Ca) VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY OPERATING MANUAL VOLUME 11 PROPYLENE RECOVERY UNIT UNIT 021 BOOK 1/1 8474L-021-ML-001 Technip cal thTechnip th Project n*-Unit Dos. type Mat code Soraln” Rev. Pago 474.021 ML 001 A OP Center Job No. BA-0736 VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY (DQR) PROJECT OPERATING MANUAL UNIT 21 Propylene Recovery Unit Document Class: Z Pages modified under this revision: = 4 | arapeo7 ISSUE FOR APPROVAL Ms Ms of Ens 4 aa re ero en DOCUMENT REVISIONS ‘Sections changed in lt evs ae ented by vical nen the margin3. ‘VIETNAM OIL AND GAS CORPORATION remp HA thi ono OPERATING MANUAL UNIT PRU (021) CONTENTS BASIS OF DESIGN 4 Duty of Plant 12 Feed Characteristics 13 Product Specification 14 Material Balances 1s Battery Limit Conditions 16 Design Features 17 Gas and Liquid Effluents DESCRIPTION OF PROCESS 2d Process Flow Description DESCRIPTION OF UNIT CONTROL 31 Deseription of Flow with Controls 32 Operating Conditions 33 Process Variables 34 Inter-Unit Control Scheme 35 Uninterruptible Power Supply (UPS) 36 Complex Control Description UTILITY, CHEMICAL AND CATALYST REQUIREMENTS 41 Utility Consumption 42 Catalyst PREPARATION FOR INITIAL START-UP. 5A Plant Check-out 5.2 Line Flushing 33 Water Circulation 54 Leak Testing (at 8 kg/em’g) 585 Catalyst Loading 56 Chemical Cleaning INITIAL AND NORMAL START-UP ‘April 2007 Rev. cA Chapter: Contents Page :1/42 10 4 4 4 4 15 15 15 16 16 16 "7 "7 7 7 7 7 7 18 84741-021-ML.001-A,7 8. i. 61 62 63 64 65 6.6 ‘VIETNAM OIL AND GAS CORPORATION. nemp ALA ti oo ‘OPERATING MANUAL UNIT PRU (021) ‘Summary of Start-up Final Preparations Purging and inerting ‘System filling and Start-up (Incl. circulation, heating-up) Increase of the Unit capacity (Normal Operation) Alternative Operations NORMAL SHUTDOWN WW 12 13 14 18 16 Summary of Shutdown Notify of Unit Shutdown Reduction of charge rate Cut out charge, Shutdown and block in all columns Purging and steaming out Preparation for Maintenance EMERGENCY SHUTDOWN PROCEDURES Bl 82 83 84 85 86 87 General Emergeney Shutdown Power Failure Feed Failure Steam Failure Instrument Air Failure Cooling Water Failure Mechanical Failure SAFETY EQUIPMENT AND PROCEDURES 9. Pressure Safety Devices 9.2 Alarm Settings 93 Trip Settings 94 Trip System Chart 95 Cause and Effeet Diagrams 96 Material Hazard Data Sheets 97 Safeguarding Memorandum INSTRUMENT DATA 10.1 Control Valves and Instruments 10.2 Orifice Plates SUMMARY OF MAJOR EQUIPMENT ‘April 2007 Rev. cA Chapter: Contents Page :2/42 18 19 20 a 24 4 26 26 26 26 26 n n 2» 29 29 29 29 29 30 30 31 31 31 31 31 31 31 31 4741-021. ML-001-A,‘VIETNAM OIL AND GAS CORPORATION ‘April 2007 Technit (PETROVIETNAM) Technip ti DUNG QUAT REFINERY Rev. A ‘OPERATING MANUAL Chapter: Contents UNIT PRU (021) Page = :3/42 11.1 Equipment List 11.2 Large Rotating Equipment 113 Heaters 114 Other Vendor information 12, ANALYSIS 12.1 Sampling and Testing Schedule 12.2 OnLine Analyzer 13. PROCESS CONTROL 13.1 Distributed System Control (DCS) 13.2 __Instrumented Protective System (IPS) and Safeguarding Systems 13.3 Control Centre 14, DRAWINGS 14.1 Plot and Hazardous Area Classification Plans 14.2 Process Flow Diagram and Material Selection Diagram 143 Piping and Instrumentation Diagrams 144 Other Drawings .TTACHMENTS. 1 Lubrication and Preventive Maintenance Schedules 34 34 34 34 35 35 39 40 40 40 40 4 4 41 41 41 a2 a2 (84741-021-ML-001-ALt 12 neinp A th VIETNAM OIL AND GAS CORPORATION “April 2007 (PETROVIETNAM) DUNG QUAT REFINERY Rev. 2A OPERATING MANUAL Chapter: 1 UNIT PRU (021) Page 34/42 BASIS OF DESIGN Duty of Plant The Propylene Recovery Unit (PRU) is designed to fractionate the treated Cy/C LPG into Mixed C,’s, Propane and Propylene and to purify the propylene to polymer grade (99.6 wt%) specification. ‘The treated Cs/C, LPG feedstock is fed from LPG Treater Unit (LTU). The product streams are rundown to storage through product cooler for mixed C,’s and purification for propylene. The PRU is designed to process 77240 kg/h of design feedstock and produces 19535 kg/h of polymer grade propylene which is corresponding to the Bach Ho Crude - maximum gasoline. When the PRU processes the design feed composition, which is shown hereunder, at the design feed capacity, the propylene recovery is a minimum of 96% by weight basis. This unit is capable of operating at a turndown of 50% of design feedstock capacity. (note that the tudown capacity of Propane/Propylene Splitter system is subject to UOP’s guaranteed value) Feed Characteristics The feedstock of the PRU is composed of treated Cs/C LPG stream coming from the LTU. a) Design feed composition ‘The design feed composition to the PRU, corresponding to the Bach Ho Crude - maximum gasoline, is as follows; Feed Component Content Methane m% 0 Ethane wi% 0.58 Ethylene wt% 0.01 Acetylene wtppm 1 Propane wt% 7.94 (max, 8.65) Propylene w% 26.24 Methyl Acetylene wt.ppm 30 Propadiene wi.ppm 10 Iso-Butane wt% 19.01 N-Butane wi% 751 Iso-Butene wi% 8.52 1-Butene wi% 8.18 Cis-2-Butene wt% 8.39 Trans-2-Butene —_wi% 12.77 ‘8474L-021-ML.001-A,tein AL 35 b) ‘VIETNAM OIL AND GAS CORPORATION. (PETROVIETNAM) DUNG QUAT REFINERY Feed Component 1,2 Butadienes Pentenes Pentanes Ce wi% w% ‘OPERATING MANUAL UNIT PRU (021) 0.4 0.59 OL Nil ‘April 2007 Rev. :A Chapter: 4 Page 35/42 (max 0.23) [Note]: Figures in brackets ( ) are for the mixed crude - maximum gasoline case. Impurities are as follows; Feed Component HS Content Mercaptans Carbonyl sulphide Total Sulphur Free Water Arsine Posphine Antimony Oxygen content Nitrogen content Hydrogen content Carbon monoxide Carbon dioxide ‘Oxygenates Chlorides Ammonia Caustic as Na’ Injected Chemicals Copper Strip Corrosion Design feed capacity Content (max) 0.5 wtppm 1S wtppm 0.5 wtppm 16 wtppm 30 weppm 35 wt ppb 35 wtppb Nil Nil Nil Nil Nil 1 wtppm 2 wtppm 2 wtppm 2 wtppm 1 weppm Nil No.1 max. (as sulphur) (as sulphur) {as sulphur) (as sulphur) ‘The design feed capacity for the PRU is 77240 kg/h when processing the feed defined in above section 1.2-a), 2474L-021-ML-001-A‘VIETNAM OIL AND GAS CORPORATION ‘April 2007, P (PETROVIETNAM) Technip th DUNG QUAT REFINERY Rev. cA — OPERATING MANUAL Chapter: 1 UNIT PRU (021) Page: 6/42 1.3 Product Specification The PRU is designed to produce Polymer Grade Propylene and Mixed Cy’s products. To meet the following specifications when the unit is processing, the design feed is defined in above section 1.2. The production capacity of the PRU is 19535 kg/h of polymer grade propylene. a) Propylene Specifications The specifications of polymer grade propylene from the PRU are as follows Component Specification Propylene wi% 99.6 min Total paraffins mol% 0.4 max Methane wt ppm 20 max Ethylene wtppm 25 max Ethane wi.ppm 300 max Acetylene, methyl acetylene, wt.ppm 5 max Propadiene (combined) ce wt ppm 50 max Hydrogen wt.ppm 20 max Nitrogen wt ppm 100 max Carbon monoxide wtppm 0.33 max Carbon dioxide wt ppm 1 max Oxygen wtppm 1 max Water wt ppm Saturated ‘Oxygenates wt ppm 15 max Chlorides wt.ppm 1 max Total sulphur wtppm 1 max Carbonyl sulphide ‘wtppm 2 max Arsine wt ppm 0.03 max Phosphine wt ppm 0.03 max b) Mixed C4’s Specifications ‘The mixed C4’s from the PRU contains not more than 1 w1% of C; and lighter components. 84 74L-021.49L-001-A14 1s 16 16.1 162 ‘VIETNAM OIL AND GAS CORPORATION ‘April 2007, —. ah Technip i DUNG QUAT REFINERY Rev. cA OPERATING MANUAL Chapter <1 ‘UNIT PRU (021) Page THA2 Material Balances ‘The overall material balances of the PRU are as follows; Bach Ho Crude - maximum gasoline a). Inlet to PRU Treated CyCs LPG 77240 kg/h b). Outlet from PRU Propylene Product 19580 ke/h Mixed C.’s Product 16827 ke/h Propane LPG (Propane + Mixed C,’s) 39972 keh PRU Off-gas (C2 rich gas to FG System) 828 keh Balance (Water to OWS) 33 ke/h Battery Limit Conditions ‘The battery limit conditions, for major feed and product streams, of the PRU are as follows; rating condition (at grade) Streatn Name Crane (tee Pressure, kg/em’g | Temperature, °C ‘Treated CyCsLPG to PRU 145 min 40 Propylene Product to Storage 28 40 Mixed C,’s Product to Storage 6.1 40 Propane LPG to Storage 15.5 39 Design Features ‘The PRU has following design features. Heat Integration Heat for the De-ethanizer Reboiler (E-2108) and De-ethanizer Blowoff Preheater (E-2107) is provided by the RFCC main fractionator’s heavy naphtha pump-around stream, Heat Pump. ‘The PRU design is based upon a heat pumped concept, which provides the reboiler duty by converting mechanical compression of the overheads into thermal energy (economizing energy), for the Propane/Propylene Splitter (T-2103) column and utilizes a non-condensing, steam turbine drive for the main heat pump compressor. The overhead vapour of the propane/propylene splitter is fed to the propylene vapour compressor via compressor feed drum. The compressor discharge vapour is de-superheated and condensed against C3 splitter reboiler and against propylene condenser cooled by cooling water. The condensed propylene flows to the propane/propylene splitter reflux 474L-021-ML-001-4‘VIETNAM OIL AND GAS CORPORATION “Apri 2007 (PETROVIETNAM) DUNG QUAT REFINERY Rev. A OPERATING MANUAL Chapter : 1 UNIT PRU (021) Page 8/42 rum, Part of the liquid is withdrawn from the reflux drum and pumped by propylene pump to BL as polymer grade propylene product after being purified in propylene purification unit which consists of 1 vessel with adsorbent. 1.6.3 Propane/Propylene Splitter Trays The Propane/Propylene Splitter (T-2103) has been adopted from UOP’s Enhanced Capacity Multiple Downcomer (ECMD) trays. 1.64 High Heat Flux Tubes for Propane/Propylene Splitter Reboiler ‘The C3 Splitter Reboiler (E-2111) has been adopted from UOP’s High Flux tubing heat exchanger. 1.6.5 Alternative Operation ‘The provision is made for the alternative operation in PRU, a bypass around the De-ethanizer (T-2102) to allow continuous operation of the C3/C4 Splitter (T-2101) in the event of the Propane/Propylene Splitter (T-2103) being shutdown. In this operation, the part of T-2101 overhead liquid from the C3/C4 Splitter Reflux Drum (D-2102) is pumped by the C3/C4 Splitter Reflux Pump (P-2102A/B) to T-2101 as reflux and the other partis directly sent to the Propane/Propylene Water Cooler (E-2109) which is used for bypass line around T-2102 by switching of manual valve. The mixed C;’s leaving from E-2109 is sent, after being mixed with C,’s from the C4 Product Cooler (E-2104) in T-2101 bottom stream, to LPG Sphere by switching of manual valve on bypass line around T2103, 1.7 Gas and Liquid Effluents Refer to Effluent Summary Table on next page. 84741-021-41-001-4Chapter : 1 YLoo-weszo-wee 9/42 FH} - oe Fle bk fF Awning ANaNTsa aes : waouise ue Lf: 8 oor Reon2 2a 24d ‘VIETNAM OIL AND GAS CORPORATION ‘April 2007, ' (PETROVIETNAM) Technip ti DUNG QUAT REFINERY Rev. cA OPERATING MANUAL Chapter: 2 UNIT PRU (021) Page: 10/42 DESCRIPTION OF PROCESS Process Flow Description Feed Preparation The treated CC, LPG stream coming from LPG Treater Unit (LTU) is fed to the LPG Receiver (D-2101). The D-2101 has a split-range pressure control (operated at 14 kg/cm’G under normal operation) either admitting C2 rich stream, which is supplied from the De-ethanizer (T- 2102) overhead vapour pass through De-ethanizer Blowoff Preheater (E-2107), or relieving it with any off-gas produced to fuel gas system In case of alternative operation (De-ethanizer and Propane/Propylene Splitter are out of operation), the overhead vapour (Mixed C's and lighter) from C3/C4 Splitter (T-2101) is used as the pressurize source of D-2101 split-range pressure control instead of C> rich stream. C3/C4 Splitter ‘The treated CyCs LPG from D-2101 is sent under flow rate control, to the tray #12 of C3/C4 Splitter (T-2101) using the C3/C4 Splitter Feed Pump (P-2101A/B). C; lighter and C; heavier are separated in T-2101, after being preheated in C3/C4 Splitter FeediC4 Bottoms Exchanger (E-2101). The level controller of D-2101 actuates by resetting the flow rate controller of feed to T-2101. The column T-2101 contains 33 stages of tray and is operated at 23.5 kg/em’G of column top pressure which permits total condensation of the overhead vapours with cooling water. The vapour leaving the top of T-2101 is totally condensed in the C3/C4 Splitter Overhead Condensers (E-2102A/BIC/D), which is cooled by cooling water, and goes to the C3/C4 Splitter Reflux Drum (D-2102) where the liquid hydrocarbon and water phases are separated. The D-2102 has a split-range pressure control (operates at 19.5 kg/em’G) either admitting part of overhead vapour by-passing the condensers or relieving it with any off- gas produced to flare. The part of condensed liquid from D-2102 is pumped by the C3/C4 Splitter Reflux Pump (P-2102A/B) as reflux to T-2101 and the other part, mixed C;'s and lighter, is pumped to the De-ethanizer, ‘The reboiler heat is supplied by two reboilers in parallel. The C3/C4 Splitter Reboilers (E- 2103A/B) is heated by LP steam, The heat input to E-2103A/B is controlled by flow rate control, which gets reset by temperature controller on the sensitive tray in T-2101, to meet, the mixed C4’s specification in the bottom product. The heating fluid of E-2103/B, after being condensed in the reboiter, is sent to condensate system under level control. The bottom product from T-2101 is mixed C4’s that, after exchanging heat with feed in E- 2101, is cooled in the C4 Product Cooler (E-2104) before being sent to storage. The mixed 4's from T-2101 is divided into two streams after being cooled in E-2104 and maintained by level control which is a split-range controller. The part of mixed C4’s is directly sent to Mixed C4°s Sphere and the other part is sent to LPG Sphere with blending propane stream from bottom of Propane/Propylene Splitter. B47AL-021-ML.001-A,‘VIETNAM OIL AND GAS CORPORATION ‘April 2007 - . (PETROVIETNAM) Technip fd th DUNG QUAT REFINERY Re. :A ‘OPERATING MANUAL Chapter :2 UNIT PRU (021) Page = :11/42 This split-range controller allows obtaining required flows to LPG Sphere and Mixed C4’s Sphere. Required flow to LPG Sphere is set on flow rate controller, which has a low set point limit to maintain a minimum flow. The flow rate controller output passes through the ow signal selector, which restricts valve opening when level controller in bottom of T- 2101 output is in the 0-33% range. Level in the Mixed C4’s Spheres is controlled by the controllers at product tankage, which are integrated with the level control valve on stream to Mixed C4's Sphere. The outputs from those controllers in product tankage pass to the low signal selector to which level controller, in bottom of T-2101, output in the 33-67% range is also sent. This allows obtaining required flow to Mixed C4’s Spheres when level in T-2101 increases enough, If level in T-2101 continues to increase then the level controller output in the 67-10% range is sent to high signal selector. This action opens control valve, thereby increasing flow to LPG Spheres. De-ethanizer The part of condensed liquid, mixed C3’s and lighter, from D-2102 is pumped by the De- ethanizer Feed Pump (P-2103A/B) under flow rate control to the tray #21 of De-ethanizer (T-2102) where the C2 and lighter contents are removed in the bottom stream. The level controller of D-2102 actuates by resetting the flow rate controller of feed to T-2102. The column T-2102 contains 66 stages of tray and is operated at 27 kg/cm’G of column top pressure ‘The vapour leaving the top of T-2102 is partially condensed in the De-ethanizer Overhead Condenser (E-2106), which is cooled by propylene from Propane/Propylene Splitter Reflux Drum under level control in E-2106 shell side, and goes to the De-ethanizer Reflux Drum (D-2103) where the liquid hydrocarbon, water and vapour phases are separated. ‘The pressure in D-2103 is controlled by relieving the small amount of C) rich vapour from D-2103 to fuel gas system under pressure control (operates at 26.7 kg/cm’G) after being heated in the De-ethanizer Blowoff Preheater (E-2107), which is heated by heavy naphtha from Residue Fluid Catalytic Cracking Unit (RFC), under temperature control at outlet of E-2107. The C: rich vapour from E-2107 is also used for pressure source of D-2101 split- range control in normal circumstance. The liquid hydrocarbon from D-2103 is pumped by the De-ethanizer Reflux Pump (P- 2104A/B) as reflux to T-2102 under flow rate control which gets reset by level controller of D-2103, The reboiler heat is supplied by the De-ethanizer Reboiler (E-2108) which is heated by heavy naphtha from RFC, The heat input to E-2108 is controlled by flow rate control, which reset by temperature controller on the sensitive tray in T-2102, to meet the removal of the ethane content in the bottom product. Propane/Propylene Splitter The bottom of T-2102 is C,'s that, after cooling in the Propane/Propylene Water Cooler (E~ 2109), exchanges heat with propylene reflux in the C3°s Splitter Reflux/Feed Exchanger (E-2110) before being directly sent to the Propane/Propylene Splitter (T-2103) where the 84741.021-M.-001-A‘VIETNAM OIL AND GAS CORPORATION’ ‘Apri 2007, Technip ta th DUNG GUAT RERVERY Rev. cA ‘OPERATING MANUAL Chapter :2 UNIT PRU (021) Page :12/42 separation of propylene and propane will take place. The C,’s stream is controlled by flow rate control which gets reset by level controller in T-2102 bottom. ‘The column T-2103 contains 190 stages of UOP Enhanced Capacity Multiple Downcomer (ECMD) tray and operates at 9 kg/cm’G of column top pressure with adopting heat pumped system, ‘The propylene vapour leaving the top of T-2103 is sent to the Compressor Feed Drum (D- 2104), where any droplets formed are removed, after being mixed with vapour from E- 2106 and Propane/Propylene Splitter Reflux Drum. The vapour from D-2104 is fed to and compressed in the Propylene Vapour Compressor (C-2101), which is utilised a non- condensing steam turbine drive. ‘The compressed gas is divided into two streams. One is sent to the C3 Splitter Reboiler (E- 2111), which has been adopted from UOP’s High Flux tubing heat exchanger, and goes to the Propane/Propylene Splitter Reflux Drum (D-2105) under flow rate control after exchanging heat with T-2103 bottoms. The other partis sent to the Propylene Condensers (E-2112A/BICIDIEIF), which is cooled by cooling water, and goes to D-210S under pressure control that is to maintain the pressure in T-2103 adjusting the flow rate of condensed propylene leaving from E-2112A to F. ‘The portion of flashed vapour in D-2105, due to pressure reduction of condensed propylene from E-2111 and E-2112A to F, is sent back to D-2104 under differential pressure control among C-2101 discharge pressure and D-2105 pressure. If further excess pressure exists in 1D-2105, the vapour from D-2105 is released to flare under pressure control (operates at 16.2 kglem’G). The liquid propylene from D-2105 is divided into two streams. One is sent to T-2103 as reflux and another to E-2106 as cooling medium after exchanging heat with feed to T-2103 in E-2110. The reflux stream leaving from E-2110 to T-2103 is controlled by flow rate controller. The other part, which is propylene product, is pumped by the Propylene Pump (P- 2106A/B) under flow rate control, which is reset by level controller of D-2105, after being purified in the Propylene Purification Unit (A-2101) which provides fine purification of propylene from COS, arsenic and phosphorous compounds. The A-2101 consists of a single vessel with catalyst bed. The catalyst is mainly used for the adsorption of impurities from propylene. ‘The purified propylene as polymer grade propylene product leaving from A-2101 is sent to Propylene Sphere. The bottom of T-2103 is propane that is pumped by the Propane Pump (P-210SA/B) under flow rate control which gets reset by level controller in T-2103 bottom and then is sent, after being mixed with C,'s from E-2104 in T-2101 bottom stream, to LPG Sphere. De-watering System ‘The objective of de-watering system is to allow intermittent drainage of water from D-2101, D-2102 and D-2103 whilst providing suitable protection against the possibility of breakthrough of volatile hydrocarbons. Those process vessel has a boots which accumulates the separated water from liquid hydrocarbons depends on water content in each feed stream, 8474L-021-ML-001-A‘VIETNAM OIL AND GAS CORPORATION ‘Apri 2007 a (PETROVIETNAM) Technip ti ouNe AT RERHERY ao A OPERATING MANUAL Chapter :2 UNIT PRU (021) Page :13/42 ‘Two De-watering Vessels in the PRU are provided. The D-2106 is provided for intermittent water stream from D-2101. The D-2107 is provided for intermittent water from D-2102 and D-2103. The stored liquid in D-2106 and D-2107 will be released to the oily surface water sewer. ‘47AL-021-ML-001-A,‘VIETNAM OIL AND GAS CORPORATION ‘April 2007 (PETROVIETNAM) DUNG QUAT REFINERY Rev. cA OPERATING MANUAL Chapter :3 UNIT PRU (021) Page: 14/42 3. DESCRIPTION OF UNIT CONTROL 3.1 Description of Flow with Controls Refer to 8474L-021-CN-0008-001 3.2 Operating Conditions Refer to 8474L-021-PFD-0010-001, 002 and 003. 3.3. Process Variables Thorough understanding of process variables and means for their control schemes are essential in understanding of multi-component fractionation systems. It is well understood that any fractionation operation is related to mere physical separation of a mixed feedstock into two or more number of pure product streams which are essentially different from each other in terms of their normal boiling points. In order (0 achieve the performance it is essential to heat up the feedstock, by the reboiler at column and/or increase of feed temperature, and let it separate into desired products in a staged counter-current column at a certain pressure with overhead condensing reflux system, In all these operations the law of conservation of heat and material is governed. Hence, in any steady state fractionation operation there is no accumulation of material and energy within the system. 33.1 Flow The feed rate to columns (T-2101/T-2102/T-2103) is controlled on level control cascaded with an PIC from another column or vessel for a stable flow control scheme. Since the feed flow rate should either be increased or decreased and other products rates will be adjusted accordingly by columns operating conditions. 3.3.2. Temperature ‘Temperature is the hardest parameter to control in a fractionation column. It exhibits high process and measurement lag. Temperature can also be used as a measure of composition. Variations in operating pressure are reflected quicker up and down the column, thus are more sensible by the operator of the unit, Therefore the column pressure should be maintained. For some purity operation, the temperature will possibly be controlled at an intermediate point in the column. The location of the temperature control of the column is determined ‘based on that the tray is the most sensitive to the change of the key component. 2474L-021-ML-001-A333 34 35 3.6 (ie ‘VIETNAM OIL AND GAS CORPORATION “April 2007 . (PETROVIETNAM) Technip ti DUNG QUAT REFINERY Rev. cA ‘OPERATING MANUAL Chapter: 3 UNIT PRU (021) Page :15/42 Pressure Virtually column pressure is not a controlling process parameter. Although any variation in operating pressure affects the product quality under normal operation, the column pressure is held constant, However in case the column operating pressure is increased the trays thermodynamic vapour/liquid equilibrium conditions change and more heat is required to be added to process liquid for the same degree of separation. Inter-Unit Control Scheme Filling of the Mixed C4’s sphere is controlled by the reverse action of 051-LIC-007A onto the control valve 021-LV-004A, through the low signal selector 021-LY-004-E. This low selector will select low signal between that from the sphere level controller 051-LIC-007A, and that from the C3/C4 Splitter (T-2101) bottom level controller 021-LIC-004. Level in the Mixed C4’s Spheres is controlled by the controllers at product tankage, which are integrated with the control valve 021-LV-004A. Outputs from those controllers pass to the low signal selector 021-LY-004-E to which level controller 021-LIC-004 output in the 33-67% range is also sent. This allows obtaining required flow to the Mixed C4’s Spheres when level in T-2101 increases enough Refer also to “Inter Unit Control Narrati 's” 8474L-000-SP-1511-101. Uninterruptible Power Supply (UPS) Will be incorporated later. Complex Control Description ‘The description of complex control is referred to “Control Narrative” 8474L.-021-SP-1SI1- lol. 84740-021-ML-001-A,VIETNAM OIL AND GAS CORPORATION ‘April 2007 a (PETROVIETNAM) Technip DUNG QUAT REFINERY Rev. A ‘OPERATING MANUAL Chapter : 4 UNIT PRU (021) Page: 16/42 ILITY, CHEMICAL AND CATALYST REQUIREMENTS 4.1 Utility Consumption Refer to Utility Summary 8474L-021-CN-0003-001. 4.2 Catalyst The propylene product from the PRU is produced at polymer grade, and requires removal of a number of contaminants by fine purification of propylene from COS, arsenic and phosphorous compounds. Following type of catalyst (adsorbent) is applied to the Propylene Purification Unit (A- 2101), © Type BASF PuriStar ® R3-12 © Form 2 Tablets, 5x3 mm height © Quantity to be filled =: 12.37 m’ © Service life of R312: >3 years 8474L-021-ML-001-A5a 5.2 53 54 55 5.6 — ‘VIETNAM OIL AND GAS CORPORATION ‘April 2007 | . (PETROVIETNAM) Technip th DUNG QUAT REFINERY Re. cA OPERATING MANUAL Chapter :5 UNIT PRU (021) Page :17/42 PREPARATION FOR INITIAL START-UP Plant Check-out Refer to Precommissioning Manual 8474L-000-PP-903, Line Flushing Refer to Precommissioning Manual 8474L-000-PP-903. Water Circulation Refer to Precommissioning Manual 8474L-000-PP-903, Leak Testing (at 8 kg/cm’g) Refer to Precommissioning Manual 84741-000-PP-903. Catalyst Loading Catalyst loading procedure for A-2101 will be incorporated later. [Note] After loaded of catalyst into A-2101 properly, it should be sealed by nitrogen to avoid contact of water before use. ‘Chemical Cleaning High pressure steam line to the turbine drive (TR-2101) of compressor C-2101 is subject to chemical cleaning, Temporary pipelines and by-passes required for chemical cleaning, as well as chemicals and auxiliary materials demand will be decided by the specialised company. Refer to Precommissioning Manual 8474L-000-PP-903, ¢74L-021-ML.001-A,6 INITIAL AND NORMAL START-UP 6.1 Summary of Start-up om oR veo! cacti Taw Oeatre an refee Sine cam Papier Compe Sib ‘VIETNAM OIL AND GAS CORPORATION (PETROVIETNAM) DUNG QUAT REFINERY ‘OPERATING MANUAL UNIT PRU (021) ‘April 2007, Rev. cA Chapter :6 Page :18/42 Tag ta tak wm aa Tair] aig id sre ft Nt fen} fe i Oar ad at ta Tay Taye ag oa belaes [mt et ay EDN Ty ss Ae om |__| rad Dt im cd ae at tied [7 tetsen | ste iat a EDN lay Site Tae oar Ted am m7 cy tae tg bond [teste | ter ie ae EDN Cay se Oa Deck Tar Tar ene rg | nian Aa Son arc] Fens cua | Fa iar coe Ey Tai Agr ie Meck, cam ay sua Cage | fn Boot wh Caoe ter Oa To _ [inte ia tse is a it 8474-021-4L-001-4‘VIETNAM OIL AND GAS CORPORATION ‘April 2007 i (PETROVIETNAM) Techy AL Bi une sneer an ‘OPERATING MANUAL Chapter :6 UNIT PRU (021) Page 19/42 62 Final Preparations 6.2.1 By the moment of hydrocarbon feedstock receipt at the unit, all the installation work should have been completed, the unit should be ready for commissioning, Before commissioning the final preparations should be performed. Prior to the final preparations, the following preliminary checks should be carried out; 1) All'concered should be informed of the proposed time for start-up. 2) All vessel internals (demister pads, etc) are installed, secured gasket, and any internal tests carried out. 3) All lines and equipments should be cleaned out and all flanges and manholes are bolted up with the correct gaskets, and equipment blinds removed or swung open. 4) Strainers should be installed where required and oriented correctly. Temporary mesh screen is installed for initial operation, if available. 5) Orifice plates should have been inspected include size, material of construction, location of the weep hole, measurement of the orifice bore, verification of the information stamped on the tab and oriented properly. 6) All control valves should have correct flow orientations and should have been stroked and left closed on manual. Their bypasses to be checked as tightly closed position, 7) All check valve orientations are signed off as correct. 8) All instruments and analyzers should have been calibrated and are ready for use, 9) All rotating machinery should have been run, has established correct lubrication inventories, checking of alignment, rotation direction checking, and guards securely installed. 10) Relief valves (systems) shop certified and installed with seals, locked open/close valves, and interlocking open/close devices checked for correctness. Blinds and restrainers are removed, 11) Unit drains and vents are not required for start-up purging or draining, these should have been checked as capped, plugged or blinded. 12) All utility services are available at the battery limit. All relief, slops and drainage systems are ready for use and the Main Flare has been commissioned. 13) The unit should have been checked free of all debris, scaffolding, planking etc., especially at the upper levels. 14) Allalarm circuits should have been checked and are ready for use. 15) Emergency shut-off valves should have been tripped and reset twice. 16) Fire fighting, safety equipment and gas emission analyzers checked for operability and completeness 6.2.2 Remove or swing blinds to normal operating positions at battery limit lines 6.2.3 Make a final check to remove or swing out of use any isolating blinds at unit equipment or in lines. Check distance spools are made up or disconnected where required. Recheck all relief systems are in operable position, any upstream and downstream isolation blinds 8474.-021-ML-001-A‘VIETNAM OIL AND GAS CORPORATION ‘April 2007, 7 (PETROVIETNAM) Techni ti DUNG QUAT REFINERY Re. cA ‘OPERATING MANUAL Chapter :6 UNIT PRU (021) Page — : 20/42 removed, and where double relief valve arrangements exist, that the installed valve in the system has its isolation valves in the locked open position. 6.2.4 Commission all utilities. 6.3 Purging and inerting Purging is provided within the scope of the precommissioning (initial start-up). Purging of the unit is mainly provided by water flushing, by steam or air purging. Refer to Precommissioning Manual 8474L-000-PP-903 6.3.1 Unit Sections Steam Purging Generally, steam and condensate system is steam purged. In this Unit, following sections are steam purged: i, High pressure steam lines to the turbine of C-2101 compressor (TR-2101) and the turbine of Lube Oil Pump. ii, Low pressure steam exhaust lines from the turbine of C-2101 compressor (TR-2101) and the turbine of Lube Oil Pump. iii, Steam line to E-2103A/B shell side. iv, Condensate from E-2103A/B and from compressor system. [Note] High pressure steam line to the turbine shall be purged with special care, because solid particles can cause the turbine damage. 6.3.2 Unit Sections Air Drying Unit sections air drying is done at maximum possible flow rates. Valves and inserts to be dismantled, if required, Prior to air drying the unit sections, which were flushed by water and/or steamed out, is thoroughly drained to eliminate liquid carry over by the air to other sections of the unit The following unit systems are dried by air: ¥. System of LPG receipt at the unit vi. Cy/Cy splitting system: —_D-2101, E-2101, T-2101, E-2102A/B/C/D, D-2102, E-2103A/B Tube Side, E-2104 Shell Side Vil De-ethanizer system: — T-2102, E-2106 Tube Side, D- 2103, E-2107 Shell Side, E-2108 Shell Side, E-2109 Shell Side vill Propane/Propylene system: E-2110, T-2103, Shell Side, D-2104, C-2101, E-2111, E-2112A/B/C/D/E/F, D-210S ix, Propylene Purification unit: A-2101 2106 x. Flare system 6.3.3 Inerting (Air Freeing) Aller the air drying step and before admitting hydrocarbon, the unit must be purged to remove all free water and the air. 24 74-021-ML-001-A‘VIETNAM OIL AND GAS CORPORATION ‘April 2007 (PETROVIETNAM) DUNG QUAT REFINERY Rev. A ‘OPERATING MANUAL Chapter :6 UNIT PRU (021) Page = :21/42 ‘The way to ensure that all piping is air-free is to divide the unit into sections and purge each section separately. Normally the piping and instrument diagrams will be checked so that all piping can be inked out as the lines are purged and sampled for oxygen. A final leak test for the unit can then be performed since all hydrotesting blinds should have been removed. Purging with nitrogen (or steaming) will be used for air free a system. The following procedure will be used. a) Bring nitrogen into the vessels and raise the pressure of the section to 2.5 kg/em’G or available nitrogen pressure if less, While the section is under full nitrogen pressure, test all flanges and screwed connections for leak with soap solution. [Note] Always follow design pressure limitations when air freeing vessels. Most tanks are designed for a maximum of 140 mm of water pressure and equipment, pressure vessels (except for tanks) are designed for 3.5 kg/cm’G as minimum design. b) Depressurize the vessels and lines to a pressure of about 0.35 kg/cm’G. It is important that the system should be depressurized at opposite end from which it is filled in order to be sure that maximum amount of oxygen is purged. Vent at each available low point drain and high point vent moving downstream from the nitrogen inlet point. ©) Perform steps “a)" and “b)” two more times. 4) Analyze the gas at the most downstream bleed points of each line and vessel being purged to eliminate the concentration of oxygen remaining in the system. ‘Theoretically, after the third displacement, the oxygen content should be down less than 1 vol%. If the analysis shows the oxygen content is less than 1 vol%, the unit has been air freed. If the oxygen content is still greater than | voI% or equal to 1 vol%, repeat the nitrogen displacement procedure. ©) After completing the air freeing operation, leave all vessels and lines under a positive nitrogen pressure of 0.35 kg/em’G. (Leave storage tanks at 25 mm of water pressure.) At this point the normal purge gas can be used to provide the positive pressure on the vessels. ‘After that the unit is considered ready for operation and to be maintained under a positive pressure with the purge gas till the unit start-up. 6.4 System filling and Start-up (Incl. circulation, heating-up) Start the Unit with at least 30% feed capacity. 64.1 Open valves at CyC; LPG pipeline ‘PL-210001" from the LPG Treater Unit (LTU) and start receiving the LPG at LPG Receiver (D-2101). Depend on the availability of LPG in storage tank, the start-up LPG from storage tank (TK-5102) can be used if the treated Cy/C, LPG from LTU is not available at the start-up period for this unit. Isolation gate valves at the suction of the C3/C4 Splitter Feed pumps (P-2101A/B) are closed. Level in D-2101 is monitored by the level gauge. 6.4.2 After establishing a level in D-2101, slowly open the gate valve at the suction of one of the pumps P-2101A/B, fill it and prepare for start-up. First start the pump P-2101A (or B) at ‘minimum flow (spillback). When pump P-2101A (or B) mode of operation is stabilized, start slowly opening the gate valve at the pipeline of pump discharge and start supplying LPG to the C3/C4 Splitter (T-2101). Activate control loop 021-LIC-001/021-FIC-001. BATAL-021-ML-001-A643 644 645 6.4.6 647 648 649 6.4.10 64.11 6.4.12 6.4.13 VIETNAM OIL AND GAS CORPORATION ‘April 2007 ' (PETROVIETNAM) Technip ti fi DUNG QUAT REFINERY Rev. :A — OPERATING MANUAL Chapter : 6 UNIT PRU (021) Page: 22/42 ‘The pressure in D-2101 is initially equal to the received LPG vapour pressure (about 9 - 9.7 kg/cm’A), When T-2101 is commissioned, gradually increase the pressure in D-2101 to 14 kgicm’G by routing vapours from T-2101 overheads to D-2101. Activate the control loop for maintaining pressure 021-PIC-001 in D-2101 From D-2101 transfer the feed LPG via E-2101 to T-2101 Commission the C3/C4 Splitter Overhead Condensers (E-2102A/BIC/D). At 50% of design feed rate or lower, and at minimum pressure, the 4 shells of E-2102 will be required in service, When the pressure increases up to the design operating pressure, only 2 shells of the 4 will be required. Start low pressure steam to the C3/C4 Splitter Reboilers (E-2103A/B) shell side. Start 021- LIC-007A (or B, selected by 021-HS-101). The thermo-siphon action should commence. Initially, establish a minimum pressure of 15 kg/em*G on T-2101, and then increase the pressure gradually to the normal working pressure (23.5 kg/em’G at top). When the overhead vapours are in T-2101, connect pipeline ‘PV-210022" to controller 021-PV-O01A and start increasing the pressure in D-2101 to 14 kg/em’G via activate the control loop for maintaining pressure 021-PIC-001 Isolation gate valves at the suction of the C3/C4 Splitter Reflux pumps (P-2102A/B) are closed. Level in C3/C4 Splitter Reflux Drum (D-2102) is monitored by the level gauge. After establishing a level in D-2102, slowly open the gate valve at the suction of one of the pumps P-2102A/B and then start one of the pumps P-2102A (or B). ‘The pressure in D-2102 is controlled by activation of the control loop for maintaining pressure 021-PIC-004 (normal working pressure is 19.5 kg/cm’). ‘As C;’s Splitter (T-2101 system) approaches operating temperature, maintain operation on total reflux. Commission the C4 Product Cooler (E-2104). Maintain the level in T-2101 while the temperature increases by routing T-2101 bottoms to off-spec LPG sphere (pipelines: PL-210005, PL-210006, PI.-210007, PL-210008, PL- 210088) pass through E-2101 and E-2104. When the design operating pressure and temperature are reached in T-2101, divert the T-2101 bottoms to C, storage (pipeline: PL- 210007), Activate the control loops 021-LIC-004 of streams CyC. to storage. Isolation gate valves at the suction of the De-ethanizer Feed pumps (P-2103A/B) are close. ‘After the normal operating conditions have been established on T-2101, slowly open the gate valve at the suction of one of the pumps P-2103A/B and then start P-2103A (or B). ‘And, pump the C;'s from D-2102 to the De-ethanizer (-2102). Activate control loop 021- LIC-008/021-FIC-006. Note that the selector switch of 021-HS-008 has to select properly to achieve the cascade control loop of 021-LIC-008 and 021-FIC-006. Phase | - De-ethanizer (T-2102) system start-up in the mode of the Stripping column, i) Deliver cut C's from D-2102 to the De-ethanizer (T-2102) using P-2103A (or B). ii) Operate T-2102 as a stripping column, Commission the heat of De-cthanizer Reboiler (E-2108) by providing the heavy naphtha from RFCC. The thermo-siphon action should commence. iii) Start slowly raising the temperature of T-2102 bottoms to 65 - 67 °C. Activate heavy naphtha flow rate control loop 021-FIC-008 without temperature correction 021-TIC- 009. Control the heavy naphtha flow rate carefully because the temperature difference between initial and end boiling points of the C;' s product stream is 2.4 °C. B474L.021-ML-0O1-A6.4.14 6.4.15 6.4.16 6.4.17 64.18 6.4.19 6.4.20 VIETNAM OIL AND GAS CORPORATION ‘April 2007, Tecmip ALA ts buNe ar RErNER? Ren: OPERATING MANUAL Chapter: 6 UNIT PRU (021) Page :23/42 iv) Route the vapours drawn-off from T-2102 overheads to the fuel gas system via De-ethanizer Overhead Condenser (E-2106), De-ethanzier Reflux Drum (D-2103) and De-ethanizer Blowoff Preheater (E-2107). Activate pressure control loop 021-PIC-007 (normal working pressure is 26.7 kg/cm’G). v) Bypass the heavy naphtha around E-2107. vi) As the operating temperature is reached at T-2102 bottoms, route the stripped Cy's to the Propane/Propylene Splitter (T-2103). vii) Do not cool the stripped C;’s in the Propane/Propylene Water Cooler (E-2109). ‘Activate control loop 021-LIC-011/021-FIC-007. Note that the selector switch of 021- HS-007 has to select properly to achieve the cascade control loop of 021-LIC-O11 and 021-FIC-007. After Phase | of the De-ethanizer start-up is completed for this particular case, start-up of the Propane/Propylene Splitter (T-2103) begins. ‘The stripped Cs’s from T-2102 bottom to T-2103 is delivered as liquid/vapour mixture. With overhead vapours from T-2103 through the Compressor Feed Drum (D-2104) start the Propylene Vapour Compressor (C-2101) according to compressor vendor's instructions (Refer to vendor's instruction). Operate C-2101 at minimum flow with spillback open. Start the Propylene Condensers (E-2112A/B/C/D/E/F). Activate temperature control loop 021-TIC-137 to avoid undesirable increasing of temperature at C-2101 suction. After C-2101 is commissioned, route the gas from C-2101 discharge to C3 Splitter Reboiler (E-2111). The thermo-siphon action should commence. Activate control loop 021- FIC-014 and 021-PIC-010. Route the liquid propylene from E-2111 and E-2112A-F to T-2103 reflux and E-2106 shell side via Propane/Propylene Splitter Reflux Drum (D-2105). Activate control loop 021-FIC- 012 for T-2103 reflux. While the propylene product is off-spec, it is necessary to maintain the minimum level in D-2105 and return it to T-2103 via pipeline ‘PL-210234 and PL- 210132" for reprocessing. Route propylene vapours from D-2105 to flare. Activate control loop 021-PIC-017 (normal working pressure is 16.2 kg/cm’G). Phase 2- switching the De-ethanizer (T-2102) operation from the stripping mode to the rectification mode. i) When C-2101 is commissioned and liquid propylene appears in D-2105, slowly feed the liquid propylene to E-2106 shell side. Monitor the level in E-2106 shell by level gauge fi) Route heavy naphtha from RFCC to E-2107 tube side. iii) Isolation gate valves at the suction of the De-ethanizer Reflux Pumps (P-2104A/B) are closed, After establishing a level in D-2103, slowly open the gate valve at the suction of one of the pumps P-2104A/B and then start P-2104A (or B). As the level in D-2103 is increased up to normal liquid level, increase reflux to T-2102 total reflux, Commission contro! loop 021-LIC-014/021-FIC-O11 iv) Activate temperature controller 021-TIC-015 to ensure that the temperature of T-2102 overheads discharged to the fuel gas system is above 0 °C. v) Replace Cy's used for maintaining pressure in D-2101 with T-2102 overheads gas. B474L-021-ML-001-A6.4.21 6.4.22 6.4.23 6.4.24 6.4.25 6.4.26 6.4.27 65 6.6 VIETNAM OIL AND GAS CORPORATION ‘April 2007 (PETROVIETNAM) DUNG QUAT REFINERY Rev. A OPERATING MANUAL Chapter :6 UNIT PRU (021) Page :24/42 vi) Activate temperature correction 021-TIC-009. vii) When T-2102 bottoms is on specification, cool T-2102 bottoms to 40 °C in E-2109. ‘Commission the propylene on-stream analyzer 021-AE-001 and 021-AE-002. As the T-2103 reaches the design operating conditions, release the off-spec propylene from D-2105. Route the off-spec propylene either to T-2103 for reprocessing if C, content in the propylene in compliance with the specification, or pump out the propylene to off-spec propylene sphere if C; content in the propylene is higher than according to the specification. Isolation gate valves at the suction of the Propylene pumps (P-2106A/B) are closed Depending on the C; content in the propylene as mentioned in above 6.4.22, slowly open the gate valve at the suction of one of the pumps P-2106A/B and then start P-2106A (or B). ‘When the propylene is on specification, stop discharging gaseous propylene from D-2105 to flare via 021-PIC-017. To route gaseous propylene from D-2105 to inlet of D-2104, activate control loop 021-PDIC-015. ‘When the propylene is on specification, route the product propylene to on-spec propylene sphere bypassing the Propylene Purification Unit (A-2101). Activate control loop 021-LIC- 019/021-FIC-018. Commission A-2101 in accordance with catalyst vendor's instructions. (Refer also to clause 5.5) Isolation gate valves at the suction of the Propane pumps (P-2105A/B) are closed. As the level increases in the bottom of T-2103, slowly open the gate valve at the suction of one of the pumps P-2105A/B and then start P-2105A (or B). The propane from T-2103 is pumped to LPG sphere after blending with mixed C,'s from T-2101 bottom, Increase of the Unit capacity (Normal Operation) When stable operating conditions are established in all systems, increase the unit to 100% feed capacity. During normal operation, the unit must be operated so that the production of various product streams is achieved at proper specification. The operating pressure and other conditions must be adjusted within tower design limits to obtain the desired product. Alternative Operations The provision is made for the alternative operation in PRU that is a bypass around the De-ethanizer (T-2102) to allow continuous operation of the C3/C4 Splitter (T-2101) in the event of the Propane/Propylene Splitter (T-2103) being shutdown. In this operation, the part of T-2101 overhead liquid from the C3/C4 Splitter Reflux Drum (D-2102) is pumped by the C3/C4 Splitter Reflux Pump (P-2102A/B) to T-2101 as reflux and the other partis directly sent to the Propane/Propylene Water Cooler (E-2109) which is used for bypass line around T-2102 by switching of manual valve. The mixed Cy’s leaving from E-2109 is sent, after being mixed with C,’s from the C4 Product Cooler (E-2104) in T-2101 bottom stream, to LPG Sphere by switching of manual valve on bypass line around 77-2103, To realize this case of operation, it is necessary to perform the following: 4741-021-ML.001-A66.1 6.6.2 6.63 6.64 6.6.5 6.6.6 ‘VIETNAM OIL AND GAS CORPORATION. ‘April 2007 7 (PETROVIETNAM) Technip th DUNG QUAT pel Rev. :A ‘OPERATING MANUAL Chapter :6 UNIT PRU (021) Page :25/42 Isolate feed to the De-ethanizer (T-2102) by the gate valves and blind at the suction line to P-2103A/B, ‘PL-210036". Isolate the bottoms from T-2102 by the gate valves and blind at the lines *PL-210054" and “PZ-210055". Start by-pass ‘PL-210064" by opening the gate valves and blind Start pipeline (by-pass of T-2103) ‘PL-210063" by opening the gate valves and blind. Isolate feed the propane to the BL by the gate valves and blind at suction line to P- 2105A/B, ‘PL-210087", and by gate valve and blind at downstream of 021-FV-013. T-2101 overheads (mixed Cs's) divert to LPG sphere via the pipeline ‘PL-210088", BA7AL-021-ML-001-A,‘VIETNAM OIL AND GAS CORPORATION ‘April 2007, -_ . (PETROVIETNAM) Technip th DUNG QUAT fae Rev. A ‘OPERATING MANUAL Chapter :7 UNIT PRU (021) Page: 26/42 i NORMAL SHUTDOWN 7.1 Summary of Shutdown The following step covers a normal planned complete shutdown such would be required for the periodic cleaning and inspection of vessels. ‘The step is divided into followings: xi, Notify operating foreman and other units of shutdown. xii, Reduction of charge rate. Shutdown and block in all columns xiii, Cut out charge, xiv. Purging and steaming out xv.Preparation for maintenance 7.2 Notify of Unit Shutdown Notify foreman and other operating units concerned as to exact time when the shutdown operations will start. Changes in utility such as steam requirements, etc., may affect other 7.3 Reduction of charge rate 73.1 Start reducit the flow rates of the feed and utilities to minimum. (50% of design feed rate) 7.3.2. Ensure the minimum level in the columns and vessels. 7.4 Cut out charge, Shutdown and block in all columns 7.4.1 Stop supplying feed to the unit, close valves at the unit battery limit. 7.4.2 Shut down Propylene Vapour Compressor (C-2101) with stop feeding high pressure steam to turbine (TR-2101) according to vendor's operation instruction, 7.43. Stop feeding low pressure steam to C3/C4 Splitter Reboilers (E-2103/B) 7.44 Stop feeding heavy naphtha to the De-ethanizer Reboiler (E-2108) and Blowoff Preheater (E-2107), close valves at the unit battery limit. 74,5 Continue reflux until the respective column has cooled down, Add nitrogen, if required, to maintain a positive pressure during cooling. 74.6 Stop column reflux. 7.4.7 Pump out the liquid from the columns to LPG sphere. Pump out the propylene from Propane/Propylene Reflux Drum (D-2105) to the on-spee propylene sphere or off-spec propylene sphere. 7.4.8 Close valves on product line at battery limits 7.4.9 Drain the residual product stock to flare. When emptying columns and vessels first drain liquid and only then depressurize. 7.4.10 Drain the residual heavy naphtha from the system to light slops. 474L-021-ML-001-A,VIETNAM OIL AND GAS CORPORATION ‘April 2007 A (PETROVIETNAM) Technip ta ti DUNG QUAT REFINERY Rev. cA OPERATING MANUAL Chapter :7 UNIT PRU (021) Page :27/42 7.4.11 Stop cooling water supply to condensers and coolers. [Note] If isolation for condensers and coolers which used cooling water as cooling medium is required, following sequences should be carried out to prevent hydrocarbon release to atmosphere via PSV on cooling water side. i) Close the isolation valve at inlet and outlet of exchanger process side. ii) Drain out the hydrocarbon to flare and depressurize the section. Close the isolation valve at inlet and outlet of exchanger cooling water side. iv) Purge by nitrogen using temporary hose and check residual hydrocarbon vapours. 7.5 Purging and steaming out 7.5.1 Purge systems with nitrogen to flare. 7.5.2 _ Start equipment steaming out. Open vents and drains at low points. 7.6 Preparation for Maintenance 7.6.1 Pump out columns and drains, and then depressurize the unit to the flare. Equipment to be gas free should then be purged with nitrogen or steamed out. 7.6.2. Any section of the pipe, equipments, such as vessel, heat exchanger or pump, to which it is required to have an access for maintenance, shall be thoroughly purged and prepared prior to being released for maintenance. 7.6.3 Low pressure steam shall be utilized for the equipment steam-out. 7.64 The following equipments shall be steamed out with low pressure steam: + T2101 + E-2103A/B (tube side) © 72102 + E-2108 (shell and tube side) © 72103 + E-2111 (shell side) * D2101 © D-2102 + D.2103 * E-2107 (tube side) + D-2106 © D-2107 © A2101 84741-021-ML-001-A165 166 16.7 168 169 7.6.10 7.6.11 7.6.12 ‘VIETNAM OIL AND GAS CORPORATION ‘April 2007, recip EQ 35 en a OPERATING MANUAL Chapter: 7 UNIT PRU (021) Page: 28/42 Prior to the steaming, isolate vessels from the non-steamed pipelines by blinds, shut-off valves or removing removable pipeline sections. Prior to the steaming, close valves at the pressure and level gauge nozzles to avoid damage due to overheating. Pumps shall not be subject to steaming. Pumps to be disconnected and purged by nitrogen to flare. Equipment steaming shall be provided by flexible hoses or semi-stationary systems. Periodically drain condensate from low point drains while steaming and run the contaminated condensate to the oily water sewer. Check for residual hydrocarbon vapours. Upon completion of the steaming process, leave the vents and drains opened. Ensure that the vessel is not under pressure or vacuum. Release the unit for maintenance under a permit-to-work, 8474L-021-ML-001-A,81 8.2 83 84 8.41 842 85 ‘VIETNAM OIL AND GAS CORPORATION ‘April 2007 Technip ti Dna ain Aerie Rev. A OPERATING MANUAL Chapter :8 UNIT PRU (021) Page 229/42 EMERGENCY SHUTDOWN PROCEDURES General Emergency Shutdown Description of the unit shutdown systems is given in document 84741 -021-CN-0008-001. Power Failure On unit general power failure, the feed, reflux and product stream pumps will fail, If a power failure of some duration is encountered, the unit should be shutdown. Activate the PRU emergency shutdown (021-UX-001). When power is again available, confirm the electrical devices (motor, electrical contro! instruments, ete) and, after that, proceed with a normal start-up. Feed Failure Loss of feed will shut down the unit as per normal shutdown. In case that loss of feed is short time, the unit will operate under total reflux operation. Steam Failure High pressure steam failure In case of high pressure steam failure to the turbine drive of Propylene Vapour Compressor (C-2101), the compressor is off: = C3 Splitter Reboiler (E-2111) is off - Propylene Condensers (B-2112A/B/C/D/E/F) are off = De-ethanizer Overhead Condenser (B-2106) is off. Inform all concerned about the change in operations. Decide if the unit should be shutdown. Switch the unit to splitting cut CyC; in T-2101 (see para. 6.6 in clause 6). Low pressure steam failure In case of low pressure steam failure to the C3/C4 Splitter Reboilers (E-2103A/B) ~ C3/C4 Splitter (T-2101) heating is stopped; - Mode of splitting cut C/Cs is disturbed. Inform all concerned immediately that the unit will be shutdown. Stop feed to the unit. Proceed as in normal shutdown (Clause 7). Instrument Air Failure Without instrument air, control valves would move to the fail safe condition and the unit would shut down. If prolonged, secure the unit as per normal shutdown. BATAL-021-ML.O01-A,86 87 VIETNAM OIL AND GAS CORPORATION ‘April 2007, (PETROVIETNAM) DUNG QUAT REFINERY Rev. A OPERATING MANUAL Chapter :8 UNIT PRU (021) Page :30/42 Cooling Water Failure In case of cooling water failure the following will occur: - Vapour condensation in C3/C4 Splitter Overhead Condensers (E-2102A/B/C/D) and Propylene Condensers (E-2112A/B/C/D/E/F), Splitters T-2101 / T-2103, will stop. + The T-2101 bottom product (mixed C:'s) routed to C4 storage will not be cooled, Immediately inform all concerned Shut the unit down. Mechanical Failure If spared equipment fails, first start the stand-by equipment if it has not started automatically. Secure and isolate the failed equipment and prepare it for maintenance. If the failed equipment is not having spared, but it is possible to bypass and isolate the equipment, while continuing to operate safely, do so. Reduce throughput if necessary, and prepare the equipment for maintenance, Following equipments are possible to do such bypass operation; - C3/C4 Splitter Feed/C4 Bottoms Heat Exchanger (E-2101) ~ De-ethanizer Blowoff Preheater (E-2107) ~ C3's Splitter Reflux/Feed Exchanger (E-2110) Following equipments are possible to continue operate by turndown (50%) capacity as a kind of spared equipment; - C3/C4 Splitter Reboilers (E-2103A/B) - C3/C4 Splitter Overhead Condensers (E-2102A/B/C/D) ~ Propylene Condensers (E-2112A/B/C/D/E/F) 4 74L-021-ML.001-Ao4 92 93 94 95 96 97 ‘VIETNAM OIL AND GAS CORPORATION ‘April 2007, . (PETROVIETNAM) Technip th DUNG QUAT REFINERY Rev. :A _— OPERATING MANUAL Chapter: 9 UNIT PRU (021) Page :31/42 SAFETY EQUIPMENT AND PROCEDURES Pressure Safety Devices Refer to Flare Discharge Summary 8474L-021-NM-0006-001 and Specification of Safety Relief Valve 8474L-021-SP-1545-001 Alarm Settings Refer to System 1/0 List 8474L-021-NM-1511-001 Trip Settings Refer to System /O List 8474L-021-NM-1511-001 Trip System Chart Refer to “Cause and Effect Chart” (see clause 9.5) and “Trip setting” (see clause 9.3), Cause and Effect Diagrams Refer to 8474L-021-DW-1514-001. Material Hazard Data Sheets MSDS for A-2101 Catalyst and Inert-Ball will be incorporated later. Safeguarding Memorandum This section is prepared to reemphasize the unit safety features incorporated in the unit. i) Interlocking system An interlocking system is provided to protect the equipment and/or the system from damage in case of emergency. (refer also to 8474L-021-CN-0008-001) The unit is controlled by DCS during normal operation, and DCS provides alarm at an event when operating parameters exceed their operating ranges. At an event of DCS alarm, the operator firstly should check the cause and should best try to return the unit to normal conditions manually. However, in the case of trouble that operator can not handle and/or control the system, the interlock system will work and shut down the equipment safely to protect from failure or damage. “Cause and Effect” is to be referred for detail ii) Flare or Sour Flare system Over pressuring of the equipment occurs in many ways. The basic cause of over pressure is imbalance in heat and material flow in the equipment or piping. Pressure ‘8474L-021-ML-001-A,VIETNAM OIL AND GAS CORPORATION ‘Apri 2007 Techni (PETROVIETNAM) Technip th DUNG QUAT REFINERY Rev. :A ‘OPERATING MANUAL, Chapter :9 UNIT PRU (021) Page :32/42 safety devices have been installed to protect equipment and/or section against over pressure, (refer also to 84741 -021-NM-0006-001) iii) Particularly summaries There is a lot of alert for operator as described in above i). ‘The followings are shown the particularly summary of operator actions in the event of abnormal or emergency situation (i.e. extreme alarm, HH/LL, situation which not relating interlock system) that were raised in Hazop study [refer also to 8474L-021- RT-1900-001]. Symptom Identified by Operator Action Excess high liquid level 021-LAHH-013 + Check duty pump status and flow in D-2103 control system of pump discharge. If duty pump is trouble, start stand-by ump. ~ Check liquid level by level gauge = Investigate cause of trouble. ~ Repair the trouble item. If required, replace it including the switching alternative operation mode or unit shut-down if necessary. - Excess high liquid level 021-LAHH-020 ~ Check duty pump status and flow in D-2105 control system of pump discharge. If duty pump is trouble, start stand-by pump. ~ Check liquid level by level gauge. + Investigate cause of trouble. - Repair the trouble item. If required, replace it including the switching alternative operation mode or unit shut-down if necessary. 84741-021-ML-001-4VIETNAM OIL AND GAS CORPORATION ‘Apri 2007 eee (PETROVIETNAM) Technip DUNG QUAT REFINERY Rev. :A ame OPERATING MANUAL Chapter : 10 UNIT PRU (021) Page: 33/42 10. INSTRUMENT DATA 10.1 Control Valves and Instruments Refer to Data Sheet of Control Valve 8474L-021-SP-1541-001 and Data Sheet of Venturi ‘Tube 84741 -021-SP-1547-0002. 10.2 Orifice Plates Refer to Data Sheet of Orifice 8474L-021-SP-1546-002 and Data Sheet of Restriction Orifice 8474L-021-SP-1546-001. 8474L-021-ML-001-Aiv Ma 112 3 echnip AY tis ‘VIETNAM OIL AND GAS CORPORATION April 2007 (PETROVIETNAM) DUNG QUAT REFINERY Rev. a OPERATING MANUAL Chapter :11 UNIT PRU (021) Page :34/42 SUMMARY OF MAJOR EQUIPMENT Equipment List Refer to Equipment List 84741-420-EL-001 Large Rotating Equipment Refer to Compressor Data Sheet 8474L-021-A1001-1010-001-007, Turbine Data Sheet 8474L-021-A1001-1010-001-012, Compressor Curve 8474L-021-A1002-1010-001-009 and Turbine Curve 8474L-021-A1002-1010-001-014 Heaters There is no fired heater in this unit. Other Vendor information Refer to Vendor's VO List for large compressor and/or important package 8474L-021- A3005-1010-001-030. ‘47AL-021-ML001-A,2 14 VIETNAM OIL AND GAS CORPORATION ‘April 2007 i (PETROVIETNAM) Technip ti DUNG QUAT REFINERY Rev. cA ‘OPERATING MANUAL Chapter : 12 UNIT PRU (021) Page: 35/42 ANALYSIS ‘Sampling and Testing Schedule Refer to Manual Sampling System List on next page. B474L-021-L-001-AChapter : 12 36/42 -Loo-w-izo-ttuee sutsmiaemion | wos woe | 03 | e260 ligereos sans (oe) 120:uNn. WEISS OTE WR soarowa ANaNLITH Iv ONNO-HLHE m ESTSTGME drajserYeLoo-Weizo-wLre sg a 3 cours | owe | om | on | ow | we | a | oman Zire | a Eey| Se ro 2 |eimoinnumicrmn| nce | anmeacieene | wrergeim Som forsee] ori eanaaeowanrs | Sts vane ona | Seemed rc i na) 20 un [ISTTRSISAS ONTTERVS WARY 19 BESTSTSE graqsexChapter : 12 WH00-IN-i20-Ee g 8 eR ep US oat Be 4 apoE se parsEOU 52 ae UE 9 SP eS "Ae ans sd en Buon enn 36a eno pnb y= eral 10m oon ‘snaoonehe tne Kap na a ‘ap ss UU = sua faebay oH ssid a ota eu Buses a eu wton ihn] ew ct pop og ew din seam uoge| swore | woo | ose | oe | om | eae 1_| seascepoyamios | 20s | srimcosanae | nasi swore | wo | os | ose |r | oe 1__| zvorunasaiios | 05 | erieaszomie | w20ss0 ate) | fo) | Saeven) | to) | Bea) (can seve | owen (11d) en pteey eneur, | utso0 | unensuns | emesag | arpundues | ansaig (emi owas onnanys | WeLSAs ward va aL! anor _[ TW sOTaNOd NOTS30_[HTSNOUTONOD BRIM Sans. (reid v20 uN, TSS ONES WT sarod ieN34 NO ONNO-HLNA 19 STa daar‘VIETNAM OIL AND GAS CORPORATION ‘April 2007, (PETROVIETNAM) DUNG QUAT REFINERY Rev. A OPERATING MANUAL Chapter: 12 UNIT PRU (021) Page :39/42 12.2, OnLine Analyzer Refer to Data Sheet of On-Line Analyzer 84741 -021-SP-1564-005. 474-021-ML-001-A13. Ba 13.2 13.3 ‘VIETNAM OiL AND GAS CORPORATION ‘Apri 2007 ; (PETROVIETNAM) Technip ti DUNG QUAT REFINERY Rev. :A OPERATING MANUAL Chapter: 13 UNIT PRU (021) Page 40/42 PROCESS CONTROL Distributed System Control (DCS) Refer to Distributed Control System Technical Specification 84741.-000-JSS-1511-001, Design and Engineering Information for Control and Instrumentation 8474L-000-JSD- 1510-001 and Control System Interconnection Diagram 8474L-000-DW-1510-001. Instrumented Protective System (IPS) and Safeguarding Systems Refer to Emergency Shutdown Control Centre 84741-000-JSS-1511-001, Design and Engineering Information for Control and Instrumentation 8474L-000-JSD-1510-001 and Control System Interconnection Diagram 8474L-000-DW-1510-001. Control Centre Refer to Design and Engineering Information for Control and Instrumentation 8474L-000- JSD-1510-001 and Control System Interconnection Diagram 8474L-000-DW-1510-001. BA7AL-021-ML.001-A,VIETNAN OIL AND GAS CORPORATION ‘Apri 2007 - (PETROVIETNAM) Technip DUNG QUAT REFINERY Rev. :A ‘OPERATING MANUAL Chapter : 14 UNIT PRU (021) Page 241/42 4. DRAWINGS 14.1 Plot and Hazardous Area Classification Plans Refer to Plot Plans 8474L-021-DW-0051-001 and Hazardous Area Classification Drawings 8474L-021-DW-1920-001 14.2 Process Flow Diagram and Material Selection Diagram Refer to Process Flow Diagram 8474L-021-PFD-0010-001/002/003/004/005 and Material Selection Diagram 8474L-021-MSD-0011-001/002/003. 143 Piping and Instrumentation Diagrams Refer to P&ID 8474L-021-PID-0021-111/112/113/114/115/116/117/118/119/120/121, 8474L-021-PID-0031-000/501/502/503/504/505/506/507/508/509/520/530/551, 8474L- (021-PID-0041-601//611/621/631. 14.4 Other Drawings Electrical Single Line Diagram 84741 -XXX-XXXX-XXxX (will be incorporated later), Fire Fighting System P&ID 8474L-021-PID-1931-001/002 and a set of drawings for Underground Sewer Network 8474L-420-DW-1453-001, 84741-021-DW-1442-001, 8474L-021-DW-1452-001/002/003, 8474L-021-DW-1453-001/002/003/004, 8474L-021- DW-1454-001/002. B474L-021-M1-007-4‘VIETNAM OIL AND GAS CORPORATION April 2007 . (PETROVIETNAM) Technip ia th DUNG QUAT REFINERY Rev. iA OPERATING MANUAL Chapter : Attachments UNIT PRU (021) Page =: 42/42 ATTACHMENTS 1. Lubrication and Preventive Maintenance Schedules Refer to Vendor's Lubricants Chant / Requirement 8474L-021-A1015-0910-207-001, 8474L-021-A1015-1010-200-751, 8474L-420-A1015-0910-202-001, B¢7AL-021-MIL-001-4,DUNG QUAT REFINERY OPERATING MANUAL PROPYLENE RECOVERY UNIT (021) Volume 11 GC) Book 1/1 8474L-021-ML-001 rom EtGDUNG QUAT REFINERY OPERATING MANUAL 84741.-021-ML-001 PROPYLENE RECOVERY UNIT (UNIT 021) BOOK 1/1 VOLUME NO 11 Technip AE th