!! CCR-Operating-Manual-Draft PDF

OPERATING MANUAL FOR CCR Doc No DRAFT
PLATFORMING UNIT, HPCL VISAKH Rev A

Page 1 of 271
OPERATING MANUAL
FOR
CCR PLATFORMING PROCESS UNIT
HINDUSTAN PETROLEUM CORPORATION

LIMITED,
VISAKH REFINERY
A 04/04/08 Issued for comments AB

Rev No. Date Purpose Prepared by Checked by Approved by
Template No. 5-0000-0001-T2 Rev. 0 Copyrights EIL – All rights reserved

Page 2 of 271
TABLE OF CONTENTS
SECTION-1 .......................................................9
INTRODUCTION ...................................................9
1.1 INTRODUCTION .........................................9
1.2 BRIEF PROCESS DESCRIPTION ............................9
1.3 PROCESS CHEMISTRY ..................................12
1.3.1 Platforming Hydrocarbon Chemistry ................13
1.3.2 Catalyst Chemistry.............................26
SECTION-2 ......................................................46
DESIGN BASIS ...................................................46

2.1 INTRODUCTION ........................................46
2.2 UNIT CAPACITY ........................................46
2.3 ON-STREAM FACTOR ...................................46
2.4 TURNDOWN CAPABILITY.................................46
2.5 FEED AND PRODUCT CHARACTERISTICS ...................46
2.5.1 Feed Characteristics ...........................46
2.5.2 Product Characteristics .........................48
2.6 BATTERY LIMIT CONDITIONS OF PROCESS LINES.............49
2.7 UTILITY CONDITIONS AT UNIT BATTERY LIMITS / AT TIE IN POINT 50
SECTION-3 ......................................................53
PROCESS DESCRIPTION ..........................................53

3.1 CCR PLATFORMING UNIT PROCESS SYSTEM ................53
3.2 CHEMICAL SYSTEM .....................................63
SECTION-4 ......................................................64
EFFECT OF OPERATING VARIABLES ON PROCESS ......................64

4.1 GENERAL.............................................64
4.3 PLATFORMING DEPENDENT VARIABLES ....................70
4.4 Catalyst Poisons ........................................90
SECTION - 5 ....................................................126

Page 3 of 271
PRE-COMMISSIONING PROCEDURE .................................126

5.1 GENERAL ............................................126
5.2 PRE-COMMISSIONING ACTIVITIES .........................126
5.2.1 Inspection / Checking ..........................126
5.2.2 Preparation for Pre-Commissioning ...............129
5.2.3 Pre-Commissioning Operation ...................129
SECTION - 6 ....................................................154
COMMISSIONING PROCEDURE .....................................154

6.1 INTRODUCTION .......................................154
6.2 PREPARE UNIT FOR CHARGING ..........................156
6.3 PURGE AND START PLATFORMING FRACTIONATION SECTION ..158
6.4 EVACUATE AND PURGE THE PLATFORMING REACTOR SECTION 160
6.6 HYDROGEN PRESSURE THE PLATFORMING REACTOR AND NET
GAS RECONTACT SECTIONS .............................163
6.7 START HYDROGEN CIRCULATION AND REACTOR WARM-UP ....163
6.8 START FEED TO THE PLATFORMING REACTORS .............164
6.9 ESTABLISH SEPARATOR OPERATION ......................165
6.10 START CHLORIDE ADJUSTMENT PROGRAM .................166
6.11 ESTABLISH NORMAL FRACTIONATION SECTION OPERATION....166
6.12 LINE OUT ............................................167
SECTION -7 ....................................................170
NORMAL OPERATING PROCEDURES ................................170

7.1 GUIDELINES FOR OPERATION ............................170
7.2 OPERATING PARAMETER ...............................173
7.3 LIST OF INSTRUMENTS .................................177
SECTION - 8 ....................................................182
SHUTDOWN PROCEDURES ........................................182

8.1 GENERAL............................................182
8.2 NORMAL SHUTDOWN PROCEDURE .......................182
8.2.1 Notify operating foreman and other units of shutdown ..183
8.2.2 Shutdown the Continuous Catalyst Regeneration section 183
8.2.3. Reduce heater temperatures and charge rates .......183
8.2.4. Cut out Platforming reactor charge ................183
8.2.5 Shutdown the Platforming separator ...............184
8.2.6 Shutdown all Platforming reactor heaters ...........184

Page 4 of 271
8.2.7 Shutdown and block in all columns ................184

8.2.8 Shutdown recycle compressor ...................185
8.2.9 Depressurize and purge the reactor system..........185
8.2.10 Isolate system and install necessary system blinds ....186
8.2.11 Remove catalyst from reactors ...................186
SECTION-9 .....................................................188
EMERGENCY SHUTDOWN PROCEDURE ..............................188

9.1 EMERGENCY SHUTDOWN PROCEDURE ...................188
9.1.1 Power Failure ...............................188
9.1.2 Total loss of Recycle gas flow....................189
9.1.3 Functional Description Of Safe Shutdown System .....191
SECTION-10 ....................................................199
SAMPLING PROCEDURE & LABORATORY ANALYSIS REQUIREMENT ........199

10.1 GENERAL............................................199
10.2 SAMPLING PROCEDURE ................................199
10.3 LABORATORY TEST METHOD AND SCHEDULE ..............202
SECTION-11 ....................................................205
TROUBLE SHOOTING ........................................205
SECTION -12 ...................................................209
SAFETY PROCEDURE ............................................209

12.1 INTRODUCTION .......................................209
12.2 SAFETY OF PERSONNEL ................................209
12.3 PREPARATION FOR VESSEL ENTRY .......................210
12.3.1 Positive Vessel Isolation........................211
12.3.2 Vessel Access ...............................211
12.3.3 Wearing of a Safety Harness ....................212
12.3.4 Providing a Man way Watch .....................212
12.3.5 Providing Fresh Air ...........................213
12.3.6 Preparation of Vessel Entry Permit ................214
12.3.7 Checkout Prior to New Unit Start-up ...............214
12.3.8 Inspections during Turnarounds ..................215
12.4 REACTOR LOADING ...................................216
12.5 REACTOR UNLOADING .................................217

Page 5 of 271
12.6 HAZARDOUS CHEMICALS ...............................217

12.6.1 Hydrogen Sulfide (H2S) ........................218
12.6.2 Hydrogen ..................................223
12.6.3 Hazards Aromatics Hydrocarbons .................224
12.6.4 Hazards Related To Catalyst ....................227
12.7 FIRE FIGHTING SYSTEM ................................229
SECTION -13 ...................................................231
ALARMS AND TRIPS ..............................................231

SET POINTS FOR ALARMS AND TRIPS ...........................231
SECTION -14 ...................................................236
UTILITY AND AUXILIARY SUMMARY ..................................236

UTILITY SYSTEM ...........................................236
SECTION -15 ...................................................240
SPECIAL PROCEDURES ...........................................240

15.1 CATALYST LOADING ...................................240
15.1.1 General Loading Guidelines .....................240
15.1.2 CCR Platforming Catalyst Loading ................242
SECTION -16 ...................................................247

BLIND LIST ................................................247
SECTION -17 ...................................................250

EQUIPMENT DETAILS........................................250
SECTION -18 ...................................................258
GENERAL OPERATING INSTRUCTIONS FOR EQUIPMENT .................258

18.1 GENERAL ............................................258
18.2 CENTRIFUGAL PUMPS ..................................258
18.2.1 Start-up ....................................258
18.2.2 Shutdown ..................................259
18.2.3 Trouble Shooting .............................259
18.3 POSITIVE DISPLACEMENT PUMPS .........................261

Page 6 of 271
18.3.1 Start-up ....................................261

18.3.2 Shutdown ..................................261
18.4 RECIPROCATING COMPRESSOR ..........................262
18.4.1 Start-up ....................................262
18.4.2 Shutdown ..................................262
18.4.3 Normal Operation ............................263
18.5 CENTRIFUGAL COMPRESSOR ............................265
18.5.1 Start-up ....................................265
18.5.2 Shutdown ..................................265
18.5.3 Normal Operation ............................266
18.6 HEAT EXCHANGERS ...................................267
18.6.1 Start-Up ...................................268
18.6.2 Shutdown ..................................269
18.7 HEATER .............................................269
18.7.1 Procedure for Refractory Drying ..................270
18.7.2 Operating Procedure ..........................270
18.7.3 Start-up ....................................270
18.7.4 Shutdown ..................................271

Page 7 of 271
ATTACHMENT
Attachment-I Process Flow Diagram
Attachment-II Piping & Instrumentation Diagram

Page 8 of 271
PREFACE
This operating manual for CCR Platforming Unit of HINDUSTAN PETROLEUM

CORPORATION LIMITED at VISAKH has been prepared by M/s Engineers India Limited.
This manual contains process description and operating guidelines for the unit and is based on
documents supplied by the process licensor M/s UOP.
Operating procedures & conditions given in this manual are indicative. These should be
treated as general guide only for routine start-up and operation of the unit. The actual operating
parameters and procedures may require minor modifications/changes from those contained in
this manual as more experience is gained in operation of the Plant.
For detailed specifications and operating procedures of specific equipment, corresponding

Vendor's operating manuals/instructions need to be referred to.

Page 9 of 271
SECTION-1
INTRODUCTION
1.1 INTRODUCTION
The catalytic reforming process has been a mainstay in most refineries throughout the
world for many years. The original function of this process was to upgrade low octane
number straight-run Naphthas to higher octane motor fuel blending components by
catalytically promoting specific groups of chemical reactions. Naphtha boiling range
products from other processes (thermal cracking, coking, etc.) were soon being included in
the charge to catalytic reforming units for octane improvement. The reforming application
was logically and rather quickly expanded to include the production of specific aromatic
hydrocarbons. High-purity benzene, toluene, and mixed Xylenes were made available to the
chemicals industry from petroleum fractions by the combination of reforming, reforming,
aromatics extraction, and fractionation. Hydrogen, the “by-product” from the aromatic
producing reactions, was found to be useful in supporting the operation of reformer feed
preparation units as well as other hydrotreating units. The light hydrocarbon gases, by-
products of the cracking reactions, were generally added to refinery fuel gas systems.
Butanes, other cracking by-products, were commonly used in adjusting vapor pressures of
gasoline pools. Thus, most refiners and many petrochemicals manufacturers have found
the catalytic reforming process an increasingly valuable tool.
Hydrotreated naphtha from Naphtha hydrotreater is used as a feed for CCR Platforming
unit. Reformate produced in CCR Platforming unit is sent to MS blending. LPG, Hydrogen,
Make-up gas, Fuel gas is also produced in CCR Platforming unit.
1.2 BRIEF PROCESS DESCRIPTION
The Platformer is designed to process naphtha from the NHT as feedstock. The Platformer
is designed to produce the maximum yield of aromatic rich reformate, a H2 stream with
minimum C5+ content and to recover LPG from the fractionation section which is sent to
Storage. Hydrogen rich gas from the existing refinery will be imported to the CCR
Platforming unit to allow start-up of the Platforming Unit.

Page 10 of 271
Feed Section:
The feed to the Platformer unit is naphtha from the NHT stripper bottoms. The
stream enters under flow control and is pre-heated by the reactor effluent in the combined
feed exchanger. A sulphur (DMDS) injection is made into the naphtha feed stream by
sulphur injection pump. During start-up, prior to the exchanger perchloroethylene is
injected by start-up chemical injection pump. At the exchanger cold condensate is injected
by the chemical and condensate injection pump. The injection is for start-up only. Chloride
is required to maintain acidic reaction sites within the catalyst for the isomerisation reactions
to occur and water injection distributes the chloride throughout the whole catalyst bed.
Reactor effluent enters the exchanger at the top and flows downwards with the cold
feed entering at the bottom and flowing upwards. In the exchanger the feed combines with
hydrogen-rich recycle gas and goes forward to be heated further in the charge heater. It is
necessary to maintain a certain H2/HC ratio for reasons of catalyst stability.
Reactor Section
The heavy naphtha stream is heated to the reactor temperature in four heaters:
Heaters Heating Medium

Charge heater Fuel Gas/Fuel oil
No 1 Interheater Fuel Gas/Fuel oil
The catalyst is capable of operating over a wide range of temperatures with little adverse
effect on product yield and catalyst stability. However, very high temperatures will affect the
yield and catalyst stability. The flue gases from the heaters are combined and used to
generate HP and MP steam in the convection section. The steam generated is used for the
reboiler and balance is exported to refinery HP header.
There are four reactors standing one above the other. The reaction being endothermic, the
effluent from each reactor is heated in the Interheater prior to entering the next reactor to
maintain the inlet reaction temperature. The reactor feed flows readily through the catalyst
bed. A small portion of hydrogen-rich recycle gas enters the stacked reactors at the bottom

Page 11 of 271
after being heated in the reactor purge exchanger by a portion of the reactor effluent
stream. This gas stream is to purge the hydrocarbon from the spent catalyst before it is
regenerated. A portion of the catalyst is continuously withdrawn from the reactors and is
regenerated in CCR regeneration section. The effluent from the reactor is cooled in the
combined feed exchanger against fresh feed, as outlined above. The combined reactor
effluents are further cooled in the product condenser before flowing to the separator.
Separator Section
In the separator the cooled reactor effluent is separated into a hydrocarbon liquid stream
which goes forward for recontacting and fractionation and a hydrogen-rich gas stream. Part
of the compressed hydrogen-rich gas stream is recycled back to the reactor section and
CCR regeneration section via recycle compressor. The hydrogen-rich off gas is also routed
to the recontacting section and net gas compressor. The gas is cooled in the net gas cooler
and passes into the first stage suction drum of the recontacting section.
Recontacting Section
The gas stream is routed to the net gas recontact section which comprises of two stage
compression and knock-out arrangement. In the net gas recontact section almost all of the
remaining reformate and LPG are removed from the gas stream. This result in a higher
purity net gas stream and an increase in reformate and LPG yield. The net gas from the
separator which is routed to the Recontacting section is cooled in the First stage suction
cooler, First stage discharge cooler, Recontact cooler, Second stage discharge cooler,
Recontact cooler, Chiller economiser and Chiller. The cooled net gas from the First stage
discharge cooler is remixed with the hydrocarbon liquid from the recontact drum. This
stream enters the Second stage suction drum. The gas is separated from the liquid and
leaves the top of the vessel. The recontact of the gas (after cooling in Second stage
discharge cooler, Recontact cooler, Chiller economiser and Chiller) with the liquid
hydrocarbon from separator at higher pressure in Recontact drum results in a purer net gas
stream and more liquid for the fractionation section. The hydrogen rich gas from Second
stage suction drum is cooled and separated in the Recontact drum. The net gas is finally
routed through the net gas chloride treaters for chloride removal. The pure hydrogen gas is

Page 12 of 271
then used for various purposes in the downstream namely 1. as a make up gas to product
condenser at naphtha hydrotreating unit 2. Fuel gas header 3. To PSA unit 4. To
isomerisation /FCC / NHT unit.
Stabiliser Section
The stabilizer section serves to remove the light ends (C4-) from the reformate. The liquid
streams from the Recontacting section are heated in the stabiliser feed bottom exchanger.
The heated material is then used as a feed to stabilizer. The stabilizer is reboiled by steam
heated stabiliser reboiler. The overhead vapor product is cooled in the stabilizer condenser
and collected in the stabiliser receiver. The off gas from the debutaniser receiver is recycled
back to the First stage suction drum. The stabiliser overhead pump returns part of the
overhead liquid to the column as reflux, ant the remaining stream is fed to the Deethaniser
through the LPG chloride treaters. The bottom product of the deethanizer is stabilized LPG
and is sent to OSBL for storage purpose and Sweet fuel gas is sent to the header from
Deethaniser receiver.
1.3 PROCESS CHEMISTRY
The following is a discussion of both naphtha and catalyst chemistry involved in the
Platforming process. The subjects of naphtha chemistry and catalyst chemistry have been
segregated as much as possible to make the discussion easy to follow. However, the two
subjects are necessarily and inherently interrelated and some overlap of subject material
has been presented with the assumption that the reader is familiar with basic organic
chemistry and the concept of thermodynamic equilibrium. For better understanding process
principles are also illustrated in figures. All figures as referred in this section are attached
after the section. The organization of process chemistry is outlined below:
1.3.1 PLATFORMING HYDROCARBON CHEMISTRY
1. Composition of Feed and Product

2. Platforming Reactions
3. Relative Reaction Rates

Page 13 of 271
4. Heats of Reaction
5. Equilibrium Considerations
6. Effects of Pressure and Temperature on Reaction Selectivity
7. Reactor Hydrocarbon Conversion Profiles
1.3.2 PLATFORMING CATALYST CHEMISTRY
1. Dual Function Catalyst Sites

2. Pressure Effects
3. UOP Platforming Catalysts
1.3.1 Platforming Hydrocarbon Chemistry

1. Composition of Platforming Feed and Product
Feed naphtha to a Platforming unit typically contains C6 through C11 paraffin, naphthenes,
and aromatics. The purpose of the Platforming process is to produce aromatics from the
naphthenes and paraffins, either for use as a motor fuel (because of their very high octane
ratings) or a source of specific aromatic compounds. In motor fuel applications the feed
naphtha generally contains the whole range of C6 through C11 hydrocarbons, essentially
maximizing the amount of gasoline produced from the crude run. In aromatics applications,
the feed naphtha generally contains a more select range of hydrocarbons (C6; C6-C7; C6-C8;
C7-C8) which serve as the source of the desired aromatic product. For either application the
basic naphtha chemistry is identical. However, aromatics processing, in most cases,
emphasize C6 and C7 hydrocarbon reactions which are slower and more difficult to promote.
Naphthas from various crude sources vary greatly in their “ease of reforming”. This “ease
of reforming” is primarily determined by the amount of the various hydrocarbon types
(paraffins, naphthenes, aromatics) contained in the naphtha. Aromatic hydrocarbons pass
through the Platforming Unit essentially unchanged. Most naphthenes react rapidly and
efficiently to aromatics. This is the basic reaction of Platforming. Paraffins are the most
difficult compounds to convert. In most low severity applications, there is only a small
amount of paraffin conversion to aromatics. In high severity applications, paraffin
conversion is higher, but still slow and inefficient.

Page 14 of 271
Figure-1 indicates the hydrocarbon conversion that must take place in a typical Platforming
operation on “lean” naphtha (high paraffin, low naphthene content) and on “rich” naphtha
(lower Paraffin, higher naphthene content). For the richer feed, less paraffin conversion will
be necessary, making the operation much easier and more efficient.
To provide a better understanding of Platforming hydrocarbon chemistry, the next sections

will detail the types of individual reactions, relative reaction rates, heats of reaction,
equilibrium constraints, and pressure and temperature effects involved in these overall
hydrocarbon conversions.
2. Platforming Reactions
The following reactions take place in the Platforming process to an extent dependent on the
severity of the operation, the quality of the feed, and the catalyst type.
a. Dehydrogenation of Naphthenes
The final step in the formation of an aromatic from a naphthene (either a cyclohexane or a
cyclopentane) is the dehydrogenation of a cyclohexane (see Figure-2). The reaction of a
cyclohexane to the corresponding aromatic is extremely rapid and essentially quantitative.
Naphthenes are obviously the most desirable feed components because the
dehydrogenation reaction is easy to promote and produces by-product hydrogen as well as
the aromatic hydrocarbons. This reaction is very endothermic. It is promoted by a metal
catalyst function and is favoured by high reaction temperature and low pressure.
The discussion of catalyst acid and metal functions is contained in the Catalyst Chemistry
section. It is now important to only note which reactions are catalyzed by the acid function
and which ones are catalyzed by the metal function.
b. Isomerization of Naphthenes and Paraffins

(1) The Isomerization of a cyclopentane to a cyclohexane, shown in Figure -3, must
occur as the first step in converting the cyclopentane to an aromatic. This Isomerization
involves ring rearrangement and the probability for ring opening to form paraffin is quite

Page 15 of 271
high. Therefore, the reaction of alkylcyclopentanes to cyclohexanes is not 100% selective.

The reaction is strongly dependent on the processing conditions.
(2) Paraffin Isomerisation, shown in Figure-4, occurs readily in commercial Platforming

operations but at typical operating temperatures the thermodynamic equilibrium is not
strongly in favour of the more desirable (higher octane) branches isomers. In motor fuel
applications this reaction does made a contribution to octane improvement of the naphtha.
Isomerisation reactions result from carbonium ion intermediate reactions. These reactions
are promoted by the acid function and are only slightly dependent on operating pressure.
c. De-hydrocyclization of Paraffins
De-hydrocyclization of paraffins, shown in Figure-5, is the most difficult Platforming reaction
to promote. It consists of a very difficult molecular rearrangement from paraffin to a
naphthene, in the case of light paraffins, equilibrium considerations limit this reaction.
The paraffin cyclization step becomes easier as the molecular weight of the paraffin
increases, because of the increased statistical probability for the formation of the
naphthene. Somewhat counteracting this effect is the increased probability of the heavier
paraffins to hydrocrack. De-hydrocyclization is favoured by low pressure and high
temperature. Both metal and acid catalyst functions are needed to promote this reaction.
d. Hydro cracking
Because of the strained ring Isomerisation and ring formation reactions that the feed
alkylcyclopentanes and paraffins must undergo, and because the catalyst needs to have an
acid function, the possibility for acid-promoted hydro cracking, depicted in Figure-6, is
strong. Paraffins hydrocracking is relatively rapid and is favoured by high pressure and high
temperature. The disappearance of paraffins from the gasoline boiling range via
hydrocracking does concentrate aromatics in the product and hence contributes to octane
improvement. The reaction does, however, consume hydrogen and result in lower reformat
yield.

Page 16 of 271
e. De-methylation
De-methylation reactions, shown in Figure-7, generally occur only in very severe
Platforming operations (high temperature and high pressure). Under certain conditions it
may occur during the start-up of a semi-regenerative Platforming Unit following catalyst
replacement or regeneration. The reaction is metal catalyzed and is favoured by high
temperature and pressure. It can be inhibited by attenuation of the catalyst metal function
by addition of sulfur or a second metal (as in some bimetallic catalysts).
f. De-alkylation of Aromatics
The de-alkylation of aromatics, shown in Figure-8, is similar to aromatic de-methylation,
differing only in the size of the fragment removed from the ring. If the alkyl side chain is
large enough, this reaction can be visualized as acid catalyzed carbonium ion cracking of
the side chain. The de-alkylation reaction is also favoured by high temperature and high
pressure.
Table-1 summarizes the conditions that promote the reactions that take place in the
Platforming process.
TABLE-1
PLATFORMING REACTIONS
Reaction Promoted By
Catalyst Temperature Pressure
Naphthene M High Low
Dehydrogenation
Naphthene Isomerization A Low* ---
Paraffin Isomerization A Low* ---
Paraffin M/A High Low
Dehydrocyclization
Hydro cracking A High High
Demethylation M High High
Aromatic Dealkylation M/A High High
* Low temperatures favour higher iso/normal ratios; rate of Isomerisation increases with increasing temperature.

Page 17 of 271
Because of the wide range of paraffins and naphthenes included in the Platforming unit
feed, and because the reaction rates vary considerably with the carbon number of the
reactant, these reactions occur in series and in parallel to each other forming the rather
complicated overall reaction scheme indicated in Figure-9
3. Relative Reaction Rates

In experimental pure component work, individual hydrocarbons were reformed in a pilot
plant unit. Compounds studied were normal hexane, methyl cyclopentane and cyclohexane
in the C6 hydrocarbon group, and normal heptane, methyl cyclohexane and dimethyl-
cyclopentane in the C7 group. Operating pressure was varied between 5 and 21 kg/cm² (70
and 300 psig) and reaction temperature was varied between 450 and 550°C. Hydrogen to
hydrocarbon mole ratios were nominally 5 to 7, using recycle hydrogen. Most tests were of
short duration and were designed to establish relative rates of reaction and the effect of
operating conditions on selectivity to aromatics.
Data from runs with pure components, made at lower conversion, were used to estimate the
relative reaction rates for the various C6 and C7 hydrocarbon types investigated. Adsorption
effects, catalyst deactivation, and other factors would alter the relative rates in a blend of
compounds or in commercial naphtha feed, but this analysis provides valuable insight into
the basic Platforming kinetic mechanism. The results of the kinetic analysis are
summarized in Table-2. The reaction rates are reported relative to the rate of de-
hydrocyclization of normal hexane.
TABLE-2
RELATIVE REACTION RATES
C6 AND C7 HYDROCARBONS
Hydrocarbon Type Paraffin Alkylcyclopentanes Alkylcyclohexanes
Carbon No. C6 C7 C6 C7 C6 C7
Reaction class Relative reaction rate*
Isomerization
Paraffin 10 13 - - - -
Naphthene - - 10 13 - -
Dehydrocyclization 1.0 4.0 - - - -

Page 18 of 271
Hydrocarbon Type Paraffin Alkylcyclopentanes Alkylcyclohexanes

Hydrocracking 3.0 4.0 - - - -
Decyclization (ring opening) - - 5 3 - -
Dehydrogenation - - - - 100 100
* Data determined from initial rates for pure components and mixtures of pure components. All rates relative to rate of de-
hydrocyclization of normal hexane.
The primary reactions for the C6 and C7 paraffins proceed at significantly different rates.
The rate of de-hydrocyclization for hexane is one-third that of hydro cracking so the fraction
of the normal hexane converted to benzene is relatively low. Normal heptane hydrocracks
at about the same rate as normal hexane so the faster rate of de-hydrocyclization (about
four times that of hexane) leads to significantly greater fractional conversion to aromatics for
normal heptane in comparison to hexane. Both paraffins are isomerised rapidly to the
various possible isomers.
Reactions of the naphthenes show marked differences between the alkylcyclopentanes and
alkylcyclohexanes. Cyclohexane types dehydrogenate very rapidly and completely to
aromatics. The cyclopentanes react at a much slower rate and undergo both Isomerisation
to form the corresponding cyclohexanes and ring opening to form paraffins.
The ratio of the rate of Isomerisation to the total rate of reaction (Isomerisation plus ring
opening) is an indication of the expected selectivity to aromatics for the alkylcyclopentanes.
This ratio is 0.67 for the methyl cyclopentane and 0.81 for dimethylcyclopentane. The ease
of Isomerization increases with carbon number and the C8+ alkylcyclopentanes have
relatively high selectivity’s to aromatics.
The paraffins show the lowest reactivity and poorest selectivity for aromatic formation. The
alkylcyclopentanes, while more reactive and selective than paraffins, still provide less than
quantitative yields of aromatics. The alkylcyclohexanes are converted very rapidly and
quantitatively to aromatics.

Page 19 of 271
4. Heats of Reaction
Generalized heats of reaction for the reactions of paraffin to naphthene, naphthene to
aromatic, and paraffin hydro cracking are shown in Table-3.
TABLE-3
TYPICAL HEATS OF REACTION
Reaction ∆H (Kcal/Mol H2)
Paraffin Naphthene + 10.5
Endothermic
Naphthene Aromatic + 16.9
Hydro cracking - 13.5 Exothermic
De-hydrocyclization of paraffins and dehydrogenation of naphthenes are both very

endothermic as manifested commercially by the large temperature decreases across the
first two Platforming reactors. Generally, the last reactor is promoting a combination of
paraffin de-hydrocyclization and hydro cracking reactions and the total kinetics in this
reactor may be either endothermic or exothermic depending on processing conditions, feed
characteristics, and catalyst.
5. Equilibrium Considerations
Most modern motor fuel Platforming Units operate at conditions such that the degree of
conversion of the major components in the feed is not limited by equilibrium. However, BTX
naphtha feeds contain high concentrations of light hydrocarbons, and for these feeds, the
level of conversion is affected by equilibrium. The least reactive and most strongly
influenced by thermodynamic factors are the six-carbon-number hydrocarbons. The effect
of temperature and hydrogen partial pressure on equilibrium conversion will be examined
for this system. A similar analysis would apply for seven and eight-carbon-number
hydrocarbon systems, but the degree of thermodynamic limitation would be much lower.

Page 20 of 271
The technique used to calculate equilibrium ratios for the various reactions is illustrated by
the following example. Consider the reactor of normal hexane undergoing de-
hydrocyclization to form methyl cyclopentane.
k1
nC6 MCP + H2
k2
Where k1, k2 are the forward and reverse reaction constants, respectively.
At equilibrium, the following equation is valid

K1 (PMCP) (PH2)
Kp = =
K2 (PnC6)
where Kp is the equilibrium constant and P is the partial pressure of the component. The
larger the value of Kp, the more favourable is the reaction.
The equilibrium ratio for this reaction then becomes
(PMCP) = Kp
(PnC6) (PH2)
Values of Kp can be calculated from the thermodynamic properties of the reactants and
products and then the extent of equilibrium limitation established.
Figure-10 shows the effect of temperature and hydrogen partial pressure on the equilibrium
ratio for the conversion of normal hexane to methyl cyclopentane (MCP). It can be seen
that, in general, the equilibrium ratio is low, but improves rapidly as temperature is
increased and hydrogen partial pressure increased. It must be noted that the level of MCP
in the reactor must be reduced below the equilibrium value before there will be any net
conversion of hexane to cyclic materials. Since the rate of hydro cracking is inhibited by
lower hydrogen pressures, the selectivity of the hexane to aromatics is greatly enhanced by
low pressure, high temperature operations.
The Isomerization of methyl cyclopentane to cyclohexane does not involve hydrogen as a

product or reactant, therefore the equilibrium ratio is a function of temperature only. The
effect of temperature on the equilibrium ratio of cyclohexane to methyl cyclopentane is

Page 21 of 271
illustrated in Figure-11. The equilibrium ratio is quite low over the normal Platforming
temperature region and decreases slightly as temperature is increased. This low equilibrium
ratio inhibits conversion of methyl cyclopentane to cyclohexane because the cyclohexane
concentration must be reduced to very low levels before the forward methyl cyclopentane
reaction can proceed. The complexity of the ring Isomerization reaction and the
unfavourable thermodynamics combine to reduce the selectivity of methyl cyclopentane to
benzene substantially below 100%.
The dehydrogenation of cyclohexane to form benzene is the most rapid and simplest of the
Platforming reactions. The effects of temperature and hydrogen partial pressure on the
equilibrium ratio for this reaction are illustrated in Figure-12. The formation of benzene is
highly favoured over the entire range of typical Platforming operating conditions. Thus, this
reaction is essentially irreversible and thermodynamic factors have little effect on selectivity.
6. Effects of Pressure and Temperature on Reaction Selectivity

As an extension of the pure component equilibrium pilot plant studies, the effects of
pressure and temperature on the selectivity of aromatics for normal hexane, methyl
cyclopentane, and normal heptane were investigated in detail. These hydrocarbons have
low selectivity, and thus optimization of operating conditions to maximize the selectivity is
the key to improved yields of aromatics.
The effect of operating conditions on normal hexane selectivity to benzene is illustrated in
FigureI-13. Here the selectivity to benzene is defined as the mole ratio of hexane converted
to benzene divided by the total moles of hexane converted (conversion was based on
disappearance of total hexane so that iso-hexanes in the product were treated as
unconverted normal hexane). This is, in essence, the extent to which the de-
hydrocyclization of hexane is occurring. As shown in Figure-13, normal hexane selectivity to
benzene increases with temperature at each pressure. This is due to equilibrium shifting in
favour of de-hydrocyclization with increasing temperature. Selectivity improvement with
decreasing pressure is due to the combined effects of improved equilibrium ratio and a
suppression of the rate of hydro cracking.

Page 22 of 271
At a reactor temperature of 538°C, decreasing the plant pressure from 14 kg/cm² to 9kg/cm²
increases the selectivity of normal hexane to benzene by 33% while a further decrease to
5kg/cm² yields a 70% improvement over the selectivity at 14kg/cm². Benzene yields from
hexane precursors will be greatly enhanced by operating at high temperature and low
pressures. At these conditions, however, the rate of coke formation is very high, and
catalyst stability becomes a primary concern.
The effect of process conditions on the methyl cyclopentane selectivity to benzene is

illustrated in Figure-14. Methyl cyclopentane shows the same trend of improved selectivity
with increased temperature and reduced pressure as noted for normal hexane. At
comparable conditions, however, the methyl cyclopentane selectivity (about 70%) was
obtained at 7 kg/cm² pressure and 538°C reactor temperature. Increasing the pressure to
one that many fixed bed BTX Platforming units operate at today, 21 kg/cm² lowered the
selectivity to about 50%. Thus a 40% improvement in methyl cyclopentane selectivity to
benzene is obtained by operating at the lower pressure.
Figure-15 summarizes the results obtained when normal heptane was processed at various
conditions. Heptane selectivity to toluene follows a pattern similar to that found for normal
hexane to benzene. Again, the improvement in selectivity as temperature is increased and
pressure decreased is due to the combined effects of improved equilibrium ratio and a
suppression of the rate of hydro cracking. For example, at a reactor temperature of 538°F
pressure from 21 kg/cm² to 14 kg/cm² increased heptane selectivity to toluene by 30%
while a further reduction to 7 kg/cm² pressure provided a selectivity 60% greater than that a
21 kg/cm² pressure. Heptane selectivity to toluene is two to three times higher than hexane
selectivity to benzene at identical operating conditions.
The preceding pure component work indicates that the processing conditions utilized can
greatly affect the selectivity to aromatics for the C6-C7 paraffins. Specifically, more
aromatics are produced at low pressure, high temperature conditions. Note, however, that
the catalyst stability becomes a constraint as moves are made toward conditions favouring
increased aromatics production.

Page 23 of 271
7. Reactor Profiles: Commercial Platforming Data

Having considered the relative rates of the various Platforming reactions, equilibrium
constraints, and heats of reaction, the overall Platforming process can now be examined.
Consider a low pressure, motor fuel operation from the aspects of hydrocarbon
concentration, product quality, and temperature profiles as the reactants pass through the
reactor system.
The following data were obtained from a commercial, four reactor Platforming Unit. Feed,
product and inter-reactor samples were taken in such a manner as to follow hydrocarbon
conversion and product quality through the reactors. The profiles from this unit vividly
demonstrate the practical aspects of the hydrocarbon chemistry discussed above.
Figure-16 shows hydrocarbon types yield, expressed as moles of the particular

hydrocarbon type per 100 moles of feed, across the reactor system. The lines at 0.1, 0.25,
0.50 and 1.0 fraction of total catalyst indicate individual reactor boundaries and points of
sampling. Note that in this particular operation, aromatic formation is 22, 10, 5.5, and 5.5
moles per 100 moles of feed respectively in reactors 1, 2, 3, and 4. Because of their rapid
reaction rate, 95 percent of the feed cyclohexanes disappear in the first reactor. Slower to
react, the cyclopentanes disappear at rates of 4.5, 4.0, 1.0, and 0.5 moles per 100 moles of
feed through reactors 1 through 4. Paraffin disappearance on an absolute molar level in
comparable to cyclopentane conversion (4.0, 4.0, 7.0, and 6.5 moles per 100 moles of feed)
but on the basis of percent converted per mole of specific hydrocarbon feed, the paraffin
conversion is much lower.
Table-4 quantifies the conversion of each hydrocarbon type based on the amount of that
hydrocarbon in the Platforming Unit feed.

Page 24 of 271
TABLE-4
PARAFFIN AND NAPHTHENE CONVERSION PER REACTOR
Reactor No. 1 2 3 4 Total Conversion
Conversion of Feed Conversion of feed, percent
Hydrocarbon Type
Cyclohexanes 95 3 0* 1* 99
Cyclopentanes 39 35 9 4 87
Paraffins 7 7 13 12 39
* Concentration Too Low To Accurately measure.
Figure-16 and Table-4 demonstrate the rapid quantitative conversion of cyclohexanes, the
slower conversion of cyclopentane, and the very slow paraffin conversion. Note that
Isomerization is not included in paraffin conversion.
Figure-17 demonstrates the effect of cyclopentane carbon number upon the rate of
conversion. In reactor one there is generally either no change at all, or actually an increase,
in the absolute amount of methyl cyclopentane. Such an increase could result from
cyclohexane Isomerization but is generally only observed in low severity units. Figure-17
shows the more rapid conversion of the heavier cyclopentanes; C9 and heavier
cyclopentanes are essentially completely converted in the first to reactors. C8, C7 and C6
cyclopentanes react progressively slower.
Figure-18 shows the paraffin content of the reactant stream (moles of paraffin per 100
moles of feed) across the reactor system. It is interesting to note that in the first two
reactors there is an increase in the absolute amount of C6 and C7 paraffins present. This is
due to cracking of the heavy paraffins (note the rapid disappearance of C9 through C11
paraffins results from increased ease of ring formation, de-hydrocyclization, and increased
rate of hydro cracking.
Figure-19 shows increasing Isomerization in the C6 through C8 paraffin fraction across the
reactors. These iso/normal ratios approach but do not reach equilibrium values.
Isomerization plays a role in octane upgrading of the remaining paraffin fraction.

Page 25 of 271
One of the more interesting aspects of these results is demonstrated in Figure-20. This
figure shows aromatic content by carbon number (again in moles of aromatic per 100 moles
of feed) across the reactors. The absolute amount of an individual aromatic formed, of
course, depends on the amount of precursors in the feed. However, the rates at which the
aromatics form are indicative of the kinetics of the aromatic-forming reactions. C10 and C11
aromatics are all formed in reactors one and two; there is no net formation of these
aromatics in the last two reactors. Figure-18 does indicate conversion of C10 and C11
paraffins in reactors three and four and it is felt that some of the converted paraffins are de-
hydrocyclizing, but that an offsetting amount of de-alkylation to lighter aromatics is
occurring.
C7 through C9 aromatics continue to be produced throughout the reactor system. Inspection

of the previous figures show that very little C7 - C9 aromatic production in reactors three and
four can be attributed to naphthene conversion, because most of these naphthene
precursors are converted in reactors one and two. This aromatic production must then be
attributed to naphthene conversion, because most of these naphthene precursors are
converted in reactors one and two. This aromatic production must then be attributed to
paraffin de-hydrocyclization and de-alkylation of heavier aromatics. Finally, very little net
benzene production occurs in reactor three and none occurs in reactor four. This is the
result of rapid cyclohexane conversion in reactors one and two, slower methyl cyclopentane
conversion in reactors two and three, and minimal hexane conversion. Hexane conversion
at these moderate severity conditions was low, as expected. More severe processing
conditions (lower pressure) are employed in modern BTX Platforming Unit designs to
increase conversion of hexane to benzene.
Figure-21 shows octane increase across the reactors. Predictably, the octane rating
increases more rapidly in the first reactors, a result of the extensive naphthene conversion.
Octane upgrading in the last reactors results from the slower Isomerization, hydro cracking,
and de-hydrocyclization.

Page 26 of 271
Finally, Figure-22 shows the reactor temperature profiles. The inlet and outlet temperatures
can be measured commercially; the shape of the profile was determined by a Plat-forming
kinetic model.
1.3.2 Catalyst Chemistry
1. Dual Function Platforming Catalyst Chemistry

Examination of the reactions listed in Table-1 and Figure-9 shows that some of them are
acid-catalyzed while others are promoted by a metallic hydrogenation-dehydrogenation
catalyst function. As such it is necessary that a Platforming catalyst have a proper balance
between the metal and the acid function as shown in Figure-23. This is important to
minimize hydro cracking while maximizing the dehydrogenation and de-hydrocyclization
reactions. This balance is maintained by proper H2O/Cl control during a semi-regeneration
catalyst cycle and proper regeneration technique.
The importance of water/chloride control can be illustrated by imagining the catalyst surface
as a ball and stick model with aluminium and oxygen and oxygen atoms in a regular pattern
upon which hydrogen and hydroxyl groups are randomly arrayed. The vapour phase HCl
and H2O are in equilibrium with the surface hydroxyl groups and chloride. Too much water
in the vapour phase will force chlorides from the surface leading to an underchlorided
catalyst. While too much chloride in the vapour phase has the reverse effect. Therefore,
proper control of water/chloride ratios is crucial in maintaining an active acid site.
On the other hand, the metal sites (and of course the acid site) are affected most
dramatically during catalyst regeneration. Using the ball and stick model, one can imagine a
platinum-chloride species somehow attached to the surface (i.e. through an oxygen or
aluminium atom). No one is quite sure of the anchoring mechanism but the presence of
chlorides in an oxidizing atmosphere is instrumental in re-dispersing the platinum on the
surface. Temperature also affects mobility of platinum and retention of chloride.
The classical picture of a dual function catalyst involves two separate and distinct sites with
the reacting molecule migrating from one site to another. Current thinking leans toward a

Page 27 of 271
modified picture in which a single site or single complex is responsible for the entire
reaction sequence. It should be pointed out that presently it is only a concept and is not
supported by unequivocal evidence. It is known that the method of catalyst preparation
affects the activity to at least the same extent as the absolute level of active ingredients,
indicating that a specific arrangement is critical. In addition, since the rates of the reactions
over a modern Platforming catalyst are high, one must question the mass transfer
limitations that would be involved in migration between separate sites.
The concept of a single complex site does not affect the innate dual-functional nature of a
Platforming catalyst. The surface must still possess both acidic and metallic characters. The
acidic character is mainly responsible for the formation of carbonium ions by either
extraction of hydride ions or addition of protons to double bonds. Carbonium ions are, in
turn, the intermediates in such reactions as isomerisation and hydro cracking. The metal
function is responsible for the extraction of hydrogen from hydrocarbons, the splitting of
hydrogen molecules and subsequent addition of hydrogen atoms to unsaturated species.
Combination of these two functions into a single complex site allows these reactions to
occur in a concerted fashion.
2. Effects of Pressure on Catalyst Design

For special purposes, the acidity of a Platforming catalyst can be increased. The best
example of this is the R-15 LPG Platforming system, where the target is the production of
propane and butane. This was accomplished by adding another acidic component to a
Platforming catalyst. Figure-25 illustrates the effect of such increased acidity on product
distribution in the case of a relatively mild processing of mid-continent naphtha.
If this same catalyst system is now operated at a lower pressure, there is a dramatic shift in
product yields because the acidity or cracking nature of the catalyst is significantly reduced.
Figure-26 illustrates the effect of lowering pressure on the performance of an R-15 catalyst.
At 7kg/cm² , R-15 behaves very nearly like a standard Platforming catalyst.

Page 28 of 271
The pressure effect translates to standard Platforming catalysts where lowering reactor
pressure reduces cracking tendencies and increases selectivities of naphthenes and
paraffins to aromatics (as previously discussed).
Figure-27 illustrates the relationship between pressure and yield of light hydrocarbons for a
given Platforming system. As the pressure is decreased, there is an increase in C5+ yield
and hydrogen with a subsequent decrease in light gases.
The source of light hydrocarbons is the cracking of paraffins. The yield of aromatics from
paraffins can increase by as much as 40% as the pressure is decreased from 35 to11
kg/cm². Figure-28 shows that this is the result of a substantial decrease in hydrocracking
and an associated improvement in the selectivity of these paraffins to aromatics.
With the increase in C5+ yield due to lowering reactor pressure, there is an increase in the
octane-barrel yield with the optimum occurring at higher octane severities*. Figure 29
illustrates that for a constant feedstock lowering reactor pressure from 21kg/cm² to 7kg/cm²
the optimum octane for maximum octane barrel shifts from around 96 RONC** to about 99
RONC. Likewise in Figure II-30, if pressure is held constant, as the feed N+2A content
increases, the optimum RONC for maximum octane barrel increases.
* Octane barrel yield is defined as C5+ volume yield (barrels) time C5+RONC.
** Research Octane Number Clear
3. UOP Platforming Catalysts

The type of information presented above on the relationship between pressure and yield
encouraged UOP of focus attention on low pressure Platforming some time ago. The yield
advantages in that region are obvious, but the problem is catalyst stability.
Figure-31 illustrates the effect of increased octane and decreased pressure on catalyst
stability. Taking advantage of the optimum octane for maximum octane barrel from Figure-
29 would result in a six fold deactivation rate.

Page 29 of 271
To achieve this objective, UOP is continually striving to develop more stable (and higher
yield) catalysts. The addition of rhenium to monometallic catalysts achieved a 4-6 fold
increase in stability (R-16 series) and an activity improvement. The R-20 series catalyst
followed shortly and demonstrated, for the first time, improved initial selectivity over all-
platinum catalysts. The R-20 catalysts also showed greatly improved stability characteristics
when compared to all-platinum, although they were not as stable as R-16 series catalysts.
R-30 series catalysts proved to be a further refinement of the high yield R-20 series
catalysts. R-30 series catalysts showed initial selectivity identical to that of R-20 series
catalysts, but also showed the benefits of improved activity and stability over R-16 and R-20
series catalysts at low pressure processing conditions. As a result, R-30 series catalysts
are used exclusively in UOP Continuous Platforming Units.
The R-50 catalyst gave a 1.7-2.0 X stability increase over the R-16 series catalyst with an
activity improvement while maintaining equivalent yields. The R-60 series catalysts further
improved upon stability above that of R-50 while maintaining equivalent activity and yields.
Figure-32 compares the UOP semi-regenerative catalysts to one another with all-platinum
catalysts as a reference point.
It should be pointed out that the bimetallic catalysts, because of their more precisely
controlled metal and acid functions, are much more sensitive to feedstock sulfur and water
levels. Many of the problems associated with bimetallic Platforming operations, especially
in older units, can be traced to excessive amounts of sulfur and water in the unit. These
contaminant problems are discussed in detail elsewhere.
The information presented in this section has been taken from other UOP Technical
Papers. The Platforming groups of the Research, Technical Service, and Process
Development Departments are responsible for most of the theories and data included
in this presentation. The information has been edited and presented with refinery
operation personnel in mind.

Page 30 of 271
FIGURE 1
HYDROCARBON TYPE VOLUME CONVERSION IN PLATFORMING
FIGURE-2
NAPTHENE DEHYDROGENATION

Page 31 of 271
FIGURE-3
NAPHTHENE ISOMERIZATION
FIGURE-4
PARAFFIN ISOMERIZATION
FIGURE-5
PARAFFIN DEHYDROCYCLIZATION

Page 32 of 271
FIGURE-6
HYDROCRACKING
FIGURE-7
DEMETHYLATION
FIGURE-8
AROMATIC DEALKYLATION

Page 33 of 271
FIGURE-9
GENERALIZED PLATFORMING REACTION SCHEME
FIGURE-10
NORMAL- HEXANE / METHYLCYCLOPENTANE EQUILIBRIUM

Page 34 of 271
FIGURE-11
CYCLOHEXANE / METHYLCYCLOPENTANE EQUILIBRIUM
FIGURE-12
CYCLOHEXANE / BENZENE EQUILIBRIUM

Page 35 of 271
FIGURE-13
SELECTIVITY OF NORMAL HEXANE TO BENZENE
FIGURE-14
SELECTIVITY OF METHYLCYCLOPENTANE TO BENZENE

Page 36 of 271
FIGURE-15
SELECTIVITY OF NORMAL HEPTANE TO TOLUENE
FIGURE-16
HYDROCARBON TYPES CONVERSION
REACTOR PROFILE

Page 37 of 271
FIGURE-17
CYCLOPENTANE CONVERSION REACTOR PROFILE
FIGURE-18
PARFFIN CONVERSION REACTOR PROFILE

Page 38 of 271
FIGURE-19
PARAFFIN ISOMERIZATION REACTOR PROFILE
FIGURE-20
AROMATIC FORMATION REACTOR PROFILE

Page 39 of 271
FIGURE-21
C5+ RESEARCH OCTANE RATING REACTOR PROFILE
FIGURE-22
TEMPERATURE REACTOR PROFILE

Page 40 of 271
FIGURE-23
PROPERLY BALANCED CATALYST
FIGURE-24
ACID SITE

Page 41 of 271

Page 42 of 271
FIGURE-27
EFFECT OF PRESSURE ON YIELD STRUCTURE
FIGURE-28
EFFECT OF PRESSURE ON PARAFFIN CONVERSION

Page 43 of 271
FIGURE-29
OCTANE-BARREL YIELD RESPONSE TO OCTANE AND PRESSURE
FIGURE-30
OCTANE-BARREL YIELD RESPONSE TO OCTANE AND FEED COMPOSITION

Page 44 of 271
FIGURE-31
EFFECT OF OCTANE AND OPEARTING PRESSURE ON CATALYST DEACTIVATION

Page 45 of 271

Page 46 of 271
SECTION-2
DESIGN BASIS
2.1 INTRODUCTION
The CCR Platforming unit is used to produce reformate from hydrotreated naphtha by
combination of reforming and fractionation processes.
For design basis of CCR Platforming Unit refer UOP document “Engineering Design
Information”. Important content of design basis is given below.
2.2 UNIT CAPACITY

The CCR Unit is designed for a capacity of 769632 metric tons per annum of Hydrotreated
and stripped naphtha from the Naphtha hydrotreating unit. The CCR unit produces 103.0
C5+ RONC reformate for motor spirit (“MS”) blending and a high purity hydrogen product.
Stabilized LPG is produced as a valuable by-product.
The CCR unit is designed with a 680 kg/hr catalyst circulation CycleMax CCR Regeneration
section to provide continuous catalyst regeneration.
2.3 ON-STREAM FACTOR

The facility is designed for 8000 operating hours per year.
2.4 TURNDOWN CAPABILITY

The facility is capable of operating at 40 percent of design feed capacity, while maintaining
the designated product specification.
2.5 FEED AND PRODUCT CHARACTERISTICS
2.5.1 Feed Characteristics

Hydrocarbon feed stream properties are provided below. This hydrocarbon stream is fed to
the NHT unit. Hydrotreated naphtha Product from NHT unit is then fed to the CCR unit as
feed. The CCR unit process 769632 MTA of hydrotreated and stripped naphtha from the

Page 47 of 271
NHT unit. The CCR unit produces 103.0 C5+ RONC reformate which is stored in storage
and a high purity hydrogen product. Stabilized LPG is produced as a by-product.
The CCR unit is designed with a 680 kg/hr catalyst circulation Cyclemax CCR Regeneration
section to provide continuous catalyst regeneration.
Table 3.1: Hydrocarbon Feed Stream Properties
Case Feed-1 Feed-2

NIT Feed (KMOL/HR) BH Feed (KMOL/HR)
NC6 0.200 0.096

MCP 0.230 0.330
CH 6.710 6.460
Benzene 0.290 0.830
22 DMP 0.530 0.083
24DMP 0.780 0.250
223MB 0.000 0.170
33DMP 1.520 1.440
23DMP 11.100 9.390
2MH 29.620 26.130
3MH 41.910 33.430
3EP 4.520 3.340
NC7 113.770 57.810
DMCP 19.710 36.450
MCH 80.750 79.680
ECP 26.490 38.370
TOULENE 51.790 179.280
IC8 75.160 73.220
NC8 55.520 49.760
C3CP 32.990 63.010
C2CH 48.150 65.350
EBZ 7.310 12.540
p-XYLENE 7.370 11.960
m-XYLENE 19.180 34.910
o-XYLENE 9.660 14.820
IC9 56.280 25.560
NC9 56.220 17.480
C4CP 24.800 11.930
C3CH 24.580 12.170
IPBZ 0.740 1.320
NPBZ 1.210 1.320

Page 48 of 271
1M3EBZ 3.160 1.060

1M4EBZ 1.850 2.460
135MBZ 2.330 2.200
1M2EBZ 1.330 1.440
124MBZ 6.220 6.240
123MBZ 2.120 1.820
INDAN 0.000 0.500
C10 PARA 11.420 1.380
C4CH 3.970 2.550
C5CP 3.870 2.490
C10 AROM 6.330 1.970
C11+PARA 8.520 0.520
C11+NAPH 6.010 0.380
C11+AROM 3.100 0.000
total 869.320 893.899
2.5.2 Product Characteristics
The CCR Unit shall produce a reformate (stabilizer column bottoms) suitable for gasoline
blending and is having a C5+ RONC of 103.0 minimum.
The CCR Unit shall also produce a hydrogen rich net gas stream. The CCR Unit shall also
produce stabilized LPG.
The CCR Unit is designed to meet the following required product properties and conditions:
Product Value
Reformate Octane Number , C5+ RONC 103.0 Min
Reformate Benzene concentration, Vol % 1.0 Max
Reformate C4-, mol% 0.5 Max
Hydrogen Rich Net Gas Hydrogen Purity, mol% 93.0 Min
Hydrogen rich Net Gas Chlorine and Chloride, ppm v 1 Max
LPG Copper strip corrosion (1 hr @ 38 C) No worse than No1a
LPG Chloride, ppm w 1 Max
LPG C5-, mol% 2.5 Max
LPG C2-, wt% 0.5 Max

Page 49 of 271
Processing Conditions:
The design of the CCR Unit is based on the following controlling conditions:
Fresh feed = 19431.8 BPSD (545 KMTA)

RONC = 103.0
LHSV = 2.60 (R-234 catalyst)
Four reactors (21/24/27/28 vol%)
H2/HC molar ratio = 2.60
Separator Pressure = 2.5 kg/cm2g
Reactor Pressure = 3.5 kg/cm2g
Recontact Pressure = 22.5 kg/cm2g
WAIT = 534 oC
CCR Catalyst Circulation Rate = 680 kg/h (1500 lb/h)
2.6 BATTERY LIMIT CONDITIONS OF PROCESS LINES

Condition for all incoming and outgoing process lines shall be as per Table below.
Streams Conditions Source/
(Operating/Design) Destination
Pressure Temperature
Kg/cm2g o
C
Raw material and feed streams
1. SR LN NHT feed 4.5 75 CDU 1,2,3
SR HN NHT feed 4.5 75 CDU 1,2,3
VB Naphtha Feed 4.5 75 Visbreaker
2 Start-up H2 20 45 From storage/

cylinder/ H2
plant surge
4. NHT Wash Water 4 100 Steam

Condensate
Products and by-products
1. Reformate 7.0 40 Storage
2. Plant Net Gas to 22.5 PSA

H2 Header

Page 50 of 271
Streams Conditions Source/
(Operating/Design) Destination
Pressure Temperature
Kg/cm2g o
C
3. Plant Net Gas To 4.5 Fuel Gas

Fuel Gas
4. Deethanizer Off 4.5 Fuel Gas

Gas To Fuel
5. LPG 16 40 Storage
2.7 UTILITY CONDITIONS AT UNIT BATTERY LIMITS / AT TIE IN POINT

(All battery limit pressures are measured at grade)
Mech.
Sr. No. Parameter Minimum Normal Maximum
Design
1 HIGH HIGH PRESSURE STEAM
Pressure, Kg/cm2g 43.5 43.5 43.5 50.5
Temperature, oC 264 264 264 395
2 HIGH PRESSURE (HP) STEAM
Pressure, Kg/cm2g 33 35 38 40
Temperature, oC 340 360 380 400
3 MEDIUM PRESSURE (MP) STEAM
Pressure, Kg/cm2g 9 10 11 12.5
Temperature, oC Sat 250 280 300
4 LOW PRESSURE (LP) STEAM
Pressure, Kg/cm2g 2.5 3 4 5.5
Temperature, oC Sat 150 170 190

Page 51 of 271
Mech.
Design
5 CONDENSATE RETURN
Pressure, Kg/cm2g 5.5

HP, MP
Temperature, oC
Pressure, Kg/cm2g 1.5

LP
Temperature, oC
6 Deareated Treated Boiler Feed Water
Very Pressure, Kg/cm2g 47 50 71

High
Temperature, oC 110 120 155
Pressure
Medium Pressure, Kg/cm2g 17.5 20.5 29
Pressure Temperature, oC 110 120 155
7 CIRCULATING/SEA COOLING WATER
Supply Pressure, Kg/cm2g 5.3 7.6
Return Pressure, Kg/cm2g 3.5
Supply Temperature, oC 33 65
Return Temperature, oC 44
8 PLANT AIR
Temperature, oC ambient
9 INSTRUMENT AIR
Temperature, oC ambient
10 FUEL GAS (SUPPLY CONDITIONS)
Pressure, Kg/cm2g 2.5 3 3.5 9
Temperature, oC 30 30-50 60 100

Page 52 of 271
Mech.
Design
11 REFINERY FUEL OIL
Supply Pressure, Kg/cm²g 7 8 11 17
Return Pressure, Kg/cm²g 2.5
Supply Temperature, oC 160 170 200
12 NITROGEN
Pressure, Kg/cm2g 5 6 7 10.5
Temperature, oC

Page 53 of 271
SECTION-3
PROCESS DESCRIPTION
3.1 CCR PLATFORMING UNIT PROCESS SYSTEM
The CCR Platforming process Unit is designed for a capacity of 769632 metric tons per
annum of Hydrotreated naphtha from Naphtha Hydrotreater unit. The feed to the
Platforming unit must be properly hydrotreated to lower the sulfur and nitrogen contents to
below 0.5 ppm, saturate all olefins and remove metals, halogens and oxygenates. The
entire unit is divided in smaller sections like reaction section, recontact section, fractionation
section and described in details.
Reaction section
Combined Feed Exchanger
Ref P&ID No 930768-120-10 Rev-5
The reactions that take place in the platforming process are mostly endothermic (require
heat input) and must occur at elevated temperatures in a hydrogen atmosphere to obtain
optimum catalyst life and product yields. There are four reactors to the CCR unit and feed to
each reactor needs to be preheated to required temperatures.
The feed preheat section includes the Combined Feed exchanger and Charge heater. Its
function is to raise the temperature of the feed plus recycle hydrogen to reaction
temperatures.
The CFE (Combined Feed Exchanger, 74-E-01) is a vertical shell-and-tube exchanger.

Reactor effluent from the last reactor (74-R-04) enters the exchanger at the top end and
flow downward. The cold fluids enter at the bottom and flow upward.
The cold fluid (feed) is the Stripper Bottoms of Naphtha Hydro treating (NHT) Unit which
along with recycle gas is preheated, in exchange with reactor effluents, in combined feed
exchanger (74-E-01). The feed is then heated to reaction temperature in the Charge Heater

Page 54 of 271
(74-F-01) and sent to Reactor No 1 (74-R-01). Feed naphtha at 10.05 kg/cm2g and flow
96204 kg/hr from NHT Stripper bottom flows to Combined Feed exchanger under flow
control (FIC-1001). Feed naphtha temperature is 910 C and is measured through TI-1002.
Recycle gas flow (23807 kg/hr, temperature 116 deg C and pressure 5.67 kg/cm2g) to
combined feed exchanger is measured through flow indicator FI-1002A/B/C, TI-1005 and
pressure indicator PI-1003 respectively. Combined feed outlet temperature is measured
through TI-1001. Reactor effluent in/out temperatures are measure by TI0904 and TI1003
resp.
The 4th reactor effluent is further cooled in product condenser (74-A-01) so as to recover
hydrogen from the reformates. The reformate is further directed to the separator (74-V-01)
for the separation.
Reactors and Heaters:

Reactor:
Ref P&ID No 930768-120-09 Rev-4
930768-120-05 Rev-2
930768-120-06 Rev-1
930768-120-07 Rev-1
930768-120-08 Rev-1
The reactor section consists of the reactors that hold the Platforming catalyst. In the
reactors, chemical reactions occur in the presence of Platforming catalyst that converts the
Platforming feed into products. The function of the reactors is to optimise catalyst utilization
and produce optimum product yields.
The purpose of the Platforming reactors is to allow the feed to contact the catalyst at
reaction conditions while not allowing the catalyst to leave with the product. The catalyst
from the CCR Regeneration unit enters the top of the reactor, flows down through the
reactor and exits at the bottom.
The reactor design is radial flow. Hydrocarbon enters at the top of the reactor and flows
across the catalyst bed from the outside to the inside of the reactor.

Page 55 of 271
Four reactors in series are stacked one on top of the other and are separated by reheat
sections or Interheater. Since the chemical reactions are endothermic in nature, the outlet
temperature of each reactor effluents drops. The function of the Interheater is to raise the
temperature of this stream back to the reaction temperature for the next reactor.
Charge Heater outlet temperature is controlled by temperature controller (TIC-0504), Apart

from temperature controller, TI-0505 is provided at charge heater outlet.
Reactor-1 outlet process fluid after heating in Inter heater No. 1 enters Reactor-2. Similarly
Reactor-2 outlet process fluid after heating in Inter heater No. 2 enters Reactor-3, Reactor-3
outlet process fluid after heating in Inter heater No. 3 enters Reactor-4.
Each heater is a radiant-convection, box-type heater with U-type process tubes. Feed
passes through the radiant section and waste heat is recovered in the convection section
for steam generation. The charge heater and the Interheater No-1 share a common
convection section and Interheater No-2 and No-3 share a common convection section.
Draft through the heater is controlled by dampers located in the stack above the convection
section.
Inter heaters outlet temperature is controlled by temperature controller (TIC-0604 for

Interheater-1, TIC-0704 for Interheater-2, TIC-0804 for Inter heater-3), Apart from
temperature controllers, TI-0605, TI-0705, TIC-0805 (for Inter heater 1, 2 & 3 respectively)
are provided at Inter heaters outlet.
All heaters are fired by both fuel gas and fuel oil. Fuel gas flow to the heaters is controlled
by pressure controllers (PIC-3101B/3201B/3301B/3401B for Charge heater and Interheater-
1/2/3 respectively) which are cascaded with heater outlet temperatures (TIC-
0504/0604/0704/0804 for Charge heater and Interheater-1/2/3 respectively. The Convection
Section is used to generate the maximum amount of HP Steam possible.

Page 56 of 271
Reactor outlet temperature is measured by temperature indicator TI-0901, TI-0902, TI-0903

& TI-0904 for Reactor 1, 2, 3, and 4 respectively.
A slipstream of the reactor effluent is used to heat a slipstream of the recycle gas in the
Reactor Purge Exchanger (74-E-02). The recycle gas slipstream is used to strip off residual
hydrocarbon from the catalyst before it is sent to the CCR Regenerator Section. Flow of
reactor effluent through Reactor Purge exchanger is controlled by the Purge Exchanger
outlet Recycle gas temperature (TIC-0905). Flow of recycle gas to Reactor Purge
Exchanger is controlled by FIC-0901. Purge exchanger inlet of reactor effluent temperature
is measured by TI-0908.
Heater firing
Ref P&ID No 930768-120-31 Rev-8
930768-120-32 Rev-8
930768-120-33 Rev-8
930768-120-34 Rev-8
The heater firing system has the provision for both Fuel Gas and fuel oil.
Pilot gas for heaters is received from a 1” pilot gas header. One common self regulating
pressure control valve (PCV-3001) is provided on pilot gas header to maintain pilot gas
header pressure. One Common pilot gas header is provided with three low-low pressure
switches (PSLL3002 A, B, C). Actuation of two out of three pressure switches will lead to all
heaters shutdown.
Fuel gas for burners of individual heaters is received from a 10” fuel gas header. Fuel gas
flow to the burners is adjusted by TIC controlling heater outlet/reactor inlet temperature.
Fuel gas flow to burners of individual heater is controlled by individual pressure/flow
controllers (PIC/FIC-3102B) for charge heater, PIC/FIC-3202 for Inter heater No. 1,
PIC/FIC-3302 for Inter heater No. 2, and PIC/FIC-3402 for Inter Heater no. 3) cascaded
with respective heater outlet temperature. Individual heater fuel gas line is provided low-low
pressure (PSLL-3103, PSLL-3203, PSLL-3303, and PSLL-3403). Actuations of any one
PSLL will shutdown all heaters.
Fuel oil for burners of individual heaters is received from 3” fuel oil header. Fuel oil flow to
the burners is adjusted by TIC controlling heater outlet/reactor inlet temperature. Fuel oil

Page 57 of 271
flow to burners of individual heater is controlled by individual pressure/flow controllers

(PIC/FIC-3103B) for charge heater, PIC/FIC-3203 for Inter heater No. 1, PIC/FIC-3303 for
Inter heater No. 2, and PIC/FIC-3403 for Inter Heater no. 3) cascaded with respective
heater outlet temperature. Individual heater fuel oil line is provided low-low pressure (PSLL-
3104, PSLL-3204, PSLL-3304, PSLL-3404). Actuations of any one PSLL will shutdown all
heaters.
Oxygen content in flue gas from individual heater is continuously measured through
analyzer (AI-3101, AI-3201, AI-3301, AI-3401). Temperature of flue gas from individual
heaters to convection section is measured by TI-3102/TI-32021/TI-3302/TI-2402.
Respectively.
Atomizing steam is added to the heating to optimise the fuel consumption. Steam is taken
from the 10” MP header. The pressure of the atomizing steam is controlled by PIC 3105A.
FI 3105 indicates the Steam supply.
Emergency shutdown switches are provided at field and panel to shutdown heater in case
of any emergency.
Product Condenser & Separator
Ref P&ID No 930768-120-10 REV-5

930768-120-12 REV-4
The separation section consists of the separator (74-V-01) that separates the hydrogen-rich
gas product from the aromatic-rich hydrocarbon liquid product. Its function is to increase
both the purity of the gas product and the recovery of the liquid product. One of the basic
components is a mesh blanket, used as a demister pad. It is enclosed is a horizontal baffle
in the top of the separator to coalesce or help remove entrained hydrocarbon droplets from
the gas stream.
This gas/liquid separation begins with a single product separator. However, lower the
pressure of the product separator, worse will be the separation between the gas and liquid.
This increases the duty of the recycle compressor, heaters, exchangers and coolers in the
reactor circuit because for a given H2/HC ratio more of the recycle gas should be

Page 58 of 271
compressed, heated and cooled. It also increases the duty of the stabilizer section because
more hydrogen in the separator liquid requires additional reflux and reboiling.
Liquid from Separator (74-V-01) is pumped by Separator Pump (74-P-01A/B) to Recontact

Drum (74-V-04) through Recontact Cooler (74-E-06A/B/C/D) and slip stream through Chiller
(74-E-08) under separator level control LIC-1202. Flow of liquid at the discharge of
Separator pump (74-P-01A/B) is measured by FI-1201. Minimum flow circulation line with
FIC-1202 is provided to ensure continuous minimum flow for Separator pump (74-P-01A/B).
The total hydrogen rich gas from the Separator is compressed in the electrically driven
Recycle Compressor (74-K-01). The recycle portion of the gas is fed to the Combined Feed
Exchanger and the net portion is sent to the recontact section. Moisture content and H2
content in Recycle gas is continuously monitored through analyzers AI-1201 and AI-1202
respectively
Recontact Section
Ref P&ID No 930768-120-13 Rev-4

930768-120-14 Rev-4
930768-120-15 Rev-4
930768-120-16 Rev-4
930768-120-17 Rev-4
930768-120-18 Rev-4
To improve the gas/liquid separation, the net gas from the recycle compressor is cooled in
first stage suction cooler (74-E-03 A/B/C/D) and the liquid part is knocked out in First stage
suction drum (74-V-02) before sending it to first stage of net gas compressor. Liquid from
the First stage suction drum is pumped by first stage suction drum pumps (74-P-02A/B) to
the stabiliser feed bottom exchanger (74-E-09 A/B/C/D) under level control (LIC/LV-1501).
The first stage discharge from the net gas compressor is recontacted with liquid from
recontact drum (through Chiller economiser (74-E-07)) in first stage discharge cooler (74-E-

Page 59 of 271
04) and separated in second stage suction drum (74-V-03). This recontact step improves
the recovery of the C3+ material from the net gas. The liquid part is sent to stabiliser
through stabiliser feed bottom exchanger (74-E-09) under level controller LIC1802 and the
net gas is further compressed in the second stage of the net gas compressor.
The compressed gas form second stage is again contacted with crude reformate from the
separator in recontact cooler (74-E-06). This repeated contacting ensures the maximum
purity of both gas and liquid phase. The mixture is passed through Chiller economiser (74-
E-07) and Chiller (74-E-08) before separating in the recontact drum (74-V-04). The liquid is
rerouted to first stage discharge cooler and the net gas is sent to chloride treaters (74-V-05)
for usage of several downstream users viz PSA Unit, NHT products condenser, fuel gas
header, or make up hydrogen to FCC NHT unit.
Pressure of recycle gas and net gas section is controlled by pressure controllers.
In this section there is recycle gas compressor in between reactor separator and recontact
section with PIC on separator and recontact section. Recontact section is provided with two
stage net gas compressor, each stage is protected from excessive compression ratio/spill
back of each stage. The sequence of event is as follows.
As pressure on the net gas section (net gas compressor first stage suction drum) rises,
PIC-1501 opens first PV-1501C to send gas to relief header.
As pressure on net gas compressor first stage suction drum falls PIC-1501 will send signal
to low signal selector PY-1501D to open PV-15001A/B.
If reactor section pressure rises PIC-1203 on separator will send signal to PIC-1501 to open
PV-1501C.
As pressure on the net gas section (second stage suction drum) rises, PIC-1801 open first
PV-1801A/B to re-circulate the gas thorough the drum, if pressure still increases, then it
opens the PV 1501C to release the gas to the relief header.

Page 60 of 271
Recontact drum pressure is controlled by PIC-1901 which acts as spill back controller for
second stage. If pressure in recontact drum rises PIC-1901 will open PV-1801A/B. In case
the pressure rises further, PIC-1901 will send signal to low signal selector to open PV-
1901A sequentially (PV-1801A/B opens first, PV-1901 opens last).
Low selector PY-1901C selects lower value between PIC-1901 and PIC-1801 and acts on
PV-1801A & PV-1801B. Similarly low selector PY-1801E selects lower value between PIC-
1801 and PIC-1501 and acts on PV-1501A & PV-1501B.
Fractionation Section
Stabiliser Section
Ref P&ID Nos are 930768-120-21 Rev 4
930768-120-22 Rev 3
930768-120-23 Rev 4
930768-120-24 Rev 4
The liquid from first stage suction Drum(74-V-02) and Second stage suction drum (74-V-
03) is pumped to the Stabiliser column (74-C-01) after preheating by Stabiliser Bottom
liquid in Stabiliser Feed – Bottom Exchanger (74-E-09 A/B/C/D).
The 30 tray Stabiliser operates at 13.5 kg/cm²g with feed introduced on tray 10. MOC for
Debutaniser shell is Carbon steel. A reboiler (74-E-11) is provided to supply the majority of
the required heat input for generating vapor. Steam condensate flow is controlled by
FIC/FV-2201.
The Reformate from the bottom of the Stabiliser is cooled in the Stabiliser Feed-bottoms
exchanger (74-E-09A/B/C/D), Stabiliser bottom cooler (74-A-02) and Stabiliser bottoms trim
cooler (74-E-12A/B/C/D) and sent to storage. The reformate is withdrawn from the Stabiliser
bottom under stabiliser level control LIC/LV-2201. Reformate is continuously measure for
Octane number by analyzer AI-2101.

Page 61 of 271
Stabiliser top pressure and temperature is measured by PI-2203 and TI-2202. Stabiliser
bottom temperature is measured by TI2207.
Stabiliser overhead vapour is cooled in Stabiliser Condenser (74-E-10A/B/C/D) and routed

in Stabiliser Receiver (74-V-06) where liquid and vapour is separated.
Vapour from the Stabiliser receiver is recycled back to First stage suction drum (74-V-01)
under Debutaniser pressure control PIC/PV-2301. Stabiliser Receiver vapour flow to the
first stage suction drum is measured by FI-2401.
The liquid from the Stabiliser receiver is pumped out by Stabiliser Overhead Pumps (74-P-
04A/B). The reflux portion goes back to the Stabiliser column under flow control FIC-2303
cascaded with Stabiliser Receiver level control (LIC-2403) and the net portion is chloride
treated in the LPG Chloride Treaters (74-V-74A/B). Flow of net LPG is controlled by FIC-
2501 cascaded with Stabiliser tray no. 22 temperature TIC-2204.
The unstabilized LPG from LPG Chloride Treater is sent to Deethanizer. A Deethanizer is
used to remove light ends (ethane, methane, hydrogen) from the debutaniser overhead
liquid product (LPG). The LPG product will consist of C3-c4 or c4-c5 LPG depending on the
platforming unit operating mode.
The overhead from the deethanizer is cooled in the Deethanizer condenser (74-E-
14A/B/C/D) and collected in the deethanizer receiver 74-V-08. The off gases from the
receiver are charged to fuel gas header. The flow of off gas in measured by FI2701. Part of
the bottoms of the deethanizer column is cooled in the Deethanizer bottom cooler (74-E-
15A/B/C/D) and sent to the storage facility under level controller (LIC2601) action.
Deethaniser reboiler maintains the bottom temperature with condensate control valve (74-
FIC2602.

Page 62 of 271
Steam Generation section

Ref P&ID No 930768-120-28 Rev 3
930768-120-29 Rev 6
Flue gases from the radiant section of the heaters are routed to the convection section for
heat recovery. The convection section consist 4 passes. BFW from Boiler Feed water
booster pump (74-P-05A/B) is routed to the 1st pass of convection section under flow control
(FIC/FV-2902) cascaded with Steam disengaging drum level controller (LIC-2801).
Superheated Water from Steam disengaging drum (74-V-09) is circulated through 2nd and
3rd pass in the convection sections by Circulating Water pumps (74-P-07A/B). Vaporized
two phase mixture from 2nd and 3rd pass is mixed with BFW from 1st pass, after convection
section and routed back to Steam Disengaging Drum for phase separation. The
superheated steam from steam disengaging drum is again passed through the 4th pass of
the convection section and then routed to Desuperheater no 1 (71-M-01) and
Desuperheater no 2 (74-M-02).
Desuperheater No 1 and Desuperheater No 2 steam is sent to Stabiliser reboiler in CCR

unit and Stripper reboiler in NHT unit. Temperature of the HP steam from No1 and No2
Desuperheater is controlled by TIC/TV-2907 and TIC/TV-2909 resp.
Intermittent and continuous blow down system is provided for steam generation system to
maintain TDS content and other properties. Continuous blow down stream from Steam
Disengaging Drum is routed to Continuous Blow down Drum (74-V-12). MP steam
separated in Continuous Blow-down drum is routed to MP Steam Header. Condensate from
Continuous Blow-down drum is routed to Intermittent Blow-down Drum (74-V-13) under
level control LIC/LV-2806. Intermittent Blow-down from Steam Disengaging Drum is also
routed to Intermittent Blow-down Drum. Flashed steam from Intermittent Blow-down Drum
is routed to Atmosphere at safe location and condensate is sent to OWS.

Page 63 of 271
3.2 CHEMICAL SYSTEM

Ref P&ID No 930768-120-11 Rev 5
CHEMICAL AND CONDENSATE INJECTION SYSTEM
Condensate from Condensate break tank in injected to Combined Feed Exchanger outlet
by Condensate injection pump (74-P-10).
Chloride is received from Chloride injection vessel at CCR regeneration section. The
chloride is fed to fresh naphtha at combined feed exchanger inlet. One Start-up Chemical
Injection Pump (74-P-09) is also provided to inject chloride during start-up.
SULFIDE INJECTION SYSTEM

Sulfide is required in CCR Platforming unit to maintain sulfur level in naphtha. Sulfide is
transferred to Sulfide Storage Vessel (74-V-11) from the drums with the help of nitrogen.
Sulfide from sulfide storage vessel is pumped by Sulfide Inhibitor Pumps (74-P-08A/B) to
the feed naphtha at Combined Feed Exchanger inlet

Page 64 of 271
SECTION-4
EFFECT OF OPERATING VARIABLES ON PROCESS
4.1 GENERAL
The purpose of this section is to discuss the major Platforming operating variables, their
relation to unit performance and the estimation of shifts in performance due to operational
changes.
The operating variables that are the most pertinent are shown in Table-1. For practical
purposes, these variables are sufficient to define a Platforming operation.
TABLE-1
MAJOR PLATFORMING VARIABLES
Independent Variables Dependent Variables
Catalyst Type Catalyst Activity
Reactor Temperature Reactor Effluent Yields
Space Velocity Product Quality
Reactor Pressure Catalyst Stability
H2/HC Ratio
Charge Stock Properties
Feed Additives
Although there are inter-relationships between the variables (for instance the reactor
temperature, reactor pressure, and reactor effluent yield relationship discussed in Section-
3: process chemistry), this section treats each independent variable separately where
possible.

Page 65 of 271
4.2 MAJOR PLATFORMING INDEPENDENT VARIABLES
It is of interest at this point to discuss briefly and qualitatively the effects of the major
process variables on Platforming Unit operations.
1. Catalyst Type
Catalyst selection has been tailored to the special processing requirements of Continuous
Platforming. The UOP Continuous Platforming catalyst has been optimized with respect to
yield, activity, and coking tendency. As such, basic catalyst formulation, chloride level,
platinum level, and activator level are not discussed in this section.
2. Reactor Temperature
The temperature at which the Platforming reactor catalyst beds are held is the major control
parameter to meet product quality requirements. Platforming catalysts are capable of
operation over a wide range of temperature with little adverse affect on product yield and
catalyst stability. However, very high temperatures, above 560°C, may cause thermal
reactions, which will decrease, reformate and hydrogen yield and increase the rate of coke
lay down.
Reactor temperature can be defined in two fashions, either Weighted Average Inlet
Temperature (WAIT) or Weighted Average Bed Temperature (WABT). These can be
calculated as follows:
WAIT =Summation of (Wt. fraction catalyst in bed X Bed inlet temperature)

WABT =Summation of (Wt. fraction catalyst in bed X Average of Bed inlet and outlet
temperature)
The WAIT is primarily used in the computations (because of ease of computation), although
the WABT is a better measure of the average catalyst temperature or reaction conditions.
Neither exactly defines the true average catalyst temperature. In the discussion to follow,
the WAIT will be used exclusively. However, there is a criterion on the difference between
WAIT and WABT, WAIT-WABT that is imposed for the computation of reactor temperature
requirement.

Page 66 of 271
3. Space Velocity
Space velocity is a measure of the amount of naphtha, which is processed over a given
amount of catalyst over a set length of time. When the hourly volume charge rate of
naphtha and the volume of catalyst are used, the term is Liquid Hourly Space Velocity
(LHSV). When weights are used, the term is Weight Hourly Space Velocity (WHSV). Either
is applicable in monitoring a Platforming Unit operation when a set catalyst density and
volume is involved. LHSV, hr1, is commonly used by UOP since most refiners define their
charge rate on a volume basis, and hourly rates given conveniently sized numbers.
Space velocity has an effect on product quality (example: octane number). The higher the
space velocity (lower residence time) the lower the product RONC or the less the amount of
reaction that occurs at a fixed WAIT. Increased reactor temperatures will offset this effect.
Within normal Platforming design parameters, space velocity has little effect on the unit
yield performance. At very low LHSV, thermal reactions can occur to a sufficient degree to
decrease reformat and hydrogen yields. While there is no known upper limit on space
velocity, reactor temperatures have to be increased in order to maintain the product quality
(RONC) and above a certain point, can again cause unfavorable thermal reactions, which
will lower, yield performance. At very low LHSV, thermal reactions can occur to a sufficient
degree to decrease reformat and hydrogen yields. While there is no known upper limit on
space velocity, reactor temperatures have to be increased in order to maintain the product
quality (RONC) and above a certain point, can again cause unfavorable thermal reactions,
which will lower yield performance.
4. Reactor Pressure
Because of its inherent effect on reaction rates, hydrogen partial pressure is the basic
variable, but for ease of use, the information, which follows, has been adjusted so the total
reactor pressure can be used and the hydrogen purity is not needed.
UOP uses the last reactor inlet pressure as the average catalyst pressure since 50% of the
catalyst is usually in the last reactor. Separator pressure, as an operating parameter, is of
limited value since the system pressure drop varies from unit to unit and can be

Page 67 of 271
considerably different even within the same unit as charge rate, recycle gas rate, recycle
gas gravity, etc. change.
The reactor pressure affects the Platforming Unit yield structure, reactor temperature
requirement, and catalyst coke rate. Reactor pressure has no theoretical limitations,
although practical design limitations have an effect.
Decreasing the reactor pressure will increase the hydrogen and reformate yield, decrease
the temperature requirement to make the product octane, and increases the catalyst coking
rate.
5. Hydrogen/Hydrocarbon Ratio
Hydrogen/hydrocarbon (H2/HC) ratio is defined as the moles of recycle hydrogen per mole
of naphtha charged to the unit.
Recycle hydrogen is necessary in the Platforming Unit operation for purposes of catalyst
coking rate. It has the effect of sweeping the reaction product and condensable materials
from the catalyst and supplying the catalyst with readily available hydrogen.
An increase in H2/HC ratio will move the naphtha through the reactor at a faster rate and
supply a greater heat sink for the endothermic heat of reaction. The end result is decreased
catalyst coking rate with little effect on the product quality or yields.
The effect of H2/HC ratio on the catalyst coking rate is not due to the recycle gas alone. The
hydrogen in the net gas has the same effect as the hydrogen in the recycle gas in
decreasing the catalyst coking rate. This effect, however, is less in the first reactor and
more in the last reactors because most of the net hydrogen is produced in the first reactor.
As will be described later, to compute the effect of H2/HC ratio on the catalyst coking rate,
Figure -20 is used. When using Figure -20, a total H2/HC ratio must be defined that takes
credit for the hydrogen produced in the reactors. The total H2/HC ratio for the effect on
catalyst coking rate only is defined as the H2/HC mol ratio in the combined feed to the
reactor plus 70 percent of the net hydrogen produced on a mol H2 in net gas to mol of feed
basis.

Page 68 of 271
6. Charge Stock Properties

The charge stock properties which are pertinent to this discussion of Platforming variables
are as follows:
SN Property Laboratory Method

1 Source of Stock -
Initial boiling point (IBP)
2 Mid boiling point (50%) ASTM D-86 Distallation
End boiling point (EP)
Paraffin Content (P)
3 Naphthene Content (N) UOP 880 (Hydrocarbon Types)
Aromatics Content (A)
Generally, the computation procedures described later on are based on correlations of pilot
plant and past commercial data. The preferred PONA analysis is UOP Method 880. The
UOP Method 273 will tend to give inaccurate naphthene results for full boiling range feed
stocks because of the presence of polycyclic naphthenes. The UOP Method 777 is the
method of choice if the olefin content is high (>2 LV %).
These correlations are to be used to characterize straight run Naphthas only. Estimation of
other feeds such as FCC and Coker Naphthas falls outside the range of these correlations.
Charge stocks with low IBP’s (less than 77°C) will generally contain a significant amount of
C5 material. The pentanes in the feed cannot be converted to aromatics and, therefore,
these pentanes will pass through unconverted, isomerized and/or cracked to light ends.
Because of their low octane, they will dilute the overall reformat octane and result in higher
(C6+) octane-severity in the Platforming Unit.
On the subsequent section example of the effect of C5’s on reforming severity is given.
Charge stocks with low EP’s have C6 and C7 hydrocarbons concentrated. These are the
most difficult species to reform. On the other hand, charge stocks with high EP’s cause
higher catalyst coking rates. They also contribute significantly to high reformat endpoint.

Page 69 of 271
The following example helps to illustrate this dilution effect and provide a means to estimate
the new RONC severity (needed for the proceeding correlations for activity, stability and
yields).
a) Process Conditions
Feed Rate 1,590 m³/day
Reformate C5+ Yield, LV-% 82.08
Reformate C5+ RONC 98.2
Total Pentanes in Feed (From Feed GC) 3.0 LV-%
n-Pentane 1.7 LV-%
i-Pentane 1.0 LV-%
Cyclopentane 0 .3 LV-%
If individual pentanes are not known, assume 40% of total is iso-pentane and 60% is n-
pentane.
b) Compute Total Product Octane-Cubic Meters

Feed x Yield x RONC
1,590 m³ x .8208 x 98.2 =128,158 octane-m³
c) Compute Product C5 Octane-Cubic Meters

(Assume 90% of C5 in Feed Goes to Product)
Feed x (C5 Fraction to Product) ∞ RONC
n-pentane 1,590 x (.017 x .9) x 63.0 = 1,532 octane-m³
iso-pentane 1,590 x (.010 x .9) x 92.3 = 1,321 octane-m³
cyclo-pentane 1,590 x (.003 x .9) x 101 = 434 octane-m³
Total C5’s 1,532 + 1,321 + 434 = 3,287 octane-m³
d) Compute Total Octane-Cubic Meters Produced in Reactor

Total Product - Total C5’s from feed = Total Produced in Reactors
128,158 - 3,287 = 124,871 octane-m³

Page 70 of 271
e) Compute Total Cubic Meters Produced in Reactor

Total Product - Total C5’s from feed = Total Produced in Reactors
(1,590 ∞ .8208) - (1,590 X .03 X .9) = 1,262 cubic meters
Total Octane Produced in reactors

f) Compute Actual RONC =
Total Product Produced in Reactors
124,871-octane -m³
= 98.9 RONC
1,262 cubic meters
Therefore the C5+ RONC that should be used for activity, yield or coking rate calculations in
this case is 98.9 rather than the reported 98.2.
The effect of C5 in feed will be greater as the product octane and/or pentanes in the feed
increase.
7. Feed Additives
It is assumed that chloride addition to the regeneration section is sufficient to maintain the
recommended chloride content of 1.1 –1.20 wt-% chloride on the regenerated catalyst for
R-30 series catalyst and 1.2 – 1.3 wt-% for R-130 series catalyst.
Normally, chloride and water addition to the Platforming feed is not necessary while the
regeneration section is in white burn operation.
4.3 PLATFORMING DEPENDENT VARIABLES
In this portion of the operating variables section, the effects of the Platforming independent
variables on the major dependent variables are discussed. More importantly, methods for
estimating the effects of operating changes on one or more of the dependent variables are
illustrated.

Page 71 of 271
1. Catalyst Activity
Catalyst activity is a term used to describe the temperature at which a particular catalyst
must be operated to produce a given product quality. In this discussion, the catalyst
temperature will be defined exclusively as the weighted average inlet temperature (WAIT).
Product quality as it applies to motor fuel operations are defined as the C5+ research octane
number clear (RONC).
The C5+ RONC is defined as the total RONC of the C5+ product reactor effluent. If the
reformat stabilizer operates as a debutaniser, then the C5+ RONC will be very close to the
RONC of the bottoms product of the stabilizer. However, if the stabilizer operates as a
depentanizer or a dehexanizer, then the C5+ RONC may be different from the RONC of the
bottoms product of the stabilizer. This is because the C5+ product that leaves as overhead
liquid from a depentanizer or dehexanizer will not be included in the bottoms product, which
is analyzed for RONC by the laboratory.
The effect of C5’s in the stabilizer overhead liquid on the stabilizer bottoms RONC varies
depending on the amount of C5’s in the stabilizer overhead and the RONC of the stabilizer
bottoms. The following example helps to illustrate this effect and provide a means to
estimate the new RONC severity (needed for the correlations for activity, yields and coking
rate).

Page 72 of 271
Feed Rate 1,590 m³/day

Stabilizer Overhead Liquid Yield 5.0 LV-%
Stabilizer Bottoms Yield 80.0 LV-%
Stabilizer Bottoms Octane 99.0 RONC
Stabilizer Bottoms C5+(from lab) 100 LV-%
Stabilizer Overhead Liquid C5+(from lab)
n-pentane 12 LV-%
i-pentane 6 LV-%
C6+ 2 LV-%
b) Compute Total Produced C5+ Octane-Cubic Meters

Feed x Yield ∞ x C5 Fraction x RONC
Stabilizer bottom 1,590 x .80 x 1.00 x 99.0 = 125,928 octane-m³
stabilizer Overhead:
n-pentane 1,590 x .05 x 0.12 x 63.0 = 601 octane-m³
iso-pentane 1,590 x .05 x 0.06 x 92.3 = 440 octane-m³
C6+ 1,590 x .05 x 0.02 x 76.5 = 122 octane-m³
Total C5+ 125,928 + 601 + 440 + 122 =127,091 octane-m³
c) Compute Total Produced C5+ Cubic meters

Feed x Yield x C5 Fraction
Debutaniser Bottoms 1,590 x .80 x 1.00 =1,272 m³
Debutaniser Overhead 1,590 x .05 x (.12+. 06+. 02) = 15.9 m³
Total C5+ 1,272 + 15.9 = 1287.9 m³
d) Compute Actual RONC = Total C5+ Octane Produced in reactor

Total Product Produced in Reactors
127,091-octane -m³
= 98.7 RONC
1287.9 m³

Page 73 of 271
Therefore, the C5+ RONC that should be used for activity, yield or coking rate computations
in this case is 98.7 rather than the reported 99.0.
The effect of C5 in the stabilizer overhead will be greater as the product octane and/or the
pentanes in the overhead liquid increase.
The WAIT requirement to meet a given C5+ RONC is obviously affected by many things. At
the outset of a run with fresh catalyst, one would expect that the WAIT required would only
be affected by the feed character, RONC desired, feed rate, and catalyst type. However,
things are not this simple. An operational upset could occur which will effect the water-
chloride balance and the apparent catalyst activity will change.
There is a calculation procedure for estimating the start-of-run (SOR) WAIT requirement.
This SOR WAIT is the temperature at which a fresh catalyst loading would operate in order
to produce a certain RONC from a feed characterized by a certain N and A content and
charged at a given LHSV. There are at least two important ways at which this estimate can
be put to use:
i. CCR Platforming Unit WAIT target at start-up.

ii. CCR Platforming Unit Delta WAIT (predicted SOR WAIT minus actual WAIT) for tracking
catalyst activity with respect to regeneration cycles.
The first use, (i), is fairly straightforward. The calculation enables the process engineer or
supervisor to estimate the WAIT required to meet product requirements.
Number (ii) requires some explanation, but the reader will note that the concept is simple.
The basic idea is to determine a number (Delta WAIT) which puts the catalyst temperature
requirement on a consistent or normalized basis for comparing day-to-day operation. This
would not be necessary, of course, if the Platforming Unit ran at the same conditions (feed
N and A, RONC, LHSV) all the time. Of course, this is seldom the case.

Page 74 of 271
What Delta WAIT does, then, is normalize reactor temperature data with respect to
Platforming feed N and A, RONC and LHSV. It is defined as the difference between the
WAIT the CCR Platforming Unit is operating at, given the three parameters above, and the
fresh catalyst WAIT requirement for the same parameters. It is the activity difference
between the real catalyst and fresh catalyst.
Tabulation or graphical plotting of Delta WAIT is a natural follow-up. In maintaining a plot,

the engineer can monitor the effects of operating changes made to remedy a catalyst
activity problem due to, for instance, a feed sulfur upset. In this case, delta WAIT can be
plotted versus regeneration cycles. It probably would take a few catalyst regeneration
cycles for the catalyst activity to get back to normal, so on a day-to-day basis; the engineer
can track the improvement in activity. Disruptions in and recovery of the water-chloride
balance can also be tracked using the Delta WAIT calculation and plot.
The SOR WAIT requirement calculation is now explained. The figures used are not meant
to cover all the variables, which can affect the apparent fresh catalyst activity. Predictions
of the SOR WAIT requirements from the figures should, however, be within plus or minus
3°C (5°F) of the actual requirement.
Below is an outline of how the computation proceeds, with reference to the appropriate
Figures for CCR Platforming applications:
Step
a. List - RONC
- N and A - Actual Unit Operating Data-
- N + 3.5A
- LHSV
- Catalyst Type
b. Estimate SOR WAIT at 1.0 LHSV Figure -1

c. Estimate Correction for actual LHSV Figure -2
d. Add the results of b and c to give SOR WAIT

Page 75 of 271
The following numerical example is presented in order to give the refiner a guide for
computing the SOR WAIT requirement.
CCR Platforming Unit
a. Process Conditions
Catalyst R-34
RONC 95
LHSV, hr1 1.9
Feed N, LV-% 15
A, LV-% 8
N+ 3.5A = 15+28 = 43 LV-%
b. From Figure -1
SOR WAIT = 494°C at 1.0 LHSV
c. From Figure -2
Correction = +16°C 1.0 to 1.9 LHSV
d. SOR WAIT requirement

SOR WAIT = 494+16 = 510°C
Suppose that the CCR Platforming Unit on the day in question was running an actual WAIT
of 518°C. The engineer would tabulate and plot for this day the following Delta WAIT (Delta
WAIT equals predicted SOR WAIT requirement minus actual WAIT):
Delta WAIT = 510-518 = -8°C
In other words, the catalyst activity is 8°C below that of fresh catalyst. Day-to-day
calculations would allow the engineer to assess the catalyst activity on a normalized basis
and determine whether it is along the lines that would be expected.
The temperature-octane response for a Platforming Unit is shown in Figure -3. This chart
can be used to estimate the changes in the WAIT required to switch daily RONC target.

Page 76 of 271
2. CCR Platforming Reactor Quench
DEFINITION: Platforming reactor quench is a phenomenon which occurs in the catalyst

bed if the feed characteristics and process conditions are such that there exists more
catalyst than required in the front reactors to convert the naphthenes to aromatics. The
result is a large temperature drop in the front reactors. A portion of the catalyst in the
reactors is at temperatures which do not thermodynamically support the forward Platforming
reactions as depicted in the SOR WAIT Figure. In fact, the catalyst volume could be
reduced somewhat in the front reactors and still maintain the same temperature drop. A
quenched reactor, therefore, appears to have less catalyst and the catalyst appears to be
less active than the SOR WAIT Figure. In fact, the catalyst volume could be reduced
somewhat in the front reactors and still maintain the same temperature drop. A quenched
reactor, therefore, appears to have less catalyst and the catalyst appears to be less active
than the SOR WAIT Figures would indicate. Therefore, if quenching is occurring in the
refiner’s unit, the catalyst’s activity may appear below that of fresh catalyst.
MEASURING QUENCH: Computing the amount of quench in a unit is an important part of

accurately computing the Delta WAIT. There is an empirical correlation to adjust the
predicted SOR WAIT requirement for the measured quench effects. It uses the reactor inlet
and outlet temperatures, the catalyst distribution, and a constraint on the difference
between the actual WAIT and the actual WABT. The constraint is shown as Basis # 5 of
Figure -1. If the term (WAIT-WABT) is greater than 20°C, then a correction for quench must
be added for SOR WAIT requirement.
CORRECTING THE SOR WAIT FOR QUENCH
a) Compute the WAIT.
b) Compute the WABT.
c) Compute the Measured Quench (MQ).

Measured Quench (MQ) = WAIT – WABT

Page 77 of 271
d) Compute the SOR WAIT Quench Correction (QC):

Quench Correction (QC) (°C) = MQ (°C) – 20°C
NOTE: If QC is less than zero, set QC equal to zero.
e) Compute the corrected SOR WAIT (SORC WAIT):

SORC WAIT = SOR WAIT (from Figures and Table) + QC
NOTE: If QC equals zero, then SORC WAIT = SOR WAIT and there is no quench correction.
f) Compute the corrected Delta WAIT:

Corrected Delta WAIT = SORC WAIT – WAIT
The following numerical examples are presented in order to give the refiner a guide for
computing the SOR WAIT requirement corrected for quench.
CCR Platforming Unit
a. Process Conditions
WAIT, °C 527
WABT, °C 503
SOR WAIT, °C 525
b. Measured Quench (MQ)=

527 – 503 = 24°C
c. Quench Correction (QC)=

24 – 20 = 4°C
d. SORC WAIT =
525+4 = 529°C
e. Corrected Delta WAIT=

529 – 527 = 2°C
In other words, the catalyst activity corrected for quench is 2°C above that of fresh catalyst,
rather than 2°C below that of fresh catalyst.

Page 78 of 271
3. Catalyst Selectivity
Selectivity is defined as the tendency of a given catalyst and the operation of that catalyst to
produce the desired material. In most Plat forming operations, the most desired material is
reformat or more specifically the yield of C5+ liquid. Also, for the purpose of this section and
those to follow, product quality will continue to be defined as C5+ RONC, the research
octane number clear.
The selectivity of a Plat forming catalyst and operation is dependent upon several variables.
The effects of Platforming feedstock characteristics (N and content, 50% boiling point and
end boiling point), product quality (RONC), and average reactor pressure on selectivity to
C5+ liquid is discussed.
There are two sets of four selectivity curves. One set is for full-boiling-range Naphthas,
which are generally defined as having an initial boiling point of 82oC and an end boiling
point in the range of 176-204°C. The other set of curves is for light-boiling-range Naphthas
which have an end boiling point in the range of 176-204°C. The other two sets of selectivity
curves are needed because in general the relative selectivity of reforming reactions
increases with increasing boiling point of the naphtha.
CCR C5+ YIELD DELTA

Straight Run Naphtha
Straight Run Naphtha
End point Less than
Full Boiling Range
Process Variable 176°C (350°F)
C5+ RONC Figure –4 Figure -8
Feed Naphtha N+2A Figure –5 Figure -9
Average Reactor Figure –6 Figure -10
Pressure
50% Boiling Point Figure –7 Figure -11
A preliminary glance at the selectivity curves allows the following general conclusions to be
made:

Page 79 of 271
1. C5+ yield increases with a decrease in average reactor pressure. Further more,
comparing the pressure effect at two octane levels and constant N+2A shows the
higher the octane, the larger the increase in yield.
2. C5+ yield decreases as octane is raised at constant reactor pressure and feed N+2A.
3. C5+ yield generally increases with an increase in feed naphtha N+2A at constant
pressure and RONC. The effect becomes less pronounced as feed changes occur at
high N+2A value.
It is important to realize that in the following procedure absolute yields are not computed.
The estimate gives the shift in yield in going from a base condition (the current Plat forming
operation, for instance) to a new case.

Page 80 of 271
Sample computations of the C5+ yield change estimate for a full-boiling range naphtha are
given below.
CCR PLATFORMING UNIT

(METRIC UNITS)
1 Process Conditions Base Case Case A
RONC 93 95
N/A, LV-% 40/10 34/10
N+2A, LV-% 60 54
50% Point, °C 130 110
Avg. Rx. Press. kg/cm²g 7.0 5.0
2 Averages
RONC 94
N+2A 57
3 RONC Effect, Figure -4
C5+ yield decrease
= -.62 LV-%/RONC
Yield Delta = (-.62) (2)
= - 1.24 LV-%
4 N+2A Effect, Figure -5
C5+ yield increase
= .195 LV-% N+2A
Yield Delta = (.195) (-6)
= - 1.17 LV-%
5 Pressure Effect, Figure -6
C5+ yield increase
= 1.4 LV-%/7kg/cm²g
Yield Delta = (1.4)(2)/(7)
= - 0.40 LV%
6 50% Point Effect, Figure -7
C5+ Yield Delta = -1.4 LV-%
7 Overall Yield Change
Net Yield = (-1.24) + (-1.17)
Delta = +(0.40) + (-1.40)
= -3.41 LV-% Total

Page 81 of 271
Sample computations of the C5+ yield change estimate for light-boiling-range naphtha are
given below:
CCR PLATFORMING UNIT
(METRIC UNITS)
1. Process Conditions Base Case Case A
RONC 98 96
N/A, LV-% 36/10 30/10
N+2A, LV-% 56 50
50% Point, °C 105 115
Avg. Rx. Press. kg/cm²g 5.5 4.5
2. Averages
RONC 97
N+2A 53
3. RONC Effect, Figure -4
A. C5+ yield decrease
= -0.92 LV-%/RONC
B. Yield Delta = (-.92) (2)

= - 1.84 LV-%
4. N+2A Effect, Figure -5

A. C5+ yield increase
= .025 LV-% N+2A
B. Yield Delta = (0.25) (-6)

= - 1.50 LV-%
5. Pressure Effect, Figure -6

A. C5+ yield increase
= 3.8 LV-%/7kg/cm²g
B. Yield Delta = (3.8)(1)/(7)

= - 0.54 LV-%
6. 50% Point Effect, Figure -7

C5+ Yield Delta = -1.0 LV-%
7. Overall Yield Change
Net Yield = (-1.84) + (-1.50)
Delta = +(0.54) + (-1.0)
= -3.80 LV-% Total

Page 82 of 271
4. Catalyst Selectivity to Aromatics

Selectivity to aromatics is defined as the tendency of a given Platforming catalyst and the
operation of that catalyst to produce aromatics. The selectivity to aromatics of a Platforming
catalyst and operation is dependent upon several variables. The effects of operating
severity (C5+RONC) and feedstock composition (paraffins, naphthenes, and aromatics in
the feed) is discussed.
For a given catalyst system and plant configuration, the conversion of an aromatic
precursor in the feed to an aromatic depends primarily on operating severity (C5+RONC).
The higher the C5+RONC, the higher the conversion of the aromatic precursor will be.
However, not all of the additional conversion that takes place at higher C5+RONC produces
aromatics; some of the additional conversion produces light gases. Aromatic selectivity is
defined for a given hydrocarbon type, as the percent of the compound that is converted that
goes to an aromatic hydrocarbon rather than light gases.
The empirical correlations show the effect of changes in benzene, toluene, xylenes, and
A9+ aromatics yields over a range of C5+RONC. Each curve uses a feedstock parameter
that is a combination of the paraffins, naphthenes, and aromatics in the feed for the
respective aromatic. These feedstock parameters are weighted toward the naphthenes
and/or aromatics because of the poor selectivity of the paraffins to convert to the respective
aromatic.
The following empirical correlations are for predicting a change in aromatics production with
R-30 or R-130 series Platforming catalyst:
AROMATIC FIGURE
Benzene Figure -12
Toluene Figure -13
Xylenes Figure -14
A9+ Aromatics Figure -15

Page 83 of 271
It is important to realize that in the following procedure absolute aromatics yields are not
computed. The estimate gives the shift in aromatics yield in going from a base condition
(the current unit operation, for instance) to a new case.
A sample calculation of the aromatics yield change estimate is given below:

Base Case LV%
-------------------------------------------
Feed: P N A
C6 8.6 1.7 0.5
C7 14.0 3.4 1.5
C8 15.3 4.4 2.8
C9+ 33.0 10.4 4.4
---------------------------------------------
Total 70.9 19.9 9.2
C5+RONC: 99
Base Case LV%
-------------------------------------------
Feed: P N A
C6 19.7 4.1 0.8
C7 35.4 9.4 3.5
C8 20.6 5.1 0.6
C9+ 0.6 0.2 -
----------------------------------------------
Total 76.3 18.8 4.9
C5+RONC: 99

Page 84 of 271
b) Parameters
Base Case Case A
P6
+ N6 + 2 A6 5.6 12.3
3
P7
+ N7 + 2 A7 11.9 30.6
2
P8
+ N8 + 2 A8 14.9 16.0
3
P9 CORR 26.2 0.6
c) Benzene, Figure -12

Base Case Delta Benzene at 5.6 = 2.0 LV-%
Case A Delta benzene at 12.3 = 5.8 LV-%
Benzene Yield Delta = 5.8 – 2.0 = + 3.8 LV-%FF
d) Toluene, Figure -13

Base Case Delta Toluene at 11.9 = 5.0 LV-%
Case A Delta Toluene at 30.6 = 18.6 LV-%
Touene Yield Delta = 18.5 – 5.0 = + 13.5 LV-%FF
e) Xylene, Figure -14

Base Case Delta Xylene at 14.9 = 11.0 LV-%
Case A Delta Xylene at 16.0 = 12.0 LV-%
Xylene Yield Delta = 12.0 – 11.0 = 1.0 LV-%
f) A9+, Figure 15
Base Case Delta A9+ at 26.2 = 23.5 LV-%
Case A Delhi A9+ at 0.6¸< 0 = -2 LV-%*
A9+ Yield Delta = -2 – 23.5 = -25.5 LV-%
[*NOTE: This value can be estimated from the curve by extrapolation because Delta A9+Aromatics Yield decreases by 1
LV-% for each 1 LV-% decrease in P9 CORR at 99 C5+RONC.]

Page 85 of 271
g) Total Aromatics Yield Change

Net Yield Delta = (3.8) + (13.5) + (1.0) + (-25.5) = -7.2 LV-% FF
5. Catalyst Stability
Catalyst stability is a measure of the coke-forming tendency of a given catalyst. For CCR
Platforming Units, apparent catalyst activity usually remains the same under normal
operating conditions. However, the coke-forming tendency of the CCR Platforming Units
catalyst will significantly affect the continuous regenerator’s operation. As more or less coke
is formed, changes in the Platforming Unit and regenerator operations will be required to
ensure that coke burned is equal to or greater than coke formed in the reactor section.
In the following discussion, calculation procedures for estimating the effects of process
variables on the coke-forming tendency of the catalyst will be illustrated. In CCR
Platforming Units, the measure of catalyst coke rate is the Relative Coking Factor. The
Relative Coking Factor is used to estimate the effect of changes in the operating conditions
of the Platforming reactor section on the rate of coke production.
The rate at which a given catalyst forms coke is set by the process variables listed below.
Process Variables CCR Relative Coking Factor

C5+RONC Figure -16
Feed Naphtha N+A Figure-17
Feed Naphtha End Point Figure-18
Avg. Rx. Pressure Figure-19
Hydrogen/Hydrocarbon Ratio Figure-20
These curves are based on a combination of pilot plant and commercial data. The data are
normalized to eliminate inter-relationships between variables as much as possible. The
figures, therefore, give the Relative Coking Factors in terms of single variables.

Page 86 of 271
The rate at which a given catalyst forms coke also depend on the charge rate to the CCR
Platforming Unit. With all the other process variables listed above constant, the change in
coke lay down rate is proportional to the change in charge rate.
The following numerical examples illustrate how the stability measures for CCR Platforming
units are estimated.
These examples demonstrate how to estimate the Relative Coking Factor and the change
in coke production between a base case (the current CCR Platforming Unit, for instance)
and a new case.
In using the procedure, one point cannot be overemphasized: To derive the greatest
possible accuracy in estimation of a new coke lay down rate, the process variables
(including feedstock) should be held constant for one complete turnover of the reactor
catalyst before actual coke lay down can be compared to the estimated value. Likewise,
when calculating the base coke lay down rate, the reactor inventory should be turned over
one full time at constant processing conditions before the base coking level can be
established. Since many refiners do not always run with constant feedstock for one full
catalyst cycle at a time, this estimation method should be used only to show a direction and
a rough approximation of expected coke lay down rates.
The reader should also realize that any significant periods of Platforming operation without
catalyst circulation will increase the amount of carbon on the spent catalyst above the level
calculated by the estimating procedure.
When used with the proper caution regarding process variable changes, this estimated
coking procedure should allow the refiner to better anticipate regenerator coke loadings as
his processing needs vary.

Page 87 of 271
CCR EXAMPLE
Base Case New Case
Charge Rate, m³/day 2500 3000

N/A, LV-% 20/10 30/10
End Boiling Point, °C 177 191
Total* H2/HC Ratio, mol/mol 2.25 1.5
Avg. Rx. Press. kg/cm²g 5 5.5
C5+ RONC 100 96
CCR, kg/hr 450 550
Spent Catalyst Coke, wt% 4.5 ?
*Total H2 /HC mol ratio equals the H2 /HC ratio to the reactor plus 70% of the net hydrogen produced on a net gas to feed
mol ratio basis
b) Coke Laydown Rate (Base Case)

Spent catalyst coke
Coke Laydown Rate= ∞ CCR
(100 – Spent catalyst coke)
4.5 kg coke
Coke Laydown Rate (Base Case) = x 450 = 21.20
(100-4.5) Hr
c) Coke Lay down Rate (New Case)
RCFB = Relative Coking Factor (Base Case)
RCFN = Relative Coking Factor (New Case)
Coke Lay down Rate =Coke Lay down Rate x m³DN (RCFN) (RCFN) (RCFN) (RCFN) (RCFN)
(New Case) (Base case) m³DB (RCFN) (RCFN) (RCFN) (RCFN) (RCFN)
RONC N+A EP Press. H2/HC

(Fig-16) (Fig-17) (Fig-18) (Fig. 19) (Fig-20)
= (21.20) x (3000) (.4) (1.05) (1.52) (1.30) (3.35)
(2500) (.98) (1.42) (1.2) (1.38) (2.0)
= 15.35 kg/hr coke

Page 88 of 271
d) Spent Catalyst Coke (New Case)

Coke Lay down Rate (New Case)
Spent Catalyst Coke = x 100%
CCR + Coke Lay down Rate (New Case)
15.35
= X 100%
550 + 15.35
= 2.7 wt-% coke
6. Effect of Non-SRN on Catalyst Stability

As mentioned previously, these relative coking factors are for straight run Naphthas
(SRNs). For situations where other stocks such as FCC and Coker naphtha are included as
part of the feed, a rough approximation can be made of their impact on coking or
deactivation. But to do this, one must have a characterization of the feeds that vent into the
Platforming Unit feedstock blend so as to evaluate each one separately and sum up their
effects to get the overall impact.
The deactivation rate or coke rate relative to a SRN will increase by about 1.6 times for an
FCC Naphtha and by 2.0 to 3.0 times for a Coker or thermally-derived naphtha depending
on end boiling point. To minimize the coking effect, the Coker naphtha end boiling point
should be constrained to a maximum of 177°C with a desired endpoint of about 160°C.
The yields on FCC naphtha will be comparable to a SRN of the same characteristics. But
because of the nature of a coker naphtha (produced in a hydrogen-deficient environment)
the C5+ yields will generally be worse than a SRN of comparable PONA. The deference
appears to be in the C5/C6 naphthene ring distribution with coker naphthas having more of
the less selective alkylcyclopentanes.
Hydrocracked naphthas have deactivation rates and yields similar to straight run naphthas
and as such can be treated like SRN.

Page 89 of 271
8. Endothermic Heat of Reaction
The final portion of this section will address an estimating procedure for the endothermic
heat of reaction for a given Platforming Unit operation.
The endothermic heat of reaction, when regularly calculated for a fairly constant charge
stock PONA and reformate octane number, may be used as an indication of catalyst
deactivation. The decreasing heat of reaction for charge stock composition or product
octane number because of the complexity of these relationships. If these values vary, the
heat of reaction will also vary.
The total delta T over the catalyst is directly related to the total heat of reaction. While the
heat of reaction is not a function of the H2/HC mole ratio, the total delta T is, due to the
diluent effect of the recycle gas. LHSV does not materially affect the heat of reaction.
Using Figures -21A and -21B, the heat of reaction may be determined when the following
are known:
Recycle gas purity (mole percent hydrogen)
H2/HC mole ratio
Total delta T
Charge stock molecular weight
The heat of reaction value as calculated from these graphs indicates the aromatization
ability more accurately than total delta T.
The following examples demonstrate the use of the figures in calculating the heat of
reaction.
HEAT OF REACTION
1. Total delta T (all Platforming reactors) 150°C

Hydrogen/Hydrocarbon Ratio 3
Recycle Gas Hydrogen Purity 80%
Charge Stock Molecular Weight (MW) 115
2. From Figure -22A
Total heat of reaction (HR) = 460 (150/100) = 690 (KJ/kg of naphtha)
3. From Figure -22B

Page 90 of 271
MW correction = +22 (150/100) = +33

4. The correct heat of reaction:
Corrected Heat of Reaction = 690 + 33
= 723 KJ/kg of naphtha
4.4 Catalyst Poisons
The purposes of this section is to discuss bimetallic Platforming catalyst poisons with
respect to:
1. Maximum allowable contaminant level
2. Methods of detection
3. Process symptoms
4. Suggested operational response
5. Possible sources of contamination
6. Consequent mechanical problems
Above the recommended maximum levels of feed stock contaminants, catalyst performance
will be measurably and negatively affected and steps should be immediately taken to rectify
the problem. In the cases of sulfur and nitrogen, UOP strongly recommends operation at as
low a severity as possible and not at the maximum allowable levels. Such minimization of
known poisons will help assure maximum selectivity of a Platforming operation.
The listings of possible sources of contamination, typical process symptoms, and possible
mechanical consequences have been compiled from operating experience of hundreds of
Platforming Units by UOP.
The suggested operational responses to the presence of poisons are those responses that,
in general, minimize catalyst and equipment damage. If often occurs that other
considerations such as product octane level, production quotas, shutdown schedules, etc.,
are in conflict with the suggested operational response. If this does occur, the refinery must
weight the alternatives of additional catalyst and/or mechanical damage versus the
economics of the situation.

Page 91 of 271
1. Sulfur
a) Maximum Allowable Concentration
Maximum allowable concentration in the naphtha feed is 0.5 wt-ppm. Operation at 0.1 to 0.2
wt-ppm in the feed is normally possible with most Naphtha Hydro treaters and will provide
added assurance of realizing maximum catalyst stability and selectivity.
b) Methods of Detection
1. Feed naphtha sulfur analyses:
Nickel Reduction Method: UOP 357
- Good for reducible sulfur
- May not give total sulfur
Microcoulometric Method: UOP 727
- Good down to 0.1 wt-ppm
Houston Atlas: ASTM D-4045

- Good down to 50 wt-ppb
- Preferred Method
NOTE: Neither a lamp sulfur method nor a doctor test are adequate for this purpose. Also, experimentation
has shown that the highly hindered (thiophenic) sulfur compounds are unreactive under the conditions of the
Nickel Reduction procedure. As a result this method may not give total sulfur results (especially for high
endpoint feeds).
2. Sniffer tube H2S determinations to quantify H2S levels in the recycle and
debutaniser overhead gas. Note that a rule of thumb estimation is 1 wt-ppm sulfur
in feed = 3 mol-ppm in recycle gas = 10 mol-ppm in debutaniser overhead gas.
c) Process Symptoms
Sulfur contamination in the Platforming Unit results in attenuation of platinum activity. This
in general means that the hydrocracking (acid catalyzed) reactions will increase relative to
the dehydrogenation and de-hydrocyclization (metal catalyzed) reactions. Resulting
observable effects include:
¾ Decreased hydrogen production;
¾ Decreased recycle gas hydrogen purity;
¾ Increased hydrocracking (higher C3 and C4 yield);

Page 92 of 271
¾ Reduced reactor delta T’s;

¾ Lower C5 plus yield;
¾ Lower catalyst activity in more severe cases; and
¾ Increased catalyst coking rate (decreased stability).
Data has shown that at levels of 10 mol-ppm H2S in the recycle gas corresponding to 2-3
wt-ppm sulfur in the feed, a CCR Platforming Unit exhibits the following relative to clean
conditions:
An activity loss of 8-11°C (15-20°F);
A C5+ yield loss of 1-2 LV-%; and
A coking rate increase of approximately 50%.
d) Suggested Operational Response

Catalyst damage will be minimized by maintaining reactor temperatures as low as possible.
[There is no need to go below 482°C] If reactor temperatures are increased to compensate
for decreasing RONC while sulfur is present in the recycle gas, this will rapidly accelerate
coke lay down.
Every attempt should be made to eliminate sulfur from the feed. Once low sulfur naphtha
feed has been restored, the sulfur will gradually desorb from the catalyst. When the recycle
gas H2S content has decreased below 1-2 ppm, normal operation may be resumed.
Slightly increased chloride addition during the time in which sulfur is present in the recycle
gas will improve the rate of sulfur de-sorption from the catalyst. An increased chloride
addition rate to the chlorination zone will be needed in order to maintain 1.1-1.2 wt-% CI on
the regenerated catalyst. Furthermore, additional chloride addition (perhaps 0.5-1.0 wt-ppm
on a fresh feed basis) into the feed may improve sulfur desorption in the reactors and help
maintain normal chloride levels on the spent catalyst. These increased addition rates may
be required for 2-3 catalyst regeneration cycles after the recycle gas H2S content has
decreased to 1-2 mol-ppm in order to completely remove the sulfur on the catalyst.
During the time in which sulfur is present in the recycle gas, the maximum allowable
catalyst circulation rate, within the constraints of the General Operating Curve, will improve

Page 93 of 271
the rate of sulfur removal from the catalyst inventory. In addition, the lower air rate should
be increased to the design rate. Regeneration tower operations must be watched carefully
because the coking rate can be expected to increase by 50-200% or more while sulfur is
present in the system.
e) Possible Sources
Inadequate naphtha Hydrotreating: This can result from low activity Hydrotreating
catalyst or from simply running at too low of a Hydrotreating reactor temperature.
Recombination sulfur from NHT: Combinations of high Hydrotreater temperature and low
Hydrotreater pressure can promote recombination of hydrogen sulfide with trace quantities
of olefins. Such problems can normally be solved by lowering the Hydrotreater temperature
below 343°C (650°F).
Hydrotreater stripper upsets: These may result in incomplete stripping of H2S. Generally,
water as well as H2S will come over from the stripper, which also aggravates the situation.
Inclusion of cracked Naphthas in the Platforming Unit charge: Most cracked naphthas
have a high sulfur content. They must, therefore, be hydro treated with a more active
Hydrotreating catalyst or at a higher Hydrotreating reactor temperature.
Processing of feeds with high end boiling points in the Platforming Unit charge: In
general, for any of the typical Platforming Unit feed stocks, as the end boiling point
increases, the sulfur content increases. In other words, compared to the lighter boiling
fractions of a given feedstock, the heaviest boiling fraction contains the highest sulfur
content as well as the sulfur compounds that are most difficult to de-sulfurize. The refiner
must monitor the sulfur content of the Platforming Unit feedstock to ensure that sulfur does
not contaminate the Platforming Unit.
f) Possible Mechanical Problems

Increased iron sulfide formation throughout the unit.

Page 94 of 271
2. Nitrogen
The maximum allowable concentration of nitrogen in the naphtha feed is 0.5 wt-ppm. Every
attempt should be made to absolutely minimize the nitrogen content of the naphtha. A real
level of 0.5 wt-ppm nitrogen in the feed to a 1590 m³/day Platforming Unit will result in the
deposition of 823 kilogram per year of ammonium chloride deposits in the recycle gas
circuit and stabilizer column overhead. Also, every kilogram of nitrogen in the feed that
reacts to form ammonium chloride combines with 2.5 kilograms chloride, which must be
made up or otherwise the catalyst chloride level will fall.
b) Methods of Detection: Analyze Naphtha Feed

Kjeldahl Nitrogen method: UOP 384
Chemiluminescence: ASTM D-4629
(Dohrman Apparatus)
- Preferred method
c) Process Symptoms
Nitrogen is an acid function poison. Organic nitrogen that enters the Platforming Unit will be
converted to ammonia. This ammonia will react with chloride on the catalyst to form volatile
ammonium chloride. The overall effect is to reduce catalyst chloride level producing the
following symptoms:
¾ Loss of catalyst activity;
¾ Increased hydrogen production;
¾ Increased hydrogen purity; and
¾ Increased reactor delta T’s.

Catalyst coking will be minimized by not raising temperature during the period of nitrogen
contamination.

Page 95 of 271
Every attempt should be made to isolate the source of nitrogen and eliminate it from the
feed.
Slightly increased chloride addition to the chlorination zone during the time in which
nitrogen is present in the feed will be needed to maintain 1.1-1.2 wt-% Cl on the
regenerated catalyst. If accurate feed nitrogen analyses are available, the increase in
chloride addition can be estimated as the amount needed to offset the nitrogen
contamination in the feed.
e) Possible Sources
1) Inadequate naphtha Hydrotreating: Most virgin straight run naphthas contain very
little nitrogen. Consequently, Hydrotreater processing such naphtha can be
designed at lower pressures than would be required if the naphtha contained higher
nitrogen levels. The difference in design pressure is normally 14 to 28 kg/cm² and
cannot be compensated for after the unit is designed. Therefore, it is necessary to
avoid processing higher nitrogen content naphthas in Hydrotreaters originally
designed for lower nitrogen naphtha. The hydrogen partial pressure is not sufficient
to accomplish complete nitrogen removal.
2) Inclusion of cracked naphthas in the Platforming Unit charge: Most cracked

naphthas have high nitrogen content. They must, therefore, be hydro treated at high
pressure in preparation for inclusion of Platforming unit feed. A stream of cracked
naphtha, even though small relative to total Platforming Unit charge, should not be
included to Platforming Unit charge if only low pressure hydrotreating is available.
3) Processing of feeds with high end boiling points in the Platforming Unit charge: In
general, for any of the typical Platforming Unit feed stocks, as the end boiling point
increases, the nitrogen content increases. In other words, compared to the lighter
boiling fractions of a given feedstock, the heaviest boiling fraction contains the
highest nitrogen content as well as the nitrogen compounds that are most difficult to
hydrotreat. If the end point of any of the naphtha hydrotreater feed stocks

Page 96 of 271
increases, the refiner must monitor the nitrogen content of the Platforming Unit
feedstock to ensure that nitrogen does not contaminate the Platforming Unit.
4) Improper use of inhibitors: Use of filming and neutralizing amines as corrosion

inhibitors throughout the refinery can sometimes lead to inadvertent naphtha
nitrogen contamination. Areas of caution are crude system overhead, hydrotreater
stripper overhead, and hydrotreater reactor effluent in addition to any other refinery
units processing naphtha, which will be sent to the Platforming Unit. Carefully
monitored ammonia and increased water injection is often a less expensive and
less risky solution than inhibitor injection. Where inhibitor usage is absolutely
necessary, strictly adhere to the recommended dosage.
5) Reprocessing of off-spec unleaded gasoline or contamination of Platforming Unit

feed tanks with unleaded gasoline: Nitrogen-containing chemicals are frequently
used as additives to unleaded gasoline.
6) Deactivation of hydrotreating catalyst: As the NHT catalyst loads up with metals, its
ability to remove organic nitrogen compounds falls off. Since nitrogen is more
difficult to decompose than sulfur or metals, it will be the first to show up in the
stripper product as the NHT catalyst fails.
Ammonium chloride deposits will accumulate in the Platforming Unit products condenser,
separator, recycle compressor suction lines, and debutaniser, Deethaniser columns. This
can result in decreased cooling capacity in the products condenser, possible compressor
damage (especially during regeneration when high water levels move the deposits onto the
compressor wheels or valves), and erratic column operation.
Moreover, extreme care must be taken when ammonium chloride contaminated equipment
is to be opened or inspected. Such equipment must first be thoroughly washed to remove

Page 97 of 271
the ammonium chloride deposits. Otherwise, the hydroscopic deposit will adsorb
atmospheric moisture and cause serious corrosion problems.
3. Water
A Platforming Unit performs best when the feed to the unit is essentially dry and the
water/chloride balance is maintained via chloride injection in to the chlorination zone of the
regeneration section. If an unknown source of water enters the system, the long term
effects can be an increase in catalyst coking rate and a decrease in yield and activity.

A recycle gas water content of 30 mol-ppm indicates excessive water, dissolved oxygen, or
combined oxygen in the feed to the Platforming Unit. Moisture levels at or above this level
may lead to excessive hydrocracking reactions and coke laydown. Additionally, the chloride
will be stripped from the catalyst, upsetting the water/chloride balance.
1) Suggested on-stream moisture analyzers:
Analyzer Stream
Du Pont 560 Recycle Gas
Panametrics 3000 Feed/Recycle Gas
Mitsubishi Water Analyzer CA-03 Feed
2) HCI in recycle gas by sniffer tube (e.g., Draeger)
c) Process Symptoms
Water tends to act as a metal function poison (much like sulfur) and enhance the acid
function. Water also strips chloride from the catalyst to form HCl in the recycle gas. In the
short term, this high level of HCl accentuates the acid function, most notably hydrocracking.
Therefore, the short term observable effects may include:
¾ Decreased hydrogen production
¾ Decreased recycle gas hydrogen purity
¾ Higher C3 and C4 yields
¾ Reduced delta T’s

Page 98 of 271
¾ Lower C5 plus yield

¾ Increased catalyst coking rate
¾ Increased recycle gas HCl levels
If feedstock with high water content is charged over a long period of time, the catalyst may
become chloride deficient. The extent of this deficiency will be apparent in a decreased
chloride contents of the spent and regenerated catalysts.
d. Suggested Operational Response

Catalyst damage will be minimized by maintaining reactor temperatures as low as possible.
[There is no need to go below 481°C] Failure to lower temperatures could result in a
substantially increased coke content of the spent catalyst. In turn, this may affect the
operation of the regeneration section, which should be kept at all times within the
constraints of the General Operating Curve.
Locate the source of the water contamination and either remove it outright or make the
appropriate process adjustments to the feed pretreating units. When the recycle gas water
has decreased to less than 30 ppm, re-establish normal operating temperatures.
An increased chloride addition rate to the chlorination zone will be needed in order to re-
establish the recommended 1.1-1.2 wt-% Cl on the regenerated catalyst.
e) Possible Sources
1) Inadequate hydrotreating of feed may allow unconverted oxygen compounds
to enter the Platforming Unit. Oxygenated hydrocarbon compounds frequently
contaminate Naphthas in storage tanks.
2) Furthermore, any properly hydro treated feed that is not completely stripped
will allow water and other catalyst poisons to enter the Platforming unit.
3) Leaks in stream or water exchangers in upstream units.
4) Platforming Unit water injection system.
5) NHT stripper feed effluent exchanger leaks.

Page 99 of 271
6) Inadequate drying in the drying zone of the regeneration tower.

7) Leaks in stream heaters or steam jackets in the regeneration section.
8) Leaks in cooling pads of blowers in the regeneration section (if applicable).
9) Leaks in cooling panel of the surge hopper in the regeneration section (if
applicable).
10) Improper operation of the reduction zone gas removal system (if applicable).

1) The excessively high HCl in the net gas from the Platforming Unit may be
corrosive to downstream equipment and units.
2) Excessively high HCl in the debutaniser, Deethaniser off-gas from the
Platforming Unit may be corrosive to the overhead system and to downstream
equipment and units.
4. Metals
a) Maximum Allowable Concentrations

Because of the quantitative and irreversible effects of Platforming catalyst metal
contamination, there should be no detectable levels of metals in the Platforming Unit
charge.
b) Method of Detection
For small concentrations in the naphtha feed there are some specific methods that are
improvements over AAS (Atomic Adsorption Spetroscopy) or more recently ICP (Induction
Coupled Plasma):
Detectability Limit
Arsenic in Petroleum Naphthas: UOP 296 1 wt-ppb
Trace Concentrations of Lead

in Gasoline or Naphtha: UOP 350 10 wt-ppb

Page 100 of 271
Copper in gasoline and Naphtha: UOP 144 6-7 wt-ppb
Silicon in Aqueous Solution: AAS 0.1 wt-ppm
For analysis of a catalyst sample for possible metal contamination:

Impurities in Alumina Base
Catalysts by Spectrography: UOP 303
c) Process Symptoms
Most metals are poisons to the platinum function of the catalyst. The observable effects will
be a loss of overall catalyst activity and selectivity as more and more catalyst is
contaminated.

Periodic checks for metal content should be made of the naphtha hydrotreater charge. Any
periods of significant metal content in the hydrotreater feed should be documented in an
attempt to quantify the total weight of metals going to the hydrotreater. Normally, UOP
hydrotreating catalyst can still function effectively with up to a total metals loading of 2 to 3
weight percent. If the hydrotreating catalyst has been exposed to sufficient metals to
approach this 2 to 3 weight percent level strong consideration should be given to replacing
the hydrotreating catalyst. Likewise, if any detectable metals levels are found in the
hydrotreated naphtha and increased hydrotreater temperature does not eliminate the
problem the hydrotreater catalyst should be changed. Any metals that do enter the
Platforming Unit will irreversibly damage the catalyst, but quick detection and subsequent
metal contaminant removal on the refiner’s part can often limit the damage to a small
percentage of the Platforming catalyst inventory.

Page 101 of 271
e) Possible Sources
1) Some virgin naphtha contains measurable levels (ppb) of arsenic.
2) Lead can be introduced by either reprocessing of off-spec leaded gasoline or
contamination of Platforming Unit feed tanks with leaded gasoline.
3) Corrosion products:
Corrosion of plant hardware can result in migration of the corrosion products
into the reactors. Iron is the most common such corrosion contaminant;
molybdenum, chrome, and copper are other possibilities. Especially in the
case of iron, these corrosion contaminants are better tolerated by Platforming
catalysts than are organic metals. These corrosion products often enter the
first Platforming reactor as sulfide scale from the charge heater, combined
feed exchanger and hydrotreater. The scale will accumulate in the first
Platforming reactor and may cause hydrocarbon flow distribution problems.
4) Water treating compounds containing zinc, copper, phosphorus, etc., have at
times been mistakenly added to Platforming Unit charge.
5) Some cracked (coker) naphthas can contain silicon, added as an antifoaming
agent elsewhere in the refinery.
6) Excessive injection of corrosion inhibitors on NHT strippers can result in the
inhibitor getting into the stripper bottoms. This is especially of concern when
there is no overhead liquid draw on the stripper.

Metallic scale migration into the Platforming reactors may cause pressure drop and
hydrocarbon flow distribution problems if the scale accumulation in the scallops is great
enough.
5. High Feed End Point

A Platforming Unit is designed to produce aromatic hydrocarbons. This aromatic production
apparently cannot occur without some very small amount of single ring aromatic
condensation into multi-ring polycylic aromatics. These polycyclic aromatic hydrocarbons
are direct coke precursors. Once they are formed, they are strongly held to the catalyst
surface and will further convert to what is typically referred to as coke on the catalyst. The

Page 102 of 271
rate of natural formation of coke on the catalyst is fortunately very slow at typical
Platforming operating conditions. As discussed earlier, coke formation does increase
significantly as Platforming Unit pressure and hydrogen circulation are decreased and/or
temperature (octane) is increased. These are all changes that would favour further aromatic
condensation to coke. One other operating variable that was shown to have a significant
effect on catalyst deactivation (coke formation) was naphtha feed end point. As the feed
end point approaches 204°C (400°F), increased levels of naturally occurring polycyclic
aromatics are carried with the naphtha. Since these compounds are still present at ppm
levels even at 204°C (400°F) naphtha end point, the absolute amount will probably vary
significantly with crude type and with fractionation efficiency. Since they are direct coke
precursors, these compounds can be considered as a catalyst poison. Once deposited on
the catalyst, they can only be removed by regeneration.

204°C is a critical temperature regime for the naphtha cut point. Above this end boiling point
(based on an ASTM D-86 distillation), the concentration of polycylic aromatics in the feed
naphtha will increase rapidly. UOP does not recommend operation above this end boiling
point.
Measure the ASTM D-86 end point of EACH FEED STREAM to the unit or hydrotreater. In
some instances where blends of various feed types are used, a GC or True Boiling Point
endpoint may better indicate a “tail” not picked up by the ASTM endpoint.
c) Process Symptoms
The effect of more rapid coke deposition will be to increase the coke content of the spent
catalyst. In turn, this may affect the operation of the regeneration section, which should be
kept at all times within the constraints of the General Operating Curve.

Page 103 of 271
c) Suggested Operational Response

Analyze EACH FEED STREAM for ASTM D-86 end point once per shift and adjust the
fractionation to maintain each stream’s end point below 204°C (400°F). Maintain sufficient
reflux to minimize “sloppy” end points on all appropriate columns.
e) Possible Sources
If the Platforming Unit feed is coming from multiple refinery sources (e.g., straight run
naphtha, hydrocraker, coker naphtha), EACH FEED STREAM should individually be
analyzed for compliance with the 204°C (400°F) end point limitation. Blending of a high end
point stream with a low end point stream will “mask” the high boiling fraction for the heavy
stream. The polycyclic aromatics will still be present, but may not be indicated or detected
by the ASTM D-86 end point.

There are no known mechanical consequences.

Page 104 of 271

Page 105 of 271
FIGURE-2
WAIT REQUIREEMNT CORRECTION FOR LHSV

Page 106 of 271
FIGURE-3
TEMPERATURE – OCTANE RESPONSE

Page 107 of 271
FIGURE-4
EFFECT OF C5+ RONC ON C5+ LV-% YIELD

Page 108 of 271
FIGURE-5
EFFECT OF CYCLE CONTENT ON C5+ LV-% YIELD

Page 109 of 271
FIGURE-6
EFFECT OF REACTOR PRESSURE ON C5+ LV-% YIELD

Page 110 of 271
FIGURE-7
EFEFCT OF BOILING RANGE ON C5+ LV% YIELD

Page 111 of 271
FIGURE-8
EFFECT OF C5+ RONC ON C5+ LV-% YIELD

Page 112 of 271
FIGURE-9
EFFECT OF FEED N + 2A ON C5+ LV- % YIELD

Page 113 of 271
FIGURE-10
EFFECT OF REACTOR PRESSURE ON C5+ LV - % YIELD

Page 114 of 271
FIGURE-11
EFFECT OF BOILING RANGE ON C5+ LV - % YIELD

Page 115 of 271

Page 116 of 271
FIGURE 13

Page 117 of 271

Page 118 of 271
FIGURE - 15

Page 119 of 271
FIGURE-16
EFFECT OF C5+ RONC ON RELATIVE COOKING FACTOR
HYDROTRETAED STRAIGHT RUN NAPHTHA

Page 120 of 271
FIGURE-17
EFFECT OF N + A ON RELATIVE COOKING FACTOR
HYDRO TRETAED STRAIGHT RUN NAPHTHA

Page 121 of 271

Page 122 of 271
FIGURE-19
EFFECT OF AVERAGE REACTOR PRESSURE
ON RELATIVE COOKING FACTOR

Page 123 of 271
FIGURE-20
EFFECT OF H2/HC RATIO
ON RELATIVE COOKING FACTOR
H2/HC RATIO = COMBINED FEED H2/HC RATIO + 0.7 H2 NET GAS MOL RATIO
(H2 NET GAS MOL RATIO IS BASED ON FRESH FEED)

Page 124 of 271
FIGURE-21A
TOTAL HETA OF REACTION FROM TOTAL DELTA T

Page 125 of 271
FIGURE-21B
MOLECULAR WEIGHT CORRECTION
TO HEAT OF REACTION

Page 126 of 271
SECTION - 5
PRE-COMMISSIONING PROCEDURE
5.1 GENERAL
As the new unit nears completion, there is a large amount of preparatory work, which should
be performed by the operating crew. A planned check of the unit will not only set the
foundation of a smooth start-up, but will also provide a firm basis for acquainting operators
with the equipment. Start-up is a critical period and the operator must exactly know the
operation of each equipment.
Some of the pre-commissioning works can be carried out simultaneously along with
construction. But, care in the organisation of this work is necessary so that it will not interfere
with construction work. It is most important to plan schedule and record with checklists and
test schedules all the preliminary operation and to co-ordinate the construction programme.
5.2 PRE-COMMISSIONING ACTIVITIES
The material in this section gives general guidelines for preparing a unit for start-up. Some
sections need to be expanded to give specific directions (water flushing procedure,
inertising procedure for example); this shall be prepared by commissioning personnel prior
to start of the pre-commissioning/start-up.
5.2.1 Inspection / Checking
Sections of the unit should be checked out as soon as the contractor completes work in
those areas. Immediately following inspection of those areas, punch lists which indicate the
deviations from the design specifications should be written and distributed to the contractor.
In this manner mistakes in construction can be found and corrected early.

Page 127 of 271
Inspection of the plant can be basically divided into the following areas:
¾ Vessels including reactor, Heaters
¾ Piping
¾ Instrumentation
¾ Exchangers
¾ Pumps
¾ Compressors
¾ Catalyst/Chemical Inventory
a. Inspection of vessel, column, heaters etc.
Inspection of the interior of the vessels, columns, heaters and other equipments not normally
accessible during operation, should be made to ensure that they are complete, clean and
correctly installed. Tray assemblies in columns should be checked with reference to the
engineering drawings to detect any defect in assembly or construction and to ensure
cleanliness. Packing if any to be done after internal inspection and flushing. The demisters to
be fitted after internal cleaning and water washing.
In heaters, the burner assemblies should be checked for easy operation of air registers,
contour of the burner throat, debris material etc. The heater coils supports to be checked for
proper installation.
b. Piping and Accessories
Piping and accessories will be checked against drawings and specifications. Piping support
and hangers will be inspected to ensure that all anchorages are firm. Valves will be checked
for proper packing and mounting direction and accessibility for operation and maintenance.
Spring supports, if any, to be checked for the cold setting and later for hot settings while plant
is in operation. Check for completion of welding work, especially on small bore piping and
socket weld valves.

Page 128 of 271
c. Instruments
All instrument tapings for pressure, level and flow should be clear and thermo wells should not
foul with the internals. These should be checked prior to box up of the equipment.
Instruments will be checked, starting from the controller and proceeding logically through the
control loop. Cascade control system will be checked from the impulse point of primary loop.
Operating crew should check proper mounting of control valves. Control valves responses
should be checked for controller outputs. The shutdown systems of the equipments should be
checked by simulating the various conditions in the control circuits.
d. Relief Valves
Relief valves will be set in the shop and mounted before the system pressure test. Block
valves ahead and after relief valves will be checked for lock open or lock close position as per
P&ID. Relief valves will be checked against specifications.
e. Rotary Equipment
All rotary equipment such as pumps, compressors, turbines etc. are to be checked for
bearings, internals and free movement. The auxiliaries, control systems on this equipment
should be thoroughly inspected.
f. Drainage System
Check the OWS and blow down system against drawings. Check for free flow.

Page 129 of 271
5.2.2 Preparation for Pre-Commissioning
¾ Check the unit for completion of mechanical work against P&ID.

¾ Check list points are liquidated. Any pending point will not affect pre-commissioning
operation.
¾ Remove all construction debris lying around in the unit and clean up the area.
¾ Install blinds as per master blind list.
¾ Safety valves should be kept blinded during flushing and re-installed afterwards. These
should be shop tested and set at the stipulated values.
¾ Ensure that underground sewerage system is in working condition. Clear plugging, if
any. Check by flushing with water.
¾ Check that communication between units, control room, offsite and utilities are
complete and in working condition.
¾ Ensure that the required lube oil, grease and other consumable are available in the
unit.
5.2.3 Pre-Commissioning Operation
Prior to the commissioning of the plant there are several pre-commissioning operations that
must be conducted to prepare the plant for the actual start-up; these are:
¾ Commissioning of utilities
¾ Final inspection of vessels
¾ Pressure test equipment
¾ Acid cleaning of compressor lines
¾ Wash out lines and equipment
¾ Functional test of rotating equipment
¾ Service and calibrate instruments
¾ Dry out fired heaters
¾ Dry out of Reactor section
¾ Chemical Boil out of steam generation facilities
¾ Purge and gas blanketing
¾ Tightness test

Page 130 of 271
It is important that these operations be carried out as thoroughly and as well as possible to
help achieve a smooth and trouble-free start-up and later steady normal operation. A
discussion detailing the major items to monitor in each of these operations follows.
The above outline may be expanded as follows:
Commissioning of Utilities
The various utility lines should be tested and placed into service as soon as the
construction schedule allows. Pressure tests should be carried out on all steam
condensate, air, fuel gas, flare, and nitrogen lines as is done on all process lines.
A. Steam Network
Network shall be blown through completely from battery limit with a strong steam flow in order
to clean the lines. The following steps are recommended:
¾ Check network, all equipment will be disconnected to avoid entry of flushed material.
¾ Drain all the low points. If necessary open steam trap inlet flanges.
¾ Open slowly battery limit valve and let the temperature rise in the header, slowly and
steadily.
¾ Check support of fixed points and expansion loops.
¾ When line is hot, blow it through completely with a strong steam flow for 5-10 times.
¾ Close battery limit valve and prepare another network. When the blowing are
satisfactory, reconnect all equipment and remount steam traps. Recharge header as
above.
¾ To gauge the effectiveness of the steam blowing (and the amount of scale left in the
lines), target plates should be installed at the blow down points. The lines should be
repeatedly blown down until virtually unmarked target plates are obtained.
Condensate lines should be continually checked and traps removed and cleaned if
plugged.

Page 131 of 271
The following precautions to be taken while blowing / commissioning steam header:

¾ To drain the low points of the lines before and during heating period in order to avoid
water accumulation as this causes hammering.
¾ To open drain / vent during cooling period to prevent vacuum formation
¾ To isolate the instruments, remove orifice plates and control valves; to re-install the
orifice plates and control valves after blowing is over.
B. Cooling Water and Service Water:
Network shall be cleaned from battery limit with a strong water flow. All equipment will be
disconnected at the inlet and reconnected when lines are cleaned. Control valves and orifice
plates will be removed and re-installed, after the lines become clean. When system has been
flushed, charge the lines to the operating pressure.
The following precautions to be taken:

¾ To open vents at high points in order to expel air from equipment and piping
¾ To open the battery limit valve, slowly and steadily.
¾ Disconnect all the connected equipments and reconnect after flushing repeatedly.
C. Boiler Feed Water:
Flanges are to be opened at the inlet of the connected equipment and at any convenient low
point. Network shall be first cleaned with raw water from battery limit with a strong water flow.
The network shall then be drained and rinsed with boiler feed water. Open flanges will be
made up and header charged after the network is clean. Usual precautions for instruments
like isolation, removal etc., are to be taken as mentioned above in case of steam network.
D. Instrument and Plant Air:
Network shall be blown through completely from battery limit with strong flow of air in order to
clean and dry the lines. All joints and connections shall be checked for tightness with soap

Page 132 of 271
solution. Header and branch lines will be blown through with a high flow rate of air. During all
tests, the instruments and control valve shall be carefully isolated from the system.
E. Fuel Gas/Oil Network:
Networks shall be blown through from battery limit with a strong air flow in order to clean the
lines. Ensure that the entire system is dry before replacing the accessories. During the
operations, orifice plates and control valves shall be removed. Special care shall be taken to
prevent water from entering the furnace. The fuel oil and fuel gas headers will be
commissioned before firing the Heaters.
F Raw Water
Raw water lines to safety eyewashes, showers, drinking fountains should be flushed then left
running to remove and dilute any harmful substance. Analysis of the water should be made at
points of human consumption to ascertain whether the water is fit for human consumption.
G Firewater and sprinkler system
After removing all nozzles, each fire hydrant and turret should be flushed. Since this may be
first time the firewater pump is operated, the pump’s operation should be observed carefully.
Replace all turrets nozzles when flushing is complete. Before flushing sprinkler system remove
all sprinkler heads; flush the entire system. When clean, replace heads. Inspect each head
before installation to make sure it is clean. Dry each piece of equipment with its head installed.
2. Final Inspection of Vessels/ Reactors
All vessels should be inspected before final closing and any loose scale, dirt, etc., should be
removed. Any line coming directly off of the bottom of a dirty vessel should be removed.
It is very important that the internals of the Plat forming reactor be inspected very carefully.
The Plat forming reactor internals should be checked for holes and/or damage and repaired

Page 133 of 271
as required. The catalyst support basket and unloading sleeve should be checked to
ensure correct fit in the nozzles.
The separator should be checked carefully to be sure the cement lining is installed well and
that the mesh blanket is securely fastened to the support ring. There should be no gaps in
the mesh blanket.
System tightness test must be conducted to check all flanges and fittings, especially the
ones opened during flushing. This final tightness test must be witnessed and is normally
done just prior to start-up.
3. Pressure test equipment
Hydrostatic pressure testing of the unit, after final construction completion, for verifying the
strength of the materials and welding integrity. General guidelines for the hydro testing of
equipment are:
¾ An air pressure test may be placed in the sections of the plant prior to hydrostatic
pressure testinh so that any open lines or flanges may be located and repair before
the test.
¾ All equipment in the section of the plant to be tested should be rated for the test
pressure.
¾ The test pressure gauge should be installed at the bottom of any vessel to include
any liquid head effects.
¾ Safety valves, rupture disk and relief valves must be removed and/or isolated from
the testing system.
¾ The water used must be clean and contains less than 50 wt-ppm chloride.
4. Acid Cleaning of Compressor suction
Mill scale, dirt, heavy greases, and other foreign materials that could enter the compressor
and result in operating and maintenance problems must be removed from the compressor
suction system.

Page 134 of 271
5. Wash out Lines and Equipment

After pressure test has been completed on any vessel with its connected piping, receivers,
exchangers, etc., required blanks are pulled and water is circulated for the purpose of
removing any dirt, scale, etc. Much of the dirt is picked up in the pump screens where it is
taken from the system by removing and cleaning the screen.
All possible lines and pumps should be used during the washing procedure for complete
cleanout of the system. Of course, no water circulation should be carried out in the gas
sections of the unit. Temporary water connections should be provided at convenient locations
in the system for carrying out water flushing.
The following points should be remembered during water flushing.

¾ Low point drains and high point vents should be purged.
¾ All instrument connection should be isolated, orifice plates removed, control valves
isolated and by-passed. In case there is no bypass, remove control valve and flush the
line. The valve will be installed after clean water starts coming out and further flushing
may be continued.
¾ If there is any heat exchanger in the line, flushing should be done up to and around the
exchanger using by-pass line. It should be ensured that dirty water from initial flushing
does not get into the exchanger. Wherever by-passes are not available, the flanged
joints at the inlet of heat exchanger should be first opened and the line flushed till clear
water starts coming out. Then reconnect flange and flush through the exchanger.
¾ At each opening of the flanged joints, a thin metallic sheet should be inserted to prevent
dirty water from entering the equipment or piping.
¾ The flow of water should preferably be from top to bottom for flushing of heat
exchanger coolers. The bottom flange of the equipment should be opened to permit
proper flushing.
¾ The flushing should be carried out with maximum possible flow of water till clear water
starts coming out.
¾ Vertical lines which are long and rather big (say over 100 mm dia) should preferably be
flushed from top to bottom. This will ensure better flushing. Filling the lines and
releasing from bottom is also helpful. The rundown lines can also be flushed
conveniently from the unit to the respective tanks.

Page 135 of 271
¾ It should be ensured in all flushing operation that design pressure of lines and
equipment are never exceeded. After flushing of lines and equipment, water should be
thoroughly drained from all low points. Lines and equipment containing pockets of
water should not be left idle for a long time; it is preferable to dry these lines and
equipment with air after water flushing.
6. Functional Test of Rotating Equipment
All rotary equipment (including dosing pumps) will undergo functional test to check their
performance.
A. Motors
Each motor should be checked and started to ensure that it has the correct direction of
rotation. The motor speed should be checked with tachometer to ensure that RPM is correct.
The manufacturer's lubrication schedule should be used to ensure that all lubrication points
have been serviced. After a short run each bearing should be felt to ensure that it is free and
not overheated.
B. Pumps
Prior to unit start up, all centrifugal pumps should be thoroughly checked and run in properly
(after pressure testing and water flushing) as indicated in the following outline: The pumps
will be started and operated according to the manufacturer’s instructions.
CAUTION: Many high head pumps are not designed to pump water. To do so can result in damage to the pump
internals. Check the vendor’s specifications before attempting to run in pumps with water.
¾ Check to see that all necessary water piping has been made to stuffing boxes,
bearing jackets, pedestals and quench glands. Make sure that all necessary lube oil
piping is installed, and that this piping is not mistakenly connected to the water
system.

Page 136 of 271
¾ Check arrangements to vent the pump for priming if the pump is not self-venting.
See that special connections such as bleeds and drains are properly installed.
¾ Check strainers in pump suction lines. Strainers must be installed before aligning
pumps. A 4 mm (three to five mesh) strainer is provided for each pump suction line
during start-up. To avoid pump damage during flushing with water, the strainers
should temporarily be lined with 1 mm (20 mesh) screen.
¾ Remove this screen after water flushing is completed. All strainers should be
flagged, and a list similar to the blind list should be kept, so as to prevent a “lost”
screen from plugging and upsetting unit operation later on.
¾ Check that power is available for running in the pump. Check that pressure gauges
and any special instrumentation are in working order.
¾ Water circulation on motor driven hydrocarbon pumps can result in motor
overloading if the full pumping capacity is used. In this type of equipment, the
capacity must be reduced by throttling the discharge during such periods. An
ammeter can be used to determine the required throttling.
¾ Before lubricating oil-lubricated bearings, check bearing chamber in pumps to see
that no flushing compounds or shipping grease is left in the chamber.
¾ Mechanical-type pumps should be flushed with water prior to pump operation so no
dirt gets into the seal and scores the seal faces.
¾ It is extremely important that the proper type and viscosity oil and proper grade of
grease is used to lubricate the equipment. Refer to manufacturer’s instructions and
lubricating schedule for this information.
¾ Motor should be checked and started to ensure that it has the correct direction of
rotation. The motor speed should be checked with tachometer to ensure that RPM is
correct. The manufacturer's lubrication schedule should be used to ensure that all
lubrication points have been serviced. After a short run each bearing should be felt to
ensure that it is free and not overheated.
¾ See that the driver rotates the pump in the direction indicated by the arrow on the
pump casing. Rotate the pump by hand to see that it is clear before starting.
¾ Couple up and align the pumps, then check for cooling water availability and start
flow of cooling water to the pumps requiring external cooling, before they are run in.

Page 137 of 271
¾ Open pump suction valve and close discharge valve (crack discharge valve for high
capacity, high head pumps). Make sure the pump is full of liquid.
¾ Start the pump. As the pump is motor driven, the pump will come up to speed.
Immediately check discharge pressure gauge. If no pressure is shown, stop the
pump and find the cause. If the discharge pressure is satisfactory, slowly open the
discharge valve and give the desired flow rate. Check the amperage of the motor.
Do not run the pump with the discharge block valve closed except for a very short
time. Note any unusual vibration or operation condition.
¾ Check bearings of pumps and drivers for signs of heating. Recheck all oil levels.
¾ Run the pump for approximately one hour, then shut off to make any adjustment
necessary and check parts for tightness. Since it is not possible to run the pump at
operating temperature, a final check of alignment must be made during normal
operation by switching to the spare pump.
¾ Start the pump and run it for at least four hours.
¾ Shut the pump down and pull the strainer. Clean the strainer and replace it in the
suction line. Remove the temporary fine mesh liner from the strainer after water
flushing is complete.
On a new unit, the screens are sometimes left in service for the first run on all locations
where spare pumps have been provided.
When water is used for pressure testing and washing, it is sometimes better to have
packing in the pumps for a seal to prevent dirt from ruining the mechanical seal.
After the lines and equipment are judged to be clean and all the pumps have been run in,
the water should be drained from the various systems. Lines containing low spots should
be broken at the low spot if no drain is provided. Underground lines, without drains, should
be blown free of water. Before draining any vessel, a vent must be opened on that vessel
so that a vacuum will not be created on draining. If the towers are to be left standing for a
long period of time before steam drying or before operation, an inert gas, such as nitrogen
or sweet fuel gas, must be introduced to the vessels to prevent rusting of the internals from
oxygen in the air.

Page 138 of 271
Of course, no water circulation should be carried out through the gas compressors. It is
important that the catalyst and the compressors are not exposed to excessive moisture.
C. Compressors / Other Special Equipments
In the case of rotating equipment, (such as the recycle gas compressor, net gas
compressor, the separator pumps and other special equipment) , vendor representatives
(motor vendor also in some cases) normally directs rotation and alignment checkout and all
other activities required to prepare the equipment for service. Rotating equipment
specialists and operations representatives should monitor and participate in this activity for
verification purposes, as well as for the opportunity to learn valuable information about the
equipment. However the following measures before compressor commissioning is
suggested.
Centrifugal Compressor
The compressors will be started and operated according to the manufacturer’s instructions.
Vendor representative should present for start-up of compressor. However general UOP
guideline is given below.
a. Pre start-up Checks

There are several points that must be checked before the compressor is ready to run. In
general manufacturer’s representative will pre-check the compressor, drivers, the lube oil
system and seal oil system prior to initial start-up.
b. Start-up Procedure for Compressor
¾ Check the rotating element of the compressor for free rotation by turning slowly by
hand. If the rotor rubs, rotation should be stopped immediately, and the difficulty
located and repaired.
¾ Line-up and start seal and lube oil circulation system to make certain that the
bearings of the compressor and driver are well lubricated.
Note: Seal system should be is in operation whenever any pressure is in the compressor, even though the machine is idle.

Page 139 of 271
1. Remove any suction/discharge line blinds.

2. Purge and pressurize the compressor as follows.
3. Close sour oil vent valve to minimize gas losses until the compressor is on stream.
4. Purge air from the compressor with nitrogen, and then pressurize the compressor to
7 kg/cm2g with nitrogen and leak test the compressor.
5. Blow down all compressor casing.
6. Pressure the compressor to the line pressure. During dry out the unit will be
pressurised with nitrogen or hydrogen. For unit start-up pressure with hydrogen.
7. Unblock the compressor suction and discharge.
8. Put stand by seal and lube oil pumps on auto start.
9. Start the compressor rotating and bring the machine speed to 500 rpm. Note any
vibration or noise. If either occurs, shutdown immediately and locate the problem.
10. Note: The machine should be brought up to operating speed in several stages.
11. Allow the compressor to run at the specified rpm until the seal and lube oil rise to
near operating temperature, usually about 50oC. Start cooling water flow through oil
cooler to maintain temperatures at the desired level.
12. Increase the compressor speed stepwise to above the critical speeds being sure to
increase the speed smoothly and rapidly through the critical speeds. Put compressor
on governor control and establish the desired flow.
13. Crack open the vent valve on the sour oil pot.
14. Make any necessary adjustment as required in the manufacturer’s instructions for
continuous operations.
Reciprocating Compressor
The compressors (Net gas compressors) will be started and operated according to the
manufacturer’s instructions. Vendor representative should present for start-up of
compressor. general guideline is given below.
a. Pre start-up Checks
There are several points that must be checked before the compressor is ready to run. In
general manufacturer’s representative will pre-check the compressor, drivers, the lube oil
system and circulating cooling water system prior to initial start-up.

Page 140 of 271
b. Start up Procedure for the Compressor

1. Purge the compressor with nitrogen through suction purge valve to the atmosphere.
2. Role the machine over to ensure complete purging.
3. After nitrogen purging of the machine, introduce hydrogen to the compressor through
the hydrogen pressuring line.
4. After partially pressuring the compressor with hydrogen, roll the machine over and
vent the hydrogen to the flare or through the atmospheric vent to displace nitrogen in
the machine.
5. Gradually open the compressor suction valve to pressure up the machine to line
pressure.
6. Start steam to the steam tracing. Drain the suction line and volume bottle of any
liquid.
7. Make sure that there are no restrictions to the gas flow from the compressor.
8. Start cooling water flow to the compressor. Check temperatures, pressure and levels
as required.
9. Start compressor auxiliary lube oil pump. Check pressure and flow as required.
10. If the machine is fully equipped with suction unloader valves, start up the machine as
follows:
a) After the machine is pressured with hydrogen, close the small bypass vent
line, unload all of the suction valves, and open the compressor discharge
line.
b) Check the compressor’s lubricating oil level in the crankcase or reservoir.
c) Start the compressor and check the oil pressure.
d) Let the compressor idle for a few minutes while closely watching the suction
temperature. Then close the suction valve loaders to put the machine on
line. Follow the manufacturer’s loading sequence if he has specified one.
11. Verify that all lubricators for the seals, packing and cylinders are working. Fill the
reservoir with correct type of oil. Adjust the drop rate as specified.

Page 141 of 271
7. Service and Calibrate Instruments
Normally, instrument lead lines will be tested hydrostatically up to block valves when the
balance of the unit is tested. Hydrostatic test pressure will not be made on instruments
which normally handle gas and no pressure-measuring element should be subjected to test
pressures above its range. Also, never pull a vacuum on a pressure instrument or gauge
unless it is specifically designed for it.
All instrument air piping should be tested at 7kg/cm2g with compressed air. Soap should be
used on all joints to check for leakage. Care should be taken to ensure that this high air
pressure is not put on any instruments or control valve diaphragms. Likewise, when
pressure testing the unit, care must be taken that the fuel gas pressure balance valves are
blinded off to keep high pressure off the diaphragm.
Before starting up, all instruments should be serviced and calibrated. This includes
carefully measuring all orifice plate bores with a micrometer. The following guidelines may
be adopted for checking and calibration of all instruments.
Orifice Plates
Before each orifice plate is installed the orifice taps should be blown clear. The orifice plate
should be callipered to check, if the correct size orifice plate is installed. The plate should then
be installed after checking for the correct direction.
Differential pressure Transmitters and Receivers

Ordinarily these should be calibrated locally against a manometer. The calibration should be
checked at the receiver, which may be board or locally mounted, recorder or indicator.
Pressure Transmitters and Receivers

These should be checked in place. The calibration of the receiver should be checked at the
same time.
Alarms
All alarms, auto start and cut off systems should be checked by simulating the conditions.

Page 142 of 271
8. Dry out Fired Heaters

Before a heater is put into service for the first time, it will be necessary to slowly expel the
excess moisture from the insulating concrete (setting) by gradually raising its temperature
before nay appreciable load is put on the heater. Heater dry out will be carried out as per
the Dry out procedure.
i) Generalised Heater Dry out

¾ Make a temporary installation of thermocouples through the pipe sleeves in the hip
section of the heater. The tips of these thermocouples should extend 150mm beyond
the inside of the insulating concrete but should not contact the tubes
¾ It is preferable to use gaseous fuel for drying out the heater. If no gas is available,
liquid fuel may be used, but it should be free of sediments and heated as required to
give the proper viscosity for good atomization and clear combustion
¾ Before starting to light any burners, all individual burner and pilot block valves are to
be closed, and the firebox steamed out to remove any gas accumulation. Open all
dampers.
¾ Light all pilots. Verify they all work
¾ Light one or more burners, as required, in each section of the heater and fire slowly
so that the temperatures as indicate by the hip thermocouples increases about 14oC
per hour until a level of 480-510oC is reached. While increasing the temperature,
rotate the burner operation frequently to disrupt the heat as evenly as possible
throughout the heater firebox. Setup a time table with burner numbers so there is no
confusion shift to shift. Problems with the burners can be corrected as found.
¾ Maintain 482-510oC on the hip thermocouples for 10 hours or two hours per inch of
refractory wall thickness exists. Rotate burners operation frequently during the hold
period to assists in equal distribution of heat.
¾ After the ten hour hold period, all burners and pilot should be shut off and the heater
refractory allowed to cool slowly by keeping the air inlet registers and stack dampers
closed. Close all pilot and burners block valves.
¾ After cool down is complete, the temporary hip thermocouples should be removed,
and the plugs replaced in the stack pipe sleeve. If the heater has been dried out as
outlines above, the heater temperature may be subsequently raised and lowered at

Page 143 of 271
rates consistent with the safe operation of the heater and unit. Is the heater has been
shut down for a prolonged period of time it may be necessary to repeat the dry down
procedure.
ii) General rules for fired heater with fuel gas mode
¾ Before starting to light any burners, see that all individual burners block valves are
closed, and steam out the firebox to remove any gas accumulation. Make sure that
dampers are opened. Continue steaming until a steady plume of steam is visible
rising from the stack. Than stop steaming and pinch in the dampers.
¾ Light each pilot individually by opening its gas valve slowly after inserting a lit torch I
front of the pilot head or light using a push button ignition system if installed. When
the pilot ignites, open its gas valve completely; gas flow to the pilot head is controlled
by an orifice in the pilot assembly
¾ Once all pilots are lit, light the required number of gas burners from their respective
pilots. After a few burners are lit, it may be necessary to open the dampers more to
provide enough graft to light additional burners.
¾ Burners should be fired to produce a blue flame with a yellow tip, obtained by
regulating the primary and secondary air supply. The heaters should be checked
frequently for the dirty burners which might give either too long or a misdirected
flame. There must be some excess of air to the burners, so that an increase in the
fuel gas flow will have sufficient air to produce complete combustion.
¾ If for any reason, the fires in the heater go out, then:
1. Shut off the gas supply immediately by closing the block valves at the fuel gas
control valves. Bypass and light pilot lines which might be located upstream of
the fuel gas control valve’s block valve must also be closed.
2. Put snuffing steam in the firebox.
3. Close all individual burners and pilot valves.
4. Only after the heater has been properly purged it can be restarted.
¾ As in all heaters, care should be taken that nn flame impingement on the tubes is
permitted.

Page 144 of 271
iii) General rules for fired heater with fuel Oil mode
¾ Before starting to light any pilot burners, see that all individual oil guns are removed
from the burners and steam out firebox to remove any gas accumulation. Make sure
that the dampers are opened.
¾ Always light the gas pilots first. Have fuel oil circulating through the fuel oil return at
normal operating temperature before attempting to light any oil burners. The
recommendation steps for safety lighting an oil burners are:
1. Push the oil guns forward, and then turn on steam by fully opening the steam
block valve and the steam control valve. Close off when the steam is dry.
2. Make sure the oil block valve is closed, and then open the stream bypass
valve to clean and warm the burners.
3. When condensate has been removed and the steam is dry, close the bypass
steam valve.
4. Adjust atomizing steam valve for a small flow of steam.
5. Open oil block valve gradually until the oil starts burning; the oil will ignite from
the pilot flame. Take care to see that unburned oil is not put into the firebox.
Accumulated unburned oil will become hazardous as the firebox heats up.
6. Adjust the atomizing steam valve and oil to obtain correct flame pattern. Never
let the flame touch the tubes.
¾ Oil burners should be fired to produce a yellow flame with a good pattern obtained by
regulating the primary and secondary air supply. The furnaces should bee checked
frequently for dirty burners which might give either too long or a misdirected flame.
There must be some excess of air to the burners, so that an increase in the fuel gas
flow will have sufficient air to produce complete combustion.
¾ If for any reason, the fires in the heater go out, then:
1. Shut off the fuel supply immediately by closing the main block valves in the
fuel supply to the furnace. This will take care of any bypass lines which might
be opened around the control valve.
2. Put snuffing steam in the firebox.
3. Block in the pilot gas line. Close all individual burners and pilot valves.

Page 145 of 271
4. Only after the heater has been properly purged it can be restarted.
¾ As in all heaters, care should be taken that nn flame impingement on the tubes is
permitted.
9. Dry out of Reactor Section

Before loading catalyst into the reactors, it is necessary that the lines and equipment be
dried to remove any traces of water which might have remained from the construction and
flushing. This step is normally carried out by using the recycle compressor and the heaters
to circulate hot nitrogen through the normal process circuit and draining condensate from
the separator. Waste heat recovery system for steam generation is installed in the
convection zone of the Platforming heaters, this system can be thoroughly cleaned out at
this time.
On units equipped with centrifugal recycle compressors, the use of air for this dry out
procedure is not recommended because of the possibility of an oxygen-seal oil explosive
mixture in the compressor at elevated temperature. Fuel gas can, however, be utilized if it is
sweet, light, and contains no contaminants which might cause equipment coking or catalyst
poisoning.
Precautions must be taken during the dry out procedure to avoid overheating of the heater
tubes, which might cause oxidation or scaling on the outer surface. The external condition
of the tubes should be observed frequently during the dry out period to assist in early
identification of any tube overheating. The heater is equipped with a waste heat recovery
steam generation section, normal operation should be established on this section during the
dry out procedure.
All of the reactor internals including the catalyst flow pipes between the reactors should be
installed prior to the dry out operation. This will minimize work to be done in the reactors
after dry out and provide an opportunity for identification/correction of any possible heat up
stresses, etc. on internals during the preloading inspection.

Page 146 of 271
The following procedure outlines a satisfactory method for carrying out this drying
operation:
Line up the reactor and recycle gas compressor circuit for dry out.
1. Block-in the recycle and net gas compressor suction and discharge lines.
2. Line up valves through the entire system to isolate the Platforming reactor system
from the fractionation section and all other units. Ensure that all drains and vents are
closed and capped. Include net gas recontact section of the unit for dry out. It is a
good opportunity to run-in the reciprocating machines and verify the split range
pressure controls work. If a CCR unit attached, pressured gas from the booster
compressors is put back into the reactors so in that case this section of the unit must
also be dry.
3. Air free the unit.

NOTE: Whether nitrogen, sweet fuel gas, hydrogen or a mixture of these is used for dry out, set the unit pressure at a
value consistent with the safe operation of the compressors.
4. After the unit is air free, purge the recycle compressor and net gas compressors with
nitrogen to remove air. Once the compressors pressure equals the unit pressure line
them up to the unit.
5. Establish normal operation of the reactor products condenser
6. Start the recycle gas compressor and net gas compressors. Establish circulation
through the system at a rate compatible with the compressor discharge temperature
and pressure differential. Slowly increase the net gas section to the limit
recommended by the compressor vendor. The pressure controls should be in auto.
NOTE: High gravity gas such as nitrogen will result in much higher compressor discharge temperatures.
7. Drain all free water from any low points in the system. This should be done both
before pressuring up and also during the heat-up and drying period.

Page 147 of 271
8. Light a few burners in each Platforming heater and bring the temperature up 55 to
83°C per hour until the reactor inlets reach about 260°C. Maintain this temperature
level until water drainage from the separator and plant low points reaches an
acceptable level (several lit/hour). During this period the entire reactor section should
be inspected closely for expansion, and problem areas noted for observation later
during the high temperature phase of the dry out.
9. Establish flows through all lines, there will be purge gas to the reduction zone, to the
catalyst collector, to lift engager No. 2, etc.
10. Once water drainage is reasonable, raise reactor inlet temperatures at 55-83°C per
hour until all inlets reach 510°C; maintain this temperature level until the drying is
complete. This will be indicated by a constant, low water draw off rate from the
separator(s) and other low points. The water draw off rate should be less than 100
ml. per hours.
11. When drying is judged complete, the heater fires can be cut. Gas circulation by
means of the recycle gas compressor, however, should be continued until all reactor
temperatures have cooled to less than 55°C.
12. After the reactors have been cooled, shutdown the compressor and de-pressure the
reactor section to a slight positive pressure in preparation for loading catalyst. If
hydrogen and/or fuel gas was used during the dry out de-pressure to the flare and
change to a nitrogen atmosphere. Before catalyst can be loaded into the reactors the
atmosphere must be changed to a dry air.
10. Chemical Boil-Out of Steam Generation Facilities
A waste heat recovery installation for steam generation is provided in the convection
section of the unit heaters, a thorough cleaning of this installation will be required following
construction. Such cleaning is generally done by performing a boil-out after all physical
inspections and checkout procedures have been performed and just prior to bringing the

Page 148 of 271
unit on stream. This boil-out is usually done with chemical enhancement to ensure complete
removal of all oil and other deposits that may have accumulated on internals during
fabrication and erection of the system components. Compete removal of any oil, grease or
oily scale from the inside of the pressure parts is required to avoid foaming and priming
during subsequent operation.
Several combinations of chemicals may be used to achieve a satisfactory job of cleaning

during the boil-out. Commercial mixtures are also on the market, which are designed to do
a very thorough and complete job of cleaning. These latter should be used strictly in
accordance with the manufacturer’s recommendations. Two satisfactory mixtures for
chemical boil-out are the following.
1. A mixture of Soda-ash (Na2CO) and Caustic Soda (NaOH) in equal proportions for a
total of 50 lbs. of chemicals per 1,000 gallons of boiler water.
2. An equal mixture of Trisodium Phosphate and Caustic Soda for a total of 40 lbs. of
chemicals per 1,000 gallons of boiler water.
These chemicals should be well mixed and thoroughly dissolved in hot water and are best
introduced into the steam drum through the temporary connection. Suitable tank for
preparation of solution and suitable pump for transferring chemical solution to steam drum
is to be arranged. Temporary line shall be installed for transferring chemicals from tank to
steam drum.
If possible, it is desirable to introduce part of the chemical solution into the feed line leading
to the boiler feed water preheat coil in order to obtain some cleaning action in the preheat
coil itself.
With the system in readiness and the chemical solutions prepared, the actual boil-out can
begin. The following suggested sequence may be used:
1. Fill the system to normal drum level, using the feed-water line and the regular feed
connections. Introduction of chemical compound into the feed water, as outlined

Page 149 of 271
above, would be desirable. The feed water should be limited to approximately 80-
90°C.
2. Make certain that the superheated steam line is closed to the refinery steam system.
Open the superheated steam coil outlet vent and drain lines, which are open to the
atmosphere and leave them partially open during boil-out. This will assure flow
through the Superheater tubes and avoid any accumulation of condensate.
3. Open the vent valve on top of the steam drum.
4. Start one of the Circulating water pumps (74-P-07A/B) to provide flow through the
steam generating coils.
5. Light fires in the heater. The boil-out procedures can be combined with the refractory
dry out or the unit reactor section dry out. Bring the heater firebox temperature up
55°C per hour maximum until the steam drum pressure is established at
approximately 3.5 to 7.0 kg/cm. Care must be taken to maintain a level in the steam
drum at this time.
6. Flow must be maintained through the boiler feed water preheat coil. Since steam will
be venting to atmosphere, this will be accomplished by charging make-up water to
maintain the level in the steam drum. If possible, a temporary line should be
connected from the discharge of the water circulating pumps to the boiler feed water
preheat coil inlet line to provide chemical to clean this section out, also.
7. Approximately once each shift, the unit should be blown down using the blow down
connections. The water should be dropped to the bottom of the gauge glass and then
fresh water added to bring the water back to the normal operating level. Chemical
solution should be added through temporary piping connection to maintain the
concentration in the boiler water as close to the recommended levels as possible.
During each blow down period, the Superheater drains should also be opened wide to
assure that no condensate has accumulated in the coil or outlet header.
The duration of boil-out will normally vary between twenty-four (24) and seventy-two (72)
hours, depending on the type and initial cleanliness of the unit, as well as the chemical
concentration and temperature maintained during boil-out. It is to be expected that twenty-
four (24) to thirty-six (36) hours should suffice to prepare the system for satisfactory
operation.

Page 150 of 271
Blow down water condition is one indication of whether the boil-out has achieved
satisfactory results. The only conclusive determination of boil-out effectiveness, however, is
by a visual internal inspection of the steam drum.
Upon completion of boil-out, the fires should be extinguished and the unit permitted to cool.
After drum pressure has reached zero, open vent valves and completely drain unit of
chemical solution.
After draining, the unit should be refilled with clean, fresh water to high drum level and
flushed through the drum blow downs, bottom drains, and the steam generation coils, after
flushing, open the steam drum for internal inspection to check on the effect of the boil-out.
The flushing procedure should remove practically all-residual chemicals and any
accumulation of sludge.
If the interior of the drum is adequately clean, the boil-out may be considered complete. If
cleaning is not adequate, the boil-out should be repeated. It must be emphasized that the
satisfactory operation of this section of the unit depends, to a considerable extent, on a
complete and thorough job of chemical cleaning.
After chemical cleaning is complete, the following steps should be taken:

1. The gauge glasses should be removed, cleaned and reassembled. Care should be
taken to be sure that all connections between the drum, gauge glasses, and water
columns are unobstructed.
Note: If desired, spare gauge glasses may be used during boil-out to be replaced by new glasses prior to normal
operation.
2. All manhole and other gaskets, which were exposed during inspection, blinding, etc.,
should be replaced with new operational gaskets.
3. All connections and closures, which were opened after hydro testing, should be
checked and tightened securely. All such connections should be watched carefully
for leakage when the unit is brought on-line later for normal operation.

Page 151 of 271
General Notes:
1. The heater refractory dry out, plant dry out and chemical boil-out procedures can be
combined in the interests of saving time. It is likely, however, that the heat input
during either the heater refractory or the unit dry out procedures may be excessive
for controlled chemical boil-out. Therefore, combining the two or three operations
may require a temporary interruption of the drying-out procedure while the flushing
operation is completed, and the steam generation facilities made completely
operational.
2. The drying-out and boil-out periods present an opportune time to check out the
operation of auxiliary equipment and instrumentation.
3. The waste heat circulating pumps should be operated in rotation to make certain that
there will be no difficulties during final start up.
11. Purging and Gas Blanketing
It must be remembered that oil or flammable gas should never be charged into process
lines or vessels indiscriminately. The unit must be purged before admitting hydrocarbons.
There are many ways to purge the unit and ambient conditions may dictate the procedure to
be followed: nitrogen or inert gas purging, displacement of air by liquid filling followed by
gas blanketing, or steaming followed by gas blanketing.
For the remainder of the unit other than the reactor section, steam purging followed by fuel
gas blanketing can be used to air free the unit. The following steps will briefly outline this
method.
Potential problems or hazards could develop during the steam purge are as follows:
1. Collapse due to vacuum: some of the vessels are not designed for vacuum. This
equipment must not be allowed to stand blocked in with steam since the
condensation of the steam will develop a vacuum. Thus, the vessel must be vented
during steaming and immediately followed up with fuel gas purge at the conclusion of
the steam out.

Page 152 of 271
2. Flange and gasket leaks: thermal expansion and stress during warm-up of
equipment along with dirty flange faces can cause small leaks at flanges and gasket
joints. These must be corrected at this time.
3. Water hammering: care must be taken to prevent ‘water hammering” when steam
purging the unit. Severe equipment damage can result from water hammering.
Block in the cooling water to all coolers and condensers.
Shutdown fans on fin-fan coolers and condensers. Open high point vents and low point
drains on the vessels to be steam purge.
Start introducing steam into the bottom of the columns, towers, and at low points of the
various vessels. It may be necessary to make up additional steam connections to properly
purge some piping which may be “dead-ended.”
Thoroughly purge all equipment and associated piping of air. Be sure to open sufficient
drains to drain condensate, which will accumulate in low spots and receivers.
When purging is completed, close all vents and drains. Start introducing fuel gas into all
vessels and cut back the steam flow until it is stopped completely when the systems are
pressured. Regulate the fuel gas flow and the reduction of steam so that a vacuum due to
condensing steam is not created in any vessel or that the fuel gas system pressure is not
appreciably reduced.
12. Tightness Test
Tightness test of reactor section will be carried out during start-up with the help of steam
ejector. Procedure is given in the next section. The guideline given below is to check the
tightness of flanges, joints, manholes etc. (except pumps and control instruments) in the other
section (feed section and fractionation section). This operation can be integrated with steam
purging activity aimed at expelling air (from feed, fractionation and the light end section) prior
to introducing hydrocarbon into the unit.

Page 153 of 271
¾ Drains at low points will be opened; after draining is over, these will be closed. Vent
will be opened; pressure gauges will be installed on each circuit.
¾ Steam is progressively admitted where connections are available. Circuits which do
not have direct admission of steam will be supplied through hoses.
¾ The temperature of the whole installation is increased slowly and free expansion of
lines is checked. The condensed water is drained while the temperature of the circuit
rises.
¾ When temperature is steady, vents are progressively closed in order to get the desired
pressure by keeping a vent slightly opened. A steam make-up is maintained. All joints
will be checked for leaks. If leaks are detected, system will be depressurised, leaks
attended and the system retested.

Page 154 of 271
SECTION - 6
COMMISSIONING PROCEDURE
6.1 INTRODUCTION
This section describes the start-up of the Platforming unit on a fresh load of catalyst.
Continuous Catalyst Regeneration (CCR) section manual for pre-commissioning and start-
up details shall be referred. The only section of the CCR that must be functional during the
Platforming Unit start-up is the Lock Hopper No. 2 system. It is needed to re-inventory the
reduction zone above reactor No. 1. During start-up thermal and mechanical effects in the
stacked reactors will result in a loss of catalyst from the reduction zone and possibly reactor
No.1 could be lost. Variations in the start-up procedure described are possible on
subsequent start-ups, depending upon how complete a shutdown has previously been
made. If a less, extensive shutdown has been made; various omissions in the following
procedure may be made as determined by the unit supervisor.
Prior to start-up, the Platforming reactor section should be dry to minimize leaching of
chlorides from the catalyst during the start-up sequence. Any water that has collected in the
system during the shutdown should be drained. The wet areas of the unit should be blown
dry if possible. For the initial unit start-up the unit should have been dried out before the
catalyst is loaded for those cases where the unit has been shutdown for catalyst change-out
and equipment has been filled with water for testing, circulation of hot gas through the
reactor section prior to catalyst loading is also advisable. A dry out procedure will ensure a
dry plant for catalyst loading.
Oil or flammable gas should never be charged into process lines or vessels indiscriminately.
If the lines or vessels have contained air, suitable purging should be done. Similarly, air
should not be allowed to enter lines or vessels which have contained hydrocarbon until
proper safety precautions have been taken. At no time should wet air (ambient or plant air)
or refinery fuel gas be purged through the catalyst bed. The moisture in the air and fuel gas
will leech the chloride off the catalyst as was mentioned earlier. Also, the fuel gas could
contain other catalyst poisons such as sulfur. The following procedure for purging and

Page 155 of 271
preparing the unit for start-up should be closely followed. If varying the purge procedure
appears necessary, the unit supervisor’s approval should always be obtained.
Before attempting to put the unit on stream, all necessary details with regard to the
mechanical condition of equipment, availability of utilities, etc., and reactor catalyst loading
should be complete. Other areas of the complex which may feel the effects of the start-up
and subsequent plant operation, such as the boiler house, units receiving products from the
Platforming Unit, and fuel and water facilities should be notified of the pending start-up.
Hydrotreated naphtha should be available for the unit start-up. If there is hydrogen
available, the Naphtha Hydrotreater unit can be placed on-line before the Platforming Unit.
Otherwise, previously treated naphtha taken from storage can be used. Typically, such
feed will have the following contaminant levels:
Boiling Range As per design
Total Sulfur 0.5 wt-ppm
Total Nitrogen 0.5 wt-ppm
Chlorides *(0.5 wt-ppm)
Lead *(20 wt-ppb)
Arsenic * (1 wt-ppb)
Water + Dissolved Oxygen + Combined Oxygen = Low enough to produce less than 5
mole ppm water in the recycle gas with no water injection.
∗ as low as the analytical method used for analysis is capable of detecting; parenthetical values are current UOP
laboratory method limits.
If hydro treated feed is not available, start-up may be done on non-hydro treated straight
run naphtha providing it meets the following limitations:
Total Sulfur 100 wt. ppm maximum
Total Nitrogen 1 wt. ppm maximum
Arsenic 5wt. ppm maximum
Lead 25 wt. ppm maximum
Halides 1 wt. ppm maximum
End Point 204°C (400°F) maximum
Bromine No. 1 maximum

Page 156 of 271
The start-up operating period on this feedstock must be limited to a maximum of twelve
hours and all reactor inlet temperatures must be maintained below 482°C (900°F) during
this period.
NOTE: Regardless of whether previously hydro treated or untreated straight run naphtha is used for the Platforming unit
start-up, the feed must be routed through a stripping column for adequate stripping and drying prior to being charged to
the Platforming unit.
The detailed start up procedure outlined below is divided into 11 sections. The timing of
some sections and steps is a matter of convenience, while others may fall into a necessary
sequence. Some of the sections and steps can or must be carried out simultaneously.
1. Prepare the unit for charging.

2. Purge and start the NHT stripper and Plat forming fractionation section.
3. *Evacuate and purge the Platforming reactor section.
4. *Evacuate and purge the net gas re-contact Section
5. Hydrogen pressurise the Platforming reactor and net gas recontact sections.
6. Start hydrogen circulation and reactor warm-up.
7. Start feed to the Platforming reactors.
8. Establish separator operation.
9. Start chloride adjustment program.
10. Establish normal fractionation section operation.
11. Lineout.
* These two steps can be done as one system.
The above outline is expanded on the following pages into more detailed steps, which cover
each operation.
6.2 PREPARE UNIT FOR CHARGING

¾ Blinds are installed as per master blind list. Each removal and insertion of a blind
should be noted and installed by the operator- in-charge.
¾ All unnecessary blind are removed.
¾ All construction tolls, debris are removed. Plant is cleaned.
¾ All vessels, piping, equipment are pressure tested, flushed and ready for service.

Page 157 of 271
¾ All rotating equipment such as pumps, compressors, motors etc. have undergone
functional test successfully.
¾ Run-in the pumps on water / oil before the reactor section is started i.e., the reboiler
and reflux pumps on towers. If possible, run-in the reciprocating compressors
before heating up the reactor section. The centrifugal compressor is typically run-in
during the reactor section heat-up.
¾ All instruments have been checked, calibrated and ready for service. Control should
be on manual.
¾ All safety valves are in position after setting and testing. Isolating valves will be left in
lock open position. Spare valves should be kept isolated.
¾ All utility headers (cooling water, steam, air, fuel gas, water etc) are charged.
¾ Flare, closed blow down and sewer systems are in operable condition.
¾ All related units are informed of the start-up plan.
¾ All other pre-commissioning activities such as flushing, cleaning, purging, tightness
testing etc are completed.
¾ Leak checks all sections of the unit including Lock Hopper No. 2 system. Slowly
pressure to 6 kg/cm2g with either nitrogen or air (instrument air in the reactor
section). Check for leaks at all flanges, valves and fittings are required. Also
monitor the individual section pressures. If no leaks are found and system pressure
holds for one hour with no more than 0.14 kg/cm2g loss, then the leak test has
been successful. The pumps and compressors should be isolated from the rest of
the unit during the leak test. They can be leak checked separately. On new units
reciprocating compressors usually have many small leaks.
¾ Check fire and safety equipment.
¾ General Service system such as lighting, PA, telephone etc is in working condition.
¾ The proper quantity and quality of nitrogen is available.

Page 158 of 271
6.3 PURGE AND START PLATFORMING FRACTIONATION SECTION

a) If the fractionation section has been washed or hydrostatically pressure tested prior
to start-up, steam dry the columns. If the columns have not had water in them prior
to start-up, the towers can be purged with an inert gas such as nitrogen until
oxygen-free (less than 0.3% oxygen).
b) To steam dry the columns, pressure up to any safe pressure with steam, while
venting air from the high points and draining condensate from the low points. When
all air has been vented, discontinue venting, and allow the equipment to approach
the steam temperature. Stop the steam flow once the vessel is hot, and open all
vessel drains and vents. The rapid depressurisation of the column will vaporize and
blow-out any condensate left in the tower. When the column approaches
atmospheric pressure, the remaining hot steam vapors should be purged out with
sweet fuel gas before the steam has an opportunity to condense. The vent valves
should be closed and the drain valves regulated to remove any condensate.
Personnel should not leave the tower unattended during these final steps. Only
after all the tower valves have been closed and the tower is safely pressured with
nitrogen or fuel gas can the start-up personnel move on to the next task.
NOTE: Gas should always be put in a vessel immediately after stopping the steam de-pressuring to avoid pulling a
vacuum on the vessel.
c) If the tower and its equipment are to be purged with nitrogen, introduce the gas at
low points. The towers should be purged from connections at the base and vented
at the highest point. All reflux and charge lines should also be purged as well by
using connections on the reflux and charge pump piping for introduction of the gas.
Continue purging until the vent gases escaping through the vents on top of the
tower and on the overhead receiver are oxygen free. Also be sure all dead legs
have been properly purged.
d) Prior to fractionation section start-up, establish column pressures at design
operating pressure or maximum sweet fuel gas header pressure, whichever is less.
e) Line up start-up naphtha from the NHT stripper tower. NHT stripper section is to
be commissioned before start-up of CCR Platforming unit.

Page 159 of 271
f) Bypass the Platforming reactor section from feed and fractionation section. Close
the block valves on the feed line to combined feed exchanger (74-E-01). Do not
flush hydrocarbons into the Platforming reactor section. Liquid lines from Separator,
74-V-01 (Separator pump discharge, line no. 4”-P-74-1207-B5A(B2A1), First stage
suction drum 74-V-02 (First stage suction drum pump discharge, line 2”-P-74-1413-
B5A(B2A1)) and second stage suction drum 74-V-03 (second stage suction drum
discharge line 6”-P-74-1806-B5A(B2A1)) going to Stabiliser are to be isolated.
Close Net gas lines to chloride treater, close stabiliser receiver overhead line to
First stage suction cooler. Use start-up bypass line (4”-P-74-1006-B5A (B2A1)) for
sending start-up naphtha to stabiliser.
g) Line–up start-up naphtha to stabiliser (74-C-01) using bypass line through stabiliser
feed-bottom exchanger (74-E-09A-D) bypassing reactor section
h) Start a flow of start-up naphtha to the stabiliser sections through the normal charge
lines using the reactor section bypass lines (Platforming Unit).
i) Build-up a good working level (50-60%) in the stabiliser bottoms. Commission
stabiliser condenser (74-E-10A/B/C/D). Start heat-up of the stabiliser column using
reboiler(74-E-11). Slowly open VHP steam to stabiliser reboiler, open reboiler
condensate outlet valve FV-2201. Drain water from the low point drain. Commission
stabiliser level control (LIC-2201). Keep reformate line from stabiliser at the B/L in
closed condition.
j) Ensure circulation of HP steam in stabiliser reboiler (74-E-11) coil and in the coils in
convection section. Circulation in convection section can be achieved by taking
BFW from BFW feed water booster pumps (74-E-05A/B) through convection
section coils and send it to Steam disengaging drum (74-V-09). Circulation in steam
generators will be achieved by circulating steam disengaging water through
Circulating Water Pump (74-P-2004A/B). For Initial circulation in Superheater coil
take HP steam to steam disengaging drum through start-up line and vent steam
through vent at the outlet of Superheater. Once steam is generated in the steam
generator close start-up steam line. Blow down condensate from steam generator
whenever required. Steam is also exported to stabiliser reboiler in stripper reboiler
in NHT unit through Desuperheaters.

Page 160 of 271
k) Heat-up stabiliser slowly. As the level builds in stabiliser receiver (74-V-05) drain
water thoroughly. When 50% level is achieved in 74-V-05, start stabiliser overhead
pump (74-P-04A/B) and establish circulation on stabiliser overhead circuit.
l) Close /start start-up naphtha flow to stabiliser as required to keep sufficient level
(50-60%) in stabiliser bottom.
m) When circulation has established in stabiliser overhead circuit, start routing
overhead liquid to LPG Chloride Treater (74-V-07A/B). Ensure that chloride treater
is ready for service before routing material through these. Liquid from the LPG
chloride treater is sent to deethanizer.
n) Open Reformate (stabiliser bottom product) line at B/L.
o) Similar take the start up of deethanizer column.
NOTE: if there is any chance that water is in the towers heat-up very slowly. If water vaporizes too quickly the pressure
surge could damage the trays.
p) Continue the start up naphtha flow until an adequate inventory has been
established in all towers then discontinue flow.
q) Raise or lower column heat inputs, as necessary, to maintain reasonable reflux to
feed ratios. It might be necessary to operate the towers at less than design
pressure in order to establish reflux.
r) Drain water from overhead receivers and system low points, as necessary.
s) Rotate pumps and commission instruments to test as much equipment as possible
before cutting charge into the Platforming reactors.
6.4 EVACUATE AND PURGE THE PLATFORMING REACTOR SECTION

a) Close all drain and vent valves in the reactor system. Isolate Lock Hopper No. 1 in
CCR Regeneration section from the Platforming reactor section with blinds as
necessary. Lift Engager No. 2 should be lined up to the reduction zone.
b) Block all instrument taps in the reactor section, including Lift Engager No. 2 block
valves on the compressor, and all valves and vents necessary to isolate the reactor
section from other sections of the unit and from other units. Feed lines and
Fractionation section is already isolated. Isolate chemical Injection system. Isolate
net gas section, Net gas coolers, Net gas compressor first stage suction drum (74-

Page 161 of 271
V-02), Net gas compressor (74-K-02A/B) 1st stage suction side will be under recycle
gas section. Close Separator pump discharge coming to Recontact Drum
c) Connect the vacuum ejector (74-J-01) to the Platforming Unit at Recycle
Compressor (74-K-01) suction.
d) Evacuate the reactor section to a minimum of 600 mm (24” Hg). Be careful with the
valving on the recycle gas purge lines to the reduction zone and the catalyst
collector. Keep the lines blocked in while evacuating the reactor section and crack
open when purging with nitrogen. This will avoid sending up too much gas up
through the catalyst bed and maximizing air freeing of the system. Repeat this step
during each evacuation and nitrogen purge. If this requires over an hour, there is
excessive system leakage or the steam ejector is not functioning properly.
e) When maximum vacuum is attained, block in the ejector and hold the vacuum for
an hour. If the unit is tight, there should be little or no loss of vacuum at the end of
the hour.
f) Break the vacuum to a positive pressure of 0.35kg/cm²g with nitrogen from the
discharge of the recycle gas compressor.
NOTE: In all cases, while adding nitrogen or hydrogen to the Platforming reactor system, normal flow through
the catalyst beds should be used. This reduces the danger of any catalyst displacement in the reactors.
CAUTION: To avoid the danger of pulling air into the compressors, no vacuum should be
put on the compressor cases. The compressors would be purged separately with nitrogen
from the suction through the discharge and out the vent line.
g) Repeat evacuation. Break the vacuum with nitrogen to 0.35-kg/cm² g.

h) Evacuate the Platforming reactor system to 600 mm Hg (24” Hg). Break the
vacuum to 0.1 kg/cm²g using electrolytic or reforming hydrogen consistent with the following
specifications:

Page 162 of 271
Source
Catalytic Reforming Electrolytic
Hydrogen purity, mol% 75 min. 99.5 min.
Carbon oxides, mol ppm Nil 20 max.
Nitrogen, mol% Nil 0.5 max.
Oxygen Nil Nil
Chlorine & Chlorides, mol ppm 50 max. Nil
Total Sulfur, Mol ppm 5 max. Nil
NOTE: Hydrogen from refinery Hydrogen Manufacturing Plants is normally not acceptable because of the inherently high
moisture content.
6.5 EVACUATE AND PURGE THE NET GAS RECONTACT SECTION
a) Close all drain and vent valves in the net gas recontact section.
b) Block in all instrument taps, isolate the reciprocating compressors, and block in all
valves and vents necessary to isolate the net gas section from other sections of the
unit and from other units.
c) Connect the vacuum ejector and evacuate this section to 600 mm (24” Hg). If it
requires over a half hour, there is probably a leak or an open valve.
d) When the vacuum is attained, block in the ejector and hold the vacuum for an hour.
If the unit is tight, there should be little or no loss of vacuum at the end of the hour.
e) Break the vacuum to a positive pressure of 0.35-kg/cm² g with nitrogen. The
nitrogen should be connected so as to maximize purging of all the piping in this
section. It may be necessary to purge with nitrogen at more than one location. All
dead legs must be properly purged. For example, the hydrogen line to lift engager
No. 2 must be back purged.
f) Repeat evacuation. Break the vacuum with nitrogen to 0.35kg/cm² g.
g) Evacuate a third time and break the vacuum with hydrogen. It must be the same
quality as that used in the reactor circuit. Pressure to 0.1 kg/cm²g.
h) Remove the last of the start-up blinds.
i) Line up the reactor section to the net gas recontact section.
j) Unblock all instruments in both the reactor and net gas recontact sections.

Page 163 of 271
6.6 HYDROGEN PRESSURE THE PLATFORMING REACTOR AND NET GAS

RECONTACT SECTIONS
a) Gradually bring the Platforming reactor and net gas recontact systems up to 7.0
kg/cm²g minimum hydrogen partial pressure or normal operating pressure,
whichever is lower, with additional hydrogen meeting the above specifications.
b) As pressure is increased, continue surveying the system for possible leakage.
NOTE: Do not exceed design-operating pressure of the product separator.
6.7 START HYDROGEN CIRCULATION AND REACTOR WARM-UP

a) Be sure the recycle gas compressor (74-K-01) has been purged with nitrogen first
and then hydrogen. Any oxygen present from air will be displaced out the
compressor discharge vent line by admission of nitrogen into the compressor
suction. The admission of hydrogen by the same route will purge out the nitrogen.
b) Open and close appropriate valves in CCR section to establish recycle gas purge
flow to the reduction zone and to the catalyst collector. Open the coalescer liquid
drain line.
c) Check the compressor suction and discharge lines for liquid. Check the separator
(74-V-01) and any drains in the recycle gas circuit for liquid.
d) Establish normal operation on the products condenser (74-A-01).
e) Establish normal operation on the net gas cooler and other coolers.
f) Start the recycle gas compressor (74-K-01) using the manufacturer’s suggested
procedure.
g) With recycle gas flowing, purge the Platforming reactor charge heater (74-F-01) and
inter heaters (74-F-02, 74-F-03, 74-F-04) as per normal practices, light fires, and
begin raising the reactor inlet temperature to 370°C at 30°C/hr. Due to the light heat
load, only a limited number of burners will be required in the heaters for the warm-
up period. Maintain maximum recycle gas circulation and line up charge to the unit.
h) While the reactors are being heated to 370°C, commission the net gas reciprocating
compressors (74-K-02A/B) as per the manufacturer’s suggested procedure. Load
the machines and slowly increase their discharge pressure, pressure
instrumentation should be in auto while the pressures are brought up. Do not
exceed design pressure.

Page 164 of 271
NOTES:
1) In order to preserve the select properties of fresh catalyst, the period of time required to heat the catalyst to
370°C should not exceed 12 hours.
2) Water circulation should be established in the steam generation section of the waste heat recover system, on
the heater prior to heater firing.
6.8 START FEED TO THE PLATFORMING REACTORS
a) Line up the gas blanketed start-up naphtha to the unit, if it was blocked in after
inventorying the tower.
NOTE: The start up naphtha shall not contain more than 100 wt. ppm – preferably less than 0.5 wt. ppm –
sulfur, and shall be as dry as possible. In order to assure a dry feed to the Platforming Unit even including the
case where start-up feed is coming from Hydrotreated storage, the feed must be routed through stripping column
of NHT and be adequately stripped prior to bring charged to the Platforming Unit.
b) Check the start-up naphtha to ascertain that it is clean, water white, and suitable for
reactor charging.
NOTE: The towers should be warmed up at or near operating pressure and on total reflux before charge is cut
into the reactor section.
c) When the reactor inlet temperatures reaches 370°C start the start-up naphtha to the
Platforming reactors at approximately one-half design rate. Close the start-up
bypass line around the Platforming reactor section if it was being used for
fractionation section circulation.
NOTE: Manpower should be available to light additional burners in the Platforming charger and inter heaters to
pick up the increased heat duty when charge is introduced.
d) Adjust firing on the charge heater and the inter heaters to hold 370-400°C on the
reactor inlet temperatures until separator operation has been established.
e) Adjust charge rate as soon as possible to achieve 0.75 LHSV minimum.
f) Care should be taken to prevent the hydrogen-to-hydrocarbon mole ratio from
dropping below design during charge-in operation. This H2/HC ratio should be
maintained as the hydrogen production commences and the unit pressure
stabilizes.

Page 165 of 271
6.9 ESTABLISH SEPARATOR OPERATION

a) When condensed reactor effluent has reached a satisfactory level in the separator
(74-V-01), start the separator pump (74-P-01A/B), unblock the separator level
control valve (LV-1202), and commission the level control instrument (LIC-1202).
b) After starting hydrocarbon flow from the separator, a level will quickly build in the
next downstream vessel, i.e., net gas recontact drums (74-V-04) or stabiliser
column (74-C-01), and equipment/instrument related to this (start separator pumps,
74-P-01A/B, first stage suction drum pump, 74-P-02A/B, commission level control
instruments, etc) should be commissioned in a similar manner to the previously
described vessel.
c) Once operation of the separator is established, the reactor inlet temperatures may
be increased according to the following criterion:
1) If the unit was started on untreated straight run naphtha the Platforming
reactor inlet temperatures can slowly be raised to produce the hydrogen
needed for start-up of the NHT unit. The Platforming reactor inlet
temperature should not be increased any higher than necessary to produce
the needed hydrogen quantity and, in any case, should not exceed 482°C
until the recycle gas moisture content has dropped below 200 mole ppm,
the sulfur content of the feed is 0.5 wt. ppm or less and the hydrogen
sulfide content of the recycle gas is below 2 mole ppm.
2) If the unit was started on hydro treated charge, the reactor inlet temperature
can be raised to 482°C at 30°C/hr. Do not exceed 482°C until recycle gas
moisture is below 200 mole ppm, the sulfur content of the feed is 0.5 wt-
ppm or less and the hydrogen sulfide content of the recycle gas is below 2
ppm.
d) During the period that reactor inlets are being raised, the charge rate may also be
increased stepwise over a two hour period to the desired rate.

Page 166 of 271
6.10 START CHLORIDE ADJUSTMENT PROGRAM
a) As soon as feed is charged to the reactor, begin injecting an organic chloride

compound into the feed for catalyst chloride adjustment by the programmed
method. Chloride will be injected by Condensate (74-P-10) and Chemical Injection
pump (74-P-11)/ Start-up Chemical injection Pump (74-P-09) at combined feed
exchanger inlet. The chloride injection rate by this method is dependent on recycle
gas moisture content as illustrated below:
Recycle Gas Moisture Chloride Addition Rate

(Mole ppm) (Wt. ppm of Feed)
Over 500 50
300-500 30
200-300 20
b) Generally, the unit will never contain less than 500 ppm moisture in the recycle gas
on start-up so the 50 ppm organic chloride injection rate should be in the initial rate
in most cases.
c) Begin sulfur injection as required to maintain 0.25-0.5 w ppm sulfur in the feed.
Sulfur will be injected by Sulfide Injection Pump (74-P-08A/B) to the feed line.
6.11 ESTABLISH NORMAL FRACTIONATION SECTION OPERATION
a) As soon as hydrocarbon flow reaches the fractionation section, line out the
stabiliser column. The column should already be warm and on total reflux so this
should require only adjusting the column reflux rates and heat inputs to obtain the
desired products.
b) Care should be exercised to ensure that material which has gone through the
Platforming reactor is not recycled to these reactors again.

Page 167 of 271
6.12 LINE OUT

a) If the charge stock used for start-up was not the normal charge stock, the normal
design charge stock should be placed in to the unit as soon as it is acceptable for
charging, i.e. meets the following requirements:
Boiling Range As per Design

Total Sulfur 0.5 wt. ppm
Total Nitrogen 0.5 wt. ppm
Chlorides 0.5 wt. ppm
Fluorides * (0.5 wt. ppm)
Lead * (20 wt. ppb)
Arsenic * (1 wt. ppb)
Water + Dissolved Oxygen + Combined Oxygen = Low enough to produce less than 5 mole
ppm water in the recycle gas with no water injection.
* as low as the analytical method used for analysis is capable of detecting; parenthetical values are current UOP
laboratory method limits.
NOTES:
1) Everything possible should be done to minimize the time non-Hydrotreated feed is brought into the unit.
2) Until the charge stock meets the above requirements, the recycle gas moisture level is less than 200 ppm
and the hydrogen sulfide in the recycle gas is less than 2 mole ppm, 482°C should not be exceeded on the
reactor inlets.
b) When the moisture content of the recycle gas is below 200 mole ppm, the hydrogen
sulfide content of the recycle gas is below 2 ppm, and the sulfur content of the feed
to the Platforming is 0.5 wt. ppm or less (by the Nickel Reduction Method, UOP
Method 357 or Microcoulometric method, UOP No. 727 or Tracor Atlas, ASTM D-
4045), the reactor inlet temperature can be increased to 493°C.

Page 168 of 271
c) As the unit continues to dry out, continue the chloride adjustment operation using
the following program:
Recycle Gas Moisture Chloride Addition Rate
(Mole ppm) (Wt. ppm of Feed)
100-200 10
30-100 5
Below 30 Normal Rate
NOTE: If the recycle gas moisture analyzer is not operating properly or cannot be properly calibrated, the following time
schedule can be used as a guide to adjusting reactor temperatures and chloride injection rates:
1) Assume 2 days are required for the recycle gas moisture content to be reduced to 200 mole
ppm.
2) Assume an additional 2 days are required for the recycle gas moisture content to be reduced to
30 mole ppm.
d) At 493°C reactor inlet temperatures the octane response should be checked. If the
response for a 2 RONC target increase is less than one clear octane number per 2-
3°C increase in reactor inlet temperatures (WAIT), the catalyst chloride balance is
low. In this event, consideration should be given to increasing the organic chloride
injection rate several ppm for several days, and remaining a reduced severity until
the octane response is back to normal. Alternatively, the reactor inlet temperatures
can be reduced below 482°C, while still maintaining sufficient hydrogen production
to keep the hydrogen users in operation; into the inlet of each reactor inject 0.1 to
0.2 wt-% chloride based on that reactor’s pounds of catalyst over a minimum of 4
hours. This operation should be closely supervised. Before increasing severity
recheck the unit octane response as discussed above.
e) When the recycle gas moisture content is less than 30 mole ppm, the reactor inlet
temperatures may be increased to achieve the desired product octane. At the
same time, the chloride injection rate should be reduced to normal. The normal
chloride injection rate will be dictated by the Platforming Unit recycle gas moisture
content and plant performance.
f) When the recycle gas moisture content decreases below 20 mole ppm, the injection
of water (clean steam condensate) to the feed should be established to maintain
the proper moisture content of the recycle gas. Condensate will be injected by

Page 169 of 271
Condensate (74-P-10) and Chemical Injection pump (74-P-11) at combined feed

exchanger outlet. Typically 1 wt-ppm water in the feed equals 3 mole ppm moisture
in the recycle gas. Assuming there is 0.5 to 1.0 wt-ppm dissolved water in the
stripper bottoms product, the normal water injection rate would then be 4 to 4.5 wt-
ppm based on the feed. Target moisture levels in the recycle gas are 15 to 25 mole
ppm.
g) As the unit is equipped with a CCR section, the reactor catalyst level will slump for
thermal and/or mechanical reasons after or during the Platforming unit start-up;
excess catalyst slump will be indicated by a low catalyst level alarm at the
Reduction Zone (top of Reactor No. 1). Fresh catalyst must be transferred to the
top of Reactor No. 1, to prevent loss of seal in Reactor No. 1. Catalyst transfer will
have to be accomplished by utilizing the regenerated catalyst transfer equipment
(Lock Hopper No. 2 system). Refer to the Catalyst Regeneration unit Operating
Manual for this procedure.
6.13 Recommendations to be taken care by operating personnel

Specific attention of the operating personnel should be paid to the following HAZOP
recommendation related with safe start-up operation:
• All instruments not suitable for vacuum service to be isolated during vacuum
pulling during start-up.
• Feed filter to be isolated during vacuum pulling at start-up.

Page 170 of 271
SECTION -7
NORMAL OPERATING PROCEDURES
During normal operation, the unit must be operated so that the two main objectives are
achieved. These are the objectives of the various product streams at proper specification
and the protection of the Platforming catalyst. These objectives can only be achieved on a
long term basis if good control is exercised on the unit. Such control requires that unit
weight balance (100+2 wt%) accurate analyses be reported on feed and product streams,
the feed be properly treated to remove contaminants, and unit operation be smooth at
proper catalyst water/chloride balance with a minimum of upsets
7.1 GUIDELINES FOR OPERATION

Control of the catalyst chloride-water balance for optimum catalyst selectivity and maximum
product octane or maximum aromatics production is one of the most critical area of
Platforming unit operation. A good technique for obtaining this objective (control) is
important for smooth operation, since such control must take into account all factors
affecting unit performance.
Typical factors involved are:

• Charge stock quality
• Average reactor pressure
• LHSV
• Product aromatics content or octane
• Recycle gas water content
• Hydrogen/hydrocarbon ratio
A change in any one of these factors can affect the unit operation sufficiently to cover up a
change in the catalyst chloride level. The unit performance interpretation technique must,
therefore, be chosen such that these factors are normalized before performance is
evaluated.

Page 171 of 271
The following data is generally plotted:

¾ Reactor inlets as WAIT, °C
¾ Total delta T, °C
¾ Reactor delta T, %
¾ C5+ yield, LV% of charge
¾ Stabilizer bottoms octane, F-1 clear
¾ Stabilizer bottoms aromatic content, LV% (Aromatics units only)
¾ Stabilizer off-gas, NM³/M³ of charge
¾ Stabilizer overhead liquid, LV% of charge
¾ H2 production, NM³/M³ of charge
¾ LHSV
¾ Molal H2 /HC ratio
¾ Separator pressure, kg/cm²g
¾ Recycle gas purity, mol% H2
¾ Chloride injection, ppm by wt.
¾ Water injection, ppm by wt.
¾ Water in recycle gas, molal ppm
From such daily operating plots, any change in unit performance that is not accounted for
by a corresponding change in unit operating variables may be readily recognized and
corrective action taken, if necessary.
The water and chloride injection amounts may seem to be insignificant by virtue of their
size, but are actually very important items in the maintenance of the unit chloride-water
balance and hence proper unit operation and catalyst activity.
Uncontrolled injection rates of either water or chloride will severely handicap stable
operation. The water and chloride injection tanks and gauge glasses should be rigorously
calibrated, chloride blends carefully prepared, and injection rates frequently checked. Under
normal conditions, the injection rates may vary from week, but, in most cases, will be
continuous.

Page 172 of 271
The water and organic chloride injection rates will be determined by monitoring the recycle
gas water and hydrogen chloride and water content of the naphtha charge, the selectivity of
the catalyst (aromatics in the product primarily), and the chloride content on the spent
catalyst. The HCI content of the recycle gas should be monitored once a shift with gas
tubes, i.e., HCI Dragger tubes. With the proper water injection rate the HCI in the recycle
gas can be obtained on a continuous basis through use of the moisture analyzer installed
on that stream. A general rule of thumb for correlation of water in the recycle gas is that one
weight ppm of water in the charge will give approximately three molal ppm water in the
recycle gas. The continuous moisture analyzer operation should be frequently cross
checked with this rule of thumb to insure its continued proper performance. Any
discrepancies on laboratory analyses should be checked. The control of catalyst chloride
levels can be as precise as operational diligence and spent catalyst chloride analyses
permit.
The operating pressure and other conditions of Debutaniser and Deethanizer must be
adjusted within column design limits to obtain the stabilised bottoms product. Analytical
results on the overhead and bottoms products are generally used as the basis of such
adjustments, i.e., changes to reboiler temperature and reflux flow rate.
Operator to check steam tracing for Fuel gas lines, pressure drop across feed strainer and
switch over to standby strainer whenever required. During switch over first line-up the
standby strainer and then close operating strainer. Operator to check for choking of pump
suction strainer

Page 173 of 271
7.2 OPERATING PARAMETER
Operating condition for CCR Platforming unit is given in the table below.
CCR PLATFORMING UNIT PROCESS SYSTEM

Description Tag no. Unit Value
(Normal)
Charge heater
o
Outlet temperature TI0505 C 549
o
Outlet temperature control TIC0504 C 549
No. 1 Interheater
o
o
No. 2 Interheater
o
o
No. 3 Interheater
o
Outlet temperature l TI0805 C 549
o
Reactors
o
Reactor 1 outlet temperature TI0901 C 421
o
o
o
Del P between inlet and outlet in R-01 PDI0901 Kg/cm2g Alarm 0.32
2
Del P between inlet and outlet in R-02 PDI0902 Kg/cm g Alarm 0.32
2
2
Reactor Purge Exchanger
Recycle gas to Reactor Purge Exchanger FT0901 m3/h 135
o
Recycle gas outlet temperature TT0905 C 316
o
Reactor effluent outlet temperature from reactor TI0910 C 181
purge exchanger
Combined Feed Exchanger
Fresh feed to combined feed exchanger FIC1001 M3/hr 140.7
2
Recycle gas pressure PI1004 Kg/cm g 5.67
o
Feed Outlet temperature TI1001 C 463

Page 174 of 271

(Normal)
o
Feed temperature TI1002 C 91
Combined feed exchanger diff pres between PDI1001 Kg/cm2g Alarm 0.7
product in and out
Combined feed exchanger diff pres between feed in PDI1002 Kg/cm2g Alarm 3.4
and out
Recycle gas to combined feed exchanger FI1002A/B/C m3/hr 12819
Product condenser
o
Separator
Level LIC1202 % LAL 20
LAH 80
Pressure PIC1203 Kg/cm2g 2.46
Recycle gas hydrogen content AI1201 %H2 ---
Recycle gas moisture content AI1202 Mole% ---
3
Separator pump discharge FIC1202 m /hr 95.4
Separator liquid to Recontact Cooler FI1201 m3/hr 95.4
Recycle compressor
Pressure drop across suction strainer PDI1301 Kg/cm2 Alarm 0.1
2
Recycle compressor suction pressure PI1302 Kg/cm g 2.46
2
Recycle compressor discharge pressure PI1305 Kg/cm g 5.67
o
Recycle compressor discharge temp TI1301 C 116
Net gas compressor first stage suction drum
First Stage Suction drum pressure PIC1501 kg/cm2g Alarm low 5
Gas to Net gas compressors first stage cylinder FI1601 M3/hr 10584
First Stage Suction drum level LIC1501 % LAL 20
LAH 80
First stage suction drum pump discharge FIC1401 m3/hr 4.9
Net gas compressor first stage discharge Cooler
o
Outlet liquid temperature TI1804 C 40
Second Stage Suction Drum
Drum level LIC1802 % LAL 20
LAH 80
Drum pressure PIC1801 Kg/cm2g 14.3
Net gas compressor second stage discharge Cooler
Net gas compressor second stage cylinder FI1701 M3/hr 4303
o
Outlet liquid temperature TI1907 C 40

Page 175 of 271

(Normal)
Recontact Cooler
o
Inlet temperature TI1906 C 54
o
Outlet Temperature TI1908 C 40
Recontact cooler outlet / feed to recontact drum diff PDI1901 Kg/cm2g Alarm high 1.1
pressure
o
Discharge cooler Outlet temperature of gas TI1908 C -14
Chiller Economiser
o
Inlet temperature from recontact drum TI1909 C -14
o
Recontact Drum
Drum level LIC1902 % LAL 20
LAH 80
2
Drum pressure PIC1901 Kg/cm g 23.8
Net Gas Chloride Treaters
Net Gas to PSA unit FI2001 Nm3/hr 2075
o
Outlet gas temperature (Net gas to B/L) TI2001 C 40
2
Outlet gas pressure (Net gas to Fuel gas header) PIC2008 Kg/cm g 22.81
Stabiliser
o
Inlet feed temperature TI2208 C 187
o
Overhead temperature TI2203 C 66
2
Overhead pressure PI2203 Kg/cm g 10.55
o
Bottom temperature TI2207 C 228
o
Reboiled liquid temperature TI2206 C 239
2
Bottom pressure PI2201 Kg/cm g 10.55
2
Diff pressure PDI2202 Kg/cm Range 0- 0.6
Reformate to storage FI2101 m3/h 105.7
Level control LIC2201 % LAL 20
LAH 80
Stabiliser reboiler
Condensate from Stabiliser Reboiler FIC2201 m3/hr 8.9
LPG Chloride Treaters
o
Stabiliser condenser
Pressure controller PIC2301 Kg/cm2g 10.16
Stabiliser receiver

Page 176 of 271

(Normal)
Stabiliser receiver gas to first stage suction cooler FI2401 Nm3/hr 386.9
Liquid level LIC2403 % LAL 20
LAL 80
Boot level LIC2401 % LAL 20
LAH 80
3
Stabiliser Reflux flow FIC2303 m /hr 41.3
Stabiliser overhead pumps discharge FIC2301 M3/hr 41.7
Deethaniser Bottom cooler
Stabilized LPG to storage FI2601 Nm3/hr 5.5
Deethaniser
Deethaniser feed FI2501 M3/h 5.3
Level Controller LIC2601 % LAL 20
LAH 80
Bottom Pressure PI2601 Kg/cm2g 28.49
Condensate from deethanizer reboiler FI2602 M3/h 0.47
Differential pressure indicator PDI2602 Kg/cm2g Range 0-0.6
Deethaniser Receiver
Level Controller LIC2704 % LAL 20
LAH80
Boot Level controller LIC2701 % LAL 20
LAH 80
Deethaniser off gas to fuel gas header FI2701 Nm3/h 20
Deethaniser reflux FI2703 M3/h 2.7
Deethanizer Reflux pump discharge flow FI2702 M3/hr 2.7
BFW Booster Pump
BFW to convection section FI2902 M3/h 36.5
Circulating water to convection section FI2802 M3/hr 465.6
BFW booster pump discharge FI2904 M3/h 4.5
Steam Disengaging Drum
Steam to convection section FI2901 Kg/h 34666
Level LIC2801 % LAL 30
LAH 70
2
Pressure PI2801 Kg/cm g 45.4
Charge heater firing
Charge heater Fuel gas to convection section PI3505 ---
Fuel gas to Charge Heater FI3101 kg/hr 1011

Page 177 of 271

(Normal)
Fuel Oil Atomizing steam to Charge heater FI3105 Kg/hr 410
Charge heater atomizing steam / fuel oil Diff pre PDI3106 Kg/cm2g ----
No. 1 Interheater firing
No 1 Interheater Fuel gas to convection section PI3501A/B/C mmH20 ---
No 1 Interheater Fuel gas to convection section PI3504 mmH20 ---
No1 1 Interheater atomizing steam / fuel oil Diff pre PDI3206 Kg/cm2g ---
Fuel gas to No 1 Interheater FI3201 Kg/hr 1529
Fuel Oil Atomizing steam to No 1 Inter heater FI3205 Kg/hr 620
No 2 Interheater atomizing steam / fuel oil Diff pre PDI3306 Kg/cm2g
No 3 Interheater atomizing steam / fuel oil Diff pre PDI3406 Kg/cm2g

7.3 LIST OF INSTRUMENTS

In this section control valves, pressure safety valves, analyzers, flame arrestor etc are
listed. Information regarding indicators & controllers (temperature, pressure, flow and level
instrument) are already given in previous section.
Control Valves:
Sl. No. Tag No. Description/Location Size Action of
(Inch) CV on Air
Failure
1 74-FV-0901 Purge gas to reactor purge exchanger 1 FO
2 74-TV-0905 Reactor effluent from Reactor purge Exchanger 1-1/2 FC
3 74-FV-1001 Fresh feed to Combined Feed Exchanger 3 FC
4 74-HV1002 Recycle gas to Combined feed Exchanger 14 FC
5 74-LV-1202 Separator liquid to Recontact Cooler 3 FC
6 74-FV-1202 Separator pump spillback 2 FO
7 74-HV-1301 Recycle compressor suction 24 FC

Page 178 of 271

(Inch) CV on Air
Failure
8 74-LV-1501 First stage suction drum liquid to Stabiliser feed –bottom 1-1/2 FC
exchanger
9 74-HC-1401 First stage suction drum pump spillback 1-1/2 FO
10 74-PV-1501C First Stage suction Drum Vent to relief header 10 FC
11 74-PV-1501A Net gas compressor first stage spillback 2 FO
12 74-PV-1501B Net gas compressor first stage spillback 3 FO
13 74-PV-1801A Net gas compressor second stage spillback 2 FO
14 74-PV-1801B Net gas compressor second stage spillback 3 FO
15 74-LV-1802 Second stage suction drum liquid to Stabiliser Feed-bottom 4 FC
exchanger
16 74-LV-1902 Recontact drum liquid to chiller Economizer 3 FC
17 74-PV-1901 Net gas to PSA unit 6 FC
18 74-FV-2201 Condensate from Stabiliser reboiler 2 FC
19 74-LV-2201 Reformate to Storage 6 FC
20 74-FV-2303 Stabiliser Reflux 1-1/2 FO
21 74-FV-2301 Stabiliser overhead pumps spillback 2 FO
22 74-PV-2301 Stabilizer Receiver Gas To First Stage Suction Drum 1-1/2 FC
23 74-LV-2401 Stabiliser Receiver Waste Water to OWS 1 FC
24 74-FV-2501 Deethaniser Feed 1 FC
25 74-LV-2601 LPG To Storage 1 FC
26 74-FV-2602 Deethaniser Reboiler Condensate 1 FC
27 74-LV-2704 Deethaniser Reflux 1 FO
28 74-FV-2703 Deethaniser Reflux pump spillback 1 FO
29 74-LV-2701 Deethaniser Receiver waste to OWS 1 FC
30 74-PV-2701 Deethaniser Off Gas To Fuel Gas 1 FC
31 74-FV-2802 MP steam to circulating water pump turbine driver - FO
32 74-PV-2901 Superheater steam to Desuperheater No 1 6 FC
33 74-TV-2907 BFW to Desuperheater No 1 1-1/2 FC
34 74-TV-2909 BFW to Desuperheater No 2 1-1/2 FC
35 74-FV-2902 BFW to Convection Section 2 FC
36 74-TV-2902 Circulating water to convection section 1-1/2 FC
37 74-FV-2904 Boiler feed water pump spillback 1-1/2 FO
38 74-PCV3001 Pilot gas to header 1 -
39 74-UV-3001 Reactors Heaters Pilot Gas To Supply Shutoff Primary 2 FC
40 74-UV-3002 Reactors Heaters Pilot Gas To Supply Shutoff Secondary 2 FC
41 74-UV-3003 Reactors Heaters Pilot Gas To Supply Shutoff Primary 8 FC
42 74-UV-3004 Reactors Heaters Pilot Gas To Supply Shutoff Secondary 8 FC
43 74-PDV-3108 Fuel Oil Atomizing Steam To chare heater 1-1/2 FC
44 74-PV-3105 Fuel oil to charge heater 2 FC

Page 179 of 271

(Inch) CV on Air
Failure
45 74-UV-3101A Charge heater fuel oil supply Shutoff primary 4 FC
46 74-UV-3102 Charge heater fuel oil supply Shutoff secondary 4 FC
47 74-UV-3101B Charge heater fuel oil return Shutoff 4 FC
48 74-PV-3102 Fuel gas To Charge Heater 2 FC
49 74-PDV-3208 Fuel Oil Atomizing Steam To No 1 Interheater 1-1/2 FC
50 74-PV-3205 Fuel oil to No 1 heater 2 FC
51 74-UV-3201A No 1 Interheater fuel oil supply Shutoff primary 4 FC
52 74-UV-3202 No 1 Interheater fuel oil supply Shutoff secondary 4 FC
53 74-UV-3201B No 1 Interheater fuel oil return Shutoff 4 FC
54 74-PV-3202 Fuel gas To No 1 Interheater 3 FC
55 74-PDV-3308 Fuel Oil Atomizing Steam To No 2 Interheater 1 FC
56 74-PV-3305 Fuel oil to No. 2 Interheater 2 FC
57 74-UV-3301 A No 2 Interheater fuel oil supply Shutoff primary 4 FC
58 74-UV-3302 No 2 Interheater fuel oil supply Shutoff secondary 4 FC
59 74-UV-3301 B No 2 Interheater fuel oil return Shutoff 4 FC

60 74-PV-3302 Fuel oil to No. 2 Interheater 2 FC
61 74-PDV-3408 Fuel oil atomizing steam to No 3 Interheater 1 FC
62 74-PV-3405 Fuel Oil To No 3 Interheater 2 FC
63 74-UV-3401 A No 3 Interheater fuel oil supply Shutoff primary 4 FC
64 74-UV-3405 No 3 Interheater fuel oil supply Shutoff Secondary 4 FC
65 74-UV-3401B No 3 Interheater fuel oil return Shutoff 4 FC
66 74-PV-3402 Fuel gas to No 3 Interheater 2 FC

Page 180 of 271
Pressure Safety Valves:
Sl. Set Pressure

Tag No. Description/Location Capacity (kg/hr) Relief Conditions
No. (Kg/cm2g)
External fire / Air cooled
st
Condenser duty lost / 1
1 74-PSV-01 A/B Separator 4.5 19796 stage suction cooler valve
closed / Electrical Power
loss to unit only
External fire/ 1st stage
Spillback valve fails open/
2 74-PSV-02 A/B First stage suction drum 8.0 20577 Stabiliser Press CV fails
open / Net gas Compressor
stop
Net Gas Compressor A
3 74-PSV-03 st
17.1 20577 Blocked outlet
1 stage Discharge
4 74-PSV-04 nd
2 stage Discharge
Net Gas Compressor B
5 74-PSV-05 st
1 stage Discharge
6 74-PSV-06 nd
29.1 17650 Blocked Outlet
2 stage Discharge
External fire / Gen cooling
water failure / 2nd stage
Second stage suction
7 74-PSV-07 A/B 16.5 7266 spillback fails open /
drum
Recontact level CV fails
open
External fire / Blocked outlet
8 74-PSV-08 A/B Recontact Drum 26.5 13510 / General Cooling water
failure / Loss of chiller duty
Net Gas Chloride Treater
9 74-PSV-09 26.5 2132 External fire
A
Net Gas Chloride Treater
10 74-PSV-10 26.5 2132 External Fire
B
Tube Rupture / Genera,
Electric Power Failure /
Pressure CV Fails Closed /
11 74-PSV-11 A/B Stabiliser Over head line 13.5 51457
Reflux Stops / External Fire /
General Cooling Water
Failure
12 74-PS-12 Stabilizer receiver 14 1109 External Fire
13 74-PSV-13 LPG Chloride Treator A 41 11108 External Fire
14 74-PSV-14 LPG Chloride Treator B 41 11108 External Fire

Page 181 of 271
Sl. Set Pressure

Tag No. Description/Location Capacity (kg/hr) Relief Conditions
No. (Kg/cm2g)
External fire / Gen Electric
power failure / Gen cooling
Deethanizer Overhead
15 74-PSV-15 A/B 31 10476 water failure / Reflux stops /
line
Electrical Loss to unit only /
Pressure CV Fails closed
16 74-PSV-16 Deethanizer Receiver 31.5 2690 External Fire
17 74-PSV-17 A/B Steam Disengaging Drum 50.5 38988 Blocked Outlet
18 74-PSV -019 Superheater Outlet 50 35474 Blocked outlet
19 74-PSV-020 BFW to Superheater No 1 50.5 2.4 m3/hr Blocked outlet
20 74-PSV-021 BFW to Superheater No 2 50.5 7.70 m3/hr Blocked outlet
21 74-PSV-022 Sulfide Storage Vessel 3.5 1776 External Fire
Analysers:
Sl. Tag No. Description Location/Service

No.
1 74-AT-1201 To measure recycle gas Hydrogen Recycle Gas Compressor Suction line
content
2 74-AT-1202 To measure recycle gas moisture content Recycle Gas Compressor Suction line
4 74-AT-3101 Charge Heater Flue gas oxygen content Charge Heater flue gas line
5 74-AT-3201 No 1 Inter Heater Flue gas oxygen No.1 Interheater flue gas line
content
content
content
9 74-AE/AT-3502 Flue gas from convection section CO and Fuel Gas from convection section
H2 content
10 74-AE-3503 Flue gas from convection section Fuel Gas from convection section
NOx/SO2/CO/CO2 content
11 74-AT-3503C SO2 analyser Flue Gas From Convection Section.
12 74-AT-3503B Flue gas from convection section NOx Fuel Gas from convection section
content
13 74-AT-3503A Flue gas from convection section CO Fuel Gas from convection section
analysis
14 74-AE/AT-3501 Opacity Monitor Fuel Gas from convection section
15 74-AE/AY-2101 Near Infrared analysers RONC of reformate to storage line

Page 182 of 271
SECTION - 8
SHUTDOWN PROCEDURES
8.1 GENERAL
While taking unit shutdown because of maintenance or emergency, care must be taken not to
admit air into the system until all hydrocarbon vapours have been removed. Operators should
be thoroughly familiar with shutdown procedures and understand the reasons for each work.
Good judgement must be exercised as no written procedure can completely cover all details or
problems that can arise in an emergency. Judgement is more likely to be exact if prior thought
and planning have been made.
In this section the activities related to the normal shutdown procedures have been briefly
outlined.
8.2 NORMAL SHUTDOWN PROCEDURE

The following shutdown procedure covers a normal planned complete shutdown such as
would be required for a catalyst change and/or the periodic cleaning and inspection of
vessels.
The operations described in these sections must overlap to some extent. The extent to
which these operations may be conducted simultaneously will depend upon the availability
of operating personnel.
The shutdown instructions, which follow, are divided into sections for convenience. Below is
a list of the various sections to be discussed:
1. Notify operating foreman and other units of shutdown.
2. Shutdown the Catalyst Regeneration Section.
3. Reduce heater temperatures and charge rates.
4. Cut out Platforming reactor charge.
5. Shutdown the Platforming separator(s).
6. Shutdown all Platforming reactor heaters.
7. Shutdown and block in all columns.
8. Shutdown the recycle compressor(s).

Page 183 of 271
9. Depressurize and purge reactor system.

10. Isolate system and install necessary system blinds.
11. Remove catalyst from reactors.
The above outline is expanded into more detailed steps, which cover each operation, as
follows:
8.2.1 Notify operating foreman and other units of shutdown

¾ Notify operating personnel and other operating units concerned as to exact time
when the shutdown operations will start. Changes in fuel gas composition, steam
requirements, etc., may affect other units.
¾ Pumpers and others who might be concerned with handling charge and product
streams should also be informed of the coming change.
8.2.2 Shutdown the Continuous Catalyst Regeneration section

¾ Shutdown the Continuous Catalyst Regeneration section as outlined in the manual
for that section. This will stop catalyst flow through the Platforming reactors.
¾ Isolate the CCR section from the Platforming reactor section by closing the
appropriate valves at the Catalyst Collector and at the Reduction Zone.
8.2.3. Reduce heater temperatures and charge rates

¾ Start reducing the Platforming reactor inlets to 455°C at 15-30°C per hour.
¾ At 482°C reactor inlets, begin reducing the feed rate stepwise to half the design rate
but not less than 0.75 LHSV. Strive to reach 455°C on the Platforming reactor inlets
simultaneously with the charge reduction rate.
8.2.4. Cut out Platforming reactor charge

¾ At 455°C, stop charge to the unit. Close B/L valve.
¾ Discontinue water and chloride injection.
¾ Adjust Platforming heater firing to hold 455°C and maintain maximum recycle gas
rate for at least one hour to sweep all residual hydrocarbons from the catalyst.

Page 184 of 271
¾ When sweeping of the catalyst is complete, cool the Platforming reactor inlets to
400°C.
8.2.5 Shutdown the Platforming separator

¾ Gas production will cease as soon as hydrocarbon stops passing over the
Platforming catalyst. Net gas compressors must be shutdown as per normal
procedure.
¾ When liquid has ceased flowing into the Platforming separator (check through LIC-
1202), stop pumps on the separator liquid outlet stream and block in the level control
valve(s). Pumps (74-P-01A/B), control valves (LV-1201).
¾ Drain all hydrocarbons from the separator, the Platforming Unit charge line
downstream of the flow control valve, and all low points in the system.
8.2.6 Shutdown all Platforming reactor heaters

¾ After the reactors (74-R-01/02/03/04) have been swept for at least one hour at 455°C
and then cooled to 400°C, shutdown all reactor heaters (74-F-01/02/03/04). Block in
fuel lines to each burner.
¾ Continue recycle gas circulation to cool the reactor bed outlets to less than 95°C at
30°C per hour. If the catalyst is to be handled during the shutdown, the catalyst beds
should be cooled to less than 65°C and preferably less then 55°C.
NOTE: If the shutdown is only of a temporary nature, do not cool below 400°C. Following heater shutdown, circulate only
long enough to cool the heater tubes (15 to 20 minutes) and then stop the recycle compressor. Block in the compressor.
Caution: Prolonged gas circulation (greater than eight hours) should be avoided in order to
preserve the catalyst properties.
8.2.7 Shutdown and block in all columns

¾ Continue reflux and reboiler flows until the stabiliser (74-C-01) have cooled down.
Add nitrogen, if required, to maintain a positive pressure during cooling.
¾ Shut stabiliser Reboiler (74-E-11). Isolate HP steam to stabiliser Reboiler.
¾ The overhead receivers (74-V-06) should be emptied by pumping (74-P-04A/B) the
liquid out the product line or back into stabiliser.
¾ The bottom levels in the column should be pumped or pressured out of the unit.

Page 185 of 271
¾ The columns, receivers and reboiler heaters may be steamed out to gas free the
equipment after the columns have been emptied of oil and depressurised. Normal
refinery practice for purging and washing of this equipment should be followed.
8.2.8 Shutdown recycle compressor

¾ When reactor outlet temperatures have cooled down to the desire level, shutdown
the recycle gas compressor (74-K-01) and take it off line.
¾ To guard against the danger of getting oil or moisture into the compressor, purge it
out with nitrogen rather than evacuating. Any moist air that gets into the compressor
will combine with deposits to form corrosive compounds. Recycle gas may be
removed from the machine by blocking off at the suction and discharge valves. After
de-pressuring, purge with nitrogen through the machine to the vent line.
¾ Leave the machine blanketed with a slight positive pressure of nitrogen.
¾ Same for net gas compressors.
8.2.9 Depressurize and purge the reactor system

Depressurising, evacuation, and purging of the reactor system should be done according to
the normal operating practices. In general, these will be similar to the following guidelines:
¾ Depressurise the Platforming reactor system into the fuel gas system until the fuel
gas system pressure is reached. Do this at product separator or piping in the net gas
recontact section.
¾ Bleed the balance of the system pressure off to flare or atmosphere, as appropriate.
Also do this from the product separator PSV bypass.
Note: During depressuring, evacuation and purging, normal flow through the catalyst beds should be used. This reduces
the danger of catalyst displacement in the reactors.
¾ Isolate the reactor section and connect the steam ejector to the Recycle gas suction.
¾ Evacuate Platforming Unit to at least 500mm (20 inches) of mercury vacuum.
¾ Break with nitrogen -injected into the discharge side of the recycle gas compressor to
0.35 kg/cm² g.
¾ Repeat evacuation and purge twice.

Page 186 of 271
NOTE: Make sure all dead legs are properly purged. Be sure to keep the recycle gas purge line to the reduction zone and
to the catalyst collector closed during evacuation. During purging open the block valves slightly so these areas are
properly purged.
¾ Check for explosive gas mixtures at various points in the unit. If any readings are
higher than the upper limits set by the safety department repeat step (f). Also check
block valves, which separate this section of the unit from others that still contain
hydrogen and/or hydrocarbon.
¾ The reactor section is now ready for insertion of the necessary blinds.
8.2.10 Isolate system and install necessary system blinds

¾ Install blinds to isolate the Platforming reactor section from the remainder of the unit.
Exercise care while installing the blinds to ensure the catalyst is not exposed to
moisture.
¾ If possible, establish a small nitrogen purge into the reactor section.
¾ Install additional blinds at the battery limits and between equipment as necessary for
safety.
8.2.11 Remove catalyst from reactors
NOTE: UNDER NO CIRCUMSTANCES SHOULD AIR BE PULLED THROUGH THE

PLATFORMING REACTORS SINCE SPONTANEOUS COMBUSTION IS POSSIBLE.
WOOD, CANVAS OR OTHER COMBUSTIBLE MATERIALS SHOULD NOT BE USED IN
THE CATALYST DUMPING OPERATION BECAUSE OF THE DANGER OF FIRE. IN
ADDITION, THE GENERAL AREA AROUND THE REACTORS SHOULD BE FREE OF
COMBUSTIBLE MATERIALS.
¾ Do not open the reactors at the top and bottom simultaneously as this can set up a
natural chimney draft effect that will pull air through the reactors.
¾ Be sure that several CO2 extinguishers are available and provide a small water hose
with a spray nozzle attachment.
¾ Catalyst is removed from fixed-bed Platforming reactors through two 4-inch
withdrawal nozzles located on the bottom of the reactor stack. The blind flange is
removed from the nozzle and a dumping spout is connected. A slide valve in the

Page 187 of 271
dumping spout allows the flow of catalyst to be stopped as necessary for catalyst
drum changing, etc. The catalyst support plate in the unloading nozzle is removed
through the opening in the dumping spout.
The inter-reactor catalyst transfer pipes will permit dumping the catalyst from all
reactors at the bottom of the stack without any additional equipment. The catalyst
can be removed from the reactors via lift engager #1 bottom head if there is enough
clearance below the vessel for a valve and 55 gallon drum.
If un-regenerated catalyst is to be unloaded, the reactors must be kept under a
nitrogen blanket so the spent catalyst does not contact air. Any personnel who enter
the reactors must be equipped with the proper safety equipment specified for entry
into a contaminated atmosphere.
¾ If the catalyst becomes bridged in the unloading nozzle or is not free flowing, break
the plug with a blast of nitrogen.
¾ Use only metal drums for unloading and if possible dump directly into drums. It is
best to screen the catalyst after it has had time to cool to ambient temperature. Each
drum should be either purged with N2 during unloading or a piece of dry ice should
be placed at the bottom of each drum. Do not seal the drum air tight since this could
result in sudden rupture of the drum should combustion occur. Burning of catalyst in
the drums is not serious and can be quickly extinguished with carbon dioxide or
nitrogen.
¾ It is expected that some “sparking” of the pyrites will take place. All workmen in the
area must be supplied with face and eye protection. In addition, they should wear
long sleeve shirts with the collars and cuffs tightly buttoned.
¾ If ignition or pyrites takes place inside a reactor, increase the N2 purge to maximum.
¾ Return spent Platforming catalyst to UOP for metals recovery. This return will
normally be made in the original empty Platforming catalyst drums.
¾ After the catalyst drums have cooled, the drums should be sealed with the proper
cover and rubber gasket to keep out moisture.
¾ With the catalyst removed, the reactors are now ready for cleaning and internal
inspection.

Page 188 of 271
SECTION-9
EMERGENCY SHUTDOWN PROCEDURE
9.1 EMERGENCY SHUTDOWN PROCEDURE

Emergencies must be recognized and acted upon immediately. The operators and
supervisory personnel should carefully study in advance, and become thoroughly familiar
with, the steps to be taken in such situations. While some of the emergencies listed in this
section 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.
Hard and fast rules cannot be made to cover all situations, which might arise. The following
outline lists those situations, which might arise and suggested means of handling the
situation.
9.1.1 Power Failure
1. The unit is equipped with motor-driven recycle compressors and it will stop. If the
failure is of sufficient duration to shut it down, follow the procedure under section -
9.1.2.
Check which pumps and air cooler motors have stopped and restart them. If the
reactor charge pump has stopped, be sure that reactor inlet temperatures have not
risen excessively before cutting oil in again. Reduced fires and use of purging
steam through the heater boxes are methods of cooling the heaters.
2. If any emergency power supply is not available or does not work properly, all
electrical control instruments will fail. Thus, all electronic controllers must be
operated manually and temperatures must be read by means of a battery-operated
potentiometer.
3. Any motor-driven pumps, which have been in service, should be swung over to
steam-driven spares, where available.
4. If the failure affects the cooling water system, action to restore normal water
circulation must be taken.

Page 189 of 271
5. If a power failure of some duration is encountered, the unit should be shut down,
following the normal procedure as much as possible.
6. When power is again available, start up in the normal manner, noting the
precautions.
9.1.2 Total loss of Recycle gas flow
1. Stop firing in all reactor heaters and introduce steam into the heater boxes for its
cooling effect.
2. Stop charging feed.
3. Block in the separator off-gas valve so that system pressure will be maintained.
Note: Steps 1,2, and 3 should be done immediately to protect equipment and the catalyst.
4. Follow the normal shutdown procedure in blocking in the separator and columns.
5. Restart the compressor if possible, or find out what is wrong. Remember that with
no flow through the furnace, the material in the heater tubes may become
excessively hot, and if it is put through the reactors, it could result in deactivation of
the catalyst. Thus, when a compressor is started after such a shutdown,
immediately check the reactor inlet temperatures. If they are 15°C higher than the
normal operating temperature, stop the recycle flow and continue cooling the heater
with purging steam until the reactor inlet temperatures, with recycle flow, are below
495°C.
6 When the compressor is again in service, proceed with a normal start-up.
Remember that normal operating pressure or 8.8 g/cm² absolute minimum H2
partial pressure whichever is lower, at the reactor products separator is required for
oil cut in.
Planned Repairs, Which Require Stopping the Recycle Compressor

1. Decrease reactor inlet temperatures to 480°C. Lower the charge rate to one-half
rate but not less than 0.75 LHSV. Decrease reactor inlet temperatures to 455°C.
Cut out charge. Maintain gas circulation for one hour at 455°C inlet temperatures.
Cut heater fires completely.

Page 190 of 271
2. For lower pressure units, it may be advisable to increase the unit pressure before
the shutdown. The purpose of the increase in pressure is to assure sufficient
hydrogen partial pressure for start-up with consideration given for gas leakage
during the shutdown period.
3. Continue to circulate recycle gas while reducing reactor inlets to 370°C.
4. Stop the recycle compressor.
5. Make the required repairs. Follow normal start-up procedures.
Explosion, Fire, Line Rupture, or Serious Leak-

(Do The Following If Possible)
1. Stop firing in all heaters. If the heaters or control valves are beyond reach, use the
battery limit block valve(s) or use emergency shutdown push button.
2. Stop the reactor charge.
3. Leave the recycle compressor running if possible while other items are attended to,
since it will contribute no extract pressure to the system and the gas circulation will
cool heater tubes and sweep hydrocarbons to the separator.
4. Depressurize the plant to the flare.
5. Shutdown the balance of the plant as circumstances permit or require. Shutdown
the recycle compressor when its lower operating pressure limit is reached.
7. In the case of a heater tube rupture, do not close the stack damper or attempt to put
the fire out with snuffing steam. The first is much safer in the firebox than outside the
heater.
Water Failure
1. If a water failure is feared, prepare for shutdown by reducing reactor temperatures
and charge rate.
2. For a partial cooling water failure, it should be necessary only to reduce the charge
rate to the unit to the extent required to maintain reasonable receiver and product
temperatures.
3. For a total loss of cooling water, the unit must be shutdown. Follow normal
shutdown procedures as much as possible, except to stop heater firing
immediately. The compressors should be left running as long as possible to sweep
hydrocarbons from the reactors to the separator. Maintain unit pressure.

Page 191 of 271
Steam Failure
1. Operation may be continued on the Platformer, depending upon the extent of steam
driven equipment in the unit.
2. If the failure affects the cooling water system, action to restore normal water
circulation must be taken.
3. If the unit must be shutdown, block in the unit and proceed with as normal a
shutdown as is possible.
4. When an adequate steam supply is again available, start-up in the normal manner.
Instrument Air Failure

1. Be familiar with the action of all control valves; memorize all actions on air failure.
2. If the reason for failure is in the air drier system, bypass that section responsible.
This can then be repaired when possible.
3. If the instrument air cannot be obtained, the alternatives are a plant shutdown or
operation of the various controls on hand control. Action will depend upon the
desires of the supervisor.
4. Under no circumstances should nitrogen be used in place of the lost
instrument air due to the possibility of asphyxiating control room personnel.
9.1.3 Functional Description Of Safe Shutdown System
A) Reactor Heater Shutdown (UC-001)
Shutdown Causes Shutdown Effect

Description Tag No/Trip Description Tag No.
points
Emergency push button activation
Emergency HS-3003A, Close pilot gas shutdown UV3001, UV3002
shutdown HS 3003B valves
Close fuel gas shutdown UV3003, UV3004
valves
Close fuel oil shutdown UV3101A, B, UV3102
valves
valves

Page 192 of 271

valves
valves
Stop induced draft fans
Close Feed to Combined FV1001
feed exchanger
Reactor Heater Pilot gas supply pressure
Pilot gas PSLL-3002 A, Close pilot gas shutdown UV3001, UV3002
pressure low- B, C, (2 out of valves
low 3) Close fuel gas shutdown UV3003, UV3004
valves
valves
valves
valves
valves
feed exchanger
Open inlet box damper of HV3501A
74-F-07A
Open inlet box damper of HV3502
74-F-07B
Fuel Gas Burner Pressure
Very low fuel PSLL3101 Close fuel gas shutdown UV3003, UV3004
gas burner valves,
pressure of Open inlet box damper of HV3501A
charge heater 74-F-07A
Open inlet box damper of HV3501B
74-F-07B
Very low fuel PSLL-3201 Close fuel gas shutdown UV3003, UV3004
gas burner valves,
No.1 74-F-07A
Interheater
74-F-07B
gas burner valves,
No.2 74-F-07A
Interheater
74-F-07B

Page 193 of 271
gas burner valves,
No.3 74-F-07A
Interheater
74-F-07B
Fuel Oil Burner Pressure
Very low fuel PSLL-3104 Close fuel oil shutdown UV3101A, B, UV3102
oil burner valves,
pressure of Close fuel oil shutdown UV3201A, B, UV3202
Charge valves,
Heater
valves,
valves,
74-F-07A
74-F-07B
oil burner valves,
No 1 valves,
Interheater
valves,
valves,
74-F-07A
74-F-07B
oil burner valves,
No 2 valves,
Interheater
valves,
valves,
74-F-07A
74-F-07B
oil burner valves,

Page 194 of 271

No 3 valves,
Interheater Close fuel oil shutdown UV3301A, B, UV3302
valves,
valves,
74-F-07A
74-F-07B
Recycle Gas Flow
Very low flow FSLL-1002 Close fuel gas shutdown UV3003
of recycle gas A,B C valves
Close fuel oil shutdown UV3101 A,B
valves
valves
valves
valves
feed exchanger
Atomizing Steam-Fuel Oil Differential Pressure
Very low PDSLL-3106 Close fuel oil shutdown UV3101 A,B
charge heater valves,
atomizing Close fuel oil shutdown UV3201 A,B
steam-fuel oil valves,
differential
pressure of Close fuel oil shutdown UV3301 A,B
Charge valves,
Heater Close fuel oil shutdown UV3401 A,B
valves,
atomizing
steam-fuel oil Close fuel oil shutdown UV3201 A,B
differential valves,
No 1 valves,
Interheater
valves,

Page 195 of 271
differential Close fuel oil shutdown UV3301 A,B

pressure of valves,
No 2 Close fuel oil shutdown UV3401 A,B
Interheater valves,
differential
No 3 valves,
Interheater Close fuel oil shutdown UV3401 A,B
valves,
Circulating water
Very low flow FSLL-2801 A, Close fuel gas shutdown
of circulating B, C (2 out of valves UV3003, UV3004
water 3) Close fuel oil shutdown UV3101 A,B
valves
valves
valves
valves
feed exchanger
Fire Box
Very high PSHH- Close fuel gas shutdown
pressure of 3501A,B,C.(2 valves UV3003, UV3004
fire box out of three) Close fuel oil shutdown UV3101 A,B
valves
valves
valves
valves
feed exchanger
74-F-07A
74-F-07B
ID Fan Failure
Both ID fan 74-FA-01A/B Close fuel gas shutdown
failure (either valves UV3003, UV3004

Page 196 of 271
from MCC or Close fuel oil shutdown UV3101 A,B

speed valves
transmitter) Close fuel oil shutdown UV3201 A,B
valves
valves
valves
Stop Induced Fan draft
74-F-07A
74-F-07B
74-FA-01 A Open inlet box damper of HV3501B
ID fan 74-FA-
74-F-07B
01A failure
(either from
MCC or speed
transmitter)
ID fan 74-FA- 74-FA-01 B Open inlet box damper of HV3501A
01B failure 74-F-07A
(either from
MCC or speed
transmitter)
B) Net Gas Compressor (74-K-02A) Shutdown (UC-002)

Description Tag No./Trip point Description Tag No.

Push button HS-1601 Stop Net gas
compressor
First stage TSHH-1603A Stop Net gas
discharge compressor
temperature high-
high
First stage suction LSHH-1502A,B,C (2 out Stop Net gas
drum level high- of 3) compressor
high Trip Net Gas UC-003
Compressor K-02B
Second stage LSHH-1801A, B, C(2 out Stop Net gas
suction drum level of 3) compressor
high-high Trip Net Gas UC-003
Compressor K-02B
Second stage TSHH-1606A Stop Net gas
temperature high-
high

Page 197 of 271
C) Net Gas Compressor (74-K-02B) Shutdown (UC-003)


Push button HS-1701 Stop Net gas
compressor
First stage TSHH-1703A Stop Net gas
temperature high-
high
First stage suction LSHH-1502A,B,C (2 out Stop Net gas UC002
drum level high- of 3) compressor
high
Second stage LSHH-1801A, B, C(2 out Stop Net gas UC002
suction drum level of 3) compressor
high-high
Second stage TSHH-1706A Stop Net gas
temperature high-
high
D) Recycle Compressor (74-K-01) Shutdown (UC-004)

Compressor stop HS-1302 Stop Recycle

compressor
Separator level LSHH-1201A, B, C (2 out Stop Recycle

high-high of 3) compressor
E) Vessel low level Shutdowns (UC-005)

Stabiliser receiver LSLL-2402 Close Stabiliser water LV-2401
interface level low- to OWS
low
Deethanizer LSLL-2702 Close Deethanizer LV-2701
Receiver Interface bottoms to OWS
LSLL-2202 LV-2201
Close Reformate to
Stabilizer Level Storage

Page 198 of 271
F) BFW Booster Pump 74-P-05A/B Shutdown (UC-006)

BFW booster PSLL-2910 Stop BFW booster
pump Pressure Pump
low-low
G) Stabiliser BTMS reboiler steam flow cut off (UC-007)

Stabilizer PSLL-2205A,B,C (2 out Close reboiler steam UV-2207
overhead pressure of 3) ilet valve
low-low
H) LP Steam Condensate Blow Down (UC-008)

High Conductivity HS-2603 Close UV 2602 UV 2602
Open UV 2603 UV 2603
I) Product Pump Condenser 74-A-01 Shutdown (UC-010)

Product VAHH-1002A/B/C/D/E/F Stop Product 74-A-01 A/B/C/D/E/F
Condenser condenser Fan
Vibration high-high
J) Stabiliser bottoms cooler Shutdown (UC-011)

Stabiliser bottom, VAHH-2102A/B Stop Stabiliser bottom 74-A-02 A/B
cooler Vibration cooler Fan
high-high

Page 199 of 271
SECTION-10
SAMPLING PROCEDURE & LABORATORY ANALYSIS REQUIREMENT
10.1 GENERAL
Control tests provide the information to the operating staff for making necessary
adjustments to get the maximum output and “on-spec” quality products. The control tests
are to be made at all steps to monitor the intermediate and final products whether or not
they are at the desired specification. Samples are taken and analyzed at regular intervals
such that the operation of the plant are monitored and any deviation (from specification will
indicate some mal operation / malfunction of the plant which can be spotted and rectified in
time without undue loss of time and product. Sometimes, samples are taken to find out the
effect of certain changes brought about in the operating conditions. The samples are to be
taken with great care so that the samples are representative samples. The frequency of
sampling, the type of analysis and points where samples are to be taken are generally
specified by t he process licensor. During guarantee tests some additional samples can be
taken at higher frequencies, which will be specified, in the technical procedures prior to test
run. The following guidelines should be followed while collecting samples.
10.2 SAMPLING PROCEDURE

a) Liquid Sampling Procedure (Non-Flashing Type)
i) The person taking samples should wear proper or appropriate safety clothing like
face shields, aprons, rubber gloves etc. to protect face, hands and body.
ii) Whenever hot samples are taken, check cooling water flow in the sample cooler is
circulating properly.
iii) Sample points usually have two valves in series. One gate valve for isolation (tight
shutoff) and other globe valve for regulating the flow. Open gate valve first and then
slowly open the globe valve after properly placing the sample containers. After the
sampling is over, close the globe valve first and then the gate. Then again open the
globe valve and drain the hold up between the gate and globe valve in case of
congealing liquid.

Page 200 of 271
iv) Sample valve should be slowly opened, first slightly to check for plugging. If the
plugging is released suddenly, the liquid will escape at a dangerously uncontrolled
rate. Never tap the line to release the plugging. Call the maintenance gang to
properly unplug the line. In case of congealing type samples, sample point should
be equipped with copper coil type steam tracer. It should be ensured that steam-
tracing line is functioning normally.
v) The operator taking the sample should be careful to stand in a position such that
the liquid does not splash on him and he has unobstructed way out from the sample
point in case of accident.
vi) While taking dangerous toxic material for sampling, it will act as an observer for
safety. Proper gas mask is to be used. It is advisable to stand opposite to wind
direction in case of volatile toxic liquid.
vii) Sample should be collected in clean, dry and stopper bottle. In case of congealing
samples use clean dry ladle.
viii) Rinsing of the bottle should be thorough before actual collection.
ix) Before collecting, ensure that the line content has been drained and fresh sample is
coming.
x) Gradually warm up the sample bottle / metallic can by repeated rinsing before
collecting the sample.
xi) Stopper the bottle immediately after collection of sample.
xii) Attach a tag to the bottle indicating date, time, and name of the product and tests to
be carried out.
xiii) A few products suffer deterioration with time.
For example, the colour of the heavier distillates slowly deteriorates with time. So
these samples should be sent to laboratory at the earliest after collection.
xiv) The samples after collection should be kept away from any source of ignition to
minimize fire hazard.
xv) Volatile samples (e.g. naphtha) should be collected in bottles and kept in ice
particularly for some critical test like RVP.

Page 201 of 271
b) High Pressure Hydrocarbon Liquid Samples (Flashing Type)
i) The person taking sample should use personal protection appliances like apron,
gas mask and hand gloves to protect himself.
ii) Ensure that sample bomb is empty, clean and dry.
iii) Connect the sample bomb inlet valve to the sample point with a flexible hose.
iv) Open the inlet and outlet valves of the sample bomb. Hold the sample bomb. Hold
the sample bomb outlet away from person. Keep face away from hydrocarbon
vapour and stand in such a way that prevalent wind should blow hydrocarbon
vapour away. Open the gate valve of sample point slowly till full open. Then slowly
cracks open the regulating valve. One should be careful at the time of draining,
because chance of icing is there. As a result, the formation of solid hydrates is a
continuing process, which leads to the plugging of valves.
v) When all the air in the hose and bomb are displaced as seen by the hydrocarbon
vapour rising from the outlet of sample bomb close the sample outlet valve. Allow a
little quantity of liquid to spill to make sure that the bomb is receiving liquid. Frosting
will be an indication of liquid spillage.
vi) Allow liquid hydrocarbon to fill the bomb. When the bomb is full up to the specified
level, close both the valves on sample point. Close inlet valve on the sample point.
vii) Carefully disconnect the hose from the sample bomb. To allow for some vapour
space in the bomb for thermal expansion in case of overfilling, crack open the outlet
valve of bomb and discharge a small part of the liquid. Close outlet valve.
viii) Closed sampling facilities are provided at some locations where it is not desirable to
waste the costly product or if the material is toxic. For filling the sampling bomb,
pressure drop across a control valve is usually utilized or across pump discharge &
suction. Air is expelled from the bomb after it is connected to upstream of control
valve or pump discharge side. The sample is then collected and bomb is detached
after closing valves on both sides.
ix) Send sample bomb to laboratory for analysis. Protect the bomb from heat
exposure.

Page 202 of 271
c) Gas Sample
For collection of gas sample, which are not under high pressure and temperature, rubber
bladders are used. For the operations under vacuum or low pressure, aspirator is used. For
representative sample, purge the bladder 3 to 4 times with the gas and then take the final
sample. Use of 3 ways valve with bladder / aspirator will facilitate purging and sampling.
Sample bombs are to be used for taking gas samples from high pressure and high
temperature source. Procedure mentioned under high-pressure liquid sampling (flashing
type) is to be used.
10.3 LABORATORY TEST METHOD AND SCHEDULE

Sample Stream Name Test Method Number Frequency
Number Test Name Normal Start
up
74-SC-01 CCR Platforming Process Unit Feed
Gravity ASTM D 4052 or ASTM 3/D 3/D
D 1298
API ASTM D 287 3/D 3/D
Distillation ASTM D 86 3/D 3/D
Colour ASTM D 156 3/D 3/D
Sulfur ASTM D 4045 1/D 1/D
Chloride UOP 395 1/W 1/D
Nitrogen ASTM D 4629 1/W 1/D
Composition (PONA) UOP 880 1/W 1/D
Paraffins UOP 690 1/W 1/D
Aromatic UOP 744 1/W 1/D
PNA UOP870 1/W 1/D
Arsenic UOP 296 or 946 1/M 1/W
Lead UOP 350 or 952 1/M 1/W
Copper UOP 144 or 962 1/M 1/W
Water Content UOP 481 Occas. 1/W
Bromine Index UOP 304 1/M 1/W
Silicones UOP 787 1/M 1/W
Fluoride UOP 619 1/M 1/W
Mercury UOP 938 1/M 1/W
74-SC-02 RECYCLE GAS

Relative Density UOP 114 1/D 3/D

Page 203 of 271
Composition UOP 539 1/D 1/D

74-SC-03 RECYCLE GAS
HCl Detector Tube 1/D 3/D
H2S Detector Tube 1/D 3/D
74-SC-04 Net Gas At Net Gas Chloride Treator Inlet

74-SC-05 Net Gas At Net Gas Chloride Treator Outlet

74-SC-06 Net Gas At Net Gas Chloride Treators

Relative Density UOP 114 1/D 3/D
74-SC-07 Stabiliser Bottoms (Reformate)

Gravity ASTM D 4052 or ASTM 3/D 3/D
D 1298
API ASTM D 287 3/D 3/D
Distillation ASTM D 86 3/D 3/D
Reid Vapor pressure ASTM D 323 or ASTM 3/D 3/D
D 5191
Octane Research ASTM D 2699 1/D 1/D
Colour ASTM D 156 1/W 1/D
Composition (PONA) UOP 880 1/D 1/D
Paraffins UOP 690 1/W 1/D
PNA YOP 870 1/W 1/D
Bromine Number UOP 304 1/W 1/D
Stabiliser Overhead Liquid

74-SC-08 H2S UOP 212 Occas Occas
Relative Density ASTM D 1657 1/D 3/D
Residues in LPG ASTM D 2158 1/W 1/D
74-SC-09 Stabilizer Receiver Gas

Relative Density UOP 114 1/D Occas
Composition UOP 539 1/D Occas
Stabilizer Receiver Gas
74-SC-10 HCl Detector Tube 1/D Occas
H2S Detector Tube 3/D Occas

Page 204 of 271
Deethanizer Off Gas

74-SC-11 Relative Density UOP 114 1/D Occas
Composition UOP 539 1/D Occas
Deethanizer Off Gas

74-SC-12 HCl Detector Tube 1/D Occas
H2S Detector Tube 3/D Occas
74-SC-13 Deethaniser Bottoms Liquid

Relative Density ASTM D 1657 1/D 3/D
Residues in LPG ASTM D 2158 1/W 1/D
H2S UOP 212 Occas Occas
74-SC-14 Steam Condensate Continuous Blowdown

Total Hardness (as CaCO3) ASTM D 1126 Occas. Occas.
Ca Hardness (as CaCO3) ASTM D 1127 Occas. Occas.
Mg Hardness (as CaCO3) ASTM D 1128 Occas. Occas.
Potassium ASTM D 4192 Occas. Occas.
Sodium ASTM D 4191 Occas. Occas.
Copper ASTM D 1688 Occas. Occas.
Iron ASTM D 1068 Occas. Occas.
Total Alkalinity (as CaCO3) ASTM D 1067 3/D 3/D
M Alkalinity (as CaCO3) ASTM D 1067 Occas. Occas.
P Alkalinity (as CaCO3) ASTM D 1067 Occas. Occas.
Chloride ASTM D 512 Occas. Occas.
Sulfate ASTM D 516 Occas. Occas.
Silica ASTM D 859 Occas. Occas.
Total Suspended Solids Standard Method Occas. Occas.
2540C
Total Dissolved Solids Standard Method 3/D 3/D
2540D
pH ASTM D 1293 3/D 3/D
Specific Conductance ASTM D 1125 3/D 3/D
Dissolved Oxygen ASTM D 888 Occas. Occas.
Turbidity ASTM D 1889 Occas. Occas.
Phosphates ASTM D 4327 3/D 3/D
Oil ASTM D 3921 Occas. Occas.
Hydrazine ASTM D 1385 1/D 1/D
74-SC-15 Steam To Steam Generation section

Deposits in saturated Steam ASTM D 2186 3/w Occas

Page 205 of 271
SECTION-11
TROUBLE SHOOTING
This section offers some guidelines for trouble shooting various problems that may be
encountered over the course of normal operation of the unit. The information is given for the
following general subject areas of the unit:
1. Low Reactor ∆T
2. High Reactor ∆T
3. Low H2 purity, production
4. Low Reformate Yield
5. High Coking
6. High Reactor ∆P
7. Low Reactor ∆P
8. Loss of Chloride Injection
9. Feed Crossovers
10. Plant upset effect on incoming/ outgoing stream B/L conditions
SL. Process
Possible Cause Operational Response
No. Symptom
1. Low Reactor ∆T Charge stock less None
naphthenic
Sulfur contamination Eliminate source
Do not increase reactor inlet
temperature (see note)
Metals contamination Eliminate source
High chloride on catalyst Reduce chloride injection
High water in unit Reduce water injection and
eliminate source of excess
water
Bad temperature indicator Repair or replace

Page 206 of 271
SL. Process
No. Symptom
2. High Reactor ∆T Charge stock more None
naphthenic
Nitrogen contamination Eliminate source
3. Low H2 Purity, Charge stock less None
Production naphthenic
Excessive chloride Reduce chloride injection rate
injection
Metals contamination Eliminate source
Water contamination Eliminate source
4. Low Reformate Charge stock less None
Yield naphthenic
High chloride Reduce chloride injection
High water Reduce water injection and
eliminate source of excess
water
5. High Coking Low H2/HC ratio Increase recycle rate
Charge stock highly None
paraffinic.
6. High Reactor ∆P Internal screens plugged Shutdown and clean reactors
Excessive coke levels Shutdown and clean reactors
Bad pressure indicator Repair or replace
7. Low Reactor ∆P Loss of catalyst bed Shutdown and repair reactors
Bad pressure indicator Repair or replace

Page 207 of 271
SL. Process
No. Symptom
8. Loss of Chloride Pump stops or valve Restart or line up
Injection closed
Suction or discharge Stop pump and repair ball
check stuck check
Note: 1. Suspected causes of operating problems should be confirmed by analysis or

otherwise before action is taken, except in extreme or emergency cases.
Feed Crossovers
Occasionally, feed other than naphtha will be accidentally charged to the Platforming unit.
Some typical feed crossovers would be whole crude or leaded gasoline or Platformate
instead of naphtha. The process symptoms would be low reactor delta T, low H2 purity, low
H2 production, low Platformate yield and excessive coking. The operational response is to
eliminate the feed crossover and restore naphtha feed to the unit as soon as possible.
Plant upset effect on Incoming/Outgoing stream B/L conditions
PROCESS POSSIBLE CONSEQUENCE REMEDIES

SYMPTOMS CAUSE
No/Less flow Problem in Loss of liquid feed Check with upstream unit and do
of feed from upstream unit leading to shutdown necessary correction in upstream
B/L (NHT). unit.
More flow of FV-1001 Gas to oil ratio will Operator to check feed flow
feed from B/L malfunctions to change leading to indicator, reactor inlet
open more. change in delta temperature, H2 and HC ratio
temperature and and do necessary correction.
delta pressure across
reactors.
Lower B/L Problem in Upset in CCR unit Check with upstream unit and do
temperature in upstream unit necessary correction in upstream
feed line (NHT). unit. Check temperature
indicator.

Page 208 of 271
PROCESS POSSIBLE CAUSE CONSEQUENCE REMEDIES

SYMPTONS
No flow of LV-2201 malfunctions Stabiliser column Operator to check level in
reformate to to close. level will increase. stabiliser column and flow of
storage. reformate and take necessary
correction.
Less flow of LV-2201 malfunctions Stabiliser column Operator to check level in

reformate to to close more. level will increase. stabiliser column and flow of
storage. reformate and take necessary
correction.
More flow of LV-2201 malfunctions Stabiliser column Operator to check level in

reformate to to open more. level will decrease. Stabiliser column and flow of
B/L. reformate and take necessary
correction.
Higher Higher pressure in Stabiliser operation Operator to check pressure of

pressure of Stabiliser (PDI-2202 will upset and may Stabiliser, monitor reformate
Reformate to malfunction). lead to off spec spec through sampling and take
B/L. reformate to B/L. necessary correction.
Lower Lower pressure in Stabiliser operation Operator to check pressure of
pressure of Stabiliser (PDI-2202 will upset and may Stabiliser, monitor reformate
Reformate to malfunction). lead to off spec spec through sampling and take
B/L. reformate to B/L. necessary correction.
No/Less flow LV-2601 malfunctions Possible flooding of Operator to check level in
of LPG to B/L. to close fully or close column leading to Stabiliser column and flow of
more. liquid carryover. LPG and take necessary
correction.
More flow of LV-2601 malfunctions Possible gas blow by Operator to check level in
LPG to B/L. to open more. through product line. Stabiliser column and flow of
LPG and take necessary
correction.

Page 209 of 271
SECTION -12
SAFETY PROCEDURE
12.1 INTRODUCTION
Safety of personnel and equipment is very important. Ignorance of the details of the unit or the
techniques of safe and efficient operation reduces the margin of safety of personnel and
subjects the equipment to more hazardous conditions. All the operating and maintenance
crew therefore must be fully familiar with the equipment and materials being handled in the
unit, and recognize the hazards involved in handling them and the measures taken to ensure
safe operations.
Since the unit handles with one of the most potential source of fire and explosion, H2, Naphtha
and chemical like caustic, therefore adherence of safety rules should be given uphill
importance.
12.2 SAFETY OF PERSONNEL

General safety rules, which shall be practised and enforces for all personnel who enter the unit
are summarized below:
i) Safety helmets, goggles and boots shall be worn by all personnel at all times in the
plant. They may be removed when inside rooms or buildings which do not have
overhead or other hazards.
ii) Smoking shall be permitted only in specified areas, which are clad as non-hazardous
and are pressurized through a ventilation system. Failure of the ventilation system
automatically cancels the smoking privilege until the system is repaired, inspected and
authorized operation.
iii) Each employees assigned to work in the unit shall know where the safety and fire
suppression equipment is located and how to operate this equipment.
iv) Safety glasses, face shields shall be worn while performing work which could result in
eye or face injury.
v) Operations personnel golden rule:
Do not open or close any valve without first determining the effect.
vi) Maintenance personnel golden rule:
Treat each piece of equipment or piping as if it is under pressure.

Page 210 of 271
12.3 PREPARATION FOR VESSEL ENTRY

Whenever a supervisor must enter a vessel a meeting should be arranged between
personnel who will be involved. The meeting should include review of the vessel entry
procedures, the refiner’s safety requirements and facilities, preparation of a vessel entry
schedule, assignment of responsibility for the preparation of a blind list, and assignment of
responsibility for the vessel entry permits.
The most common tasks of a supervisor which could involve a potentially hazardous vessel
entry are:
- Unit Checkout Prior to Start-up
- Turnaround Inspections
- Reactor Loading
- Reactor Unloading
The precautions apply equally to entry into all forms of vessels, including those enclosed
areas, which might not normally be considered vessels.
Examples include:
Reactors, Columns, Separators, Receivers, Drums, Fired heaters, Sumps
General Precaution:
¾ The vessel must be positively insulated
¾ Safe access to the vessel must be assured
¾ Ladder or safe internal access, must be provided
¾ Personal entering the vessel must be provided with safety harness
¾ Standby personal must be available outside the vessel to assist the personnel inside
¾ The safety of the atmosphere inside of the vessel must be confirmed by checks for
the toxic gases before entry
¾ A dedicated supply of the fresh air must be available for the standby personnel who
assist personnel in the vessel in the event that they encounter difficulty.
¾ A vessel entry permit must be obtained and registered with the responsible persons

Page 211 of 271
12.3.1 Positive Vessel Isolation

Every line connecting to a nozzle on the vessel to be entered must be blinded at the vessel.
This includes drains connecting to a closed sewer, utility connections and all process lines.
The location of each blind should be marked on a master piping and instrumentation
diagram (P&ID), each blind should be tagged with a number and a list of all blinds and their
locations should be maintained. One person should be given responsibility for the all blinds
in the unit to avoid errors.
The area around the vessel man ways should also be surveyed for possible sources of
dangerous gases, which might enter the vessel while the person is inside. Examples
include acetylene cylinders for welding and process vent or drain connections in the same
or adjoining units. Any hazards found in the survey should be isolated or removed.
12.3.2 Vessel Access
Safe access must be provided both to the exterior and interior of the vessel to be entered.
The exterior access should be a solid, permanent ladder and platform or scaffolding strong
enough to support the people and equipment who will be involved in the work to be
performed.
Access to the interior should also the strong and solid. Scaffolding is preferred when the
vessel is large enough to permit it to be sued. The scaffolding base should rest firmly on
the bottom of the vessel and be solidly anchored. If the scaffolding is tall, the scaffolding
should be supported in several places to prevent sway. The platform boards should be
sturdy and capable of supporting several people and equipment at the same time and also
be firmly fastened down. Rungs should be provided on the scaffolding spaced at a
comfortable distance for climbing on the structure.
If scaffolding will not fit in the vessel a ladder can be used. A rigid ladder is always
preferred over a rope ladder and is essential to avoid fatigue during lengthy periods of work
inside a vessel. The bottom and top of the ladder should be solidly anchored. If additional
support is available, then the ladder should also be anchored at intermediate locations.

Page 212 of 271
When possible, a solid support should pass through the ladder under a rung, thereby
providing support for the entire weight should the bottom support fail. Only one person at a
time should be allowed on the ladder.
When a rope ladder is used, the ropes should be thoroughly inspected prior to each new
job. All rungs should be tested for strength, whether they be made of metal or wood. Each
rope must be individually secured to an immovable support. If possible, a solid support
should pass through the ladder so that a rung can help support the weight and the bottom
of the ladder should be fastened to a support to prevent the ladder from swinging. As with
the rigid ladder, only one person should climb the ladder at a time.
12.3.3 Wearing of a Safety Harness
Any person entering a vessel should wear a safety harness with an attached safety line.
The harness is not complete without the safety line. The harness should be strong and
fastened in such a manner that it can prevent a fall in the event the man slips and so that it
can be used to extricate the man from the vessel in the event he encounters difficulty. A
parachute type harness is preferred over a belt because it allows an unconscious person to
be lifted from the shoulders, making it easier to remove him from a tight place such as an
internal man way.
A minimum of one harness for each person entering the vessel and at least one spare
harness for the people watching the man way should be provided at the vessel entry.
12.3.4 Providing a Man way Watch

Before a person enters a vessel, there should be a minimum of two people available
outside of the vessel, one of whom should be specifically assigned responsibility to observe
the activity of the people inside of the vessel. The other person must remain available in
close proximity to the person watching the man way so that he can assist the or go for help,
if necessary. He must also be alert for events outside of the vessel, which might require the
people inside to come out of the vessel, for example, a nearby leak or fire. These people
should not leave their post until the people inside have safely evacuated the vessel.

Page 213 of 271
A communication system should be provided for the man way watch so that they can
quickly call for help in the event that the personnel inside of the vessel encounter difficulty.
A radio, telephone, or public address system is necessary for that purpose.
12.3.5 Providing Fresh Air

The vessel must be purged completely free of any noxious or poisonous gases and
inventoried with fresh air before permitting anyone to enter. The responsible department,
usually the safety department, must test the atmosphere within the vessel for toxic gases,
oxygen and explosive gases before entry. This must be repeated every 4 hours while there
are people inside the vessel. When possible the UOP technical advisor should personally
witness the test procedure. Each point of entry and any dead areas inside of the vessel,
such as receiver boots or areas behind internal baffles, where there is little air circulation
should be checked.
Fresh air can be circulated through the vessel using an air mover, a fan, or, for the cases
where moisture is ca concern, the vessel can be purged using dry certified instrument air
from a hose or hard piped connection. When an air mover is used, make certain that the
gas driver uses plant air, not nitrogen, and direct the exhaust of the driver out of the vessel
to guarantee that this exit gas does not enter the vessel. When instrument air is used, the
responsible personnel must check the supply header to ensure that it is properly lined up
and that there are no connections where nitrogen or a contained backup source can enter
the system. The fresh air purge should be continued throughout the time that people are
inside of the vessel.
A minimum of one fresh air mask for each person entering the vessel and at least one
spare mask for the hole watcher should be provided at the vessel entry. These masks
should completely cover the face, including the eyes, and have a second seal around the
mouth and nose. When use of the mask is required, it must first be donned outside of the
vessel where it is easy to render assistance in order to confirm that the air supply is safe.
Each mask must have a backup air supply that is completely independent of the main
supply. It must also be independent of electrical power. This supply is typically a small,
certified cylinder fastened to the safety harness and connected to the main supply line via a

Page 214 of 271
special regulator that activates when the air pressure to the mask drops below normal. The
auxiliary supply should have an alarm, which alerts the user that he is on backup supply
and it should be sufficiently large to give the user 5 minutes to escape from danger.
12.3.6 Preparation of Vessel Entry Permit

Before entering the vessel a vessel entry permit must be obtained. A vessel entry permit
ensures that all responsible parties know that work is being conducted inside of a vessel
and establishes a safe preparation procedure to follow in order to prevent mistakes, which
could result in an accident. The permit is typically issued by the safety engineer or by the
shift supervisor. The permit should be based on a safety checklist to be completed before it
is issued. The permit should also require the signatures of the safety engineer, the shift
supervisor, and the person that preformed the oxygen toxic and explosive gas check on the
vessel atmosphere. Four copies of the permit should be provided. One copy goes to the
safety engineer, one to the shift supervisor, one to the control room, and one copy should
be posted prominently on the man way through which the personnel will enter the vessel.
The permit should be renewed before each shift and all copies of the permit should be
returned to the safety engineer when the work is complete. Additional requirements or
procedures may be imposed by the refiner, but the foregoing is considered the minimum
acceptable for good safety practice.
12.3.7 Checkout Prior to New Unit Start-up

The risk of exposure to hydrocarbon, toxic or poisonous gases, and catalyst dust is low
during a new unit checkout; the primary danger is nitrogen. There will be pressure testing,
line flushing, hydro testing, and possibly chemical cleaning being conducted in the unit and
nitrogen may be used during any of these activities. Some of the equipment may have
been inventoried with nitrogen to protect the internals from corrosion. An additional hazard
is posed by operations in other parts of the plant, which may be beyond the control of the
people entering the vessel so that action taken at a remote location could admit nitrogen,
fuel gas, steam, or other dangerous material through a connecting process line into the
vessel, which is being entered. For these reasons vessel entry procedures must still be
rigorously followed during the checkout of a new unit.

Page 215 of 271
Each vessel should be blinded using blinds at each vessel nozzle. However, in the event
that many vessels are to be entered in a new unit that is isolated from other plants, the
entire unit can be isolated by installing blinds at the battery limits rather than by individually
isolating every vessel nozzle.
The oxygen content of the atmosphere inside a vessel should be reached before every
entry.
12.3.8 Inspections during Turnarounds

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

Page 216 of 271
12.4 REACTOR LOADING

Catalyst loading has perhaps the highest risk for asphyxiation or injury because some of the
safety practices could be overlooked in the rush to complete the loading and get the unit on
stream. If the reactor being loaded is new, the main concerns are catalyst dust and
nitrogen. If the loading is a reload of an existing unit, any of the dangerous conditions
described for turnaround inspections may also be present.
During reactor loading, dust will always be present. The effect of dust on the lungs is
cumulative and even small concentrations with short exposure times should not be
tolerated. Spent catalyst dust is especially hazardous because it can contain hydrocarbon
that may be flammable or other absorbed material that may be toxic, such as arsenic.
Whenever possible, fresh air should be supplied from above the catalyst bed and
exhausted from below the bed so that the downward flow of air will hold the dust down and
prevent hazardous material from being carried into the working space inside of the reactor.
This might not be possible when spent catalyst is present because of residual hydrocarbon
and carbon on the spent catalyst. In either case, the fresh air should never be supplied from
below the catalyst bed because the air may carry hazardous gases into the working space
of the men inside of the reactor.
People who are exposed to the catalyst either outside or inside the reactor should wear
MOSHA/NIOSH approved dust masks or fresh air respirators. Goggles are also
recommended. Exposure to catalyst dust can be minimized greatly by staying outside of
the vessel during catalyst loading and by allowing the dust to settle before entering the
vessel for inspection after loading.
Platforming unit can have another danger from iron sulfide. Iron sulfide is pyrophoric, which
means that under favourable conditions it can ignite on exposure to air. The iron sulfide can
be present on the vessel and piping walls, as loose scale, or in the catalyst bed. When this
danger could be present, special precautions have to be taken to either keep iron sulfide
moist or to prevent the iron sulfide from being exposed to air.

Page 217 of 271
12.5 REACTOR UNLOADING

Reactor unloading can present extraordinary health risks, especially to personnel working in
the reactor. During the unloading, large quantities of catalyst dust may be generated.
Additional hazards may include a contaminated or inert atmosphere in the reactor, residual
hydrocarbons or toxic forms of catalyst chemicals reactants.
UOP believes that the OSHA exposure limits to catalyst chemicals will not be exceeded if
proper handling procedures are followed, and the proper protective clothing and safety
devices are used. It is recommended that the following minimum safety procedures be
established and adhered to:
- Personnel working in reactors being unloaded should wear a fresh air respirator
with a hood or helmet, operated in a pressure demand or other positive pressure
mode, or in a continuous flow mode (NIOSH Respirator Code SAFE: PD, PP, CF).
This respirator should have a primary, secondary, and emergency supply of air.
- Personnel in the reactor should be equipped with safety harnesses and safety lines
for rescue and a means for visual, voice or signal line communication with standby
personnel, who should be strategically located with suitable rescue equipment.
- The OSHA regulations concerning use of respirators (29 CFR, Subpart 1, Section
1910.134) should be read and thoroughly understood before undertaking to place
personnel in reactors during catalyst loading and unloading operations.
- Protective clothing and all safety devices should be thoroughly decontaminated
after each use. Worn-out, broken or defective safety equipment and clothing
should be removed from service and repaired or replaced. Good personal hygiene
after handling a catalyst or being exposed to catalyst dust is an essential part of a
responsible catalyst safety program. Do not eat, drink, or smoke in areas where the
catalyst is being handled or there exposure to catalyst dust is likely.
12.6 HAZARDOUS CHEMICALS

Hazardous properties of chemicals and their handling procedure is available in Material Safety
Datasheet. Hazards and handling procedure of some the material is discussed below.

Page 218 of 271
12.6.1 Hydrogen Sulfide (H2S)

A hazard and handling procedures of H2S is as follows:
A) Potential for Exposure

The existence of H2S concentration with the fluids normally handled in this unit constitutes an
additional hazard to operating personnel that demands special attention. The properties of
H2S make exposure to even very low concentrations extremely dangerous. However, many
years of industry experience in handling the problems associated with H2S have resulted in
procedures which, if properly implemented, permit a reasonable level of safety for unit
personnel.
The danger of exposure of H2S cannot be lessened. The potential for exposure can only be
minimized.
The procedures and precautions contained within this section and elsewhere in this manual
constitute minimal requirements for dealing with H2S only. The implementation of additional
safety measures which can be found in various industry manuals is encouraged.
B) Detection and Alarm

Hydrogen sulphide detectors are located in all process areas of the unit where conditions
might occur which would permit H2S to escape into the atmosphere. The H2S detection
system includes local audio/visual alarms to alert all unit operators, should H2s be detected.
Each person in the unit must be familiar with the different alarms. Know the location of air
breathing units and portable H2S detectors and the emergency procedures to be followed.
Practice drills must be held to insure each and every person of the unit knows how to put the
breathing air unit on and adjust it for proper fit-up.
C) Properties of H2S (Hydrogen Sulphide)
The chemical formula H2S represents a compound, which is made up of two hydrogen atoms
and one sulphur atom.H2S (Hydrogen Sulphide) is a colourless (transparent), gas heavier than
air.
Hydrogen sulphide is a poisonous gas that can paralyse the breathing system and kill a
person in minutes. In small amounts it is dangerous to health. This risk is increased by heat or
hot weather.

Page 219 of 271
At low concentrations (small amounts) H2S has an offensive odour similar to rotten eggs. At
slightly higher concentrations (small amounts), H2S may have a sick-sweet odour. At high
concentrations no smell can be detected, because H2S rapidly deadens the sense of smell by
paralysis of the Olfactory-Nerve. Consequently the sense of smell cannot be depended upon
to detect H2S.
Property table Of H2S
1. Auto ignition Temperature 260°C
2. Boiling Point @ 1 atm -60.33°C
3. Critical Density 0.349 g/ml
4. Critical Pressure 92 kg/cm2, absolute
5. Critical Temperature 100.4°C
6. Density, gas @ 0°C 1 atm 1.5392 g/l
7. Density, Liquid @ b.p. 0.993 g/l
8. Flammable Limits in Air 4.3-4.5% (by volume)
9. Freezing Point @ 1 atm -85.49°C
10. Latent Heat of Fusion @ m.p. 508 cal/mole (16.7 cal/g)
11. Latent Heat of Vaporization @ b.p. 4.463 kcal/mole (131 cal/g)
12. Molecular Weight 34.08
13. Solubility in Water @0°C 1 atm 0.672 g/100 ml water
14. Specific Heat, Gas @ 25°C 1 atm
Cp 0.240 cal/(g) (°C)
Cv 0.181 cal/(g) (°C)
15. Specific Gravity Gas 1.1895
15°C, 1 atm (Air = 1)
16. Specific Heat Ratio, Gas 1.32
@25°C, 1 atm, Cp/Cv
17. Thermal Conductivity @ 0°C 0.305 cal/(Sec) (Cm2) (°C/cm)
18. Vapor Pressure @ 70°F 252 psig (17.7 kg/cm2g)
19. Specific Volume @ 70°F, 1 atm 11.23 cu ft/lb (701 ml/g)
20. Viscosity of Gas @ 0°C 1 atm 0.01166 centipoise
21. Explosive limits: Lower 4% volume in air upper 44% volume in air

Page 220 of 271
D) Effects of H2S on Personnel

Itemized concentrations of Hydrogen Sulphide as prepared by American National Standards
Institute (ANSI Standard No. Z37.2-1972) are tabled below:
0.13 ppm Minimal perceptible odour
4.60 ppm Easily detectable, moderate odour
10 ppm Beginning eye irritation
27.0 ppm Strong, unpleasant odour, but not intolerable
100 ppm Coughing, eye irritation, loss of sense of smell after 2-15 minutes.
200-300 ppm Marked conjunctivitis (eye inflammation) and respiratory tact
irritation after one hour of exposure.
500-700 ppm Loss of consciousness, possible death in 30 minutes to 1 hour.
700-1000 ppm Rapid unconsciousness, cessation (stopping or pausing) of
respiration and death.
1000-2000 ppm Unconsciousness at once, with early cessation of respiration and
death in few minutes. Death may occur even if individual is
removed to fresh air at once.
E) H2S handling procedure
General Procedures:
Industry practice mandates that the following precautions procedures should be followed by all
personnel:
When approaching the work area it is necessary to take the following precautions to insure
safe entry
1. Observe “Condition” signs and observe for audio/visual alarms.
2. Check for wind direction.
3. Look for personnel and their activity.
4. Enter work area slowly.
5. Maintain mental image of two (at least) escape routes preferably cross wind.
6 Continuous atmosphere monitoring or detecting equipment is required along with and
adequate audio/visual alarm warning system. Portable detectors and combustible gas
meters give an additional degree of safety.
7 Gas ignition hazard must be eliminated and “No Smoking” regulations strictly enforced.

Page 221 of 271
8 Continued observation of wind indicators, windsocks and streamers is a must. During

atmospheric contamination by H2S, move upwind/cross wind from source, not
downwind.
9 Select a partner and use the “Buddy System” for mutual safety.
10 Maintain and observe warning signs.
11 Post emergency numbers in a conspicuous place. Maintain reliable communication
systems.
12 Locate emergency stations a minimum of 250 feet or as far from the H2S source as
practical. During an emergency all personnel will assemble at the briefing stations for
instructions and for refilling air bottles.
13 Hazardous concentrations of H2S can be disposed of by discharging through flare
stacks with automatic ignitions.
Note : Burning H2S produces Sulphur Dioxide (SO2), a deadly toxic gas that is heavier than H2S. Because of the heat it
rises and disperses into the upper atmosphere.
∗ Know your Company’s Emergency Procedures.
F) Emergency Procedures
If all the above procedures have been adhered to strictly, a catastrophic release of H2S should
never occur. In the unlikely event such a release does occur, the emergency procedures
detailed in this section should be followed.
a) Egress
H2S is a dangerous, deadly gas; however serious injury or death can be avoided by simply
evacuating the contaminated area and moving to a safe area upwind. Therefore, the most
important things to remember are to Stay Calm and Get Away.
Precise emergency escape procedures will be defined by the operations management of the
complex, however the following general procedures should be followed:
¾ Remain Calm-Do Not Panic
¾ Hold your breath
¾ Extinguish all fires
¾ Alert the rest of the crew

Page 222 of 271
¾ Make a quick, cursory check of the area to see if the source of the gas is obvious.
¾ Do not spend time looking for a leak
¾ Observe windsock to determine wind direction. Move upwind or crosswind, not
downwind, until the “safe breathing area” is reached.
¾ Active alarms if not already done.
¾ Once assembled at the safe briefing area, the foreman will make a head count to
determine if all personnel have evacuated safely.
b) Rescue and First Aid

Although H2S is a dangerous, deadly gas, its effects are readily reversible provided the
appropriate action is taken in a timely manner. In the event a fellow worker is down or
overcome by H2S, the necessity of an immediate and effective rescue effort is or utmost
importance. A natural reaction is to unthinkingly rush to the side of the downed victim, which
could be a fatal action.
Instead, before proceeding into the hazardous area to rescue a downed victim, stop, think
and:
¾ Put on an appropriate safe breathing apparatus.
¾ Move quickly, but carefully to the victim, side. Move the victim to a safe area; either
upwind or crosswind from the hazardous area. Do not evacuate in a downwind
direction.
¾ Begin mouth-to-mouth artificial respiration if the victim has stopped breathing. Check
the victim’s pulse periodically to ensure that the victim’s heart is still beating. If the
victim’s heart stops beating, administer CPR. Artificial respiration or CPR should be
continued until:
- The victim begins to breathe and, if applicable, the heart begins to beat.
- He is pronounced dead by a doctor.
- He is dead beyond any doubt.
¾ Seek assistance at the first opportunity and make arrangements for transportation to a
medical facility to seek medical attention by a physician.

Page 223 of 271
c) Abatement Procedure
Once the safety of all personnel has been determined, the next order or business is to
determine the source of H2S and stop it, if possible.
Control Room personnel
¾ Stay in the Control Room since it is equipped with a positive ventilation system pulling
suction from an higher elevation. Since H2S is heavier than air, the Control Room
should be safe.
¾ If leak can be located, activate the deluge system for that area.
Field Personnel
¾ Use breathing apparatus (Respirator).
¾ Establish communication with Control Room.
¾ Communicate with first personnel to sound alarm/notice of the H2S.
¾ To determine the general area of the source, slowly begin searching the source from
the upwind side.
12.6.2 Hydrogen
Hydrogen is a colourless, tasteless, odourless and highly flammable gas and is the lightest
element. Since hydrogen is lighter than air, less danger exists of it collecting in pockets in
low areas. However, the potential danger from fire or explosion is high. Gaseous fuels such
as hydrogen can mix with air or oxygen in all proportions. However, the proportions must be
within certain limits before those mixtures will burn. The limiting proportions are referred to
as “flammable limits” or “explosive limits” and are expressed as the percentage by volume
of the fuel in the air-fuel mixture. Fuel-air mixtures outside of the flammable range will not
explode. Hydrogen has a very wide range (4-75%) of “flammability or explosive limits” in air
at atmospheric pressure. In addition, the flammability range becomes wider at higher
pressure or if oxygen is substituted for air. Thus, explosions can occur over a very wide
range of hydrogen concentrations in air. The safest approach to safeguard against possible
fires or explosions is to make sure that hydrogen leaks do not develop.
The autoignition temperature of a substance is the lowest temperature required to initiate or

cause self-sustained combustion in the absence of a spark or flame. The autoignition

Page 224 of 271
temperature of hydrogen in air is 580°C at atmospheric conditions. However, other factors

such as the nature, size, and shape of the igniting surface can affect this temperature.
Unlike most gases, which cool when expanded or bled off, hydrogen heats up when
expanded and great care must be exercised when bleeding down lines or compressors to
the atmosphere. In its pure state, hydrogen burns with a bluish white flame (almost
invisible) that is extremely hot. Such a hot flame can weaken any support beams or lines on
which it may impinge. Any leaks should be put under a steam blanket immediately to
prevent the possibility of a fire. Be aware, however, that many leaks can autoignite and will
be difficult to see. Replacing the source of the hydrogen with a nitrogen or steam purge is
the most effective way of combating a hydrogen fire.
Hydrogen, although a not a poisonous gas itself, is an asphyxiant (i.e. cuts off oxygen
supply to the body by displacing air in the lungs) and can cause unconsciousness and even
death if the victim falls and remains in a high hydrogen atmosphere.
Because of the small size of hydrogen molecules, a pressure check with air or nitrogen or a
hydrostatic test will not always show all leaks that will occur with hydrogen.
12.6.3 Hazards Aromatics Hydrocarbons

A. Benzene
Benzene will be present in the Platforming process. Benzene is extremely toxic.
Special Instruction: If clothing (including gloves, shoes) becomes contaminated with

benzene, the clothing should be removed immediately. Wash any skin area exposed to
benzene with soap and water. Take a complete bath if the body is wetted with benzene. Do
not wear clothing that has been wet with benzene until the garment has been
decontaminated by washing or dry cleaning. Wearing clothing that has been wet with
benzene almost assures that the person will inhale benzene vapours over a long period of
time, resulting in potential health hazards.

Page 225 of 271
Avoid draining benzene to the concrete or into the sewers where it can vaporize and create
a health hazard. If benzene is accidentally spilled, flush it from the concrete and sewer
catch basin with large quantities of cold water. Do not use hot water or steam, which
increases the vaporization of benzene. If you must enter an area of high benzene vapour
concentration, wear appropriate respiratory protection, such as self-contained breathing
apparatus or an air mask with an external air supply.
Though not specifically a health hazard, an environmental problem can result from benzene
entering the sewer since benzene is much more soluble in water than any other
hydrocarbon. This places an extra load on the effluent treating system.
B. Toluene, Xylenes and Heavier Aromatics

These aromatic compounds are also present in the Platforming process. These
compounds are moderately toxic and are believed to not have the destructive effect on the
blood-forming organs as does benzene. If clothing (including gloves, shoes, etc.) becomes
wet with such aromatics, remove the clothing, bathe and put on fresh clothing. Avoid
breathing aromatic vapours.
C. Toxicity Information
Toxicity and safe handling information on most of the materials used in the unit is available
in Material safety Datasheet.
D. Minimizing Exposure to Aromatics

Operating and laboratory personnel involved in obtaining samples should wear chemical-
type safety goggles or shield, protective apron or laboratory coat, solvent-resistant gloves,
and approved respiratory protective equipment where ambient concentrations exceed
allowable limits. This protective equipment is not, however, a substitute for safe working
conditions, proper ventilation, safe sampling practices, and proper maintenance of both
operating and safety equipment. In all cases, skin contact (especially eyes) and installation
must be minimized.

Page 226 of 271
Sampling liquid hydrocarbons always requires some care to limit personal exposure and
release to the atmosphere. Even greater care is needed when the liquid to be sampled
contains aromatic hydrocarbons, especially benzene.
In order to minimize vaporization, hot hydrocarbon streams must be routed through a cooler
before drawing a sample, in all sampling situations, the personnel involved should be
instructed to remain at arm’s length from the sample container and to situate themselves
upwind of the container if at all possible. These simple precautions will greatly minimize
exposure to the hydrocarbon vapours.
E. Medical Attention
The US NIOSH/OSHA guidelines attached for ethyl benzene, toluene and xylene set forth
recommendations for medical monitoring of personnel working in environments where
exposure to these materials can occur. NIOSH/OSHA guidelines for medical monitoring be
considered in development and implementation of an occupational health-monitoring
program for employees who may be exposed to toluene, xylene and/or ethylbenzene.
OSHA has recommended the following medical monitoring for employees who may
be exposed to benzene:
¾ Pre placement and quarterly examinations, including a history which includes past
work exposures to benzene or any other hematologic toxins, a family history of
hematological neoplasms, a history of blood dyscrasias, bleeding abnormalities,
abnormal function of formed blood elements, a history of renal or liver dysfunction,
a history of drugs routinely taken, alcoholic intake and systemic infections; complete
blood count including a differential white blood cell count; and additional test, where
in the opinion of the examining physician, alterations in the components of the
blood are related to benzene exposure.
These guidelines be considered in development and implementation of an occupational

health- monitoring program for employees who may be exposed to benzene.

Page 227 of 271
All new or current employees should be alerted to the early signs and symptoms resulting
from exposure to aromatics, and any workers experiencing such symptoms should seek
professional medical attention. In addition to the above, all employees should be advised of
the hazards involved and precautions to be taken when working with aromatics.
12.6.4 Hazards Related To Catalyst

It is during periods of opening and cleaning or in sampling that bodily exposure to UOP
Platforming can occur and caution must be exercised.
The major constituent of the UOP Platforming catalyst is alumina, which is not currently
listed by OSHA as hazardous substances. These catalysts do contain other constituents, in
lesser amounts, which might present hazards to human health and/or the environment if
handled or disposed of improperly. It is the purpose of this safety section to provide
information and recommendations that will allow safe handling and proper disposal of these
catalysts.
Only the following fresh catalyst (R-11, R-12, R-14, R-16, R-18, R-19, R-50, R-51, R-55, R-
60, R-62) contain hydrogen sulfide.
Spent Platforming catalysts may also contain additional hazardous chemicals, such as
arsenic, carbon, hydrocarbons, iron pyrites, iron sulfide, lead, and vanadium. The toxic
properties and exposure limit of the most hazardous of these chemicals follow:
HYDROGEN SULFIDE: Hydrogen sulfide is both an irritant and an asphyxiant. The current
OSHA permissible exposure limits are 20 ppm ceiling concentration and 50 ppm peak
concentration for a maximum 10-minute exposure.
ARSENIC: Arsenic is a recognized carcinogen and can cause acute and chronic toxicity.
Symptoms of acute toxicity are somewhat dependent upon the route of contact and can
include (for ingestion or inhalation): Irritation of the stomach and intestines, with nausea,
vomiting and diarrhea; liver damage; kidney damage; blood disturbances; and allergic

Page 228 of 271
reactions. The OSHA 8-hour time weighted average exposure limit to inorganic arsenic
compounds is 10 micrograms per cubic meter of air.
The greatest potential for human exposure to catalyst materials comes from catalyst dust
during reactor loading, and from dust, fumes, and vapors during catalyst unloading
operations. For the unprotected worker, hazardous dust, fumes, and vapors may be
inhaled, ingested, or contaminate the eyes and skin.
Handling Catalyst Spills and Deposited Catalyst Dust

Always wear NIOSH-approved self-contained breathing apparatus or the combination of
toxic dust respirator-rubber frame eye goggles, protective clothing, and gloves. Acid
cleaning methods that raise dust, dispose of all catalyst wastes properly in containers,
which should then be labeled as to the contents and hazards.
Do not dispose of catalyst wastes in a public water system or in the normal solid waste.
Return material to supplier for metal recovery.
Handling of UOP catalysts safety

If proper handling procedures and worker protective clothing/safety devices are used OSHA
exposure limits to catalyst chemical will not be exceeded. Following minimum safety
procedures be established and adhered to:
¾ Handle catalysts only in well ventilated area.

¾ In areas where natural ventilation is insufficient, use local mechanical ventilation.
¾ Wear an approved toxic dust respirator with full face-piece, protective clothing, and
gloves for normal catalyst handling operations.
¾ Reactor loading and unloading operations present extraordinary health risks,
especially to personnel working in the reactor. During loading operations, large
quantities of catalyst dust may be generated. During unloading, the hazards may be
include inert (nitrogen) atmosphere, toxic feed stock, product or purge materials
present with the catalyst, or toxic forms of catalyst chemicals. Personnel working in
reactors should wear a supplied air respirator with a hood or helmet, operated in a

Page 229 of 271
pressure demand or other positive pressure mode or in a continuous flow mode.

This respirator should have a primary, secondary and emergency supply of air. In
addition, personnel in the reactor should be equipped with safety harnesses and
safety lines for rescue and a means for visual, voice or signal line of communication
with standby personnel, who should be strategically located with suitable rescue
equipment.
¾ Protective clothing and all safety devices should be thoroughly decontaminated
after each use. Worn-out, broken or defective safety equipment and clothing should
be removed from service and repaired or replaced. Good personal hygiene after
handling a catalyst or being exposed to catalyst dust is an essential part of a
responsible catalyst safety program. Do not eat, drink, or smoke in areas where the
catalyst is being handled or where exposure to catalyst dust is likely.
12.7 FIRE FIGHTING SYSTEM
The operating personnel should be fully conversant with Fire Fighting system provided in the
unit. All of them should have adequate fire fighting training and will serve as an auxiliary Fire
Squad in the event of a fire breakout. It will be the primary responsibility of unit personnel to
fight the fire at the very initial stage and, at the least, localize it.
Major Fire fighting facilities provided in the unit comprise the following:
i) Fire Water System

Water is most important fire fighting medium. Water is used for fire extinguishment, control,
equipment cooling & exposure protection of equipment/personnel from heat radiation.
An elaborate fire water distribution network is provided around unit. Fire Water
Hydrants/Monitors are provided around unit, which give coverage to most of equipment.
ii) Foam System

Page 230 of 271
For containing large Hydrocarbon fires, foam systems are useful. They have inherent
blanketing ability, heat resistance and security against burn back. Low expansion foam is
used for hydrocarbon oil fire.
Foam can be applied over burning oil pool with the help of foam tenders/foam delivery system.
iii) Portable Fire Extinguishers

Fire should be killed at the incipient stage. Portable fire extinguishers are very useful in
fighting small fires. All extinguishers in the unit must be located in specified places only. The
operating crew should be acquainted with exact location of the extinguishers. They also must
know most suitable type, which, when and how to use an extinguisher. For example, electrical
fires should be put out with CO2 or dry power extinguishers; water and foam should not be
used. The used extinguishers should be checked and restored by fire station personnel.
iv) Fire Signal
Break Glasses have been provided at strategic locations of unit to see fire alarm in fire station.
if a fire is sighted, glass of window should be smashed, causing fire alarm switch to actuate.
This is an emergency call & should be periodically tested for proper functioning.
v) Steam Smothering
LP Steam hose connections have been provided at every convenient point inside unit. Steam
lances of standard 15M length can be fitted with these hose stations. Wherever hydrocarbon
leakage is detected which is likely to catch fire, Steam blanketing may be done. Apart from
diluting combustible Hydrocarbons, steam prevents atmospheric oxygen from taking part in
combustion & thus help in extinguishing fire. However, steam should never be applied on
large pool of hydrocarbon fire. Direct application of steam on burning oil may result in spillage
of burning hydrocarbon & spread of fire. Similarly use of fire water on hot oil surfaces may
cause sputtering & spread of fire.

Page 231 of 271
SECTION -13
ALARMS AND TRIPS
SET POINTS FOR ALARMS AND TRIPS
CCR PLATFORMING UNIT PROCESS SYSTEM

Tag no. Description Unit Signal Setting
o
74-TIC-0504 Charge heater outlet C TAH 550
o
74-TDIC-0503 Charge heater diff temp C TDAH 90
o
74-TIC-0604 No. 1 Interheater outlet C TAH 550
o
74-TDIC-0603 No. 1 Interheater Diff temp. C TDAH 135
o
o
o
o
kg/cm2
74-PDI-0901 Reactor 1 Diff pr PDAH 0.32
kg/cm2
kg/cm2
kg/cm2
o
74-TIC-0905 Purge gas from Reactor C TAH 175
Purge exchanger TAL 140
74-FIC-0901 Recycle gas to Reactor Nm3/hr FAH 540
Purge exchanger FAL 240
74-PDI-1001 Combined Feed Exchanger Kg/cm2 PDAH 0.7
Differential Pressure
74-PDI-1002 Combined Feed Exchanger Kg/cm2 PDAH 3.4
Differential Pressure
74-FIC-1001 Fresh feed to combined feed M3/hr FAL 44
exchanger
74-FI-1002A /B /C Recycle gas to CFE Nm3/hr FAL 30000
74-PIC-1203 Seperator Kg/cm2 PAH 4.2
74-FIC-1202 Separator pumps discharge M3/hr FAL 69
74-LIC-1202 Separator % LAH 80
LAL 20
74-LI1201 A/B/C Separator % LAH 40
74-PDI-1201 Separator pumps suction Kg/cm2 PDAH 0.1
strainer diff pr

Page 232 of 271

74-PDI-1202 Separator pumps suction Kg/cm2 PDAH 0.1
strainer diff pr
74-PDAH-1301 Recycle compressor suction Kg/cm2 PDAH 0.1
strainer diff pr
o
74-TAH-1301 Recycle Compressor C TAH 190
Discharge
o
74-FIC-1401 First stage suction drum C FAL 2.4
pumps discharge
74-TI-1501 Reduction Gas from CCR % TAH 90
Regeneration Section TAL 50
74-LIC-1501 First stage suction drum % LAH 80
LAL 20
74-LI-1502A/B/C First stage suction drum % LAH 40
74-PIC-1501 First stage suction drum Kg/cm2 PAL 5
74-PDI-1601 Net gas compressor A 1st Kg/cm2 PDAH 0.1
stage suction strainer dif pr
74-PDI-1602 Net gas compressor A 2nd o
C PDAH 0.1
stage suction strainer diff pr
74-TI-1603A Net gas compressor A 1st o

C TAH 143
stage discharge
74-TI-1605A Net gas compressor A 2nd o
C TAH 113
stage discharge
74-FI-1701 Net gas compressor B 1st Kg/cm2 PDAH 0.1
stage suction strainer dif pr
74-PDI-1702 Net gas compressor B 2nd o
C PDAH 0.1
stage suction strainer diff pr
74-TI-1703A Net gas compressor B 1st o
C TAH 143
stage discharge
74-TI-1705A Net gas compressor B 2nd o
C TAH 113
stage discharge
74-LIC-1802 Second stage suction drum % LAH 80
LAL 20
74-LI-1801A/B/C Second stage suction drum % LAH 40
74-PIC-1801 Second stage suction drum Kg/cm2g PAL 12.6
74-PDI-1901 Recontact Cooler Outlet Kg/cm2 PDAH 1.1
74-PIC-1902 Recontact Drum % LAH 80

Page 233 of 271

LAL 20
o
74-TAH-2104 Reformate to storage C TAH 45
74-LIC-2201 Stabiliser % LAH 80
LAL 20
74-LI-2202 Stabilizer % LAL 60
74-FIC-2301 Stabilizer Overhead pump M3/h FAL 23
Discharge
74-LIC-2403 Stabiliser receiver % LAH 80
LAL 20
74-LI-2402 Stabiliser receiver Interface % LAL 60
o
74-TAH-2605 LPG to storage C TAH 45
o
74-LIC-2601 Deethaniser C LAH 80
LAL 20
74-LIC-2704 Deethaniser receiver % LAH 80
LAL 20
74-LI-2703 Deethaniser Receiver % LAH 80
74-LIC-2701 Deethaniser Receiver % LAH 80
interface LAL 20
74-LI-2702 Deethaniser receiver % LAL 60
Interface
74-LIC-2801 Steam disengaging drum % LAH 70
LAL 30
74-2801A/B/C Circulating water to M3/h FAL 225
convection section
74-FI-2802 Circulating water to M3/h FAL 225
convection section
74-TIC-2907 VHP Steam to header oC TAH 365
TAL 355
74-TIC-2909 VHP Steam from de- Oc TAH 270
Superheater No 2 TAL 260
74-FIC-2902 BFW To convection section M3/h FAL 15
74-PI-2910 BFW booster Pumps KG/cm2g PAL 42
Suction
74-PI-2911 BFW Booster Pumps Kg/cm2g PAL 42
Suction
74-PI-3002A/B/C Pilot Gas To heaters Kg/cm2g PAL 0.6

Page 234 of 271

74-PIC-3102A Fuel gas to charge heater Kg/cm2g PAH 1.7
PAL 0.2
74-PI-3101 Fuel Gas To charge Heater Kg/cm2g PAL 0.1
74-PDI-3103 Fuel oil To Charge Heater Kg/cm2g PDAH 0.1
74-PIC-3105A Fuel Oil To charge Heater Kg/cm2g PAH 7.0
PAL 2.4
kg/cm2g
74-PI-3107 Fuel Oil Atomizing Steam to PAL 4.5
charge heater
74-PDIC-3108 Fuel Oil Atomizing steam to kg/am2g PDAL 1.0
charge heater
74-PI-3104 Fuel Oil To Charge Heater kg/am2g PAL 2
74-PDI-3106 Charge Heater Atomizing Kg/cm2g PDAH 3.2
Steam / Fuel Gas Diff. Pres PDAL 1.0
74-AI-3101 Charge Heater flue gas Mol% AAL 2 mol% O2
oxygen
74-TAH-3102 Charge Heater fire box oC TAH 870
74-PIC-3202A Fuel gas to no 1 Interheater Kg/cm2g PAH 1.7
PAL 0.2
74-PI-3201 Fuel Gas To no 1 Kg/cm2g PAL 0.1
Interheater
74-PDI-3203 Fuel oil To No 1 Interheater Kg/cm2g PDAH 0.1
74-PIC-3205A Fuel Oil To No1 Interheater Kg/cm2g PAH 7.0
PAL 2.4
kg/cm2g
No 1 Interheater
No 1 Interheater
74-PI-3204 Fuel Oil To No 1 Interheater kg/am2g PAL 2
74-PDI-3206 No 1 Interheater Atomizing Kg/cm2g PDAH 3.2
74-AI-3201 No 1 Interheater flue gas Mol% AAL 2 mol% O2
oxygen
74-TAH-3202 No 1 Interheater fire box oC TAH 870
74-PIC-3302A Fuel gas to no 2 Interheater Kg/cm2g PAH 1.7
PAL 0.2
Interheater

Page 235 of 271

74-PIC-3305A Fuel Oil To No 2 Interheater Kg/cm2g PAH 7.0
PAL 2.4
kg/cm2g
No 2 Interheater
No 2 Interheater
oxygen
74-PIC-3402A Fuel gas to no 3Interheater Kg/cm2g PAH 1.7
PAL 0.2
Interheater
74-PIC-3405A Fuel Oil To No 3 Interheater Kg/cm2g PAH 7.0
PAL 2.4
kg/cm2g
No 3 Interheater
No 3 Interheater
oxygen
74-PI-3501A/B/C No 1 Interheater Flue Gas Mmh2o PAH 3
To convection Section
74-TAH-3501 Flue Gas from Convection oC TAH 200
section

Page 236 of 271
SECTION -14
UTILITY AND AUXILIARY SUMMARY
UTILITY SYSTEM
The utility system consists of Sea cooling water distribution (SWS/SWR), HP/ML/LP steam
distribution (SH/SM/SL), Bearing cooling water distribution (WCS/WCR), Instrument Air (AI).
Plant Air (AP), Nitrogen (N2) Distribution, Fuel gas/Fuel Oil distribution (FG/FO), Flare
distribution (FL), Closed Bow down (CBD) distribution etc. Common utility distribution system
is provided for NHT Unit, CCR Plat forming Unit and NSU. Description for the utility system is
given below.
SEA COOLING WATER DISTRIBUTION SYSTEM

The cooling water requirement for cooling purpose is met through offsite cooling water system.
A 26” cooling water supply header supplies water to CCR Platforming Unit. The header is
provided with a non-return valve and a spectacle blind at the battery limit. The supply header
is provided with PI-8102 with PAL and PAH, FI-8101 with FAH/FAL and FQ, TI-8102 with TAH
and TAL in DCS and local TI & PI are provided on the 26” header at B/L.
Cooling water from the supply header is taken to the various equipment and returned through
the return header.
The return water is collected in a 26” return header and sent to B/L. The return header is
provided with an NRV and a spectacle blind at the battery limit. The return header is also
provided with TI-8104 with TAH and TAL, PI-8104 with PAH and PAL and flow indicator FI-
8102 with FQ, FAL and FAL.
INSTRUMENT AIR SYSTEM

A 6" Instrument Air header supplies IA to various units. The header is provided with isolation
valve and a spectacle blind. Various Instrument air tapping are taken from this header. In
DCS FI-8301 with FQ, and PI-8302 with PAL and PAH and local TI, PI are provided on the 6”
header at B/L.

Page 237 of 271
PLANT AIR SYSTEM
A 4" plant air header supplies plant air to the unit to cater the requirement in various units. The
header is provided with isolation valve and a spectacle blind for positive isolation at the battery
limit. A number of utility points are provided from this header. In DCS FI-8302 with FQ, and PI-
8304 with PAL and PAH and local TI, PI are provided on the 4” header at B/L.
BEARING COOLING WATER SYSTEM
The 8” Bearing cooling water supply header is receiving water from C. W. Supply header from
the supply header. BCW is distributed to the pumps and compressors. After cooling, the
return water from the pumps is collected in BCW Return header. The return header is of 8”
size and is provided with Temperature indicator TI8204 with high and low alarm. Flow indicator
FI8202 with high and low alarm and pressure indicator PI8204 with high and low alarm. Local
temperatures and pressure gauges are also
SERVICE WATER SYSTEM

The 3” common service water header supplies service water to the units. It is provided with an
isolation valve and a spectacle blind at battery limit. DCS FI8303 with FQ and PI8306 with
PAH and PAL are provided. Local PI & TI are provided at the battery limit. The service water
header supplies water to various hose stations in the units. Service water is required mainly for
cleaning and washing.
NITROGEN
A 6” header supplies N2 to various units. N2 is used for various purposes in equipment, line
etc. for inertisation, blanketing, purging etc. The supply header is provided with DCS FI-8601
with FAL and FAH and PI-8602 with PAL and PAH. Local PI & TI are also provided at B/L.
LP STEAM SYSTEM
A 14” header supplies LP steam to NSU/NHT/CCR units. FI/FQ-8801 with FAH and FAL, PI –
8802 with PAL and PAH and TI-8802 with TAH and TAL are provided in DCS to monitor LP

Page 238 of 271
steam B/L condition. Also local PI & TI are provided. At B/L block valve along with spectacle
blind are provided for positive isolation.
MP STEAM SYSTEM
A 12" medium pressure steam header has been provided for NSU/NHT/CCR units with an
isolation valve and a spectacle blind at battery limit. PI-8804 with PAH and PAL, TI-8804 with
TAH and TAL and FI-8802 with FQ, FAH and FAL indicate MP steam pressure, temperature
and flow rate in DCS. Local PI and TI are also provided at battery limit.
HP STEAM SYSTEM
An 8" high pressure steam header has been provided for NSU/NHT/CCR units with an
isolation valve and a spectacle blind at battery limit. PI-8702 with PAH and PAL, TI-8702 with
TAH and TAL and FI-8701 with FQ, FAH and FAL indicate HP steam pressure, temperature
and flow rate in DCS. Local PI and TI are also provided at battery limit.
FUEL GAS SYSTEM

The FG header is provided with DCS FI-8405 with FQ, FAH and FAL, TI-8410 with TAH and
TAL, PI-8410 with PAH and PAL. FG supply is received in a 10” header and sent to various
units and heaters. The fuel gas is then supplied to heaters in 10” pipe as fuel gas and in 2”
pipe as pilot gas. The common header provides FG to the heaters. The trip system for each
heater is provided to trip the heater firing in case of low flow and low pressure.
FUEL OIL SYSTEM

The FO header is provided with DCS FI-8401 with FQ, FAH and FAL, TI-8402 with TAH and
TAL, PI-8402 with PAH and PAL. The common header provides FO to the heaters. The trip
system for each heater is provided to trip the heater firing in case of low flow and low pressure.
FLARE SYSTEM
Flare header is of 36” size and is connected to the Flare KOD after collecting gases in the flare
header from all the equipment. From the Flare KOD the liquid free gases are discharged to
Flare. TI-7802, FI-7801 with FQ and PI-7802 are provided at Flare inlet. Flare KOD level is

Page 239 of 271
controlled by LI-7802 with LAH and LAL. High-high level and low-low level alarms are also
provided for level control.
CBD SYSTEM
Blowdown header is of 6” size and is connected to the Closed Blowdown Drum (74-V-55) after
collecting liquid from all the equipment. The CBD liquid is cooled by passing BCS through
cooling coils. The liquid separated from the CBD is pumped (by CBD submersible pump, 74-
P-52A/S) to the SLOP header. From the CBD vessel, the liquid free gases are discharged to
Flare. TI-8001 is provided with TAH and TAL. LI-8002 is provided with LAH and LAL. HC
detector is located near the CBD pump with the high and high-high alarm, is case of leak.

Page 240 of 271
SECTION -15
SPECIAL PROCEDURES
15.1 CATALYST LOADING
15.1.1 General Loading Guidelines
Observance of the following guidelines during preparation for and completion of the catalyst
loading procedure are recommended.
a. An inspection of the reactors and their internals should be completed as soon as

possible prior to loading.
b. An inventory of catalyst, support material, and any reactor internals stored outside
the reactors should be made well in advance of the loading.
c. When the loading procedure is scheduled as a round-the-clock operation, adequate
lighting should be provided for safe night time activity in the working area.
d. The placement of catalyst drums in the unit area and the stacking of empty drums
should be planed in advance to prevent confusion while reactor loading is
underway. The catalyst drums should not be unsealed until just prior to loading.
e. Do not discard empty catalyst drums. Store them with their lids and clamp rings in a
dry location. Normal practice is to use the empty catalyst drums for return of
catalyst fines or spent catalyst and for handling catalyst during unloading.
f. All catalyst loading equipment should be checked for availability and operability.
This would include loading hoppers, socks, hoists, safety equipment, lights, ladders,
etc.
g. Frequently, the personnel doing the work involved with catalyst loading do not
understand the operation of the unit or why loading details must be followed exactly
as designated. All personnel involved should be properly informed as to the
reasons and requirements for correct catalyst loading. In addition, procedure for
rigorous follow-up and attention to detail on the part of supervisory personnel
should be established prior to the loading.
h. Keep the tops of the scallop risers covered by caps to ensure no extraneous
materials fall or drop into the scallops.
i. No extraneous material should be left or dropped into the reactors. Aside from the
embarrassment of unloading a reactor to retrieve an object dropped or over looked

Page 241 of 271
during the loading period, serious problems during operation of the unit are likely to
occur as a result of an oversight in this matter.
j. Every effort must be made to minimize the time each reactor is open to the
atmosphere. A dry instrument air purge or blanket should be maintained on the
reactor system throughout the entire loading period to prevent moist air from
entering the reactor system. All reactor man ways must be kept covered or closed
except during actual loading.
k. The catalyst loading should not take place during rainy or inclement weather as
exposure to any excessive moisture can alter the catalyst chemical properties and
reduce its activity.
l. Do not allow a natural draft of air to flow up through a reactor bed at any time.
Regardless of the state of the catalyst – fresh, spent, regenerated, hot or cold –
such a flow of air for a prolonged period may cause serious damage to the catalyst
and reactor internals.
m. For any Platforming unit loading in which the catalyst is sold in the pre-reduced and
pre-sulfided state, the following precaution must be observed.
CAUTION
Some of the UOP Platforming catalysts are pre-sulfide. These pre-sulfided Platforming
catalysts contain sulfur; this results in a small partial pressure of H2S, which may become
significant if the catalyst is exposed to temperatures above ambient temperature. Since
both excess nitrogen and possible hydrogen sulfide could be present in the reactors at
some time during the loading, if it becomes necessary to have personnel enter the reactor
during the catalyst loading they should be provided with proper protection for entering a
contaminated atmosphere. No one should be allowed to enter the reactor unless equipped
with the proper equipment and safety backup as specified for work in a contaminated
atmosphere.
A UOP representative will be able to confirm if the particular catalyst supplied is sold in the
pre-reduced and pre-sulfided state.
Determine the correct catalyst loading for each reactor before beginning the loading
operation. Actual measurements should be used to calculate each bed depth and volume.

Page 242 of 271
15.1.2 CCR Platforming Catalyst Loading

Overview
Three different methods are recommended by UOP loading catalyst into CCR Platforming
unit reactors. All three are acceptable regardless of unit design or reactor size. Differences
in the quantity of fines generated from one method of loading to another are minimal. All
fines that are generated from handling and loading will be removed from the system during
the first two or three catalyst cycles. If the loading is done correctly, these fines will have no
effect on the long-term operation of the unit.
Description for each procedure is given below. At this point it is assumed that all of the
reactors and internals have been assembled correctly, cleaned, and dried out (new units).
A) Reactor by Reactor Loading Procedure

Of the three procedures, this has been the most common method used in the past. Drums
of catalyst are hoisted up to the reactor man way area where a temporary loading hopper is
situated. As catalyst is dumped into the hopper, it flows out the bottom through piping or
conduit and enters the reactor through the reactor man way. At the end of the pipe or
conduit is a loading sock, which extends a few feet below the reactor cover deck. From the
other end of the sock the catalyst free falls to the bottom of the reactor. During the loading
procedure, the sock is shifted to different areas of the catalyst bed annulus so that catalyst
fills the reactor uniformly. If the catalyst falls in only one area, it will put an uneven stress on
the center pipe, and cause variations in the loading density. Obviously, this frequent
movement of the loading requires that a man be in the cover deck area of the reactor
throughout the loading. Dust protection is required. The loading hopper can be bolted to
the man way but it is usually easier to locate it a deck (permanent or temporary) above the
man way. The layout of the piping and sock must be arranged so that catalyst flows freely.
An angle greater than 35 degrees from horizontal should be acceptable. When everything
is running smoothly the loading crew should be capable of moving approximately 20 drums
per hour or 2050 kg per hour.
A small variation to this approach can increase this loading rate significantly to cover 60
drums per hour or 6150 kg/hr. It calls for loading the catalyst into large bins at grade and
then lifting the bins up to the hopper. Typical bins used by catalyst handling companies hold

Page 243 of 271
approximately 1400kg of catalyst. A separate crew at grade would be responsible for

loading the catalyst into the bins, always staying ahead of the bin transfers.
Regardless of whether drums of bins are used, loading should always start in the lowest
reactor and move up to the next highest when done. Loading in a reactor is complete when
the catalyst level is approximately one foot below the open end of the catalyst transfer
pipes. Short loading a reactor does not present a problem. However, if a reactor is
overfilled, it will make it impossible to install the few cover deck segments and catalyst
transfer pipes not yet in place.
For reactors with a conventional regeneration section, the reduction zone can be loaded in
a similar manner as the reactors by placing a catalyst loading funnel above the catalyst inlet
flange on top of the reduction zone. Lift catalyst (drums or bins) and empty into the funnel.
The reduction zone is full when the level instrument is satisfied.
For reactors with a pressurised regeneration section, the reactor surge zone on top of
reactor no 1 can be inventoried the same way the reactors were; using loading hopper,
loading sock and crane to lift the catalyst up to that elevation. The output of the level
instrument could be compared to a physical gauging of the zone to verify the accuracy of
the level instrument. This zone should be filled to slightly more than the normal working
volume to makeup for slumpage during the initial start-up.
On units where the top of the reduction zone (or reactor surge zone for pressurised
regeneration sections) reactor no 1 is too high for access or on new units or when extensive
work was performed on the regenerated catalyst transport system.

Page 244 of 271
Step by step description is given below.
After a final reactor inspection following unit dry out or turnaround, the reactors may be
loaded by the following procedure:
a). Confirm that the man ways on all reactors except the lowest reactor in the stack are
closed to prevent a natural draft.
b). Establish dry instrument air purges to the reactor stack by connection air hoses to
the reactor outlet line pressure gauge connections or placing air hoses in the man
way of the open reactor.
c). Remove two or three cover plate segments at equal spacing around the cover deck
in the lowest reactor in the stack.
d). Plumb bob each catalyst transfer pipe to insure it is unobstructed.
e). Place covers over top of each scallop riser prior to reactor loading. (Should be
done as soon as the reactor man way is opened.)
f). Locate the catalyst loading hopper above the reactor man way. The deck above,
temporary scaffolding or a special structure can be used to support the hopper. The
loading hopper should be sized larger than the catalyst drums or bins.
g). Attach piping or flexible hose from the loading hopper outlet to the reactor man way.
h). Attach the loading sock to the piping or flexible hose; the sock should be long
enough to extend at least two feet below the cover deck level at each of the open
cover plate locations.
i). If bins will be used to lift catalyst up to the reactor catalyst loading hopper, set up
scaffolding and a catalyst addition hopper at grade to facilitate loading of the bins.
j). Start catalyst loading by lifting catalyst drums or bins up to the loading hopper
located above the reactor man way.
NOTE: If the reactor catalyst disposal nozzles were not filled during the final reactor inspection with ceramic alumina balls,
this should be completed prior to catalyst loading.
k). As catalyst is loaded to the reactor, move the loading sock to the different open
cover plate locations; this will minimize the chance of loading at different densities
at different points in the reactor bed. Raising the catalyst level evenly over the
entire cross section of the reactor will also facilitate a constant density loading and
reduce centre pipe stress.

Page 245 of 271
l). Continue sock loading until the catalyst level is within a foot of the bottom of the
catalyst transfer pipes.
m). For record purposes, measure the catalyst bed outage with respect to the bottom of
the cover plate and note the total number of drums loaded.
n). Restore all cover plate segments along with their respective catalyst transfer piping.
Carefully check transfer-piping bolting for tightness and gaskets for gaps with a
feeler gauge. A 0.13 mm blade is recommended.
o). Remove any debris or catalyst spillage from the cover plate area and remove the
covers from the scallop risers.
p). Close reactor man way.
q). Proceed to load the other reactors in the same manner as described above, moving
from lowest to successively higher reactors in the stack.
r). Load the top of reactor no. 1 and the reduction zone (or reactor surge zone for
pressurized regeneration sections) via lift engager no. 2.
s). after the stacked reactors are loaded, load the regeneration tower and disengaging
hopper via the catalyst bins or drums. Load through the top flange or man way on
the disengaging hopper until the nuclear level device indicates a level.
t). After catalyst loading is complete and the reactors are headed up, the reactor
system should be evacuated and placed under a positive nitrogen pressure to await
unit start-up.
u). At the conclusion of the catalyst loading activities, the quantity of catalyst contained
in each reactor should be determined. In addition, the loaded density should be
computed based on measured reactor volumes.
B) Entire Reactor Stack Loading Procedure

This procedure calls for loading all the catalyst through the top of the reduction zone (or
reactor surge zone for pressurized regeneration sections) on top of reactor no. 1. In many
respects it is identical to the reactor-by-reactor loading procedure except there is only one
loading point. This is the preferred procedure when the appropriate equipment is available
to raise the catalyst to this height. Usually, a large hopper is centred over the catalyst inlet
flange on the top of the zone head and a sock or sleeve joins the hopper to the catalyst inlet
nozzle. Either butterfly or slide valve is located on the hopper outlet nozzle.

Page 246 of 271
As the catalyst falls from the zone to reactor no. 1, to reactor no. 2 and so on, it spreads out
in each reactor, filling the reactor uniformly, there is no problem with variations in loading
density or uneven stresses on the centre pipe. It is felt that this method will produce
marginally more fines than the previous procedure discussed but this should not pose a
problem. As mentioned previously, the fines will be removed during the first two or three
catalyst cycles.
Steep-by-Step Description is given below.

a). Use catalysts bins or drums to lift catalyst to the top of the reactor stack.
b). Load catalyst for all reactors through the catalyst inlet nozzle on top of the reduction
zone (or reactor surge zone for pressurized regeneration sections).
c). Follow all the precautions and steps mentioned in the reactor-by-reactor loading
procedure as they apply in this case.
NOTE: All man ways must be covered to minimize a natural draft through the catalyst as it falls through each reactor.
C) Pneumatic Catalyst Loading Procedure

The pneumatic catalyst loading system consists of a stainless steel line running up the
reactor structure. At grade this line is connected to a rotary valve unit which includes a
rotary valve, catalyst hopper, and a dry air injection system. This pneumatic loading system
is permanent and is ready to use at a moments notice. With the system there is no need to
plan ahead for a crane, hoist, temporary scaffolding, or equipment to be installed on the
reactor structure.
Based on commercial experience to date the pneumatic system can load approximately 20
to 30 drums per hour.
Catalyst is loaded into the hopper above the rotary valve or wheel. As the rotary wheel
turns. it moves the catalyst from the hopper to the lift line pipe. Dry air injection into the
bottom of the pipe pushes the catalyst up the pipe to the reactor at approximately 10.5 m/s.
the rotary valve makes it possible to continuously take catalyst from atmosphere pressure
up to approximately 1kg/cm2 in the lift line. The lift line sections are connected by special
couplings. These are located so that the lift can be diverted into any one of the four reactors
man ways and into the catalyst inlet line o the top of the reduction zone.

Page 247 of 271
SECTION -16
BLIND LIST
S. Location/Description Size Line No. P&ID No. Position during
No (Inch) Start-up Normal
Operation
1 Combined feed 1.5” 1.5”-P-74-1007-A1A 930768-120-10 Open Close
exchanger drain to
CBD
2 Separator safety valve 2” 2”-P-74-1211-A5A 930768-120-12 Open Close
PSV 01B bypass line
3 Recycle gas 30" 30”-P-74-1201-A5A 930768-120-13 Open Open
compressor suction line
4 Recycle gas 24” 24”-P-74-1301-A5A 930768-120-13 Open Open
compressor discharge
line
5 Nitrogen purge to 1.5” 1.5”-IG-74-1312-A1A 930768-120-13 Open Close
recycle gas compressor
7 Hydrogen addition to 11/2” 11/2”-P-102-4216-B5A 930768-120-13 Open Close
9 Evacuation line from 10" 10”-P-74-1306-A5A 930768-120-13 Open Close
suction to Ejector
10 Evacuation line from 8" 8”-P-74-1612-A5A 930768-120-13 Open Close
net gas compressor to
Ejector
11 Evacuation line from 6" 6”-P-74-2018-B5A 930768-120-13 Open Close
Net gas chloride treater
to Ejector
12 Evacuation line from 1.5” 1.5”-P-74-2508-B1A 930768-120-25 Open Close
LPG chloride treater to
Ejector
13 Net gas compressor 2” 2”-P-74-1507-A5A-IT 930768-120-15 Open Close
first stage suction drum
Safety valve PSV-02B
bypass
14 Net gas compressor 18” 18”-P-74-1601-B5A-IT 930768-120-16 Open Open
st
(74-K-02A) 1 stage
suction
15 Net gas compressor 12" 12”-P-74-1602-B5A-IS 930768-120-16 Open Open

st
(74-K-02A) 1 stage
discharge
16 Net gas compressor 12” 12”-P-74-1605-B5A 930768-120-16 Open Open
(74-K-02A) 2nd stage
suction
17 Net gas compressor 10 10”-P-74-1606-B5A-IS 930768-120-16 Open Open
discharge
18 Net gas compressor 1” 1”-V-74-1603-B5A 930768-120-16 Close Close
(74-K-02A) 1st stage
discharge header vent
nd
(74-K-02A) 2 stage

Page 248 of 271
20 Net gas compressor 18” 18”-P-74-1701-B5A-ST 930768-120-17 Open Open

st
(74-K-02B) 1 stage
suction
21 Net gas compressor 12" 12”-P-74-1702-B5A-IS 930768-120-17 Open Open
st
(74-K-02B) 1 stage
discharge
22 Net gas compressor 12” 12”-P-74-1705-B5A 930768-120-17 Open Open
suction
23 Net gas compressor 10 10”-P-74-1706-B5A-IS 930768-120-17 Open Open
nd
(74-K-02B) 2 stage
discharge
(74-K-02B) 1st stage
nd
(74-K-02B) 2 stage
26 Second suction drum 2” 2”-P-74-1817-A5A 930768-120-18 Open Close
Safety valve bypass
27 Recontact drum Safety 2” 2”-P-74-1926-B5A 930768-120-19 Open Close
valve bypass
28 Net gas Chloride 8" 8”-P-74-1906-B5A 930768-120-20 Open Open
Treater (74-V-05A) inlet
Treater (74-V-05B) inlet
30 Nitrogen to Net gas 1” 1”-IG-74-2007-A1A 930768-120-20 Open Close
Chloride Treater (74-V-
05A/B)
31 Net gas Chloride 2” 2”-P-74-2011-A11A 930768-120-20 Open Close
Treater PSV 09 bypass
32 Net gas Chloride 2” 2”-P-74-2012-A11A 930768-120-20 Open Close
Treater PSV 10 bypass
33 Net gas Chloride 8" 8"”-P-74-2001-B5A 930768-120-20 Open Open
Treater (74-V-05A)
outlet
Treater (74-V-05B)
outlet
35 H2 rich gas to PSA unit 8" 8”-P-74-2020-B5A 930768-120-20 Open Open
36 Reformate as start-up 4” 4”-P-74-2108-A1A 930768-120-21 Open Close
bypass to NHT
37 Offspec reformate to 8" 8”-P-74-2107-A1A 930768-120-21 Open Close
slop header
38 Stabilizer safety valve 2” 2”-P-74-2212-B1A 930768-120-22 Open Close
PSV-11B bypass
39 Nitrogen to Stabiliser 1.5” 1.5”-IG-74-2407-A1A 930768-120-24 Open Close
receiver
40 Drain from Stabiliser 1.5” 1.5”-OWS-74-2404-A9A 930768-120-24 Open Open
Receiver boot to CBD
41 LPG chloride Treater 1.5" 1.5”-P-74-2501-B1A 930768-120-24 Open Open
(74-V-07A/B) outlet
42 Nitrogen to LPG 1” 1”-IG-74-2509-B5A 930768-120-24 Open Close
chloride Treater (74-V-
06A)

Page 249 of 271
43 Nitrogen to LPG 1” 1”-IG-74-2510-B5A 930768-120-24 Open Close

chloride Treater (74-V-
06B)
44 LPG to storage 2" 2”-P-74-2606-BIIA 930768-120-26 Open Open
45 Deethaniser PSV 15B 2" 2”-P-74-2613-B1A 930768-120-26 Open Close
bypass
46 Drain from Deethaniser 1.5” 1.5”-OWS-74-2709-A9A 930768-120-24 Open Open
Receiver boot to CBD
47 Deethanizer receiver 1.5” 1.5”-P-74-2718-B1A 930768-120-27 Open Close
PSV-016 bypass
Notes:
1. For shutdown case position of blind may be open or close depending on situation.
Example: In case after shutdown vessel is required to be depressurized, PSV
bypass line spec blind will be in open position. In case depressurization is not
required PSV bypass line spec. blind will in closed position.

Page 250 of 271
SECTION -17
EQUIPMENT LIST SUMMARY
EQUIPMENT DETAILS
PUMPS (CENTRIFUGAL TYPE):

Rated Discharge Rated
Item No. Item Description Diff.
Capacity Pressure power
Head (m)
(m³/hr) (Kg/cm²g) (KW)
74-P-01 A/B Separator pumps 110.1 27 299.2 120
First stage suction drum

74-P-02 A/B 5.5 9.2 117.5 6
pump
Stabiliser overhead
74-P-04 A/B 45.9 21.3 410.3 49
pump
74-P-05 A/B BFW booster pumps 49 60.8 152.1 35
Deethanizer Reflux
74-P-06 A/B 4.5 30.8 71.9 2
Pump
74-P-07 A Circulating Water Pump 465.6 3.5 45.1 54

Page 251 of 271
PUMPS (PROPORTIONING TYPE):
Item No. Item Description Maximum Discharge Diff. Pressure

Capacity Pressure (kg/cm2)
(lt/hr) (Kg/cm²g)
74-P-08 A/B Sulfide injection pump 0.0529 10.83 10.83
Start up chemical 5.21 10.12 10.12
74-P-09
injection pump
Chloride and 0.966 10.91 10.91
74-P-10 Condensate injection
pump
VESSELS:
Internal Design Design
Tag No. TL-TL
Item Description Diameter Temperature, Pressure
(mm)
(mm) °C Kg/cm²g
74-V-01 Separator 3100 4700 120 4.5
74-V-02 First stage suction drum 2100 3100 120 8
Second stage suction
74-V-03 2600 4400 70 16.5
drum
74-V-04 Recontact Drum 1800 5500 65 26.5
74-V-
Net gas chloride treaters 1900 8800 70 26.5
05A/B
74-V-06 Stabiliser receiver 1400 4900 215 14
74-V-
LPG Chloride Treater 750 4900 70 40.5
07A/B
74-V-08 Deethanizer Receiver 800 2400 120 31.5
Steam Disengaging
74-V-09 1800 6400 305 50.5
drum
74-V-10 Condensate break tank 300 1500 100
74-V-11 Sulfide Storage Tank 600 1800 65 3.5
* FV= Full vacuum

Page 252 of 271
COLUMNS:
Tag No. Item No. of ID TL-TL Operating Temperature

Description tray/fee (mm) (mm) °C
d Top Bottom
location
1900/
74-C-01 Stabiliser 30/10th 24700 66 239
1200
Packed 800
74-C-02 Deethanizer bed /600 16200 67 113
(2 Nos) /300
HEAT EXCHANGERS (TUBULAR):
Shell Side Tube Side

Heat
Tag duty Op. Temp. Op. Press. Op. Temp. Op. Press.
6
Item Description
No. 10 Fluid °C Kg/cm²g Fluid °C Kg/cm²g
Kcal/hr
In Out In In Out In
74-E- Combined Feed HC+H2 514 109 3.25 HC+H2 88 463 5.83
38.92
01 Exchanger
74-E- Reactor purge
0.04 HC & H2 116 316 3.7 H2+HC 514 181 3.3
02 exchanger
74-E-
First stage suction Sea
03 1.86 HC+H2 113 40 5.8 33 44 5.3
cooler Water
A/B
74-E- First stage
Sea
04 1.48 discharge HC+H2 60 40 14.9 33 44 5.3
Water
A/B cooler
74-E- Second Stage
0.82 HC+H2 82 42 25.7 HC+H2 -14 40 23.9
05 Discharge Cooler
74-E-
Sea
06 0.85 Recontact cooler HC+H2 54 40 25.4 33 44 5.3
Water
A/B
74-E- Chiller
1.55 HC+H2 40 14 24.8 HC+H2 -14 30 16
07 Economiser
74-E- Refrigeran
1.56 Chiller HC+H2 14 -14 24.4
08 t

Page 253 of 271
Shell Side Tube Side

Heat
Tag duty Op. Temp. Op. Press. Op. Temp. Op. Press.
6
Item Description
No. 10 Fluid °C Kg/cm²g Fluid °C Kg/cm²g
Kcal/hr
In Out In In Out In
74-E- Stabiliser Feed-

7.3 HC+H2 40 187 12.8 HC 228 80 11
09 bottom exchanger
74-E- Stabiliser HC+H2+W Sea
1.89 66 40 10.5 33 44 5.3
10 A/B condenser ATER Water
74-E- VHP
3.59 Stabiliser Reboiler 256 256 43.5 HC 228 239 11
11 Steam
74-E-
Stabiliser bottoms Sea
12 0.99 HC 65 40 8.9 33 44 5.3
trim cooler Water
A/B
74-E- Deethanizer
0.24 LP Steam 139 139 2.5 HC 110 113 28.3
13 reboiler
74-E- Deethanizer Sea
0.08 HC 59 40 27.9 33 44 5.3
14 condenser Water
74-E- Deethanizer Sea
0.15 HC 110 40 28.3 33 44 5.3
15A/B Bottom Cooler Water
HEAT EXCHANGERS (AIR COOLED):
Tube Side
Heat duty
Tag No. Item Description Operating Operating Pressure
106 Kcal/hr Temperature, °C Kg/cm²g
Fluid
In Out At Inlet
74-A-01 8.68 Products Condenser HC, H2 107 55 2.58
Stabiliser bottoms
74-A-02 0.72 HC 82 65 8.33
cooler

Page 254 of 271
COMPRESSORS:
Discharge
Rated Capacity Inlet Press.
Tag No. Item Description Type Pressure
(Nm³/hr) (Kg/cm²g)
(Kg/cm²(a))
74-K-01 Recycle Compressor Centrifugal 110024 3.5 7.1
Net Gas
74-K-02 A/B Reciprocating 3766 15.2 27.5
Compressors
Heaters
Radiant Section
Inlet Condition Outlet Condition

Op. Temp Op. Press Op. Temp Op. Press
Service oC Kg/cm2g oC Kg/cm2g

Feed Preheat 463 5.4 549 5.17
Heating feed to Reactor 421 4.84 549 4.57
2

3

4
Convection Section:
Steam
Service generation ( Steam
Upper & lower) Superheater BFW economizer
Inlet o
Op. Temp C 258 258 152
2
Op. Press Kg/cm g 47.3 45.4 45.71
Outlet o
Op. Temp C 258 393 221
Op. Press Kg/cm2g 45.4 45.24 45.4
Notes : Two convection sections are provided. One is above Charge heater and No 1 Interheater and the
other one is above No 2 Interheater and No 3 Interheater.

Page 255 of 271
MISCELLANEOUS EQUIPMENT:
74- M-04 (Silencer)

a) Service = Silencer
b) Gas Throttled = Steam
c) Molecular weight = 18
d) Pressure upstream of valve, kg/cm2 g = 44.5
e) Temperature upstream of Valve, °C = 393
f) Valve size, inches = 3
g) Maximum Flow Rate for noise Attenuation, = 34688
Kg/hr
74-M-01 (Desuperheater No 1)
a) Service = Desuperheater No 1
b) Desuperheater Type = Variable orifice
c) Inlet steam
Maxm flow rate, kg/hr = 34666
Maxm flow rate (% of maxm flow) = 10
Maxm Temperature, °C = 442
Normal Temperature, °C = 393
d) Maximum Steam Pressure drop (kg/cm2) = 0.35
e) Outlet steam
Pressure, kg/cm2g = 35
Temperature, °C = 360
Allowable Temperature Variation, °C = 3
f) Desuperheater water
Maxm flow rate, m3/h = 2.7
74-M-02 (Desuperheater No 2)

Page 256 of 271
a) Service = Desuperheater No 1
b) Desuperheater Type = Variable orifice
c) Inlet steam
Maxm flow rate, kg/hr = 25370
Maxm flow rate (% of maxm flow) = 33
Maxm Temperature, °C = 448
Normal Temperature, °C = 393
d) Maximum steam Pressure drop (kg/cm2) = 0.35
e) Outlet steam
Pressure, kg/cm2g = 43.5
Allowable Temperature Variation, °C = 3
f) Desuperheater water
Maxm flow rate, m3/h = 5.7
74-X-01 (Condensate Injection Pump Suction Filter)
a) Fluid = Condensate
b) Maximum Flow Rate, It/hr = 0.966
c) Inlet Pressure, kg/cm²g = Atmospheric
d) Temperature, °C = 38
e) Particle retention rating, microns = 30
74-X-02 (Start-up Chloride Injection Pump Suction Filter)

a) Fluid = Perchloroethylene
d) Temperature, °C = Ambient
74-X-03 A/B (Sulfide Injection Pumps Suction Filters)

Page 257 of 271
a) Fluid = Dimethyl Disulfide

d) Temperature, °C = Ambient

Page 258 of 271
SECTION -18
GENERAL OPERATING INSTRUCTIONS FOR EQUIPMENT
18.1 GENERAL
This section covers the general procedure for operation and trouble shooting of
commonly used equipment like pumps, heat exchangers and furnace etc. For specific
information and more detail refer to vendor's manuals.
18.2 CENTRIFUGAL PUMPS
18.2.1 Start-up
¾ Inspect and see if all the mechanical jobs are completed.
¾ Establish cooling water flow where there is such provision. Also open steam for
seal quenching in pumps having such facilities.
¾ Check oil level in the bearing housing, flushing may be necessary if oil is dirty or
contains some foreign material.
¾ Rotate the shaft by hand to ensure that it is free and coupling is secure. Coupling
guard should be in position and secured properly.
¾ Open suction valve. Ensure that the casing is full of liquid. Bleed, if necessary, from
the bleeder valve.
¾ Energise the motor. Start the pump and check the direction of rotation. Rectify the
direction of rotation if it is not right.
¾ Check the discharge pressure. Bleed if necessary to avoid vapour locking.
¾ Open the discharge valve slowly. Keep watch on the current drawn by the motor, if
ammeter is provided. In other cases check at motor control centre.
In some pumps a by-pass has been provided across the check valve and discharge valve to
keep the idle pump hot. In such pumps, the by-pass valve should be closed before starting
the pump. It should be ensured that casing of these pumps are heated up sufficiently prior to
starting of the pump to guard against damage of the equipment and associated piping due to
thermal shock.

Page 259 of 271
18.2.2 Shutdown
¾ Close discharge valve fully.
¾ Stop the pump
a) If pump is going to remain as standby and has provision for keeping the pump
hot, proceed as follows:
Open the valve in the by-pass line across the discharge valve and check
valve.
The circulation rate should not be so high to cause reverse rotation of idle
pump and also overloading of the running pump.
b) If pump is to be prepared for maintenance, proceed as follows:
Close suction and discharge valves.
Close valve on check valve by-pass line, if provided.
Close cooling water to bearing, if provided. Also shut off steam for seal
quenching, if provided.
Slowly open pump bleeder and drain liquid from pump if the liquid is very
hot allow sufficient time before draining is started. Ensure that there is no
pressure in the pump. Also drain pump casing.
Blind suction and discharge and check valve by-pass line and flare
connection if any.
Cut-off electrical supply to pump motor prior to handling over for
maintenance.
18.2.3 Trouble Shooting
i) Pump not developing pressure

¾ Bleed to expel vapour/air
¾ Check the lining up in the suction side.
¾ Check the suction strainer.
¾ Check the liquid level from where the pump is taking suction.
¾ Check pump coupling and rotation.
¾ Get the pump checked by a technician.

Page 260 of 271
ii) Un usuel Noise

¾ Check the coupling guard if it is touching.
¾ Check for proper fixing of fan and fan cover.
¾ Check for pump cavitations.
¾ Get the pump checked by a technician.
iii) Rise of Bearing Temperature

Generally the bearing oil temperature up to 80oC or 50oC above ambient whichever is lower
can be tolerated.
¾ Arrange lubrication if bearing is running dry or oil level is low.
¾ Adjust cooling water to the bearing housing, if there is such provision.
¾ Stop the pump, if temperature is too high, call the pump technician.
iv) Hot Gland

¾ Adjust cooling water if facility exists.
¾ Slightly loosen the gland nut, if possible.
¾ Stop the pump and hand over to maintenance.
¾ Arrange external cooling if pump has to be run for sometime.
v) Unusual Vibration
¾ Check the foundation bolts.
¾ Check the fan cover for looseness.
vi) Leaky Gland

¾ Check the pump discharge pressure.
¾ Tighten the gland nut slowly, if possible.
¾ Prepare the pump for gland packing or adjustment/replacement of mechanical seal
as the case may be.
vii) Mechanical Seal Leak

¾ Stop and isolate the pump and hand over to maintenance.

Page 261 of 271
18.3 POSITIVE DISPLACEMENT PUMPS
18.3.1 Start-up
i) Check if all mechanical jobs are completed.
ii) Flush and renew oil in pump gearbox.
iii) Check whether suction strainer is installed.
iv) Check for proper lining up including the pressure safety valve in the discharge. Open
suction valve fully.
v) Check that the motor shaft is reasonably free and coupling secured. Coupling guard
should be in position.
vi) Energise motor. Open discharge valve. Start the motor and check direction of rotation.
Stop and rectify if direction of rotation is wrong.
vii) Adjust the pump stroke and run the pump at different settings. Watch discharge
pressure and check the rate of pumping using the flow meter or by taking suction from
the calibration pot. In case the pumps are provided with a pressure controller adjust it
to obtain the required discharge pressure.
viii) Care should be taken to avoid dry running of pump and back flow of liquid. Bleed if
necessary to expel vapour/air.
i) Check for unusual noise, vibrations, and rise of temperature of both motor and
gears.
18.3.2 Shutdown
¾ Stop the pump.
¾ Close the suction and discharge valves.
¾ Drain the liquid if maintenance jobs are to be carried out on the pump.

i) Insufficient Discharge Pressure
¾ Check the lining up in the suction side.
¾ Check the functioning of the safety valve and pressure control valve on discharge
to suction.
¾ Check the strainer on the suction side.

Page 262 of 271
¾ Check for insufficient liquid level in the tank.

¾ Check pump coupling and rotation.
¾ Get the pump checked by pump technician.
ii) High Discharge Pressure

¾ Check the line up on the discharge side.
¾ Check pressure control valve opening.
iii) Leak Gland

¾ Check for normal pump discharge pressure.
¾ Tighten the gland nut slowly if possible.
¾ Hand over the pump for replacing gland packing.
iv) Unusual Vibrations

¾ Check the foundation bolts.
¾ Check motor fan cover for looseness.
18.4 RECIPROCATING COMPRESSOR

18.4.1 Start-up
Information for reciprocating gas compressor is already given under section-5, Pre-
commissioning.
18.4.2 Shutdown
i) Unload the compressor in descending sequence of steps and bring it to o%
capacity.
ii) Stop the motor.
iii) Close the discharge valve.
iv) Close N2 purge to piston rod packing, if provided.
v) Close suction valve.
vi) Turn off cooling water to cylinders, packing and frame oil cooler.
vii) If the compressor is to be given for maintenance, isolate, depressurise and purge
with inert gas to make the compressor free of hydrocarbon gas, if handled.

Page 263 of 271
18.4.3 Normal Operation

i) Check oil level in frame sump and add oil as required to maintain the proper level
as indicated on sight glass.
ii) Log all temperatures, pressures, levels and amperage.
iii) Adjust cooling water flows to compensate for changes in inlet water temperature or
ambient temperature and for change in compressor loading.
iv) Listen for any unusual noise while the machine is operating. These should be
investigated immediately and periodically.
v) Periodically drain from volume bottles, distance piece etc.
vi) Watch differential pressure across oil filter to check cleanliness. Changeover filters,
if necessary and arrange for the cleaning of choked filter.
vii) Keep the exterior of the compressor and the compressor room floor clean.
vii) DATA TO BE MONITORED:
¾ Suction and discharge pressures per stage
¾ Suction and discharge temperature per stage
¾ Lubricating oil pressures and temperatures
¾ Bearing temperatures
¾ C.W pressures and temperatures
¾ Current/voltage/power factor of driver motor
¾ Temperatures of each cylinders
ix) VISUAL INSPECTION
a) Level of liq. Separators, oil levels
b) Local pressures and temperatures
c) Differential pressures across oil filters
d) Temperature at suction / discharge valve covers to determine eventual valve
leakage
e) Check for possible gas/water/oil leakages

Follow vendor's recommendation. Some guide lines are given below:
1. LOW LUBE OIL PRESSURE
¾ Low oil level

Page 264 of 271
¾ Plugged oil pump strainer

¾ Leaks in suction and discharge lines of the oil pump.
¾ Worn out bearings of the oil pumps.
¾ Defective oil pump.
¾ Dirt in oil filter check valve.
¾ Broken oil filter check valve spring
¾ PSV/ by pass of PSV passing.
¾ Defective pressure gauge.
2. HIGH OIL PRESSURE

¾ Plugged oil pressure lines.
¾ Defective oil filter mechanism.
¾ Excessive spring tension in oil pressure adjusting mechanism.
¾ Defective pressure gauge.
3. OVERHEATED CYLINDERS
¾ Insufficient cooling water, scoured piston or cylinder.
¾ Broken valve and valve springs.
¾ Insufficient lubrication
¾ Packing too tight.
¾ Choked cooling water passage.
4. KNOCKING SOUND
¾ Scoured piston or cylinder.
¾ Defective lubrication.
¾ Foreign material in cylinder.
¾ Piston hitting cylinder head.
¾ Loose piston or piston pin.
¾ Loose main bearing.
¾ Scoured cross heads or crosshead guides.

Page 265 of 271
5. HIGH SUCTION TEMPERATURE

Broken or leaking suction valves.
- Due to Increased circulation of gas due to internal leakage as a result of 'O' ring of
end cover/diaphragm damage.
18.5 CENTRIFUGAL COMPRESSOR

The pre-commissioning of the centrifugal compressor and turbine should follow the equipment
manufacturers recommended procedures. The following general procedures shall not be
construed as a replacement for the manufacturer procedures.
Verify that the lubrication, seal gas, and coolant systems are clean and free of contamination
and that all control systems function properly. The pre-commissioning of these package units
should follow the manufacturers recommended procedures.
Verify that the shutdown system on the compressor function according to design. The
temporary strainers on the suction should be removed prior to full-time operation.
Verify that the compressors and turbine rotate freely. Verify that the proper steam supply is
provided to the turbine. Check to ensure that suction and discharge-piping slope away from
the compressor stages and no pocketing occurs. Blow steam lines clear prior to placing in
service.
18.5.1 Start-up
Information for reciprocating gas compressor is already given under section-5, Pre-
commissioning.
18.5.2 Shutdown
i) Stop the drive.
ii) Start the oil pump to lubricate the bearing till required.
iii) Close the discharge valve.
iv) Close the suction valve.
v) Turn off cooling water to oil cooler as applicable.

Page 266 of 271
vi) If the compressor is to be given for maintenance, isolate, depressurise and purge
with inert gas to make the compressor free of hydrocarbons.
18.5.3 Normal Operation

i) Check oil level in lube oil tank and add oil as required to maintain the proper level
as indicated on sight glass. Periodically check level in emergency lubricating oil
overhead tank.
ii) Log all temperatures, pressures, levels, flows.
iii) Adjust cooling water flows to compensate for changes in inlet water temperature or
ambient temperature.
iv) Listen for any unusual noise while the machine is operating. These should be
investigated immediately.
v) Periodically drain from suction pot etc.
vi) Watch differential pressure across oil filter to check cleanliness; change over filter, if
necessary and arrange cleaning of choked filter.
vii) Keep the exterior of the compressor and the compressor room floor clean.

Follow vendor's recommendations. However, some general guidelines are given below:
1. SURGING
¾ Restricted flow due to plant operating at partial load or throttling at discharge.

¾ Blocked suction due to strainer choking or line choking if a permanent strainer is not
provided.
¾ Liquid carry over from suction K.O. drum.
2 HEAVY VIBRATIONS IN MACHINE

¾ Misalignment
¾ Bent rotor
¾ Damaged rotor

Page 267 of 271
¾ Imbalance
¾ Weak foundation
¾ Mechanical Loosening etc.
¾ Bearing damage
18.6 HEAT EXCHANGERS

GENERAL
The unit has a number of heat exchangers, air coolers. Suitable valving for bypassing and
isolation was provided wherever necessary to offer the required operational flexibility.
The exchangers have been provided with draining and flushing connections. The coolers and
condensers have been provided with TSV's on the cooling water side to guard against
possible rise of pressure due to faulty operations with the safety release to atmosphere.
Temperature gauges or thermo wells have been provided at the inlet and outlet of exchangers.
Where water is the cooling medium, no temperature measurement is provided for water inlet
temperature, which is the same as cooling water supply header temperature.
AIR COOLERS
The air coolers/condensers comprise of a fin tube assembly running parallel between the
inlet and outlet headers. These are of the forced draft type. The forced draft fans provided
have auto variable speed rotors in which the fan speeds are adjusted during rotation. This
allows variation in air flow as per the cooling requirements. A high vibration switch is
provided with alarm to indicate any mechanical damage.
EXCHANGERS
Shell and Tube type heat exchangers can be broadly classified into following types:-
¾ Water Coolers/condensers
¾ Steam heaters (reboiler)
¾ Exchangers
Start-up/shut down procedures for each unit shall vary slightly from case to case. However,
general start-up/shut-down procedures are discussed in the following paragraphs.

Page 268 of 271
18.6.1 Start-Up
After the heat exchanger has been pressure tested and all blinds removed, proceed as
follows:
i) Open cooling medium vent valve to displace non-condensable (air, fuel gas, inert
gas etc.) from the system. Ensure the drain valves are capped. For high pressure
system, drain valves should be flanged. This activity is not required if gas is the
medium.
ii) Open cooling medium inlet valve. Close vent valve when liquid starts coming out
through it, then open cold medium outlet valve and fully open the inlet valve also.
Where cold medium is also hot, warming up of cold medium side gradually is also
essential.
iii) Open hot medium side vent valve to displace non condensable (air, fuel inert gas
etc.). Check that the drain is closed and capped. This activity is not required if gas
is the medium.
iv) Crack open hot medium inlet valve. When liquid starts coming out from the vent
valve, close it. Open hot medium inlet valve and then open the outlet valve fully. In
case of steam heaters, initially the condensate shall be drained to sewer till
pressure in the system builds up to a level where it can be lined up to the return
condensate header.
v) In case by passes are provided across shells and tube side, gradually close the
bypass on the cold medium side and then the bypass across the hot medium side.
vi) Check for normal inlet and outlet temperatures. Check that TSVs are not popping.
vii) The operation of inlet and outlet valves should be done carefully ensuring that the
exchangers are not subjected to thermal shock.
viii) In case of coolers/condensers, adjust the water flow to maintain the required
temperatures at the outlet.
ix) For avoiding fouling, velocity of water should be at least 1 m/sec in a
cooler/condenser.

Page 269 of 271
18.6.2 Shutdown
Shut down of an exchanger, coolers, condenser is considered when the equipment is to be
isolated for handling over to maintenance while the main plant is in operation. The following is
the suggested procedure for isolation of the piece of equipment
i) Isolate the hot medium first. In case both hot and cold medium are from process
streams, exchanger shall remain in service till the hot stream has cooled down
enough.
In case of a cooler, adjust cooling water flow to the cooler, which is in line so that
product temperature is within allowable unit.
ii) Isolate the cold medium next.
iii) Drain out the shell and tube sides to OWS/Sewer/Closed blow down system as
applicable. In case flushing oil connection is given flush the exchanger to CBD.
Ensure that the CBD drum has sufficient ullage to receive the flushing of the
exchanger
iv) Depressurize the system to atmosphere/flare/blow down system as applicable.
v) Purge/flush if required. This is particularly important in congealing services.
vi) Blind inlet and outlet lines before handing over the equipment for maintenance.
18.7 HEATER
The charge heater is box type, bottom fired furnace with radiation and convection sections. It
has an upright steel structure with an outer steel casing. The casing is lined with refractory
material on the inside and forms the combustion chamber.
The combustion chamber houses the radiant section tubes. In this section heat is transferred
primarily by radiation from the flame and the hot combustion products. The convection section
provided at the top of the radiant section serves to increase thermal efficiency of the furnace
by recovering more heat from the flue gases leaving the radiant section. The convection
section houses is meant for reboiling of stripper bottom by the flue gases from the radiant zone
pass to the convection zone of the furnace. The floor is elevated above grade so that the
foundations are air cooled. This also helps in burner operation and maintenance. Peepholes
are provided on the floor as well as radiant chamber side walls to facilitate inspection of the

Page 270 of 271
inside of the furnace. The furnace operates on natural draft. The damper can be operated
from the grade.
Draft gauges and sample nozzles are provided in the heater to measure draft and to take flue
gas samples. Snuffing steam connection are given for the furnace box purging which can be
operated in emergency during fire on the floor box or purging the box.
18.7.1 Procedure for Refractory Drying

General procedure is already given under section-5.
18.7.2 Operating Procedure

The furnace will be fired on fuel gas. Each main burner is provided with a pilot gas burner.
The furnace should be fired so that at no time flame impinges on the tube. The burners should
be operated to provide fires, which are as uniform in length as can be obtained. It is normally
desirable to fire all burners even at reduced operating capacities for a uniform heat flux
distribution.
Excess air for satisfactory combustion is to be maintained. The amount of excess air should
be measured at the inlet to convection and at the base of the stack. The excess air in the
furnace should be reduced till the flue gas analysis indicates traces of carbon monoxide. It
must then be increased till no carbon monoxide exists. The pass outlet temperature should be
maintained the same. Skin, box temperature indicators have been provided. Refer to vendors
instructions on operation of the burners.
18.7.3 Start-up
¾ Ensure cleanliness inside the heater.
¾ Keep stack damper wide open. Close all peepholes and explosion doors.
¾ Keep all burners valves closed. Bypass shut down circuit and open fuel oil and fuel gas
shut down valves.
¾ Commission the fuel gas system and check and rectify any leaks in the system.
¾ Steam purge the furnace chamber and ensure that the burner gaskets are not leaking.

Page 271 of 271
¾ Keep the primary air register completely closed and secondary air register open. Cut
the snuffing steam and light the pilot burner with an external torch. If the pilot burner
does not light, shut off fuel gas and steam the furnace again and light the pilot. While
lighting the burner, it is advisable not to stand under the burner.
¾ For lighting the burners operate the FG valves and maintain 1.5 kg/cm2g on fuel gas
header pressure.
¾ Insert a lighted torch and open fuel gas valve for a small flame.
¾ When required more number of burners have been lighted, open the FG full and control
the flames by adjusting the fuel gas pressure.
¾ Maintain furnace draft about minus 1 to 2 mm water gauge at the inlet to convection.
¾ Check excess air in the furnace and adjust the damper, primary and secondary air
registers to give the required excess air.
¾ When the unit stabilises, take all controls and commission the TRC control cascading
either on fuel gas pressure controller
¾ Commission the shut down circuit of the furnace.
18.7.4 Shutdown
Fuel to the heater should not be cut off abruptly unless an emergency shut down is called for.
The heater temperatures should be slowly reduced. As burners tend to become unstable
when fired at low rate, reduce the number of burners as required.
¾ For shutting down the furnace, cut the burners one by one till all fires are cut off.
Bypass the shut down circuit of the furnace, so that fuel gas supply are not interrupted
when the feed flow to the furnace is reduced.
¾ After shutting down of furnace Install blinds on fuel gas line to furnace.
¾ Open all air registers and all the peepholes. Stack dampers should be opened fully to
permit ingress of air into the furnace to cool it.

!! CCR-Operating-Manual-Draft PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

!! CCR-Operating-Manual-Draft PDF

Uploaded by

Copyright:

Available Formats

OPERATING MANUAL FOR CCR Doc No DRAFT

PLATFORMING UNIT, HPCL VISAKH Rev A

HINDUSTAN PETROLEUM CORPORATION

A 04/04/08 Issued for comments AB

Template No. 5-0000-0001-T2 Rev. 0 Copyrights EIL – All rights reserved

DESIGN BASIS ...................................................46

PROCESS DESCRIPTION ..........................................53

EFFECT OF OPERATING VARIABLES ON PROCESS ......................64

Template No. 5-0000-0001-T2 Rev. 0 Copyrights EIL – All rights reserved

PRE-COMMISSIONING PROCEDURE .................................126

COMMISSIONING PROCEDURE .....................................154

NORMAL OPERATING PROCEDURES ................................170

SHUTDOWN PROCEDURES ........................................182

Template No. 5-0000-0001-T2 Rev. 0 Copyrights EIL – All rights reserved

8.2.7 Shutdown and block in all columns ................184

EMERGENCY SHUTDOWN PROCEDURE ..............................188

SAMPLING PROCEDURE & LABORATORY ANALYSIS REQUIREMENT ........199

SECTION -12 ...................................................209

SAFETY PROCEDURE ............................................209

Template No. 5-0000-0001-T2 Rev. 0 Copyrights EIL – All rights reserved

12.6 HAZARDOUS CHEMICALS ...............................217

SECTION -13 ...................................................231

ALARMS AND TRIPS ..............................................231

SECTION -14 ...................................................236

UTILITY AND AUXILIARY SUMMARY ..................................236

SECTION -15 ...................................................240

SPECIAL PROCEDURES ...........................................240

SECTION -16 ...................................................247

SECTION -17 ...................................................250

SECTION -18 ...................................................258

GENERAL OPERATING INSTRUCTIONS FOR EQUIPMENT .................258

Template No. 5-0000-0001-T2 Rev. 0 Copyrights EIL – All rights reserved

18.3.1 Start-up ....................................261

Template No. 5-0000-0001-T2 Rev. 0 Copyrights EIL – All rights reserved

Template No. 5-0000-0001-T2 Rev. 0 Copyrights EIL – All rights reserved

This operating manual for CCR Platforming Unit of HINDUSTAN PETROLEUM

For detailed specifications and operating procedures of specific equipment, corresponding

Template No. 5-0000-0001-T2 Rev. 0 Copyrights EIL – All rights reserved

1.2 BRIEF PROCESS DESCRIPTION

Template No. 5-0000-0001-T2 Rev. 0 Copyrights EIL – All rights reserved

Heaters Heating Medium

Template No. 5-0000-0001-T2 Rev. 0 Copyrights EIL – All rights reserved

Template No. 5-0000-0001-T2 Rev. 0 Copyrights EIL – All rights reserved

1.3 PROCESS CHEMISTRY

1.3.1 PLATFORMING HYDROCARBON CHEMISTRY

1. Composition of Feed and Product

Template No. 5-0000-0001-T2 Rev. 0 Copyrights EIL – All rights reserved

1.3.2 PLATFORMING CATALYST CHEMISTRY

1. Dual Function Catalyst Sites

1.3.1 Platforming Hydrocarbon Chemistry

Template No. 5-0000-0001-T2 Rev. 0 Copyrights EIL – All rights reserved

To provide a better understanding of Platforming hydrocarbon chemistry, the next sections

b. Isomerization of Naphthenes and Paraffins

Template No. 5-0000-0001-T2 Rev. 0 Copyrights EIL – All rights reserved

high. Therefore, the reaction of alkylcyclopentanes to cyclohexanes is not 100% selective.

(2) Paraffin Isomerisation, shown in Figure-4, occurs readily in commercial Platforming

Template No. 5-0000-0001-T2 Rev. 0 Copyrights EIL – All rights reserved

Template No. 5-0000-0001-T2 Rev. 0 Copyrights EIL – All rights reserved

3. Relative Reaction Rates

Template No. 5-0000-0001-T2 Rev. 0 Copyrights EIL – All rights reserved

Hydrocarbon Type Paraffin Alkylcyclopentanes Alkylcyclohexanes

Template No. 5-0000-0001-T2 Rev. 0 Copyrights EIL – All rights reserved

De-hydrocyclization of paraffins and dehydrogenation of naphthenes are both very