o# % .%#i%<-e (i5n%- into t)e t#%n(mitte#.
T)e !#o$e'"#e i( %( ;o--o>( @
1. T)e (en(o# i( #emo.e' ;#om t)e t#%n(mitte# to <e $%-i<#%te' %n' t)e '"mm (en(o# i(
;itte' in it( !-%$e.
1. T)e t#%n(mitte# -o$%- 'i(!-% ()o"-' ()o> F7%"-tG %n' no 5%( #e%'in5.
*. T)e t#%n(mitte# ()o"-' ()o> Ae#o #e%'in5 >)en t)e (>it$) on t)e '"mm i( in Ae#o
!o(ition. I; not8 it ()o"-' <e m%'e Ae#o < %'I"(tin5 t)e (i5n%- -e.e- &no< "nti- Ae#o i(
'i(!-%e'. Le#o $%-i<#%tion $omm%n' i( 5i.en ;#om t)e CALCOM Dt)#o"5) t)e PCE
$onne$te' to t)e D%t% Con$ent#%to# o; t)e ((tem.
2. T)e (>it$) o; t)e '"mm (en(o# i( $)%n5e' to t)e S!%n !o(ition. T)en t)e (i5n%- -e.e-
&no< i( t"#ne' to inIe$t % (im"-%te' F5%( (i5n%-G into t)e t#%n(mitte#. T)e 'i(!-% on t)e
t#%n(mitte# ()o"-' ()o> 30J LEL. 30J S!%n $%-i<#%tion $omm%n' ;#om CALCOM i(
5i.en.
3. T)e t#%n(mitte# ()o"-' in'i$%te Ae#o >)en t)e (>it$) on t)e '"mm (en(o# i( &e!t in
Ae#o !o(ition. T)e t#%n(mitte# ()o"-' %-(o in'i$%te t)e $o##e$t .%-"e >)en t)e (>it$) i(
&e!t on t)e (!%n !o(ition.
CHECKED BY PAGE 11
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SECTION MODULE NO.
!

CKR-PR-P-001
9. A;te# $om!-etin5 t)e te(t(8 t)e '"mm (en(o# i( #emo.e' %n' t)e $o##e$t (en(o# i(
#e;itte' to t)e t#%n(mitte#.
T)e !#o$e'"#e i( #e!e%te' i; #eB"i#e'.
14. '0&'K(N/ P.+'&DU.&
14.1 Smoke Detectors %
Smo&e o# (!#% i( %!!-ie' to t)e 'ete$to#( to $)e$& t)ei# %$t"%tion.
14.2 Heat Detectors %
He%t i( %!!-ie' to t)e 'ete$to# >it) t)e )e-! o; He%t B-o>e# to (ee t)e %$t"%tion.
14.3 IR Flame Detectors %
S!%#& o# ;i#e ;-%me i( 5ene#%te' in ;#ont o; t)e 'ete$to#( %n' $)e$&e' t)ei# %$t"%tion.
14.4 MAC %
A (!e$i%- &e to $)e$& it( o!e#%tion o!e#%te( MAC. T)e LED in t)e ;#ont (i'e 'oe( not 5-o> >)en t)e
MAC i( in ;%"-t $on'ition.
A-- t)e $)e$&in5 !#o$e'"#e( 5i.en %<o.e %#e 'one on-ine.
15. /.AP0('S PA'KA/&
A G#%!)i$( $om!"te# )%.in5 t)e (ntell#tion )(2 >rapAics so$t<are )%( <een in(t%--e' in t)e $ont#o-
#oom ;o# B"i$& %n' e6%$t 'ete$tion o; t)e -o$%tion o; %n ;i#e o# 5%( -e%&%5e. B t)e 5#%!)i$(
inte#;%$e8 %n o!e#%to# 5et( %n o!tim"m !#e(ent%tion o; (ite in;o#m%tion. He $%n %-(o .ie> (en(o# %n'
%-%#m '%t% %t %n -e.e- o; t)e )ie#%#$)i$%- '%t% (t#"$t"#e.
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!

CKR-PR-P-001
An +8er8ie< screen !#o.i'e( t)e o$$"##en$e o; %-%#m in %n Aone. It i( in'i$%te' < t)e $)%n5e o;
<o#'e# $o-o# o; t)%t !%#ti$"-%# Aone. T)e Men# 4ar %t t)e <ottom #i5)t $o#ne# in t)e o.e#.ie> ($#een
)%( 'i;;e#ent ;"n$tion &e(8 e.5. Alar9@ 0istorB@ &n>ineer@ et$.
C)en A-%#m ($#een i( o!ene'8 % ($#een Men" %!!e%#( %t t)e #i5)t )%n' (i'e o; t)e A-%#m S$#een >it)
o!tion(@ Alar9 ,o> )iles : ,o> )iles. T)e A-%#m Lo5 7i-e en%<-e( t)e "(e# to .ie> t)e %-%#m -o5
;i-e( -i(te' in t)e '%te o#'e#. Lo5 ;i-e o!tion $%n <e "(e' to (ee t)e -o5 on,o;; e.ent( %n' (e$"#it
.io-%tion(.
A-%#m Hi(to# 5i.e( t)e -i(t o; %-- t)e %-%#m( in t)e <";;e#.
T)e En5inee#in5 ($#een -i(t( %-- t)e t%5(8 t)ei# 'e($#i!tion(8 $"##ent .%-"e(8 $"##ent (t%t"(8 %n'
GDACS %''#e((e( ;o# %-- t)e (en(o#( in e%$) Aone. No#m%-iA%tion %n' C%-i<#%tion o; t)e 5%( (en(o#(
$%n <e $%##ie' o"t ;#om t)e En5inee#in5 ($#een Men".
T)e 7i#e %#e% (e-e$t Men" on t)e to! #i5)t $o#ne# o; t)e O.e#.ie> ($#een en%<-e( t)e "(e# to .ie> %n
!%#ti$"-%# ;i#e %#e%. A #e' ("##o"n'in5 o; % ;i#e %#e% <"tton in'i$%te( t)e o$$"##en$e o; %n %-%#m.
T)e 'ete$to#( on t)e ($#een %( >e-- %( t)e %-%#m me((%5e %!!e%#in5 in t)e Alar9 S#99arB $ield %t
t)e <ottom o; t)e ($#een $)%n5e( t)ei# $o-o# $o##e(!on'in5 to t)e t!e o; %-%#m8 e.5. % 5%( 'ete$to#8
>)i$) )%( <een ()o>n %( G#een %t no#m%- (t%te8 >i-- <e$ome O#%n5e to in'i$%te % Hi5) %-%#m8 Re' to
in'i$%te HiHi %-%#m %n' Ye--o> to in'i$%te % ;%"-t. T)i( )e-!( t)e o!e#%to# to $)e$& >)et)e# %$t"%-
;i#e o# 5%( -e%& )%( t%&en !-%$e o# not. T>o <"tton( -- FA$$e!tG %n' FA-%#m Re(etG %#e "(e' ;o#
%$$e!tin5 %n' #e(ettin5 %n %-%#m.
A SBste9 screen $%n <e .ie>e' >it) t)e )e-! o; t)e FS(temG <"tton %t t)e #i5)t (i'e o; t)e O.e#.ie>
($#een.
B 'o"<-e $-i$&in5 %t % (en(o# t)e "(e# $%n .ie> t)e *rend /rapAs. T)e t#en' -o5( #e$o#' *0 '%( o;
'%t% %t 1-min"te inte#.%-(. T)e t#en' 5#%!)( o; t)e 5%( 'ete$to#( $%n <e "(e;"- ;o# #e-%tin5 o#
$om!%#in5 t)e 5%( -e.e-( o; t)e !-%nt %#e% %t 'i;;e#ent time(.
CHECKED BY PAGE 13
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B. DAS AUTHOR BMK

Reliance Industries Limited Cracker Plant Process Description and Utilities Manual

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SECTION MODULE NO.

RELIANCE INDUSTRIES LIMITED

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