Recovery Plus Operating Manual

RELIANCE PETROLEUM LIMITED
OPERATING MANUAL
RECOVERY PLUS
JAMNAGAR
UNIT 233
RECOVERY PLUS OPERATING MANUAL

Table of Contents
1.0
General
1.1
1.2
Introduction
Glossary
1.3
2.0
3.0
4.0
Abbreviation
Unit Description
2.1
Design Basis
2.2
Process Flow Description and Controls
2.3
DCS Description
2.4
Design Flow Plan
2.5
Refinery Site, Underground Piping and Unit Layout Plan
2.6
Material Balance
2.7
Feed and Product Specifications
2.8
Catalyst and Chemicals Details
2.9
Utility conditions and requirement
Interconnectivity
3.1
Inter Unit Relationship
3.2
Inter Plant Relationship
3.3
Utility / Offsite Relationship
Preparing the Unit for Initial Start-up

4.1
Introduction
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4.2
Utility System Readiness
4.2.1
Piping Network
4.2.2
Commissioning of Utilities
4.3
Inspection of Equipments
4.3.1
Piping and Supports

4.3.1.1
Visual Inspection
4.3.1.2
Hydrostatic Test
4.3.1.3
Flushing
4.3.1.4
Air Blowing and Drawing
4.3.1.5
Tightness Test
4.3.2
Vessels
4.3.3
Exchangers
4.3.4
Pumps
4.3.5
Compressors
4.3.6
Instrumentation System
4.3.7
Electrical System
4.4
Chemical Cleaning and N2 Blaketing
4.5
Run-in Pumps
4.6
Run-in Compressors
4.7
Tightness Test and Inertisation
5.0
4.7.1
Tightness Test
4.7.2
Vacuum Test and Inertisation
4.8
Safety Checks Before Start-up
OPERATING MANUAL
RECOVERY PLUS
UNIT 233
Commissioning / Initial Start up

5.1
notification to other departments
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6.0
7.0
UNIT 233
5.2
Utilities Start-up
5.3
Outline of Initial Start-up
5.4
Evacuation of Air, Nitrogen and Water Removal
5.5
Charging of Lube Oil
5.6
Oil Circulation
5.7
Inventory Refrigeration Circuit with Refrigerant
5.8
Initial Compressor Start-up
Start up
6.1
General
6.2
Notification to Other Departments
6.3
Utilities Start-up
6.4
Outline of Initial Start-up
6.5
Compressor Start-up
Normal Shutdown
7.1
General
7.2
7.3
Preshutdown Preparation
7.4
General Outline of Normal Shutdown
7.5
Refrigeration Circuit Shut Down
7.6
Process Circuit Shut Down
7.7
Refrigerant Retained in Receiver
7.8
Post Shutdown Checks
7.9
Equipment Handing/Taking Over to/from Maintenance
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8.0
9.0
10.0
OPERATING MANUAL
RECOVERY PLUS
UNIT 233
Normal Operation
8.1
Process Principles
8.2
Process Variables
8.3
Control Philosophy & Key Analyses
Unit Safeguarding System

9.1
Relief Device Summary
9.2
Instrument Alarm
9.3
Instrument Trip
Emergency Shutdown
10.1
General
10.2
Interconnectivity During Emergencies
10.3
Process and Utility Failure
10.3.1 Power Failure

10.3.2 Loss of Cooling Water
10.3.3 Loss of Refrigerant
10.3.4 Loss of Instrument Air
11.0 Special Procedures

11.1 Initial Refrigerant Loading
12.0
Fire & safety

12.1
Introduction
12.2
Repair Work, Permit to Work System, Housekeeping and

Maintenance on
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UNIT 233
12.3
Safety During Sample Withdrawal
12.3
Fire Fighting and Safety Equipment
12.5
Precautions for Entering any Contaminated or Inert Atmosphere
12.6
General RECOVERY PLUS Unit Safety Notes
12.7
Material Safety Data Sheet (MSDS)
13.0
Laboratory Requirements and Schedule
14.0
Major Equipment and Instruments Summary

14.1.1 Vessels
14.1.2 Shell and Tube Exchangers
14.1.3 Pumps
14.2
15.0
Instruments Summary
List of Reference Drawings

PFD, P & ID, MFD, Plot Plan, PSFS, MSD, Area Protection Layout, Safety
Equipment Layout, Safety Signs Layout, PIB#4 Gaseous Fire Extinguishing
System
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1.O
GENERAL
1.1
Introduction
The Aromatics plant at Jamnagar is designed to produce 1,200,000 tons of
Paraxylene per annum and 150,000 tons of Orthoxylene from naphtha feed
stock (2641 KTPA) available from Jamnagar Refinery Complex and Mixed
Xylenes (80 KTPA) from Hazira.
Feed Naphtha from the refinery consists of:
Straight run naphtha
Delayed Coker naphtha
FCC heart cut Naphtha

Paraxylene Plant basic technology has been provided by UOP. It will process
special cut Naphtha (105 oC 165 oC) to produce Paraxylene as the major
product and other side cut products. These are as follows.
LPG
= 305
TPD
Light Reformate
= 752
TPD
Benzene
= 326
TPD
Toluene
= 300
TPD
Paraxylene
= 3600 TPD
Orthoxylene
= 450
TPD
Heavy aromatics to blend = 407
TPD
Heavy aromatics to fuel
48
TPD
Hydrogen
= 171
TPD
In addition some gases will go to fuel gas system.

JAMNAGAR
OPERATING MANUAL
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UNIT 233
Paraxylene plant in Jamnagar consists of the following units:

1.
Heavy Naphtha Unionfining Unit
Unit No.221
2.
Platformer Unit
Unit No.231
3.
Cyclemax Continuous Regeneration Unit
Unit No.232
4.
Recovery-Plus
Unit No.233
5.
PSA
Unit No.234
6.
Xylene fractionation unit (3 trains)
Unit No.241/242/243
7. Orthoxylene fractionation unit
Unit No. 251
8. Parex Unit (3 trains)
Unit No. 261/262/263
9. Isomar Unit (3 trains)
Unit No. 271/272/273
10. Tatoray Unit
Unit No.281
11. Aromatics Tankage
Unit No.201
12. Aromatic Blowdown
Unit No.202
Key Features
As a part of the Jamnagar Refinery complex, aromatic plant is being
established. A great emphasis has been placed on maximizing the ratio of
Paraxylene to Benzene product. This serves to minimize the quantity of
naphtha feed stock required per ton of Paraxylene product and avoids excess
production of Benzene.
A key element of UOPs strategy is to maximize Paraxylene to Benzene ratio by
controlling the Naphtha initial points and end points upstream in the refinery.
Heavy Naphtha feed stock for Platforming unit is obtained from three sources
as follows.
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UNIT 233
Boiling range
a. Saturate Gas Concentration Unit Naphtha 105 to 165 oC
b. Sydec Delayed coker Unit Naphtha
105 to 165 oC
c. FCC heart cut naphtha
105 to 180 oC
For naphtha streams initial boiling point of 105 oC has been selected and a wide
gap specified. This cut point, combined with a sharp fractionation, will serve to
drive most of the C7 paraffins up into the light naphtha storage, but retain most
of Toluene in the heavy naphtha to be used for aromatics production via
Platforming units. The 105 oC cut point also eliminates Benzene precursors
from the Platforming unit feed stock.
The end point of 165 oC will ensure that almost all C8 molecules and many C9
molecules will go into the heavy naphtha feed stock for aromatics production.
To maximize Paraxylene production, it is important to retain all the C8
precursors and obtain just the right amount of C9 to generate enough C9
aromatics to fully load the Tatoray unit.
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1.2
OPERATING MANUAL
UNIT 233
Glossary
Terms
Absorption
Description
The process by which one substance draws into itself
another substances i.e. CO2 absorbed in K2CO3
solution, HC absorbed in lean oil from net gas
stream, etc.
Accumulator
A vessel for the temporary storage of a gas or liquid

usually used for collecting sufficient material for a
continuous charge to some refining process.
Adsorption
The physical separation of multiple components by

solid adsorbent. i.e. removal of moisture, CO2 from
air by air dryer using silica / alumina as adsorbent.
API
An arbitrary scale expressing the gravity or density of

liquid petroleum products. The measuring scale is
calibrated in terms of degrees API. It may be
calculated in terms of the following formula :
Deg. API = (141.5/sp.gr. @60 F) - 131.5
Aromatic
Derived from, or characterized by the presence of the

benzene ring and having sweet odor. The name
usually
applied
to
the
benzene
series
of
hydrocarbons; derived from the characteristic odor of

the series; Paraxylene, Ethyl Benzene(EB), Tri-
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Terms
UNIT 233
Description
methyl benzene(TMB), Para di-ethyl benzene(PDEB).
Aromatic
A naphtha rich in aromatics precursors
Naphtha
Atom
The smallest complete particle of an element which

can be obtained which retains all physical and
chemical properties of the element.
Atomize
To divide a liquid into extremely minute particles,

either by impact with a jet of steam or compressed
air, or by passage through some mechanical device.
Back pressure
1. The pressure on the outlet or downstream side of a

flowing system. 2. In an engine, the pressure which
acts adversely against the piston, causing loss of
power.
Barrel
A common unit of measurement of liquids in the

petroleum industry; it equals 42 U.S. standard
gallons.
Baume
Specific gravity of liquids expressed as degrees on

the Baume scale. For liquids lighter than water, the
formula is :
Sp. gr. 60 F/600 F = 140 /(130+deg. Be)
For liquids heavier than water, the formula is :
Sp. gr. 60 F/600 F = 145 / (145 - deg. Be)
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Terms
UNIT 233
Description
Bleeding
Blend
Diverting a small portion of the material contained in
a line or vessel, usually by opening a valve slightly.

Any mixture prepared for a special purpose; e.g. the
products of a refinery are blended to suit market
Boiling Point
requirements.
The temperature at which a substance boils or is
converted into vapor by bubbles forming within the
Boiling Range
liquid; it varies with pressure.

The range of temperature, usually determined at
atmospheric
pressure
in
standard
laboratory
apparatus over which the boiling or distillation of an

oil commences, proceeds, and finishes.
Bottoms
The liquid which collects in the bottom of a vessel /

column / tank during processing/storage. i.e. column
bottom
Byproduct
A secondary or additional product produce during

production
of
Major
product,
not
of
primary
importance. i.e. Benzene byproduct in production of

Paraxylene.
Calibration
Determination of the accuracy of an instrument by

finding its variation from true measurement.
Carryover
1. Relatively nonvolatile contaminating material

which is carried over by the overhead effluent from a
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Terms
OPERATING MANUAL
UNIT 233
Description
fractionating column, absorber, or reaction vessel. It
may be carried as liquid droplets or finely divided
solids suspended in a gas/vapor/discrete liquid. 2.
That portion of a finely divided catalyst
which
escapes the cyclones of cracking units.

Catalyst
A substance which affects, provokes, or accelerates

reactions without itself being altered.
Caustic Soda
Sodium hydroxide, a very strong alkali.
Centrifugal
Consists of one or more impellers mounted on a
Pump
(Volute
rapidly rotating shaft. The liquid enters the impellers
Type)
at the center, or eye, and is thrown outward at a

high velocity into the volute of the pump casing. The
function of the volute is to catch the impeller
discharge and convert velocity head into pressure
head while conducting the liquid to the discharge
nozzle of the pump casing.
Compressor
A machine which draws in air or other gas, compress

it and discharges it at a higher pressure.
Condensation
The act or process of changing a vapor to a liquid, or

a lighter liquid to another and denser form by
depression of temperature or increase of pressure.
Condenser
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Ordinarily a water-cooled heat exchanger used for

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Terms
OPERATING MANUAL
UNIT 233
Description
cooling and liquefying oil vapors. Where the cooling
medium used is air, the condenser is called an air
condenser.
Conduction
The flow of heat by contact.
Convection
The flow of heat through liquid or gas by actual
mixing of the fluids

A heat exchanger whose primary purpose is to
Cooler
reduce the temperature of one of the passing fluids.

Cracking
A phenomenon by which large oil molecules are

decomposed into smaller, lower boiling molecules; at
the same time, certain of these molecules, which are
reactive, combine with one another to give even
larger molecules than those in the original stock. The
more stable molecules leave the system as cracked
gasoline, but the reactive ones polymerize, forming
tar and even coke.
Note: Cracking may be in either the liquid or vapor
phase. When a catalyst is used to bring about the
desired chemical reaction, this is called catalytic
cracking; otherwise, it is assumed to be thermal
Crude Oil
cracking.
A synonym for petroleum. A naturally occurring
mixture consisting predominantly of hydrocarbons
and/ or sulfur, nitrogen, and oxygen derivatives of
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Terms
OPERATING MANUAL
UNIT 233
Description
hydrocarbons which is removed from the earth in a
liquid state or is capable of being, so removed.
Discharge Line
Product line usually under pressure due to a

pumping force being applied.
Distillate
That portion of a liquid which is removed as a vapor

and condensed during a distillation process.
Distillation
Vaporization
of
liquid
and
its
subsequent
condensation in a different chamber. The separation

of one group of petroleum constituents from another
by means of volatilization in some form of closed
apparatus, such as a still, by the aid of heat.
Drawoff
A connection which allows liquid to flow from the side

or bottom of a vessel.
Effluent
Outflow from vessel/equipment/tank
Extraction
The process of separating a material, by means of a

solvent, into a fraction soluble in the solvent (extract)
and an insoluble residue.
Flammable
Capable of being easily set on fire; combustible.
Flash
1. A sudden release in pressure resulting in partial or

complete vaporization. 2. A sudden burst of light; a
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Terms
OPERATING MANUAL
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UNIT 233
Description
momentary blaze.
Flash Point
The lowest temperature at which vapors arising from

the oil will ignite momentarily (i.e. flash) on
application of a flame under specified conditions.
Flooding
Flue Gas
In a fractionating column, the filling up of a liquid due
to high pressure drop across trays or packing.

Gas from the combustion of fuel, the heating value of
which has been substantially spent and which is
therefore, discarded to the flue or stack.
Fuel Oil
Any liquid or liquefiable petroleum product burned for

the generation of heat in a furnace or firebox, or for
the generation of power in a engine (exclusive of oils
Header
with a flash point below 100 F )

A common manifold in which a number of pipelines
are united.
Heat
Exchanger
Apparatus for transferring heat from one fluid to

another. Specifically, a piece of equipment having a
tubular piping arrangement which effects the transfer
of heat from a hot to a relatively cool material by
conduction through the tube walls.
Heater
The furnace -and- tube arrangement which is the

principal heating element in a processing unit.
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Terms
Hydrocarbon
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Description
A compound containing only hydrogen and carbon.
The simplest hydrocarbons are gases at ordinary
temperatures, but with increasing molecular weight,
they change to the liquid form and finally to the solid
state. They form the principal constituents of
petroleum.
Impingement
The contact of flame on skin of radiant tubes in the

furnace.
Induced Draft
Air drawn rather than forced into a furnace.
Inert gas
A noncombustible gas such as nitrogen or carbon

dioxide.
Inhibitor
A substance the presence of which, in small

amounts, in a petroleum product prevents or retards
undesirable chemical changes from taking place in
the product, or in the condition of the equipment in
which the product is used. In general, the essential
function of inhibitors is to prevent or retard oxidation
or corrosion.
Knockout Drum
A drum or vessel constructed normally with baffles,

through which a mixture of gas and liquid is passed
to disengage one from the other. As the mixture
comes in contact with the baffles, the impact frees
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Terms
UNIT 233
Description
the gases and allows them to pass overhead; the
heavier substance falls to the bottom of the drum.
Liquefied
Petroleum Gas
Light hydrocarbon material, gaseous at atmospheric

temperature and pressure, held in the liquid state by
pressure
to
facilitate
storage,
transport,
and
handling. Commercial LPG consists essentially of

propane, butane, or mixtures thereof.
Manifold
A piping arrangement which allows one stream of liquid or gas

to be divided into two or more streams, or which allows several
streams to be collected into one.
Molecule
Unit of matter; the smallest portion of an element or a

compound which retains chemical identity with the
same particular substance enmasse.
Multi-Stage
Centrifugal
Pump
Naphthene
Centrifugal pump which has two or more impellers

mounted on the same shaft.
A saturated hydrocarbon having the general formula

CnH2n and a cyclic molecular structure; i.e. cyclopropane, cyclo-butane, cyclo-pentane, cyclohexane.
Natural Gas
Naturally occurring mixtures of hydrocarbon gases

and vapors, the more important of which are
methane, ethane, propane, butane, pentane, and
hexane.
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Terms
UNIT 233
Description
Olefin
An open chain, unsaturated hydrocarbon having one

double bond.
i.e. Ethylene C2H4
Orifice
A device for restricting the flow through a pipe. The

difference in pressure on the two sides of an orifice
plate can be used to measure flow through the pipe.
Packed Tower
A fractionating or absorber tower which is filled with

small objects (packing material, i.e. rasching ring,) to
effect an intimate contact between rising vapor and
falling liquid.
Paraffin
That series of noncyclic hydrocarbons having the

general formula CnH2n
, and having no double &
+ 2
triple bonds. i.e. Butane C4H10 , Hexane

C6H14 , etc.
.
Petrochemical
A naphtha lean in aromatics precursors
Naphtha
Petroleum
material
occurring
naturally
in
the
earth,
predominantly composed of mixtures of chemical

compounds of carbon and hydrogen with or without
other nonmetallic elements such as sulfur, oxygen,
nitrogen,
etc.
Petroleum
may
contain,
or
be
composed of, such compounds in the gaseous, liquid,
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Terms
OPERATING MANUAL
UNIT 233
Description
and / or solid state, depending on the nature of these
compounds
and
the
existent
conditions
of
temperature and pressure.

Petroleum
Naphtha
A generic term applied to refined, partly refined, or

unrefined petroleum products and liquid products of
natural gas, not more than 10 per cent of which distill
below 175 C, and not less than 95 percent of which
distill below 240 C, when subjected to distillation in
accordance with ASTM Method D-86.
pH Value
The logarithm of the reciprocal of the hydrogen ion

concentration. This indicates the acid or alkaline
condition of a substance, pure water and neutral
solutions having a pH of 7. Acid solutions have a pH
less than 7 ; alkaline solutions, a pH greater than 7.
Polymer
Product of polymerization of normally gaseous olefin

hydrocarbons.
Power pump
A reciprocating pump in which the liquid pistons are

driven by other means than direct acting steam
pistons and rods.
Preheater
Any form of equipment in which heat is applied to a

material prior to its introduction into the main heating
equipment. The application of heat is usually
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Terms
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UNIT 233
Description
accomplished by means of hot fluid which have to be
cooled and whose heat would otherwise be wasted.
Pressure Drop
The decrease in pressure due to friction/plugging,

which occurs when a liquid or gas passes through a
pipe/filter/vessel, etc.
Pressure
Vessel
An enclosed container in which greater than

atmospheric pressure is maintained.
Pump Priming
The filling of the liquid end of a pump with liquid to

remove vapors present and eliminate the tendency to
become vapor lock.
Purging
The displacement of one material with another in

process equipment; frequently, displacement of
hydrocarbon vapor with steam or inert gas.
Quench
To suddenly cool hot material discharging from a

cracking coil, usually by injecting cool oil into the
discharge line; its purpose is to check the cracking
reaction quickly.
Radiation
The act of emitting energy, particularly rays of light or

heat.
Reactor
The vessel in which the major part of a reaction or

conversion takes place. In catalytic cracking it is the
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Terms
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UNIT 233
Description
enlarged space in which hot oil is converted to
simpler compounds.
Reciprocating
Pump
A Positive displacement type of pump consisting of a

plunger or a piston moving back and forth within a
cylinder. With each stroke of the plunger or piston, a
definite volume of liquid is pushed out through the
discharge valves.
Reflux
In fractional distillation, that part of the distillate which

may be returned to the column to assist in making a
better separation into desired fractions is called
Reflux. Reflux may be either circulating or induced.
Circulating reflux is liquid/vapor which is withdrawn
hot, normally cooled, and pumped back to the tower.
Induced reflux is liquid formed within a fractionation
tower by condensation of vapors by means of an
internal cooling coil.
Residue
Heavy oil or bottoms left in the still after gasoline and

other relatively low-boiling constituents have been
removed.
Rich Oil
The oil drawn off the bottom of an absorber tower

containing fractions absorbed from a gas.
Riser
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That portion of the bubble plate assembly which
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JAMNAGAR
Terms
OPERATING MANUAL
UNIT 233
Description
channels the vapor and causes it to flow downward
to escape through the liquid.
Rotary pump
A positive displacement pump used mainly to pump

liquids which are either too viscous or too difficult to
pick up suctions with a centrifugal pump. There are
many types of rotary pump designs, one of the most
common being the gear type - in which two gears
mesh and rotate toward each other within a very
close fitting casing. The liquid is trapped between the
gear teeth and the casing and carried around to the
discharge side of the pump. The meshing gear teeth
prevent the liquid from returning to the suction side.
Rundown Tank
One of the tanks in which product is received from

the plant and from which the product is pumped to
larger tanks known as storage tanks. Rundown tank
is also known as Receiving tank or Day tank,
designed to store only one days production(with
enough cushion) . If the product was received
directly into the large storage tanks, the offspec.
product due to plant upset would contaminate
unnecessarily larger size product storage tank.
Scrubbing
Purifying a gas by washing with water or chemical;

less frequently, the removal of entrainment. The
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equipment used to give intimate contacting of the

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Terms
OPERATING MANUAL
UNIT 233
Description
material to be purified is called a scrubber.
Separator
A holding vessel used to aid in the separation of light

and heavy gravity material. i.e. Separator in reactor
section separate liquid and recycle gas.
Simplex pump
A reciprocating pump that has one liquid cylinder on

a single drive.
Sour Crude
Crude oil containing an abnormally large amount of

sulfur compounds which, upon refining, liberate
corrosive sulfur compounds.
Specific Gravity
The ratio of the weight of a volume of a body to the

weight of an equal volume of some standard
substance. In the case of the liquids and solids, the
standard is water. In the case of gases, the standard
is hydrogen or air.
Stabilizer
A fractionating tower for removing light hydrocarbons

from an oil to reduce vapor pressure; particularly
applied to gasoline.
Steam
Water in the vapor state.
Straight Run
Product of distillation of crude petroleum without

subjected to cracking.
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JAMNAGAR
Terms
Stripping
UNIT 233
Description
Removal of the lightest fractions from a mixture. The
process is usually carried out by passing the hot
liquid from a flash drum or tower into a stripping
vessel or section (stripper), through which open
steam or inert gas is passed to remove the more
volatile components of the cut.
Suction Line
Intake
line
leading
from
vessel/storage
to
pump/compressor suction.
Superheated
Water vapor above the saturation temperature at a

given pressure.
Surge Drum
A vessel or accumulator which serves as a reservoir

for liquid being pumped through a line, thereby
overcoming fluctuations in the rate of flow caused by
the pump.
Sweet
Having a good odor; pleasant to the sense of smell;

negative to the doctor test. i.e. sweet naphtha lean in
sulphur content.
Temperature
An
arbitrary
measurement
of
the
amount
of
molecular energy of a body, or the degree of heat

possessed by it. It should be distinguished from heat
itself. Heat is a form of energy; temperature is a
measurement of its intensity.
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JAMNAGAR
Terms
UNIT 233
Description
Thermocouple
The junction of two wires of dissimilar metals, which

develops an electrical potential that is a function of
the temperature; an instrument for measuring
temperature by means of the electrical potential
produced at a heated junction of two dissimilar
metals.
Thermowell
A tube having one end closed, inserted into a vessel

pipe, or furnace as protection for a thermocouple or
thermometer bulb.
Throttling
To control a flow by operating a valve by hand

,making moves in small increments; such as closing
a valve in the steam line of a boiler for controlling the
flow of steam to any apparatus.
Treating
The contacting of petroleum products with chemicals

to improve the quality.
Turnaround
Time necessary to clean and make repairs on

refinery equipment after a normal run. It is the
elapsed time between drawing the fires (shutting the
unit down) and putting the unit on stream again.
Vapor Pressure
The pressure exerted by the vapors released from

any material, at a given temperature, when enclosed
in a vapor tight container.
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JAMNAGAR
Terms
OPERATING MANUAL
UNIT 233
Description
Vessel
A closed container to hold gas and/or liquid under

pressure or vacuum. It may be used solely for
storage, in which case it is often called a drum, e.g.,
butane drum, reflux drum, etc. Process vessels will
permit volume fluctuations, settling of mixed stocks,
demisting of vapors, or reactions (such as treaters or
reactors).
Viscosity
The measure of the internal friction or the resistively

to flow of a liquid. In measuring viscosity of
petroleum products, the values of the viscosity are
usually expressed as the number of seconds
required for a certain volume of the oil to pass
through a standard orifice under specified conditions.
Volatility
The extent to which liquids vaporize; the relative

tendency to vaporize.
Water Hammer
The energy or impact developed by the sudden

collapse of vapor bubbles.
Weathering
The exposure of crude oils or light oils to the

weather, with subsequent evaporation of volatile
constituents, resulting in loss; in some cases,
oxidation and polymerizing effects are noted also,
particularly with cracked and asphalt oils.
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Terms
OPERATING MANUAL
RECOVERY PLUS
UNIT 233
Description
Wet steam
Steam containing entrained water droplets.
Wet Gas
A gas containing a relatively high proportion of

hydrocarbons which are recoverable as liquids.
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1.3
OPERATING MANUAL
RECOVERY PLUS
UNIT 233
Abbreviation
Item
0
C
0
F
Amps
API
ASME
Details
Degree Centigrade
Degrees Fahrenheit
Amperes
American Petroleum Institute
American Society of Mechanical
ASTM
BD
BFW
BPD
Btu.
Cat.
Col.
Cond.
CS
Dept.
Div.
EB
Eng.
EOR
EP
GC
HC
HP
Kg/cm2.g
Lab
LPG
Maint.
MP
MW
MX
OX
PARAXYLENE
Engineers
American Standard Testing Method
Blow Down
Boiler Feed water
Barrels per day
British thermal unit
Catalyst
Column
Condensate
Carbon steel
Department
Division
Ethylbenzene
Engineer
End of run
End boiling point (of a distillation)
Gas chromotagraph
Hydrocarbon
High pressure
Pressure Unit
Laboratory
Liquefied Petroleum Gas
Maintenance
Medium pressure
Molecular weight
Metaxylene
Orthoxylene
Paraxylene
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Item
,PX
SAE
SOR
Supt.
Xyl. Frac.
PCC
PIB
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RECOVERY PLUS
UNIT 233
Details
Society of Automotive Engineers

Start of Run
Superintendent
Xylene Fractionation
Plant Control Center, control room
Plant Interface Building
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2.0
UNIT DESCRIPTION
2.1
Design Basis
The UOP RECOVERY PLUS system has been designed to improve the
recovery of LPG and Reformate from Platforming Process Unit net gas streams.
Increased hydrocarbon liquid recovery translates into improved liquid product
yields and, therefore, higher production of more valuable products. Added
benefits are improved LPG recovery.
Under the design conditions, the RECOVERY PLUS system improves C5 +
yields by 4 LV% and LPG yields by 0.5 LV% based on fresh feed H2 purity of
the net gas is increased by 8 mol%.
2.2
Process Flow Description and Controls

RECOVERY PLUS system is composed of a process circuit and a closed loop
refrigeration circuit. The process circuit consists of a net gas stream and a
slipstream of liquid from the platforming Unit Debutanizer column feed. The
refrigeration circuit provides cooling to promote the absorption of LPG and
reformate hydrocarbons that would normally exit the Platforming Process Unit in
the net gas stream. The net gas & liquid streams are individually cooled & then
enter the Absorber, MV-AY233-V01. Vapor & liquid separation occurs through
counter current flow. The recovered liquid is sent to the Platforming process
Units Debutanizer column for stabilization prior to being sent to storage. The
gas stream exits the RECOVERY PLUS system to chloride Treaters (MVAY231-V04 A/B).
The RECOVERY PLUS system contains four circuits.
a. Closed loop Refrigeration circuit
b. Oil Reclaimer / oil separator circulation

JAMNAGAR
OPERATING MANUAL
RECOVERY PLUS
UNIT 233
c. Net Gas Circuit

d. Liquid Circuit
a) Closed loop Refrigeration circuit
Starting at the Refrigerant Subcooler 233-S06, the propylene refrigerant (liquid)
is pressured through LV014 and enters into the receiver / Economiser (233V03). From the Receiver / Economiser (233-V03), the vapor portion of the
refrigerant is sent to a side port of the compressor (233 C01) through a back
pressure control valve (PV 038). This ensured there is enough driving force
between the 233-V03 and 233-C01 Suction during low load conditions. 233-V03
improves the efficiency of the Refrigeration compressor.
The refrigerant remaining in 233-V03 is pressured to the Combined VaporLiquid Chiller (233-S03) via control valve LV002. The chilled liquid refrigerant is
maintained 2 below the top of the tubes of the chiller. Frothing of the refrigerant
in the chillers covers the rest of the tubes. Process fluids (H2 / HCBN) pass
through the tubes of Combined Vapor-Liquid Chiller (233-S03) where they are
cooled by evaporation of the refrigerant. The Disengaging drum on Top of the
chiller shell allows any entrained liquid to be removed from the vaporized
refrigerant.
The vaporized refrigerant leaving the Chiller (233-S03) passes through PV012.
PV012 controls the compressor 233-C01 suction pressure during startup only.
During normal conditions PV012 is 100% open.
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UNIT 233
Within the compressor, refrigerant vapor comes in contact with circulating

synthetic oil and the compressed gas/oil mixtures discharges from the
compressor to the oil separator # 1, 233 V02.
In the oil separator #1 (233-V02), the refrigerant disengaged from the oil and
passes overhead though a series of coalescing elements where entrained oil is
removed. The oil is recycled to the Compressor. Refrigerant is then sent
through oil separator #2 233-V04, where oil is removed to below 10 ppm level.
Oil build up in the 233-V04 is sent back into the 233-C01 suction via FO-004.
Any entrained oil will settle in the chiller and is recovered in the Oil Reclaimer
Circuit.
The refrigerant leaves oil separator #2 & enters the shell side of the condenser
233-S05, where it exchanges heat with cooling water (tube side) & condenses.
Condensed refrigerant drains from the condenser (233-S05) in to the tube side
of the subcooler, 233-S06. In 233-S06, the condensed refrigerant is cooled
further by the Rich oil leaving the liquid Exchangers, 233-S02 A/B. This
subcooling allows the compressor capacity to increase without affecting the
energy requirements. The subcooled refrigerant is collected in 233-V03
Receiver / Economiser. 233-V03 is designed to hold the total circuit charge at
90% level.
b) OIL RECLAIMER / OIL SEPARATOR CIRCULATION
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OPERATING MANUAL
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UNIT 233
Entrained oil in the refrigerant stream settles in the Combined Vapor-Liquid

Chiller (233-S03), where refrigerant boiling occurs. With liquid refrigerant boiling
off at - 29 0C the heavier oil settles to bottom of the chiller. The drained oil /
refrigerant mixture from 233-S03 goes to Oil Reclaimer (233-Vv07). The oil is
reclaimed through a batch process of draining, boiling off the refrigerant and
pumping the oil back to the suction of compressor 233-C01. The batch
operation is controlled by a logic system.
After compression, a refrigerant / oil mixture is discharged into the oil separator
#1 (233 V02). The separation between the oil / gas mixture is achieved in the
body
of the separator and further separation takes place in coalescing
elements positioned inside the separator close to the separator outlet. The
bottom of the separator serves as an oil reservoir and is equipped with a level
gauge (LG-012) for positive oil level indication. A temperature controlled oil
heater (233-Y01) is inserted in the separator to maintain the oil temperature for
proper oil viscosity and to minimize oil dilution by the refrigerant during
compressor shutdown. Lube Oil is pumped from the 233-V02 by oil pump 233P02 A/B. The oil then flows through the shell side of the Lube oil coolers (233S04 A/B) oil passes through a 25 micron element filter 233-F01 A/B before the
oil is fed to the bearings, balance piston, shaft seal, compression chamber and
compressor slide valve actuator.
c) NET GAS CIRCUIT
The Net gas in (Rich Gas) passes through the tube side of the vapor exchanger
(233-S01), where it is cooled by exchanging heat with NET OFF GAS (Lean
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OPERATING MANUAL
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UNIT 233
Gas shell side). The RICH NET GAS IN then enters the tube side of the 233S03, where it is further cooled by exchanging heat with refrigerant (shell side).
The temperature of the vapor out of the chiller is controlled by TIC-009. As the
vapor outlet temp begins to decrease, TV 009 begins to open causing a position
of the warm Lean oil to bypass the Liquid Exchangers (233-S02 A/B), and mix
with the vapor entering the tube side of the Chiller, causing a change in the heat
capacity of the fluid. If the temperature of the Vapor leaving the chiller is too
warm, TV 009 will close.
The partially condensed Net Gas, leaving the 233-S03 enters the lower section
of Absorber 233-V01. The rich liquid is removed from the bottoms of 233-V01
on LIC-004. The Absorber off gas (NET OFF GAS) is then heated through the
shell side of the vapor exchangers 233-S01 & is sent to chloride treaters 231V04 A/B.
d) LIQUID CIRCUIT
The liquid into the RECOVERY PLUS system is a slipstream from the
Debutanizer column feed, and is controlled by FIC-002. This stream is pumped
by 233-P01 A/B to the tube side of Liquid Exchanger 233-S02 A /B, where it is
cooled by exchanging heat with the Absorber rich liquid (shell side). The lean
liquid enters the second tube bundle of the Combined Vapor-Liquid Chiller, 233S03 and flows to the top of the Absorber. The temperature of the lean liquid
entering the absorber is controlled by TIC-011.
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UNIT 233
As the temperature of the lean oil exiting the chiller, fluctuates, TIC-011 adjusts
the compressor capacity control by varying the slide valve position. The rich oil
is removed from the bottom of the Absorber, 233-V01 on level control LV-004.
The net liquid is heated through the shell side of the subcooler 233-S06, and
then flows to the Debutaniser feed Bottoms Exchanger 231-S05 A / B on
pressure.
2.3
DCS Description
Distributed Control System for Jamnagar Refinery Complex is of Foxboro I/A
series 50 and is capable of plant wide automation.
The architecture of the system will accommodate both functional and
geographical distribution of the hardware, software, and database over the
plant while allowing system wide access to the distributed data.
The DCS hardware will be state of the art, microprocessor based design, that
will be fully tested and reliable. It will permit control and data acquisition
functions to be distributed to remote Plant Interface Buildings (PIBs) with
operator-consoles located in Plant Control Centre (PCCs).
As stated above all DCS hardware will be in the PIBs, all field inputs will be
terminated in the PIBs, all controllers will be in the PIBs and field outputs will be
from PIBs only.
Monitoring and Control will be by Operator Console located in the PCC, which
in turn is connected to all the PIBs through Fibre Optic Plantwide Control
Network.
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UNIT 233
Foxboro I/A series 50: Following are the main hardware of the system.
WP51B Operator console with two 19 CRT, Keyboard, trackball and

touchscreen.
CP30 & CP40 Control processor for control and data acquisition.
AW51C Engineering Station for configuration of the system.
FBM & FBC Field I/O card.
The entire operator console will be mounted in two tier consoles in the PCCs.
The hardware distribution and configuration of the Platforming Unit is as under:
For HNUU (221), Platformer (231), CCR (232), Recovery Plus (233) and
PSA (234), CP40.
FBMs/FBCs will be in PIB 4 and will be linked to
Aromatics PCC with Fibre optic cable. PIB 4 is a SCS having two operators
console (two CRTs) for start-up and shutdown.
2.3.1
DCS Graphics
Process graphics show process equipment, piping and the instrumentation and
control.
They closely follow the project PFDs and P&IDs.
They will be
arranged in four hierarchy levels:

Plantwide (Level 1)
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OPERATING MANUAL
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UNIT 233
Complex (Level 2)
Unit (Level 3)
Detailed (Level 4)
At each of these levels, the graphics provide the means to move up and down
the graphic hierarchy, and also sideways.
The Plantwide Level graphic shows an overview of the whole Reliance
Jamnagar Refinery Plant. It displays the main plant areas, their statuses and
primary plant data. There shall be no control or process information at this
level. The main purpose of this display is for navigation to other displays.
The Complex Level graphics show overview of the Aromatic complex of
Reliance Jamnagar Refinery. Only the major flows and other important data
specific to each area will be shown. There shall be no process control from this
level. Additionally, the Complex Level graphics should indicate when a fault
occurs at any point within the process, which will allow the operator to navigate
to detailed graphic.
The Platforming Unit Level graphics show most process equipment and major
piping and instrumentation. All controllers, important process variables and
general monitoring parameters are indicated at this level. ESD trips are also
indicated. Facilities are provided for operator actions such as alarm
acknowledgement, manipulation of control loops, operation of valves, pumps,
etc. Each plant unit is represented by several unit level graphics. The graphics
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OPERATING MANUAL
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UNIT 233
at this level follow the project PFDs. Unit Level graphics are intended to be
used most of the time for plant operations.
The Detailed Level graphics show all instrument functions implemented in the
I/A Series indicating loops, monitoring functions, equipment statuses, trips,
ESDs, etc. Facilities are provided for alarm acknowledgement; access to all
control loops, faceplates, groups and trends. The graphics at this level closely
follow the project P&IDs and indicate almost all P&ID level information. This
level of graphics is used to pursue detailed information on the process and the
instrumentation.
2.3.2
Graphic Displays
The console subsystem has facility of viewing multiple windows on one screen
enabling the operator to conveniently access and control all the necessary
factors at the same time.
The graphics shall consist of the following types and overall content:
Overview.
Plant graphics.
Group loop displays.
Loop display.
Trend display
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OPERATING MANUAL
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UNIT 233
Alarm and event summary

At a minimum, the operator will be able to operate, via touch screen or track
ball the control strategies i.e., change set points, control modes,
Page linking to more detailed process graphics, as well as alarm summaries
will be made from these overviews. The operator can call up directly, any
group display covered by the overview screen.
In addition, linking will also be possible to:
2.3.3
Group loop display
Loop display
Alarm and event summaries
Group Displays
Important analog measurements grouped according to the process will be
implemented as vertical bar graphs. Measurements, such as pressure,
temperature etc profiles will give a meaningful operator-overview of the
normal/upset status of the plant.
Bar graphs will include operator adjustable set points and high/low alarms
when measurement deviates from the desired set point. In this case, Set
point may include both controller set points and normal operating parameters
for indication-only measurements.
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UNIT 233
The group displays will consist of measurements and statuses presented in

vertical bar graph formats. These are often referred to as face plate displays,
since the vertical bar graphs are arranged in the manner of single-loop
controller or indicator faceplates. The grouping is defined on logical grouping of
related controllers and indicators within the process unit.
The displays will indicate the following information per group:
Loop tag number and description.
Process variable (measurement, set point and output).
Status indication (on, off, run, stop, open, close, etc.).
Alarm status
Mode (auto/manual, remote/local (set point), tracking, etc.).
Units of measurement.
The operator will be able to quickly address any point and make appropriate
changes to mode, set point and output and so forth. This display will give the
operator direct access to all status and parameters related to one loop,
including the ability to change set points, modes of operation and give on/off
output commands.
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OPERATING MANUAL
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UNIT 233
Several of the operator actions will be password (preferred) or key-lock

protected, such as:
2.3.4
Changing controller-tuning constants.
Controller configuration data.
Enable/disable of alarms, control actions, changing of alarm settings.
Trend displays
In addition to trending shown on the loop displays, the DCS shall provide the
capability of displaying both real time (short-term) and historical trending of
process variables with a facility to change the trended variable on the trends
display.
The trend displays are operator assignable to group in graphical
presentation with :
Vertical axis variable, including measured range/units.
Horizontal axis time base.
All points shall be available on real-time trend with a minimum sample interval
of one (1) second.
2.3.5
Alarm and Event Summary

Either as a standard or a custom display, the DCS will provide a separate
tabular listing of alarms and events, which can be called up by the operator with
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UNIT 233
a single keystroke. Each alarm or event will be listed in order of occurrence

and will include a buffer memory so that no alarms are lost.
The alarm and event summary will include:
Date and time.
Tag and service.
Alarm type and priority.
Alarm limit.
Current process variable with Engineering units.
Alarms acknowledge will be possible, using this display or the loop display.
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2.4
OPERATING MANUAL
RECOVERY PLUS
UNIT 233
Design Flow Plan
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2.5
OPERATING MANUAL
RECOVERY PLUS
UNIT 233
Refinery Site, Underground Piping and Unit Layout Plan
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OPERATING MANUAL
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2.6
OPERATING MANUAL
UNIT 233
Material Balance
INPUT
Kg/Hr
169953
44578
Lean Oil
Net Gas
OUTPUT
Kg/Hr
Hydrogen rich gas to refinery hydrogen 25309
header
Rich oil to debutaniser Feed/Bottom 189222
exchanger at platforming
NOTE:
2.7
Liquid recovered
19269 Kg/Hr
Feed and product Specification

Component
Gas In
Gas Out
Liquid
Kg-mol/h
H2O
H2
C1
C2
C3
IC4
NC4
IC5
NC5
0.19
4836.2
201.03
417.11
299.61
34.86
36.50
4.89
5.11
0.114
4814.30
186.77
263.53
79.92
8.12
8.23
0.92
0.84
Recovered
0.07
21.90
14.26
153.58
219.67
26.74
28.27
3.98
4.27
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Component
Gas In
Kg-mol/h
C5OLEFIN
CP
C6+
Total, Kg/hr
Temperature, 0C
Pressure, Kpag
Molecular Weight
2.8
0.34
0.15
9.94
44578.07
37
3.601
7.63
OPERATING MANUAL
UNIT 233
Gas Out
Liquid
0.07
0.02
0.77
25309.19
28.7
3.474
4.72
Recovered
0.27
0.13
9.17
19268.88
--------43.1
Chemicals - Details
Chemical
Propylene
Service
Refrigerant
Required Quantity
250ft3 ( 7 m3 )
Specification for propylene product

PROPERTY VALUE
Propylene, vol.%
Methane plus Ethane, vol. ppm
Ethylene, vol. ppm
C4 & Heavier, vol. ppm
Acetylene, vol. ppm
Butadiene, vol. ppm
Methyl Acetylene
+ Propadiene, vol. ppm
Hydrogen, vol. ppm
Carbon Monoxide, vol. ppm
Carbon Dioxide, vol. ppm
Oxygen, vol. ppm
Ammonia, vol. ppm
Ammonia, wt. ppm
Nitrogen (molecular), vol. ppm
Sulfur, vol. ppm
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MAX / MIN
99.50min.
500max.
50 max.
20 max.
10 max.
10 max.
20 max.
20 max.
5 max.
5 max.
10 max.
12.1 max.
5.0 max.
30 max.
3 max.
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PROPERTY VALUE
Water, vol. ppm
Green Oil, vol. ppm
Carbonyl Sulfur (COS), vol. ppm
Arsine, vol. ppm
Phosphine, vol. ppm
Propane
2.9
Utility conditions and requirement
2.9.1
Utility Conditions
UTILITY
MAX / MIN
10 max.
1 max.
1 max.
0.03 max.
0.03 max.
Balance
UTILITY BATTERY LIMIT CONDITIONS

PRESSURE
TEMPERATURE
(KG/CM2G)
Normal
Design
4.5
2.5
3.0
7.0
3.0
7.0
3.0
7.0
7.0
10
7.7
10
7.7
10
Fresh CW Supply
Fresh CW Return
Desal, Water
Potable Water
Utility Water
Plant Air
Instrument Air
Breathing Air
Nitrogen
Fuel Gas Import
Fuel Gas Export
LPG
2.9.2
OPERATING MANUAL
7
3.5
3.9
3.5
( 0C )
Normal
Design
32
150
45
150
44
44
65
44
65
40
65
40
65
40
65
10.5
6.5
25
38
65
122
6.5
38
122
Utilities Requirements
Reliance Estimated Utility Consumption
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Electric Power, KW
(High Voltage >415V)
Electric Power, KW
(Low Voltage =<415V)
Cooling Water, m3/hour
Instrument Air, Nm3 /hour
Nitrogen, Nm3/hour
Refrigerant (Propylene)
Lube Oil, Kg/Annum
OPERATING MANUAL
RECOVERY PLUS
UNIT 233
RECOVERY PLUS
3000
30
520 m3
580 m3
To be determined2
None3
7 m3
To be determined2
Reliance Estimated Waste Discharges

RECOVERY PLUS
None4
None3
Vents, Nm3/hour
Drains, Kg/hour
The above numbers are estimates.
1. The 520 m3 is the estimated cooling water during normal operation with the
straight run feed case. The 580 m 3 is the estimated cooling water usage during
turn-down with the straight run feed.
2. Instrument air and lube oil usage not known at this time.
3. Nitrogen is not required for regular operations. However, nitrogen is required for
start-up and shut down. Once the compressor section is finalized, a
specification will be provided to determine the amount of nitrogen needed in
these instances.
4. During normal operations, there will be no regular discharges to vents or drains.
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3.0
OPERATING MANUAL
RECOVERY PLUS
UNIT 233
INTER CONNECTIVITY
General
This section examines the interfaces of the Recovery Plus system with the
other processing units of Aromatic Complex.
3.1
Inter Unit Relationship

The Unit obtains its feed from the Platforming unit
Lean oil from Recontact Drum No.1 (MV-231-V02) through pumps MP231-P02
A/B at 21.17KSC & 300 C at Platforming unit to the Recovery Plus Unit.
Net Gas from Recontact drum no.2 MV-231-V03 at Platforming unit to Recovery
Plus Unit at 37.13 KSC & 370C
Reach oil goes to Debutaniser Feed-bottoms Exchanger ME231-S05 A/B at
18.6 KSC & 300 C to the Debutaniser MV231-C05 at Platforming unit.
Net Gas (Hydrogen Rich Gas) to chloride Treaters MV-231-V04 A/B at 35.86 KSC &
28.70 C at platforming Unit to Hydrogen Purification system (PSA)
Start up
The Platforming Unit will be started up prior to the Start up of Recovery Plus
system.
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Once the Platforming unit is on stream, Net Gas can be supplied to Recovery
Plus from Recontact drum no.2 231-V03, and Lean oil can be supplied from
MV-231-V02 (Recontact drum No.1) through pumps MP231-P02 A/B.
Shutdown
If the Platforming unit shutdowns, then Recovery Plus unit and hence
subsequent downstream units i.e. Net Gas chloride treater 231-V04 A/B &
Hydrogen Purification system (PSA) will also shutdown respectively.
Normal operations
During normal operations, the Recovery Plus Unit must be operated so that the
main objective to recover. LPG and Reformate from Platforming net gas stream
is achieved.
3.2
Inter Plant Relationship

General
This section explores the interfaces of the Recovery Plus system with other
processing Units in Refinery complex.
Inter Relationship
Propylene, which is used as a liquid refrigerant, will be available from propylene
Recovery plant of Fluidized Catalytic cracking complex, once refinery will be
started.
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Start up
Before attempting to allow any of the above feeds/ products between the
Plants, all necessary details with regard to the operating unit must be complete.
Additionally, the foreman and the operating units concerned should be notified
of the impending startup.
Shutdown
For normal planned shutdowns, each plant will be responsible for notifying the
foreman and operating units concerned, of all shutdown operations.
Emergencies between the plants must be recognized and acted upon
immediately. Plant operators must aware of steps to be taken in such situations.
While some of the emergencies may not result in shutdown, it could cause
serious trouble on the units if not properly handled.
3.3
Utility /Off site Relationship

General
This section describes the interfaces of the Recovery Plus Unit with the utility
and offsites Areas.
Inter Relationship
The Recovery Plus Unit inter relationship with the following Utilities.
Cooling Water Supply
Cooling Water Return
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Potable Water
Fire Water
Plant Air
Instrument Air
Breathing Air
Nitrogen
Fuel Gas
Start-Up
Before attempting to allow any of the above feeds/ products between the
Plants, all necessary details with regard to the operating unit must be complete.
Additionally, the foreman and the operating units concerned should be notified
of the impending startup.
Shutdown
For normal planned shutdowns, each area will be responsible for notifying the
foreman and operating areas/ units concerned, of all shutdown operations.
Emergencies between the plants must be recognized and acted upon
immediately. Plant operators must aware of steps to be taken in such situations.
While some of the emergencies may not result in shutdown, it could cause
serious trouble on the units if not properly handled.
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4.0
PREPARING THE UNIT FOR INITIAL START-UP
4.1
Introduction
This phase of the work covers the requirements and activities to be performed
prior to commissioning the Platforming Unit.
The objective of the pre-commissioning phase is to:
Verify that the unit and all parts thereof comply with the project
specifications, data sheets and design drawings
Ensure that all items and equipment forming part of the unit have been
installed correctly and in accordance with the manufacturers instructions.
Check the integrity of the unit and all parts thereof.
To prepare the equipment for operation by washing, running in, etc.
To acquaint the operators with the unit

The pre-commissioning works will encompass general activities as follows:
a) Check that all vendors documents for all equipment such as test certificates,
inspection certificates and performance test certificates, etc., are available and
acceptable.
b) Check that all necessary documentation of the tests carried out during the
construction phase including hydrostatic tests, radiographic inspection and any
other relevant electrical, mechanical and civil works tests is available and
satisfactory.
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c) Carry out site checking of all items of the unit and equipment and piping
systems as indicated in Inspection Section herein.
d) Prepare a punch list of outstanding items, and assign action parties.
e) Complete and sign all checklists, test reports and log sheets as applicable to
the pre-commissioning works. Use applicable standard checklist for monitoring
progress and recording of the Contractors pre-commissioning works.
f) Ensure that the Reliance/Bechtel/UOP representative witness all check lists,
test reports and log sheets as required.
g) Procedures for storing pre-commissioning documentation shall be provided by
the Contractor and approved by RPL in order to establish a clear audit trail for
all pre-commissioning activities.
h) Complete all punch list items which affect the safety and operability of the unit.
4.2
Utility system readiness:
4.2.1 Piping Network

Please refer interconnectivity P and I. D. of Platformer Unit for Utility distribution
and network
4.2.2
Commissioning of Utilities
For ease of operation, the utility systems such as water, air, N2, firewater, etc.
should be put in operation as soon as construction schedule allows. Fuel Gas,
Flare, etc. should be prepared but not to be commissioned until process units
are ready for hydrocarbon entry.
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Fresh Cooling water supply/return
Desalinated/Potable/Utility/Fire water
Plant /Instrument/Breathing Air
Nitrogen
Fuel Gas Import/Fuel Gas Export/LPG
Flare/Blowdown system, aromatic closed drain
Other system i.e. Feed, Product, Chemical, etc.
Communication System
Fire detection/protection and gas detection system
Cooling Water system:

After mechanical completion of CW Supply/Return system, ensure flushing /
testing of each system. Ensure that all-utility valves at equipment / service
stations are closed. Charge the header up to battery limit and then charge
header/ sub header in Plot.
Water system (Desalination Water / Potable Water / Utility water / Fire
Water)
After mech. Completion of various water system, ensure through flushing
/testing of each system. Ensure that all utility valves at equipment / service
stations are closed. Change the header up to battery limit and then charge
header / sub-header in Plot.
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Air system (Plant Air/ Instrument Air/ Breathing Air)

After pneumatic test, system should be blown with air. These systems should
be as dry as possible. Instrument air system to be dried with instrument air and
after checking dew point (-40 0C) at various points, system can be charged.
Ensure that all utility valves at equipment/service stations are closed. Carry out
tightness test /leak test at service pressure, check and rectify leaks.
Nitrogen system
Carryout the blowing and flushing operation of the Nitrogen system with air.
Carryout the tightness / leak test with air. Once system became leak free, air
free the system with N2 purging. Ensure that the nitrogen system oxygen
content is within limit prior to charging of header/ sub-header with N2. Ensure
that all utility valves at service stations are closed and connections to all
equipment are blinded.
Caution: Nitrogen is an asphxyant gas and is both odourless and
colourless. Installation causes rapid unconsciousness by blocking of the
oxygen supply followed by death within a short time.
Fuel Gas Import / Fuel Gas Export / LPG
Carryout the blowing and flushing operation of the above system with air.
Carryout the tightness / leak test with air. Ensure that all utility valves at
equipment are closed. Once system became leak free, air free the system with
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N2 purging. Ensure that the system oxygen content is within limit (< 0.2%) prior
to charging of header / sub-header wit FG/LPG.
Flare / blow down system, Aromatic closed drain
Carryout the thorough blowing and flushing operation of the above system with
air. Carryout the tightness / leak test with air. Ensure that all utility valves at
equipment are closed. Once system became leak free, air free the system with
N2 purging. Keep the system under positive pressure of N2 and monitor.
Ensure that the system oxygen content is within limit prior to charging of
header/ sub header with Hydrocarbon. Keep flare header under positive flow of
N2 still purge FG is available (the jobs are pertaining to the offsites).
Other system
All feed, product, chemical, etc. piping to / from battery limit and storage facility
thoroughly flushed, blown, leak tested, dried and air free prior to charging
hydrocarbon.
Communication system
Ensure that Public address system/ Walkie talkie/ Pagers / Telephone system
etc. as per project specification and drawings are installed in plant. System
must be functional checked and performing as required. A clear, loud and
uninterrupted
communication
link between
field
and
Control
room
Maintenance / Utility block / Laboratory / offsite, etc. must be established.
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Fire Detection/ Protection system and Gas Detection System

Fire and gas detection system as per project specification and drawings are
installed in plant. System must be functionally checked and performing as
required. Energise the system and make it functional prior to commissioning of
unit. Ensure that fire protection system and potable fire extinguishers are
installed at specified place, prior to entry of Hydrocarbon in process/ utility
system.
4.3
Inspection of Equipment
General Checks
For most of above items, general checks are required and can be carried out
as follows: Refer UOP/ Bechtel data sheet and compare against vendors data
sheet and actual equipment at site.
A. Specifications check for
a. Pressure, Temperature and vacuum, flow ratings, Capacity, surface area, etc.,
b. Material of construction, thickness and corrosion allowance
c. Head, capacity, speed, NPSH requirement, type, seals, bearings, number of
stages, lubrication and cooling systems, etc.
d. Type of driver, its power ratings, etc.
e. Nozzle sizes and orientation, flange rating, type and finish
f. Type of lining, thickness and material
g. Stress relieving and / or heat treatment
h. Foundation design for full water weight
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B. Confirm that the equipment is hydrotested and date / time/ witness by, etc. are
recorded (wherever it is applicable and agreed upon). In case of rotary
equipment ensure the test run carried out at shop and results are available.
C. Verify that all code plate information are correct
D. Material test certificates are available
4.3.1 Piping and Supports
The unit must be constructed in accordance with the Bechtel P & ID and
Isometrics. The note, elevations, dimensions, etc. must be correct. One should
be able to start and shutdown the unit as per suggested procedure. Piping for
special procedure like dryout special material preparation as well as alternate
flow schemes must be incorporated into the system. If the unit is connected to
other process facilities adequate means must be provided to receive feed and
send products to various facilities without contaminating any stream with
another streams. To check and ensure that adequate means for measuring flow
temperature pressure and sampling as well as is available.
4.3.1.1 Visual Inspection
Line by line visual inspection of the complete piping system and associated
parts there of to ascertain completeness against P and I D drawings and
accepted practice for installed piping systems.
a.
Verify that all quality control inspection requirements (X-rays, stress

relieving, etc.) have been fulfilled.
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b. Check that piping system has been pressure tested in accordance with the
code governing their design and approved by Reliance.
c. Check that piping system have been properly flushed / blown as required.
d. Check that piping system has been properly supported. Pipe hangers/ supports
are allowed expansion in proper direction.
e. Check that drains in the process / utility lines are at the lowest points.
f. Check that spectacles are in their correct position as identified on the P & ID
drawings.
g. Check that insulating joints are proper at interface & electrical continuity /
bonding is proper.
h. Check that lines are connected to the correct nozzles of the equipment.
i. Check for desired flange ratings, bolts & gaskets specifications.
j. Check and inspect that all flanges are properly aligned and tightened.
k. Check that all temporary strainers are presently fitted in the required positions
l. Check that all inline instruments are correctly mounted
m. Check that all instruments connections are proper
n. Check insulation and colour code as specified
o. Check that piping routing is proper and all valves are accessible without any
hindrance for movement
4.3.1.2 Hydrostatic Test
The piping system will be pressure tested to prove the pressure integrity of the
main components (pipe, valves, flanges, gaskets) of the system. The test shall
be performed in accordance with Standard Construction specification,
supplemented by the Contractors standard hydrostatic test procedure
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approved by RPL. For test purposes, the piping system has been divided into a
series in Document Line Designation Table.
All the piping systems will be hydrostatically tested except specific system
where hydraulic fluids are not allowed due to operation reasons. Those
systems will be subject to pneumatic testing.
A pressure test report will be completed for each test loop for record purposes
using Reliance Standard Form. All untested joints shall be clearly shown on the
hydrotest diagrams.
SAFETY NOTE: Hydrostatic testing is carried out to prove the pressure
integrity of the piping system under test. Accidents, sometimes fatal, have been
recorded during such testing. Manning levels in areas where hydrostatic testing
is to be performed should be kept to a minimum. All personnel engaged in the
test should be fully briefed and all precautions taken in respect of personnel
safety. Danger signs and notices should be erected at all strategic locations.
Piping routed outside of the main plant boundary should be cordoned off and
manned to prevent accidental access by unauthorised or third party personnel.
All safety equipment shall be on site for the duration of testing. All personnel
directly or indirectly engaged during the test shall be equipped with personnel
protective and safety equipment.
Important Checks and Guidelines
a. On line instruments and instrument impulse lines will be temporarily removed
and / or disconnected before testing.
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b. Check that hydrotest pump, valve, fittings, pressure gauge are in good working
order. Filling line/ test equipment shall be connected at lowest possible point to
avoid entrapment of air in the system while filling.
c. Check that all test gauges are available with relevant latest test certificates,
with direct reading gauge and suitable range so that test pressure readable in
40-60% range. The test gauge shall be mounted at lowest point to account
liquid head of system.
d. Check that all in-line valves are in fully open position.
e. Check that all safety equipment like cordoning rope, sign board, etc. are
available at testing site and placed at strategic location.
f. Check that check valves are removed from the line or its internal removed, if
required.
g. All welds shall be free of slag, grease, oil, paint and any other foreign materials,
which prevent proper examination.
h. Vents to be provided on test fittings if it is not provided on the line
i. Blinds used shall be in accordance with Pipe Line Class
j. There are sufficient numbers of vents/ drains located in suitable position. While
filling the piping, ensure that all air is vented at highest point and system is full
of test fluid.
k. Vessel and water temperature should be always above 15 0C to eliminate the
possibility of cold fracturing of the metal.
l. Hydrotest pressure should be as per LDT (line designation table) or as per
piping class & should not be higher than lowest rated component of system.
ANSI B 31.3 must be followed while testing piping system.
m. The weld joints, flange connections and the sections of greatest strain (the
areas close to opening and those where two different types of materials are
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connected) must be checked visually. The test is acceptable if no loses,

sweating or fall of pressure are detected for the time of test.
n. Test pressure will be held for sufficient time to visually determine if there are
any leaks, but not less than 2 hours.
o. Drain out the water from the section after the hydrotest is completed.
Note:
Ensure that under no circumstances the pressure applied does not exceed the
allowable test pressure of the lowest rated component in the loop.
Keep the vents open to prevent from pulling a vacuum and possibly collapsing
equipment, while draining the system after hydrotest.
Ensure that, chloride content of the treated water used for hydrotest of the
section that contains austenitic steel is below 50-ppm wt%. If this is not
possible then the test water should have a max. of 0.5 wt% sodium nitrate /
specific chemical added to it. Such system should be drained and dried after
hydrotest as soon as possible.
4.3.1.3
Flushing
The piping system will be flushed in order to remove construction debris,
accumulated corrosion products and scale to prevent blockages and damage to
equipment during actual start-up
Prior to commencing the flushing operation, the contractor will divide the piping
system into a series of flushing loops. Configuration of flushing loop mostly
remains as hydrotest loop. The loops will be presented in diagrammatic form,
as a markup to the plant P & Ids using local site knowledge and the guidelines
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presented below, as the basis for determining the extent and the number of
flushing loops needed. Use this opportunities to break in and run in as many
pumps as possible (High head pumps should not be run on water). Water
flushing helps in spotting the problems and correcting the problems before the
start-up. The progress of the flushing operation will be recorded by marking up
the flushing loop diagrams.
Important Checks and Guidelines
a. Install blinds the flanges of the equipment, which will not be operated on water.
b. Install fine mesh screens on the pump suction lines.
c. Bypass the filters and traps in line, as per requirement.
d. Identify and ensure suitable water hose connection points and draining points
for injection and draining of water.
e. In case of exchangers, flush the inlet line upto the exchanger inlet flanges and
then connect the inlet flanges, and flush the exchangers.
f. Restriction orifices must be removed prior to flushing.
g. Control Valves and in line instrumentation must be removed prior to flushing
h. Instrument impulse lines and sampling systems will be disconnected prior to
flushing. During flushing, each process valve on instrument process
connections should be opened to flush the connection and be checked for
tightness after closure.
i. Check valves should be removed, or installed in reverse (subject to selected
direction of flow for flushing) and all other valves fully opened.
j. Flow rates should be maintained in the range 3 to 4 m/s for water flushing, 30
to 40 m/s for air blowing.
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k. The flushing water is fully drained (properly) and system dried with air
immediately after completion of flushing, water containing upto 20 mg/kg
chlorides may be used for flushing of austenitic stainless steel piping systems
or sub-systems. In cases where proper drainage is not possible, and the metal
temperature in operation exceeds 50 0C, general recommended practice is to
use water containing less than 1 mg/kg chloride; i.e. condensate or
demineralised water for austenitic SS piping.
l. Isolate vessels and equipment from the flushing loop to prevent damage/
accumulation of debris within these items.
m. Flush through open end lines. Do not restrict flow in principle.
n. Flush through all drains and vents.
o. Where possible, flush downward or horizontally
p. Flush the main header from source-to-end, each lateral header from the mainto-end, and each branch line from the lateral header to end.
q. Always flush through bypasses, where provided, to an open end before flushing
through equipment.
r. On completion of flushing, reinstate all removed equipment items (control
valves and in-line instrumentation), install orifice plates and reconnect
instrument lines to process valve connections.
s. On completion of flushing, standard RPL form, duly signed by the RPL /
Bechtel/ UOP / Contractor representative will be prepared and placed on file for
record purposes
4.3.1.4 Air Blowing and Drying
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The piping system will be blown using compressed air to remove entrained
water in the pipes after draining of test and / or flushing water. The system will
be blown utilising the same piping configuration as that used for the hydrotest
test. A blowing record will be completed for each loop as defined in Hydrotest
diagram using RPL Standard Form.
A temporary air compressor will be used for the work. Temporary connections
will be installed between the compressor and piping loops to be blown. All drain
lines will be fully opened.
The test will be completed when only dry air is seen to exit the system.
On completion, the blown system will be fully reinstated with all items
previously removed and / or disconnected in preparation for hydrostatic testing
replaced in accordance with the reference drawings and removal records.
4.3.1.5 Tightness Test
On completion of hydrotest and blowing, and after reinstating the piping system
in accordance with the design drawings and removal records, the entire
process system will be subject to a pneumatic soap bubble test maximum
pressure of 5 bar. This action required just prior to inerting of process unit.
All flanged joints and the bonnets and glands of any item which were not
subjected to hydrostatic test will be tested with soap solution. Any leaks
detected by the formation of bubbles will be retightened or attended to arrest
the leak.
After the system has been leak tested, the air of the system will be displaced
with N2 for inerting of unit and hydrocarbon entry.
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A tightness test and purge record will be completed using RPL Standard Form.
4.3.2
Vessels
1. Absorber
MV-AY233-V01
2. Oil Separator # 1
MV-AY231-V02
3. Refrigerant/Receiver Economiser
MV-AY231-V03
4. Oil Separator # 2
MV-AY231-V04
Specifications
1. Pressure, temperature and vacuum ratings
2. Shell metallurgy, thickness and corrosion allowance
3. Nozzle size and orientation, flange rating, type and finish
4. Type of lining, thickness and material
5. Stress relieving and/or heat treatment
6. Foundation design for full water weight
7. Confirm that the vessels are hydrotested and that the date / time /
witnessed by etc. are recorded.
8. Verify that all code plate information are correct
9. Material test certificates are available
Internal Inspection
1. Mesh blankets and outlet screens
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size,
location,
OPERATING MANUAL
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levelness, tight fit up (no bypassing allowable) blanket
metallurgy, blanket support tie-wires and grids

2. Vortex breakers
Type ,size and orientation
3. Baffles
Type, orientation and levelness
4. Instrument nozzles
Location, orientation, cleanliness, thermowell length and metallurgy
5. Inlet distributors
Type, size, orientation, levelness and freedom to expand
External Inspection
a. Manways and nozzles
Location, size and flange rating / finish metallurgy, proper gasket, proper
nuts and bolts
b. Ladder and platforms
Correct positioning, secure and free to expand
c. Insulation
Properly provided
Correct grounding of vessels
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Correct vessel elevation
Valves and instrumentation
4.3.3
UNIT 233
Easily accessible from platform and grade.
EXCHANGERS
1.
Vapor Exchanger
ME-AY231-S01
2.
Liquid Exchanger
ME-AY231-S02 A/B
3.
Combined Vapor Liquid ChillerME-AY231-S03
4.
Lube Oil Coolers
ME-AY231-S04 A/B
5.
Refrigerant Condenser
ME-AY231-S05
6.
Refrigerant Subcooler
ME-AY231-S06
Refractory lining, metallurgy, tubes, grounding wires, expansion provisions
Manufacturers rating for temperature, pressure & pressure drop
Nozzle size, flange type, rating, facing and metallurgy
Vent and drain connections
Design differential pressure between shell and tube sides of the exchanger
Piping symmetry for parallel exchangers
Slot length of sliding plates adequate for expansion.
Ensure that sliding ends of multi-shell exchangers make sense with
regard to expansion of exchangers and connecting pipe.

4.3.4
PUMPS
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1. Lean Oil Pump
MP-AY231-P01A/B
2. Lube Oil Pump
MP-AY231-P02A/B
3. Oil Reclaimer Pump
MP-AY231-P03A/B
Centrifugal pumps:
Centrifugal pumps should be reviewed against the curves and data provided by
vendor to confirm agreement on the following:
Head and capacity
Pressure and temperature rating
Speed
NPSH requirement
Pump type, MOC, flange ratings, seals, bearings, number of stages,

lubrication and cooling systems etc.
Type of driver
Balancing lines for multistage pumps must have flange joints
Proper direction of rotation
cooling water to pedestals for pumps operating above 250 oC
Cooling water to pumps operating above 120 oC
Proportioning pumps
Proportioning pumps should be reviewed to confirm agreement on the
following:
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Head and capacity
MOC
Cooling and lubrication systems
Pressure and temperature ratings
Testing of relief valve setting on the bench
Pump speed and stroke
Pulsation damper devices
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UNIT 233
General check for pumps
Lubrication and cooling systems are operational
Pumps and drivers are aligned correctly
Check valves are installed in the correct direction
All drains from pumps and associated piping are routed to safe location
Adequate means for venting and draining the pump casing are available
Restriction orifice in the minimum flow line as required
Warm up lines are provided across discharge check valve, when pumping
hot liquid
4.3.5
COMPRESSOR
1. Refrigerant Compressor
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MC-AY231-C01A/B
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Start-up of compressors should be carried out according to manufacturers

instructions.
Pre-start-up checks
a. The lube oil system must be cleaned. Ensure that 20 mesh wire screen is
installed at the lube oil supply to each bearing remove the 20 mesh wire screen
when the lube oil system is ready for service.
b. Check the driver for correct direction before coupling to the compressor.
c. Remove paint and slushing compounds from all moving parts before starting
the compressor.
d. Check that the lube oil level is sufficient and there is no leakage from the
system.
e. Ensure that all trips and alarms are simulated and are operational. In addition
the lube oil pump auto start is functional.
f. Ensure that the compressor suction lines and suction drums are acidified as
per the procedure for the removal of dirt and fine scales that would otherwise
land up in the compressor, damaging the compressor valves.
g. Commission cooling water to the lube oil cooler.
4.3.6
Instrumentation System
Carry out the following inspection and tests in preparation of the unit
instrumentation for start-up and operations:
a.
Visual inspection of instruments to verify compliance with specifications
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b.
OPERATING MANUAL
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Visual inspection of instrument installation to verify compliance with

installation specifications in the instrument instruction manual
c.
Pressure testing of instrument piping
d.
Testing and calibration of instruments
e.
Testing of instrument air signal lines
f.
Testing of thermocouple wiring
g.
Loop checking
h.
Testing of safety relief valves
i.
Final preparation
While inspecting the instruments for compliance to specification, give
attention to the following
Instrument range, pressure rating, connections, MOC, size, electrical features,
and special features
Inspection of orifice plates for size, MOC, location of weep hole (if any), counter
bore, overall condition, measurement of orifice bore, verification of information
stamped on tab
While inspection of the installation attention should be given to the
following:
Location of transmitters with respect to the connection point
Control valves and transmitters are not installed backwards
Orifice installation for the straight run requirement
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Insulation/steam tracing provision
Point by point verification of the multi point temperature indicator

Testing and calibration of instrument should include the following:
a. Calibration of Transmitters
b. Control Board equipment
c. Local Controllers
d. Stroke checking of the control valves and adjustment of positioners Special
attention to the instruments used in critical services such as, Heater firing
control, automatic shutdowns, etc.
Loop checking: Carry out loop checking of the loop to ensure that the piping
and wiring are properly installed. Give special attention to the critical loops such
as Reactor loop. All transmitters should be checked by simulating signal from
field and observe correct response in control board. Similarly signal from
controller on control board should get response from control elements. ESD
should be simulated for each trip signal and observe responses on all tripping
elements.
Final Preparation: Final preparation check should include the following:
-
Valves are in the proper position
Preliminary control mode adjustments
Filling seal pots and seal legs
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Making sure that instrument air and electrical power are supplied to all the
instruments
Commissioning of steam tracing
Commission the instruments as the unit comes on stream.
Commission the analysers in accordance with the instructions in the instruction

manual.
4.3.7
Electrical system
Carry out the following inspection and tests in preparation of the unit electrical
system for start-up and operation:
Electrical equipment and system precommissioning has to be performed to
ensure that:
All electrical equipment performs as per the required specifications. The
installation of the electrical equipment is complete and in accordance with
design drawing and good engineering practice.
The systems are not damaged during transportation and storage phases and
function satisfactorily during start-up and operations. The precommissioning
plan described below has been defined taking into consideration the functional
performance of the electrical equipment in the plant. The Precommissioning
plan has been subdivided in the following phases:
a) Checks before installation
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b) Checks after installation

All tests and operations shall be recorded and maintained in typical RPL check
list. The presence of Vendor representative will be required wherever
necessary.
Check Before Installation
Visual Checks:
Verify the equipment and for correct storage in the warehouse.
Check for physical damages.
Check for correct application of conservation.
Check for proper environmental condition limit during the storage as specified
by the manufacturer.
Check for correct tag.
The technical compliance of equipment with the individual specification.
Check for availability of testing equipment.
Check for equipment and accessories as per part list.
Checks after Installation
After installation, the following checks shall be performed to ensure
correct mechanical completion of electrical installation.
a.
Preliminary checks common to all electrical installation:
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After erection and before testing, all the equipment, including their accessories,
will be checked to verify:
Compliance with the general procedures for installation of electrical equipment.
That the paint, grease, oil , etc. necessary for good material and equipment
conservation have been applied.
That all the supports are complete and rigid and the equipments are correctly
installed.
Equipment and their connections have not been damaged during the
installation stage.
Check for manufacturers test certificates.
Equipment must be free of dust, moisture and oily chemicals.
b.
Electric Installation and cable connections check:

The following checks shall be carried out:
Cable trays, conduits, junction boxes, equipment housing and supports are
correctly installed as per design requirement and protected from heat source.
Conduit radius bends are as per design specification
Conduit termination shall not damage the cable and threaded joints are
properly tightened.
Flexible pipes, and terminal boxes are located as per design requirements.
All cables should have their proper identification tag in switch gear room
panels, junction boxes, at MCC cabinet and racks, and along the cable route.
Cables are properly fastened on cable trays.
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Buried cables are completely covered.

All cables are properly connected at the terminals of the equipment.
c.
Testing and functional checks of electrical installations:

All the electrical installation are subjected to applicable test and functional
checks as soon as their installation are completed.
These test are normally insulation test, applied voltage test, continuity test,
resistance measurements, setting of protective relays, polarity test, no load
motor run, operational test of MCC, switch gear and local/remote switches,
specific test for transformers and specific equipment. All the test must be
recorded.
After satisfaction of competent authority, electrical system can be charged
(energised).
In order to fully execute the instrumentation pre-commissioning and functional
tests, LV switchboard will be energised as soon as practical after
precommissioning completion.
The power supply will also be utilised to commission the switchboard, plant &
building lighting, motors, compressors, pumps, package units, etc.
4.4
Chemical Cleaning and N2 Blanketing
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The purpose of the chemical cleaning is to remove the mild scale, dirt, heavy
greases, and other foreign materials that would enter the compressor, there by
resulting in operating and maintenance problems.
Carry out chemical cleaning of the following items as per the cleaning
procedure supplied by the cleaning contractor, who must ensure that the
chemicals and chemical solutions used in carrying out the operation will not be
injurious to the items cleaned.
The acid cleaning step includes the following:
4.5
Flushing
Degreasing
Chemical cleaning
Neutralizing
Passivating
Run-in Pumps
While starting all the moving equipment watch for,
excessive vibration
overheating of bearings
excessive heating of the driving motor
unusual noises
Before any attempt is made to run the pumps and drivers ensure that the
pumps and drivers are properly aligned by qualified personal and the cooling
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water systems and lubrications are placed in service. It is always advisable to

run the drivers in the decoupled condition and then coupled to the pumps.
Before putting the pumps into operation check the following
Proper lubricants are provided and lubricators filled.
Cooling water circulation established through bearing housings, stuffing box

jackets and pedestals.
Fine mesh strainers are installed in the pump suction line.
Pumps are not field hydrostatically tested.
All pumps are in good mechanical condition and are ready to break them in.
The length of time for break in may vary for different pumps but a period of four
hours are usually considered satisfactory.
Check the push buttons of all the motor driven pump to ensure that they are in
proper working order.
The pumps and drivers are free by rotating them by hand
(at least one
revolution)
NO WATER CIRCULATION SHOULD BE CARRIED OUT THROUGH THE

GAS COMPRESSORS.
4.6
Ensure that the compressor is not exposed to excessive moisture.

Run-in Compressor
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Start up of compressor should be carried out according to manufacturers

instructions.
Pre-start-up checks
The lube oil system must be cleaned. Ensure that 20 mesh wire screen is
installed at the lube oil supply to each bearing remove the 20 mesh wire screen
when the lube oil system is ready for service.
Check the driver for correct direction before coupling to the compressor.
Remove paint and slushing compounds from all moving parts before starting
the compressor.
Check that the lube oil level is sufficient and there is no leakage from the
system.
Ensure that all trips and alarms are simulated and are operational. In addition
the lube oil pump auto start is functional.
Ensure that the compressor suction lines and suction drums are acidified as
per the procedure for the removal of dirt and fine scales, that would otherwise
land up in the compressor, damaging the compressor valves.
Commission cooling water to the lube oil cooler.
4.7
Tightness Test and Inertisation
4.7.1
Tightness Test
After water flushing/drying steps and before admitting hydrocarbon, the plant
must be subjected to tightness test/pneumatic soap bubble test. On completion
of hydrotest and blowing, and after reinstating the piping system in accordance
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with the P and I. D., the entire system along with equipment will be subject to a
pneumatic soap bubble test at maximum pressure of 15 kg/cmg. Always follow
design pressure limitation of the system.
Check all flanged joints and the bonnets and glands of all items, which were not
subject to hydrostatic test with, soap solution. Check the manways of
equipment, its connecting flanges, etc. for leakage. Any leaks detected by the
formation of bubbles will be retighten / repaired. Hold the air pressure in the
system for specific time and estimate drop in pressure to determine leakage
rate. Once such system passes the tightness test, it is to be subjected to
vacuum hold test.
4.7.2
Vacuum Test and Inertisation

Pull vacuum in the system with the help of a vacuum pump. Required vacuum
is 1 mmHg A. If the desired vacuum is not achieved, it is the indication of leaks
or moisture in the system. Break the vacuum with N 2. Pressure test the system
and fix the leaks. For removing moisture from the system, purge the system
with dry N2 several times. Check water in all low point drains. Pull the vacuum
and hold it for 4Hrs. Once the vacuum test is over, break the vacuum with N 2
and keep the system under slight positive pressue.
Nitrogen is an asphxyant gas and is both odourless and colourless.
Inhalation causes rapid unconsciousness by blocking of the oxygen
supply followed by death within a short time.
Strict safety precautions must therefore be applied when using nitrogen
gas for purging operations and especially when a high concentration of
nitrogen may be present.
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If any doubt exists personal breathing apparatus must be worn. Fatal

accidents have occurred during purge operations.
Before purging operations commences, the area shall be chained off and
adequate warning notice displayed. These shall remain inplace until
purge operations are complete.
4.8
Safety Checks Before Startup

The following safety related checks are to carry out before startup.
1. All fire extinguishers should be available at site in their respective positions.

2. Fire detectors and Hydrocarbon detectors should be functional.
3. Firewater network is charged and hose boxes are having hoses, branches or
nozzles, etc.
4. Safety shower / eye washer and other Personal Protective equipments are in
position.
5. Plant area declared operational with no unauthorised entry to plant and work permit
system implemented.
6. Necessary safety and warning sign boards are placed as required.
7. Communication systems i.e. Public Address, Telephone, Walkie Talkie,etc. are
functional.
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5.0
COMMISSIONING / INITIAL START-UP
5.1

a.
OPERATING MANUAL
UNIT 233
Inform concerned intraplant department i.e. Mech. / Electrical /

Instrument / Laboratory / etc. prior to startup so that they will be ready
for action.
b.
Inform concerned inter plant department i.e. off site, utility, CES,
Central Lab., safety and fire prevention, refinery units, etc. prior to
startup so that they will be ready for action.
c.
Notify the operators of the other process units in the aromatic complex
of the intended Recovery Plus startup.
d.
Plant supervisor and other operating units in the complex which are
related with the unit should be informed well in advance about the
exact time of start up by proper communication media, preferably in
writing.
5.2
Utilities Startup
Inform Utility department about the Startup and also the approximate quantity
that will be required. Cooling Water Supply / Return headers and Nitrogen
headers are to be charged and made ready for consumption by different users.
Electrical power should be available and charged up.
5.3
Outline Of Initial Startup
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The initial startup of the Recovery Plus section can be divided into the following
steps:
1. Evacuation of Air, Nitrogen and Water Removal
2. Charging of Lube Oil
3. Oil Circulation
4. Inventory Refrigerant Circuit with Refrigerant
5. Initial Compressor Start-up
5.4
Evacuation for Air, Nitrogen and Water Removal
All air must be removed and purged before safe system operation is assured.
The system should be purged with nitrogen until the vent gas has an Oxygen
content of < 0.5%.
The refrigerant circuit must be evacuated to remove Air Nitrogen and Moisture.
Consequently a vacuum pump is required. A vacuum pump capable of creating
a vacuum of less than 1 mm Hg absolute pressure is required. To accurately
measure the vacuum an absolute pressure gauge is required. This should be a
Meriam closed end U-tube type gauge or equal.
To ensure that the refrigeration circuit is properly dehydrated with the least
amount of time, it is recommended that a vacuum point be provided on each of
the modules. This will ensure that the entire circuit is being pulled down and
help in isolating sections if necessary. Pipe all the vacuum points to the suction
of the vacuum pump. Provide an isolation valve on the suction the vacuum
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pump to allow for isolation of the circuit when the vacuum pump has been
stopped to change oil or after a low vacuum has been reached.
When the vacuum pump is started, the vacuum should pull down rapidly to
approximately 25 mm Hg. At approximately 10 mm Hg evaporation of free
water in the circuit will be rapidly accelerated and the vacuum tend to remain
constant as the evaporation rate approaches the vacuum pump capacity.
Depending upon the total amount of water, ambient temperature and vacuum
pump capacity, it may take several hrs or days to make any noticeable
decrease in vacuum below 10 mm Hg.
After pulling down the circuit to below an absolute pressure of 1 mm Hg or
below, check to see that the vacuum reading is stable and does not rise above
1 mm Hg Abs. If the vacuum reading is stable at a value below 1 mm Hg than
the test is considered acceptable.
5.5
Charging of Lube Oil

Inventory Oil Separator # 1 (MV-AY233-V02) through a 2 oil flushing nozzle.
Initial inventory of Oil Separator # 1 should be 152-229 mm below the top of the
level glass, LG-012, when the oil circuit is full. The recommended level when
the compressor is 100% loaded is 400 mm below the top of the level glass, LG012. Fill Oil Separator # 1 for initial circulation so as to not cavitate the oil pump
when it is first started. While the oil circuit is being inventoried, add sufficient oil
to the Oil Reclaimer to cover the heater.
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5.6
OPERATING MANUAL
UNIT 233
Oil Circulation
The following steps are recommended to commission the lube oil circuit:
A temporary jumper line will be required to connect 233-LO-124-3-ES32EH-NI at

valve 630 to Oil Separator # 1, MV-AY233-V02, AT VALVE 931. Valves 614, 615 and
618 at the Refrigerant Compressor, AY233-C01 must be closed.
Commission cooling water to the lube oil coolers, ME-AY233-S04 A/B.
The lube oil should be circulated a minimum of 4hrs bypassing the compressor, prior
to start-up and until the oil is free of debris.
After removal of debris replace filters if required. Bleed of gas from oil filters until oil
is present. Set the safety valves at 25 Kg/Cm 2.
Inventory oil if required. The level in Oil Separator # 1 should be 152-229 mm below
the top of the level glass.
Remove temporary piping when circulation is complete.
Replace the oil with new, clean oil for operations.
5.7

After the dehydration, charge the circuit with vapor refrigerant to create a positive
pressure of 1 Kg/Cm2.
Close the inlet valves (valves 1004 and 1019 around LV-014) to the Refrigerant
Receiver/Economiser, MV-AY233-V03.
Close the filter inlet valve (valve 1013) of Refrigerant Receiver/Economiser, MVAY233-V03.
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UNIT 233
Open the Refrigerant Filter/Dryer, F02, outlet valve (valve 1017) and Refrigerant
Receiver/Economiser, MV-AY233-V03, outlet valve (valve 1018).
Connect refrigerant charging and equalising lines from tank, truck or refrigerant
source to the 2 flanged connection provided on the refrigeration circuit.
Gradually pressurise the Refrigerant Receiver/Economiser, MV-AY233-V03, by

slowly opening the equalising stop valve (valve 1006). Note that the entire refrigerant
circuit vacuum will have to be broken before a positive pressure will be indicated at
PG-039.
As soon as the pressure is equalised, gradually open the charging valve (valve
1015) and start the charging pump. The charging pump should not be started with
the pressure below 1.03 Kg/Cm2 g.
Use the Refrigerant Receiver/Economiser, MV-AY233-V03, level gauge LG-016 to

verify the desired level. The normal operating level is 120 mm from the bottom of the
vessel. The receiver should be filled to 1080 mm if there is no refrigerant in the
remainder of the system. Stop the pump when the charging is completed.
Close charging valve (valve 1015), equalizing valve (valve 1006) and fitter/dryer
outlet valve.
Venting of Non Condensibles
The presence of non-condensibles affects the heat transfer area in the
Refrigerant Condenser, which leads to a higher Refrigerant Compressor
discharge pressure and an increased power consumption. Non-condensibles
and air should be purged from high point vents in the Refrigerant Compressor
discharge circuit.
5.8
Initial Compressor Start-up
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Refrigerant circuit is inventoried with refrigerant. The Oil Reclaimer has been
inventoried with oil and oil has been circulated through the Oil Separator to
remove dirt and debris. The Net Gas In has been pressured and is flowing
through the circuit.
The Refrigerant Compressor is controlled by the Distributed Control System
DCS and a PLC. The PLC control circuit is designed to ensure the compressor
is unloaded prior to start-up.
1. Check level in Oil Separator # 1. Initial inventory of the Oil Separator # 1 should be
152-229 mm below the top of the level glass.
2. Check oil level in Oil Reclaimer. The oil level should be such that the electrical
heater element is immersed in oil and oil level should be above level switch setting.
3. Ensure the Oil Heaters Y-01/02 are energised. The heaters are designed to turn on
only when the oil temperature is less than the designed setpoint and when the
compressor is not running.
4. Line out cooling water to lube oil coolers S04 A/B and refrigerant condenser S05.
5. Line out refrigerant circuit and check that all block valves are open or in normal
operating position.
6. Check that PDV-018 is set to obtain a 3.5 Kg/Cm 2 differential between the lube oil
pump discharge pressure and the Oil Separator # 1 operating pressure. This will
ensure a 4.5 Kg/Cm2 differential between the oil header pressure and Refrigerant
Compressor discharge pressure.
7. Set the Refrigerant Receiver/Economiser pressure PV-038 to design pressure. This
will ensure that there is sufficient driving force between the Refrigerant
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Receiver/Economiser and the Combined Vapor-Liquid Chiller, during low load

conditions when the suction port and Economiser port are at the same pressure.
8. Ensure that the compressor is unloaded prior to start-up. If the Compressor is
started in loaded condition then the motor will draw a higher starting torque and can
get damaged.
9. Start Net Gas In circulation. Ensure the 12 bypass valve is open.
DO NOT CUT IN NET GAS FLOW UNLESS H2O IS < 35 MOL PPM.
Gradually open the valves located at battery limits Tie points # 1 and 2 for the
net gas in and pressure up the circuit.
Lean Oil: Establish a liquid level in the Absorber V01. Temporarily start the lean
oil pump, P01 A/B, in order to establish a liquid level in the Absorber.
10. Ensure that the refrigerant for the Combined Vapor-Liquid Chiller is on level control,
LIC-002. Initially keep a low setting of LIC-002. Gradually increase the level setpoint
to the desired operating level. A high level can lead to entrained liquid carry over to
the Compressor.
11. Set capacity switch to auto.
12. Ensure the Compressor is 10% loaded. This is the minimum loading of the
compressor.
13. The starting of the Compressor consists of a sequence of events when the start
button is pushed. The first task is to clear all the trips and permissive. Next the
sequence will start with the starting of the lube oil motor. As soon as the lube oil
pressure is build up the compressor motor should start. Once the Compressor motor
starts, valves open or close automatically.
14. Check the temperature of the Rich Gas stream (TIC-009) and Lean oil Stream (TIC011). Set TIC-009 and TIC 011 in automatic at approximately 5 oC higher than the
refrigerant in the Combined Vapor-Liquid Chiller. The signal resulting from TIC-011
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UNIT 233
being set at 5 oC higher than the refrigerant temperature, will start closing the slide
valve, thereby increasing the mass flow rate of refrigerant pushed through the
Compressor. This will increase the current drawn to the motor. An override activated
by the motor current draw is provided to regulate the time it takes the slide valve to
close to avoid drawing too much current. This ensures the capacity of the
compressor is gradually increased and subsequently the process temperature is
decreased.
15. If the suction pressure decreases below 0.35 Kg/Cm 2 and the refrigerant compressor
shuts down, decrease the temperature of TIC-011 approximately 2-4 oC, thereby
increasing the load and suction pressure of the refrigerant compressor.
16. Gradually decrease the temperature of TIC-009 to approximately 5 oC. hold the lean
oil temperature TIC-011 constant and start the lean oil pump. Set the lean oil rate at
50% of design flow. Gradually increase the lean oil rate to design.
17. Hold the net gas into the Absorber temperature constant, 5 oC, and gradually
increase the Rich Gas In flow to design by closing the bypass.
18. Before the Rich Gas In and Lean Oil In temperature can be decreased to design,
ensure that the circuit is dried out.
19. Gradually decrease the Combined Vapor-Liquid Chiller temperature to design.
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6.0
6.1
OPERATING MANUAL
UNIT 233
START UP
General
For subsequent start-ups, the procedure as described in the initial start up
procedure is to be followed except the following:
a) Evacuation of Air, Nitrogen and Water removal will not be required.
b) No need to inventory the refrigerant since it is already available in the
system.
The following procedure is to be followed for subsequent startups:
6.2

a) Inform concerned intra plant department i.e. Mech. / Electrical / Instrument /
Laboratory / etc. prior to startup so that they will be ready for action.
b) Inform concerned inter plant department i.e. off site, utility, CES, Central Lab.,
safety and fire prevention, refinery units, etc. prior to startup so that they will be
ready for action.
c) Notify the operators of the other process units in the aromatic complex of the
intended Recovery Plus startup.
d) Plant supervisor and other operating units in the complex which are related with
the unit should be informed well in advance about the exact time of start up by
proper communication media, preferably in writing.
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UNIT 233
e) Tank farm/Refinery Control Room should be informed as startup of Recovery

Plus will require Tank farm/Refinery to supply the necessary raw materials.
6.3
Utilities Startup
Inform Utility department about the Startup and also the approximate quantity
that will be required. Cooling Water Supply / Return headers and Nitrogen
headers are to be charged and made ready for consumption by different users.
Electrical power should be available and charged up.
6.4
Outline Of Initial Startup

The initial startup of the HNUU section can be divided into the following steps:
Compressor start-up
6.5
Compressor Start-up
The Refrigerant Compressor is controlled by the Distributed Control System
DCS and a PLC. The PLC control circuit is designed to ensure the compressor
is unloaded prior to start-up.
Check level in Oil Separator # 1. Initial inventory of the Oil Separator # 1 should
be 152-229 mm below the top of the level glass.
Check oil level in Oil Reclaimer. The oil level should be such that the electrical
heater element is immersed in oil and oil level should be above level switch
setting.
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Ensure the Oil Heaters Y-01/02 are energised. The heaters are designed to turn
on only when the oil temperature is less than the designed setpoint and when the
compressor is not running.
Line out cooling water to lube oil coolers S04 A/B and refrigerant condenser S05.
Line out refrigerant circuit and check that all block valves are open or in normal
operating position.
Check that PDV-018 is set to obtain a 3.5 Kg/Cm 2 differential between the lube
oil pump discharge pressure and the Oil Separator # 1 operating pressure. This
will ensure a 4.5 Kg/Cm2 differential between the oil header pressure and
Refrigerant Compressor discharge pressure.
Set the Refrigerant Receiver/Economiser pressure PV-038 to design pressure.

This will ensure that there is sufficient driving force between the Refrigerant
Receiver/Economiser and the Combined Vapor-Liquid Chiller, during low load
conditions when the suction port and Economiser port are at the same pressure.
Ensure that the compressor is unloaded prior to start-up. If the Compressor is

started in loaded condition then the motor will draw a higher starting torque and
can get damaged.
Start Net Gas In circulation. Ensure the 12 bypass valve is open.

DO NOT CUT IN NET GAS FLOW UNLESS H2O IS < 35 MOL PPM.
Gradually open the valves located at battery limits Tie points # 1 and 2 for the
net gas in and pressure up the circuit.
Lean Oil: Establish a liquid level in the Absorber V01. Temporarily start the lean
oil pump, P01 A/B, in order to establish a liquid level in the Absorber.
10
Ensure that the refrigerant for the Combined Vapor-Liquid Chiller is on level
control, LIC-002. Initially keep a low setting of LIC-002. Gradually increase the
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level setpoint to the desired operating level. A high level can lead to entrained
liquid carry over to the Compressor.
11
Set capacity switch to auto.
12
Ensure the Compressor is 10% loaded. This is the minimum loading of the
compressor.
13
The starting of the Compressor consists of a sequence of events when the start
button is pushed. The first task is to clear all the trips and permissive. Next the
sequence will start with the starting of the lube oil motor. As soon as the lube oil
pressure is build up the compressor motor should start. Once the Compressor
motor starts, valves open or close automatically.
14
Check the temperature of the Rich Gas stream (TIC-009) and Lean oil Stream
(TIC-011). Set TIC-009 and TIC 011 in automatic at approximately 5 oC higher
than the refrigerant in the Combined Vapor-Liquid Chiller. The signal resulting
from TIC-011 being set at 5 oC higher than the refrigerant temperature, will start
closing the slide valve, thereby increasing the mass flow rate of refrigerant
pushed through the Compressor. This will increase the current drawn to the
motor. An override activated by the motor current draw is provided to regulate the
time it takes the slide valve to close to avoid drawing too much current. This
ensures the capacity of the compressor is gradually increased and subsequently
the process temperature is decreased.
15
If the suction pressure decreases below 0.35 Kg/Cm 2 and the refrigerant
compressor shuts down, decrease the temperature of TIC-011 approximately 2-4
o
C, thereby increasing the load and suction pressure of the refrigerant
compressor.
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16
OPERATING MANUAL
RECOVERY PLUS
UNIT 233
Gradually decrease the temperature of TIC-009 to approximately 5 oC. hold the

lean oil temperature TIC-011 constant and start the lean oil pump. Set the lean oil
rate at 50% of design flow. Gradually increase the lean oil rate to design.
17
Hold the net gas into the Absorber temperature constant, 5 oC, and gradually
increase the Rich Gas In flow to design by closing the bypass.
18
Before the Rich Gas In and Lean Oil In temperature can be decreased to design,
ensure that the circuit is dried out.
19
Gradually decrease the Combined Vapor-Liquid Chiller temperature to design.
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7.0
Normal Shutdown
7.1
General
OPERATING MANUAL
UNIT 233
The following shutdown procedure covers a normal planned shutdown such as

would be required for periodic cleaning and inspection of vessels.
The shutdown instructions, which follow, are divided into sections for
convenience.
7.2

Notify Shift superintendent and other units, which are likely to be affected.
Inform the Shift superintendent and other affected/concerned operating
units about the exact date and time of the impending shutdown. This will
facilitate various planning activities at their end.
7.3
Preshutdown Preparation
Planning of unit shut down along with other unit of the aromatic plant / other
plants of complex require thorough understanding and review of pre and post
effect of shutdown. All the concerned intra departments and inter department
like, Off Site, Utility, CES, Central Lab., Safety supporting services, Fire
Prevention, Refinery Units, Production Planning, etc. must be informed in
advance and action plan for all of them must be prepared.
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Prior to shut down of unit, list out the activities to be carried out in the unit,
other units and other plants. Prepare detailed action plan for each activity and
schedule those activities in a shutdown period with action party assigned to
each activity. Plan the availability of resources, spare parts, special materials,
special tools and tackles, safety equipment, etc. Ensure that above items are
available or will be available at the time of need.
Prepare the action plan of preparation / shutdown / post shut down preparation
of the unit for operation group and list out all the activities required to be
performed prior to shutdown, during shutdown, after shutdown and prior to
startup of the unit.
7.4
General Outline of Normal Shutdown

Normal Shutdown of the Recovery Plus can be broadly divided into two steps:
1. Refrigerant Circuit
2. Process Circuit
3. Refrigerant Retained in Receiver
7.5
Refrigerant Circuit Shutdown

The Refrigerant Compressor should always be shutdown first to avoid any
possibility of freeze up at the Combined Vapor-Liquid Chiller.
Manually unload the compressor. Press the system stop push button. The
following will be observed at once:
Compressor will stop.
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UNIT 233
Lube oil pump continues to run.
Slide valve will return to 10% load if the compressor was not already 10% loaded.
7.6
Process Circuit Shutdown

Stop the lean oil pump and block in the Platforming process unit liquid to the
Recovery Plus System. The Platforming process unit liquid will continue to flow to
the fractionation section via the separator level control.
Open the 12 block valve on the Net Gas bypass line and then close both double
block valves on the Net Gas inlet and outlet lines.
7.7
Refrigerant Retained in Receiver

This procedure assumes the system is to be taken out of service and the
inventory of propane refrigerant is to be retained in the receiver.
Reduce the rich gas and lean oil flow.
Adjust Combined Vapor-Liquid Chiller level control, LIC-002, and Refrigerant

Condenser level Control, LIC-014, to their minimum set point.
Close the outlet valve on the Refrigerant Receiver/Economizer (valve 1018) and
block in LV-002.
The above action will unload the refrigeration circuit returning as much of the
refrigerant as possible to the Refrigerant Receiver/Economizer.
Continue vaporising refrigerant from the Combined Vapor-Liquid Chiller,
condensing the compressor discharge and collecting liquid in the Refrigerant
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Receiver/Economizer, until the compressor suction pressure is reduced to the

low pressure shutdown. The logic system will then shutdown the compressor.
When the refrigerant level in the Combined Vapor-Liquid Chiller is as low as
possible close the Rich Gas and Lean Oil into the Recovery Plus system and
open the 12" bypass line for the Rich Gas.
7.8
Post Shutdown Checks

Post shut down checklist should be prepared for each unit and should consist
of critical parameters of critical sections/equipment of unit. This is required to
assure that unit was placed in best possible safe condition during shut down
and for any corrective action if required. The checklist must cover level of tanks,
HC ingress to equipment open for inspection, specific cooling requirement,
barring of compressor, etc. The checklist must be monitored by each shift and
ensure that plant is safe even under shutdown and will not endanger /
detriment to the unit/equipment.
7.9
Equipment Handing / Taking Over to/from Maintenance.

The general procedure must be prepared for overall complex to safely hand
over the equipment / piping system to Maintenance department for the shut
down activity. Similarly general procedure must be prepared for overall complex
to safely hand over the equipment / piping system to Operation department
after completing jobs on equipment/ piping. These procedures must be in line
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OPERATING MANUAL
RECOVERY PLUS
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with RPL safety policy and should aid RPL work permit system and good
housekeeping.
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8.0
NORMAL OPERATION
8.1
Process principles
OPERATING MANUAL
RECOVERY PLUS
UNIT 233
The purpose of the Recovery Plus unit is to improve the recovery of LPG and
Reformate from Platforming Process Unit Net Gas streams. Increased HCBN
recovery translates into improved liquid product yields and therefore higher
production of more valuable product. Added benefits are increased Hydrogen
purity of net gas stream and improved LPG recovery and Reformate recovery.
The RECOVERY PLUS system is composed of a process circuit and a closed
loop refrigeration circuit. The process circuit consists of a net gas stream and a
slipstream of liquid from the Platforming Unit Debutanizer (MV-AY231-V05)
feed. The refrigeration circuit provides cooling to promote the absorption of
LPG and Reformate hydrocarbons that would normally exit the Platforming Unit
in the net gas stream. The net gas and liquid streams are individually cooled
and then enter the Absorber, MV-AY233-V01. Vapor and liquid separation
occurs through counter-current flow. The recovered liquid is sent to the
Platforming Process Units Debutanizer column for stabilization prior to being
sent to storage. The gas stream exits the RECOVERY PLUS system to
Chloride Treaters (MV-AY231-V04A/B).
Under the design conditions, the RECOVERY PLUS system improves C5 +
yields by 4 LV% and LPG yields by 0.5 LV% based on fresh feed. Hydrogen
purity of the Net Gas is increased by 8 mol%.
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8.2
OPERATING MANUAL
RECOVERY PLUS
UNIT 233
Process Variables
The two major variables that effect the RECOVERY PLUS efficiency are
temperature (TIC-009 and TIC-011) and lean oil rate (FIC-002). The set points
of these parameters were considered to optimize recovery operation.
A.
Adsorber Inlet Temperatures

The temperature at which RECOVERY PLUS system operates is the variable,
which has the greatest effect on the Reformate and the LPG recovery.
Generally the colder the system operates the greater the recovery. Lower
operating temperatures are considered after analyzing metallurgical constraints
and icing.
The temperature TIC-009/011 of the vapor and liquid entering the Absorber are
used as the temperature control points. Temperature of the liquid stream is
controlled by regulating the loading and unloading of the compressor, which
determines its capacity. Temperature of the vapor stream is controlled by
regulating the amount of liquid, which mixes with the vapor prior to entering the
Combined Vapor-Liquid Chiller.
B.
Lean Oil Rate

The second process variable which has an effect on recovery is the Lean Oil
Rate, FIC-002. This rate has also been established based on process
economics and hydrocarbon recovery.
The lean oil flow rate should be maintained at a constant liquid to vapor ratio
(L/V) depending upon desired recovery. A lower liquid rate results in a decrease
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in Reformate and LPG recovery, while a higher rate may produce no marked
increase in Reformate and LPG recovery but will result in higher utility cost.
8.3
Control Philosophy and Key Analysis
A.
Compressor Control Logic

The starting of refrigerant compressor consists of a sequence of events when
the start button is pushed. The first task is to clear all the trips and permissive.
Next the sequence will start with the starting of the lube oil pump motor. As
soon as the lube oil pressure is developed the compressor motor should start.
Once the compressor motor starts valves open or close automatically.
Control logic is as follows:
The following permissive have to be satisfied before starting the compressor:
Refrigerant Receiver/Economizer high level switch LAH-015B indicates level is not

high.
Refrigerant Compressor discharge high pressure switch PAHH-016A indicates

pressure is not high.
Refrigerant Compressor suction low pressure switch PALL-014A indicates pressure

is not low.
Combined Vapor-Liquid Chiller high level switch LAHH-003A indicates level is not
high.
Lube oil high temperature switch TE-025 indicates temperature is not high.
System stop switch is not in the stop position.
Refrigerant compressor motor has not been started within the past 60 minutes.
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UNIT 233
Refrigerant compressor slide valve position switch ZSL-39 indicates slide valve is in
the 10% loaded position.
Low temperature switch TE-029 indicates temperature in the oil separator # 1 is not
low.
Remote stop if used does not indicate the stop position.

Once the above permissive are met the remaining shutdown must be bypassed
by pressing the local panel system reset push-button. The following will occur.
The lube oil low differential switch PDAL-015A will be bypassed and remain
bypassed for 5 seconds.
Compressor suction high pressure switch PAHH-014A will be bypassed and remain
bypassed for 3 minutes. It is expected that within three minutes of compressor
starting the suction pressure will drop down below the alarm value.
Once the shutdowns are clear the compressor start button at the local panel
can be pressed. The following will occur:
The lube oil motor will start.
Lube oil low differential pressure switch PDAL-0015A indicates the differential
pressure has exceeded the switch setting, clearing switch.
Compressor start contact is closed.
Oil separator heater Y01 is locked out.
The following solenoid valves will get energised
1. LY-002B
2. LY-014B
3. PY-038B
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UNIT 233
4. PY-012
B.
Compressor motor will start.

Refrigerant Compressor Load Control Logic
The loading of the compressor is accomplished by adjustment of slide valve.
The slide valve is positioned by actuating one of two solenoids conducting lube
oil to either extend or retract the slide valve on the compressor casing. One
solenoid causes the slide valve to retract, increasing the load on the
compressor and one solenoid causes the slide valve to extend unloading the
compressor.
The load solenoid XY-011A is energised if the following requirements are
satisfied:
The compressor motor running indication is on.
The compressor motor amperage is not high.
The logic determines additional loading is required based on the DCS temperature
output signal TT-011.
The local panel compressor Capacity Control switch is in auto position.

The unload solenoid XY-011B is energised if any of the following groups are
satisfied. All items in the group must be satisfied.
1. Unload on high current
The compressor motor amp switch IT-004 indicates amperage is high.
2. Unload on compressor shutdown.
The compressor motor stopped.
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One of the lube oil motor is running.
Compressor slide valve position switch ZIL-002b indicates slide valve is not in the
10% loaded position.
3. Unload on Combined Vapor-Liquid Chiller outlet temperature.
TIC-011 output is indicating a reduction in load is required via a low output signal.
The local panel compressor switch is in auto posiyion.
4. Manual unload
The local panel compressor capacity control switch is in manual position.
The local panel compressor unload push button is pressed.
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9.0
UNIT SAFEGUARDING SYSTEM
9.1
Relief Devices Summary
OPERATING MANUAL
UNIT 233
Set
Tag
Service
P&ID No.
Pressure
Discharge
G41-
(kg/cm2g)
Disposition
RA221-
PSV-007
Liquid Exchanger Shell Side
103
41.85
HP Flare
PSV-008A/B
Outlet
Combined Vapor-Liquid Chiller
104
21.09
HP Flare
PSV-010A/B
PSV-019
PSV-023
PSV-025A/B
PSV-027A/B
PSV-030A/B
Disengaging Drum
Absorber
Lean Oil Pump Discharge
Oil Reclaimer
Lube Oil Filter
Lube Oil Cooler Shell Side
Lube
Oil
Pump
P02a/B
105
107
107
108
108
109
41.85
21.09
21.09
25.0
25.0
21.09
HP Flare
Oil Reclaimer
HP Flare
HP Flare
HP Flare
Oil Separator
PSV-031A/B
PSV-033
PSV-036A/B
PSV-037A/B
Discharge
Oil Separator # 1
Oil Separator # 2
Condenser Shell Side
Refrigerant
21.09
21.09
21.09
21.09
#2
HP Flare
HP Flare
HP Flare
HP Flare
109
109
110
110
Receiver/Economiser
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9.2
OPERATING MANUAL
UNIT 233
Instrument Alarm
Tag No.
FI-001
FIC-002
TAH-010
TIC-011
TIC-011
LIC-002
LIC-002
LIC-004
LIC-004
PIC-002
PIC-002
PAH-016B
TAH-020B
PDAL-015B
TXI-022
LI-009
LI-009
TI-021
TI-021
PDAH-026B
TAH-025B
TXI-030
PDAH-034B
LAH-011B
LI-015
LAH-018B
ZIL-002B
ZIH-002B
LSH-
Description
Rich Gas Flow Low
Lean Oil Low Flow
Chiller Low Vapor Temperature
Chiller Low Liquid Temperature
Chiller High Liquid Temperature
Chiller Low Level
Chiller High Level
Absorber Low Level
Absorber High Level
Compressor Low Suction Pressure
Compressor High Suction Pressure
Compressor High Discharge Pressure
Compressor High Discharge Temperature
Low Lube Oil Differential Pressure
Oil Reclaimer Heater High Temperature
Oil Reclaimer Low Level
Oil Reclaimer High Level
Oil Reclaimer Low Temperature
Oil Reclaimer High Temperature
Lube Oil Filter High Differential Pressure
Lube Oil High Temperature
Oil Separator Heater High Temperature
Oil Separator # 2 High Differential Pressure
Relief Knockout Drum # 1 High Level
Receiver/Economiser High Level
Relief Knockout Drum # 2 High Level
Compressor Side Valve Minimum Position
Compressor Side Valve Maximum Position
Lean Oil Pump Seal Pot High Level
019A/020A
LSL-
Lean Oil Pump Seal Pot Low Level
Set Point
98,000Nm3/Hr
160 M3/Hr
-2.2 OC
-23 OC
-15 OC
380 mm
990 mm
860 mm
3300 mm
1.0 Kg/Cm2 g
3.8 Kg/Cm2 g
18.0 Kg/Cm2 g
100 OC
2.5 Kg/Cm2
140 OC
100 mm
275 mm
40 OC
50 OC
0.5 Kg/Cm2
55 OC
140 OC
0.4 Kg/Cm2
250 mm
800 mm
300 mm
10%
100%
-
021A/022A
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9.3
UNIT 233
Instrument Trips
Tag No.
PALL-014B
PAHH-014B
PDALL-015B
PAHH-016B
TAHH-020B
TAHH-025B
TALL-029B
LAHH-015B
LAHH-003B
TALL-010B
TALL-012B
TXAHH-030B
TXAHH-022B
LI-005
LI-006
Description
Compressor Low Suction Pressure
Compressor High Suction Pressure
Low Lube Oil Differential Pressure
Compressor High Discharge Pressure
Compressor High Discharge Temperature
Lube Oil High Temperature
Lube Oil Low Temperature
Refrigerant Receiver/Economiser High Level
Chiller High Level
Chiller Low Vapor Temperature
Chiller Low Liquid Temperature
Oil Separator Heater High Temperature
Oil Reclaimer Heater High Temperature
Absorber High Level
Absorber Low Level
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Set Point
0.8 Kg/Cm2 g
4.0 Kg/Cm2 g
2.0 Kg/Cm2
19.0 Kg/Cm2 g
110 OC
60 OC
40 OC
890 mm
1100 mm
-28.8 OC
-28.8 OC
150 OC
150 OC
3680 mm
250 mm
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10.0
EMERGENCY SHUTDOWN
10.1
General
OPERATING MANUAL
UNIT 233
Emergencies must be recognised and acted upon immediately. The Operators

must be able to take the necessary steps in such situations. While some of the
emergencies may not result in a unit shutdown, they could cause serious
trouble on the unit if not handled properly. In addition damage to the catalyst
might occur.
The following outlines some situations, which might arise and suggested means
of handling the situation.
10.2
Interconnectivity During Emergencies
10.2.1 Loss of Net Gas Compressor in Platforming Unit

Loss of Net Gas Compressor in Platforming unit will result in stoppage of gas
feed to RECOVERY PLUS unit. Refrigeration Compressor will go to minimum
load. If the suction pressure goes low because of lack of evaporation in VaporLiquid Chiller then Compressor will trip on low suction pressure.
Actions to be taken:
Shut down the refrigeration compressor.
Block in the lean oil and shut down lean oil pump.
10.2.2 Loss of Lean Oil from Platforming Unit
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LPG and C5+ recovery will fall drastically because of lean oil failure.
RECOVERY PLUS operation can be continued for some time but if the fault is for
longer duration bypass recovery plus.
10.2.3 PSA failure

In case of PSA failure divert Net Gas Chloride treater outlet to unsaturated
sweet gas collection header.
10.3
Process and Utility Failure
10.3.1 Power Failure

When the compressor logic system detects a power failure, it will immediately
initiate a compressor shutdown.
Do following:
Isolate lean oil and net gas in to the system
Isolate lean oil going to debutaniser feed bottom exchanger
10.3.2 Loss of Cooling Water

Hook up
Refrigerant condenser S-05
Lube oil cooler S-04 A/B
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A loss of cooling water will cause the lube oil temperature to increase and
increase in the discharge pressure of the compressor. Eventually one or both of
these will cause a compressor shutdown.
Action required:
Stop the compressor at once and isolate the net gas and lean oil circuit.
10.3.3 Loss of Refrigerant
Loss of refrigerant is a dangerous situation. The system should be shut down
immediately. Leak in the refrigerant system will cause the loss of refrigerant.
Bypass the rich gas and lean oil circuit. Identify the leak and fix the leak. If it is
not possible to fix the leak depressurise the refrigerant system.
10.3.4 Loss of Instrument Air
A loss of instrument air will result in control valves moving to their fail safe
position. Stop the compressor immediately.
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11.0
SPECIAL PROCEDURE
11.1
Initial Refrigerant Loading
OPERATING MANUAL
UNIT 233
Evacuation for Air, Nitrogen and Water Removal
All air must be removed and purged before safe system operation is assured.
The system should be purged with nitrogen until the vent gas has an Oxygen
content of < 0.5%.
The refrigerant circuit must be evacuated to remove Air Nitrogen and Moisture.
Consequently a vacuum pump is required. A vacuum pump capable of creating
a vacuum of less than 1 mm Hg absolute pressure is required. To accurately
measure the vacuum an absolute pressure gauge is required. This should be a
Meriam closed end U-tube type gauge or equal.
To ensure that the refrigeration circuit is properly dehydrated with the least
amount of time, it is recommended that a vacuum point be provided on each of
the modules. This will ensure that the entire circuit is being pulled down and
help in isolating sections if necessary. Pipe all the vacuum points to the suction
of the vacuum pump. Provide an isolation valve on the suction the vacuum
pump to allow for isolation of the circuit when the vacuum pump has been
stopped to change oil or after a low vacuum has been reached.
When the vacuum pump is started, the vacuum should pull down rapidly to
approximately 25 mm Hg. At approximately 10 mm Hg evaporation of free
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water in the circuit will be rapidly accelerated and the vacuum tend to remain
constant as the evaporation rate approaches the vacuum pump capacity.
Depending upon the total amount of water, ambient temperature and vacuum
pump capacity, it may take several hrs or days to make any noticeable
decrease in vacuum below 10 mm Hg.
After pulling down the circuit to below an absolute pressure of 1 mm Hg or
below, check to see that the vacuum reading is stable and does not rise above
1 mm Hg Abs. If the vacuum reading is stable at a value below 1 mm Hg than
the test is considered acceptable.
After the dehydration, charge the circuit with vapor refrigerant to create a positive
pressure of 1 Kg/Cm2.
Close the inlet valves (valves 1004 and 1019 around LV-014) to the Refrigerant
Receiver/Economiser, MV-AY233-V03.
Close the filter inlet valve (valve 1013) of Refrigerant Receiver/Economiser, MVAY233-V03.
Open the Refrigerant Filter/Dryer, F02, outlet valve (valve 1017) and Refrigerant
Receiver/Economiser, MV-AY233-V03, outlet valve (valve 1018).
Connect refrigerant charging and equalising lines from tank, truck or refrigerant
source to the 2 flanged connection provided on the refrigeration circuit.
Gradually pressurise the Refrigerant Receiver/Economiser, MV-AY233-V03, by

slowly opening the equalising stop valve (valve 1006). Note that the entire refrigerant
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circuit vacuum will have to be broken before a positive pressure will be indicated at
PG-039.
As soon as the pressure is equalised, gradually open the charging valve (valve
1015) and start the charging pump. The charging pump should not be started with
the pressure below 1.03 Kg/Cm2 g.
Use the Refrigerant Receiver/Economiser, MV-AY233-V03, level gauge LG-016 to

verify the desired level. The normal operating level is 120 mm from the bottom of the
vessel. The receiver should be filled to 1080 mm if there is no refrigerant in the
remainder of the system. Stop the pump when the charging is completed.
Close charging valve (valve 1015), equalizing valve (valve 1006) and fitter/dryer
outlet valve.
Venting of Non Condensibles
The presence of non-condensibles affects the heat transfer area in the
Refrigerant Condenser, which leads to a higher Refrigerant Compressor
discharge pressure and increased power consumption. Non-condensibles and
air should be purged from high point vents in the Refrigerant Compressor
discharge circuit.
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12.0 Fire & Safety

12.1
Introduction
Safety of individual overrides all production targets. This is the safety policy of
Reliance Group. Hence safety has to be ensured in all walks of life especially
in plants and operating areas.
Though plants are designed properly considering hazards involved in process,
effective use of safe working procedures and practices cannot be
underestimated. Regular checks of plant atmosphere for inflammable material
and through investigation of accidents/near miss incidences is a must.
The principal objective of fire and safety equipment is to minimize the risk and
consequences of accidental event, minimize the potential for hazardous
occurrences, ensure a safe working environment and minimize the potential for
pollution of the environment.
This section of manual briefly describes fire and safety equipment and
procedures. This section should be read in conjunction with Safety manual of
Aromatics Complex, which describe various safety procedures to be followed in
Aromatics Complex.
12.2
Repair work, Permit to work system, housekeeping and maintenance of

onstream equipment
Maintenance on any equipment will be carried out as per Works Procedure
adhering strictly to Permit To Work system. There are various types of work
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permits viz. fire permit, vessel entry permit and excavation permit which are
issued depending on type of hazard involved in maintenance work.
Issuer of permit ensures that equipment under maintenance is isolated from
hazards. If it is not possible to nullify the hazard involved in maintenance work,
issuer of permit clearly identifies the type of hazard and precautions to be taken
during maintenance. Person in Plant area should always wear helmet. Safety
goggles should be used as and when required. Safety belts should be used
while working at heights.
Fire permits or hot work permits are issued if there is likelihood of fire during
maintenance. Hence Explosivity check is carried out in work area before issue
of fire permit and issuer of permit ensures that work area is free from
inflammable hydrocarbons. Issuer of permit ensures that adequate precautions
are taken for fire fighting in case of fire during maintenance.
Entry to confined space is governed by vessel entry permit. Issuer of permit
ensures that atmosphere is free from hydrocarbons and toxic materials. Issuer
of permit also ensures that atmosphere is safe for breathing with oxygen check.
If it is not possible to make atmosphere safe, then use of breathing air should
be considered.
During normal operations housekeeping is primarily the responsibility of
Production department. However clearing up of work area after maintenance
before returning Permit is the responsibility of Maintenance department. All
stairways, passageways and gangways must be kept free of materials, supplies
and obstructions of every kind. Materials and supplies must be kept away from
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the edges of hoistways, ladder access and floor openings. Spillage of oil or
other substances must be cleaned up immediately using the appropriate
procedure. Tools not in use should be placed in a toolbox and not strewn about
to cause tripping hazard. Remove scrap and rubbish regularly to the allocated
containers or disposal units. Toilets wash up facilities and drinking water
facilities should be kept clean.
Special precautions are to be taken while performing maintenance on onstream
equipment. All hazards involved in maintenance work should be clearly
identified and precautions to be taken accordingly.
12.3
Safety during sample withdrawal

Exposure of hydrocarbons during sampling should be minimized. Operation
and Laboratory personnel involved in sampling should wear chemical safety
goggles/shield, protective apron, laboratory coat, solvent resistance gloves,
respiratory protective equipment, etc. These protective equipment are no
substitute to safe working conditions, proper ventilation, good personal
practices, proper maintenance of operating/safety equipment and proper
procedure.
Please
refer
sampling
procedure
AYJ/PDN/GEN/051
AND
AYJ/PDN/GEN/052.
Some of the hydrocarbons handled in Aromatics Complex are toxic in nature.
Material safety data sheet (MSDS) on such hydrocarbons gives information on
nature of toxicity, potential health effects and precautions to be taken during
handling and storage. It also gives information on measures to be taken during
accidental release of chemicals. MSDS of some of the hydrocarbons handled in
Aromatics Complex are attached at the end of this section of Operating
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Manual. Precautions mentioned in MSDS on chemicals/hydrocarbons should

be obeyed religiously.
12.4
Fire fighting and safety equipment

Fire and safety is an integral part of Petroleum & Petrochemical Industry and it
has always has been considered as of prime importance. The Petroleum and
Petrochemicals being processed and handled in the Refinery Complex are
highly inflammable & volatile in nature. Therefore Fire & Explosions are some
of the potential hazards in such process industries resulting in property damage
and loss of human lives.
Fire is a rapid, self sustaining oxidation process accompanied by the evolution
of heat and light of varying intensity. Fire results from the combination of fuel
vapor, heat and oxygen in proper proportion. This combination of elements
causing combination is referred to as FIRE TRIANGLE. The definition of these
three elements is given below:
1. Fuel: combustible substance in the from of vapor, Liquid or incandescent solid.
2. Heat: a source of Ignition sufficient to initiate and propagate the Chemical
Reaction of Combustion.
3.
Oxygen: Oxygen content in atmospheric Air in sufficient proportion to form a

combustible Vapor-Air mixture.
Fire Extinguishment principle involves removal or limiting of one or more of the
factors depicted by the Fire Triangle. The Principle of Extinguishment of fire
may be classified under the following heads:
Starvation
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This is accomplished by removing combustibles from the scene of fire e.g.,

transferring fuel from burning tanks, cutting of fuel supply by closing of valve
etc. It is also achieved by subdividing the burning material to small isolated
pockets of fire.
Smothering
This is accomplished by eliminating air supply of diluting the available air
(Oxygen) to the fuel e.g., blanketing, inerting the atmospheric air by nitrogen/
steam etc.
Cooling
If the rate at which the heat is generated by combustion is less than the rate at
which is dissipated then the combustion does not persist. The application of
water spray or jet results in Extinguishment of fire by this principle. The cooling
principle is also adopted to protect neighbouring equipment/facilities from the
radiation exposure hazards.
RESPONSIBILITY OF PERSON NOTICING A FIRE
1. Activate the nearest manual call point. Inform plant control centre of respective
area.
2. Alert nearby people for help.
3. Try to extinguish the fire with the help of nearby fire extinguisher.
4. Carry out the instructions of shift / operation incharge.
12.5
Precautions for Entering Any Contaminated or Inert Atmosphere
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Nitrogen is non-toxic. 79 mol-% of the air we breath is nitrogen, 21 mol % is

oxygen. However, in vessels or areas where there is a high concentration of
nitrogen, there is also a deficiency of oxygen for breathing. Breathing an
atmosphere deficient in oxygen (i.e. an inert atmosphere) will rapidly result in
dizziness, unconsciousness or death depending on the length of exposure. Do
not enter or even place your head into a vessel, which has a high concentration
of nitrogen. Do not stand close to a valve where nitrogen is being vented from
equipment at a high rate, which might temporarily cause a deficiency in oxygen
close to the valve.
It is also important to emphasize that if a person has entered a vessel and
becomes unconscious, no individual should go in to help him without first
putting on a fresh air mask, confirming that the air supply is safe, wearing a
safety harness, and enlisting the aid of a minimum of two other people to
remain immediately outside of the vessel to assist him. This may seem an
obvious warning, but people do forget this in the trauma of an emergency
situation. Often the first thought is to save the person in distress and people
enter the vessel without proper protection only to succumb to the same hazard
without anyone else being present to save them.
12.6
General RECOVERY PLUS Safety Notes

RECOVERY PLUS is part of Platforming plot. All the lists, which are attached at
the end of this chapter includes RECOVERY PLUS.
Fire extinguishers
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There are various types of fire extinguishers whose location depends on type of
fire likely to occur at such location. List of fire extinguishers is given at the end
of this section of manual. Location of fire extinguishers has been given in safety
equipment layout drawing G56-AY231-007 for Platformer plot.
Fire and gas detector
Automatic Fire and Gas detectors are placed at strategic locations in
Platforming plot at aromatics complex. List of Fire and Gas detectors is
attached at the end of this chapter.
Refer drawing J61-AY231-017 for details.
Hydrants and monitors
For fire fighting, hydrants and fire monitors are installed at strategic locations in
Platformer plot at aromatics complex. List of hydrants and monitors in
Platformer plot is enclosed as annexure. Refer drawing safety equipment layout
G56-AY231-007 and safety signs layout G56-AY231-010 for details.
Manual call points for fire
Manual call points are installed in the plot. Observer on sight of fire can activate
manual call point . Refer drawing safety signs layout G56-AY231-010 for
details.
Locations of manual call points are as follows.
South of plot
East of plot
West of plot
Substation 200-50
CHECKED BY
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APPROVED BY
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2
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OPERATING MANUAL
RECOVERY PLUS
UNIT 233
South of PSA
North/East of PSA
North/East of net gas compressor
East side Pillars of walkway
West side Pillars of walkway
South of CCR
12.7
1
1
1
5
1
1
Material Safety Data Sheets (MSDS)

The MSDS requirement falls primarily on chemical manufacturers, importers
and distributors. The OSHA standard requires them to develop and provide a
MSDS for each hazardous chemical they produce or handle. Each MSDS can
vary in format but should include the following information:
Chemical and common name
Ingredient information
Physical & chemical characteristics
Physical hazards - potential for reactivity, fire and/or explosion
Health hazards
Symptoms of exposure
Primary route of likely entry into body upon exposure
OSHA permissible exposure level
Precaution for use
Waste disposal
Protective measures and equipment , including during spills & maintenance
Emergency & first aid procedures
CHECKED BY
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OPERATING MANUAL
RECOVERY PLUS
JAMNAGAR
UNIT 233
Date of MSDS preparation and last revision
Emergency contact of manufacturer of distributor
MSDS for chemicals used in the Platforming process are included at the end of
this section.
CHECKED BY
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JAMNAGAR
13.0
UNIT 233
LABORATORY REQUIREMENTS AND SCHEDULE

Laboratory Test Methods / Schedule
Sample No.
PA-231-003
Name of the Stream &
Test Method
Frequency
Parameters
Number
Normal
Treater)
U114
2/M
Relative density
U539
2/M
Composition
Dragger
2/M
H2S
Dragger
2/M
Net Gas (After Chloride
HCl
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JAMNAGAR
14.0
OPERATING MANUAL
RECOVERY PLUS
UNIT 233
MAJOR EQUIPMENT AND INSTRUMENT SUMMARY
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OPERATING MANUAL
RECOVERY PLUS
JAMNAGAR
14.1
UNIT 233
Equipment Summary
14.1.1 Vessels
Item No.
MV-AY
Equipment
Title
ID
T/T
(mm)
(mm)
Material
Of
Pressure
Temperature
(kg/cm g)
( C)
Construction
233-V01
233-V03
Absorber
1575(T)
Refrigerant
2080(B)
1200
9600
(Head & Shell)

Killed carbon
6000
steel
Killed carbon
Receiver/
Operating
Design
Operating
Design
41.85
-11
-28
steel
Economiser
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Remarks
OPERATING MANUAL
RECOVERY PLUS
JAMNAGAR
UNIT 233
14.1.2 Shell and Tube Exchanger
Item No
Equipment
Heat
ME-AY
Title
Duty
Shellside
Fluid
(MMKcal/hr)
233-S01
Vapor
1.577
Lean Gas
Tubeside
Flow
Op. Press
Op. Temp
(kg/hr)
(kg/cm2g)
In/Out
25309
37.96
(C)
-11.1/28.4
MOC
KCS
exchanger
233-
Liquid
S02A/B
exchanger
233-S03
Vapor
Fluid
Rich
Flow
Op. Press
Op. Temp
MOC
(kg/hr)
(kg/cm2g)
In/Out
44579
38.59
(C)
37.2/6.1
KCS
169995
40.21
37.2/8.9
KCS
-11.8/
KCS
Gas
2.077
Rich oil
1.26
Propylene
189224
23.83
-3.9/21.1
KCS
Lean oil
-23.5
KCS
Gas
Chiller
-23.5
Exchanger
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Item No
Equipment
Heat
ME-AY
233-S03
Title
Liquid
Duty
1.97
Chiller
(MMKcal/hr)
Exchanger
Refrigerant
3.927
Propylene
47074
0.515
Rich oil
189588
233-S05
UNIT 233
Shellside
Propylene
Tubeside
-23.5
KCS
Liquid
19.56
69.4/42.8
KCS
Water
415000
23.48
23.3/29.4
KCS
Propyle
45208
9.2/-20.9
KCS
4.5
31.4/40.9
KCS
19.11
43.3/27.2
KCS
condenser
233-S06
Refrigerant
subcooler
ne
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JAMNAGAR
UNIT 233
14.1.3 Pumps
Item No
Equipment
MP-AY
Title
Type
Rated
Pumping
Suct.
Disch.
Diff.
Capacity
Temp
Press
Press
Head
Driver
(kW)
233P01A/B
Lean oil
Centrifugal
(m /hr)
( C)
(kg/cm g)
(kg/cm g
(m)
239
37
20.9
40.5
251
RPM
Installed
2950
280
1 stage
Casing
Dia
Centerline
Between
Radial
bearings
Double
volute
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Impeller
Rated
Mount

JAMNAGAR
14.2
OPERATING MANUAL
RECOVERY PLUS
UNIT 233
Instruments Summary
Tag No.
Description
Normal Value
FI-001
FIC-002
TI-001
TI-002
TI-020
TI-021
TI-026
TIC-009
TIC-011
PI-001
PI-016B
PIC-012
PIC-038
PDIC-018
PDI-026
PDI-034
LIC-004
LIC-002
LIC-014
LI-009
LI-015
Gas To Vapor Exchanger

Lean Oil Flow Rate
Net Gas Inlet Temperature
Net Gas From Recovery Plus Temperature
Compressor Discharge Temperature
Oil Reclaimer Temperature
Lube Oil Temperature From Cooler
Lean Gas From Chiller
Lean Oil From Chiller Temperature
Net Gas Inlet Pressure
Compressor Discharge Pressure
Compressor Suction Pressure
Refrigerant Receiver/Economiser Pressure
Lube Oil Differential Pressure
Lube Oil Filter Differential Pressure
Oil Separator # 2 Pressure Differential
Absorber Level
Combined Vapor-Liquid Chiller Level
Refrigerant Condenser Level
Oil Reclaimer Level
Refrigerant Receiver Economiser Level
131,039 Nm3/Hr
213 m3/Hr
37 oC
28.4 oC
70 oC
15 oC
50 oC
-12.2 oC
-21.2 oC
36.6 Kg/Cm2 g
17.0 Kg/Cm2 g
2.7 Kg/Cm2 g
3.59 Kg/Cm2 g
14.3 Kg/Cm2
< 0.35 Kg/Cm2
< 0.2 Kg/Cm2
1720 mm
890 mm
350 mm
30-275 mm
445 mm
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OPERATING MANUAL
RECOVERY PLUS
UNIT 233
15.0
P&IDS AND LIST OF REFERENCE DRAWINGS
15.1
PFD
REFERENCE DRAWINGS
MS0004-LAC-C01-001
15.2
P & ID
REFERENCE DRAWINGS
G41-AY231-017
G41-AY231-019
G41-AY231-020
G41-AY231-025
G41-AY231-041
15.3
MFD
REFERENCE DRAWINGS
MS0004-LAC-C02-003
MS0004-LAC-C02-004
MS0004-LAC-C02-005
MS0004-LAC-C02-006
MS0004-LAC-C02-007
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OPERATING MANUAL
RECOVERY PLUS
UNIT 233
MS0004-LAC-C02-008
MS0004-LAC-C02-009
MS0004-LAC-C02-010
MS0004-LAC-C02-011
MS0004-LAC-C02-012
MS0004-LAC-C02-013
MS0004-LAC-C02-014
15.4
PLOT PLAN
REFERENCE DRAWINGS
P50-AY231-002 (SHEET 1 OF 2)
P50-AY231-002 (SHEET 2 OF2)
15.5
PSFS (Safe Guarding)

REFERENCE DRAWINGS
G55-AY231-001
G55-AY231-002
G55-AY231-003
G55-AY231-004
15.6
MSD
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JAMNAGAR
OPERATING MANUAL
RECOVERY PLUS
UNIT 233
REFERENCE DRAWINGS
G34-AY231-001
G34-AY231-002
G34-AY231-003
G34-AY231-004
15.7
Area Protection Layout

G56-AY231-004
15.8
Safety Equipment Layout

G56-AY231-007
15.9
Safety Signs Layout

G56-AY231-010
15.10
PIB#4 Gaseous Fire Extinguishing System

G56-AY221-203
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