Revision

Indication
UOP LLC
PROCESS DESIGN INFORMATION
25 E. Algonquin Road
Des Plaines, Illinois 60017-5017, USA PROJECT 953000 B2. SHEET 1
REV DATE BY APVD REV DATE BY APVD
O 14Aug09 CVZ JQ
PROCESS CONTROL PHILOSOPHY A 22Sep09 JQ JQ

HYDROCRACKER (HCR) UNIT 214

Most of the process control strategies utilized in the HCR Unit 214 are control schemes that are typically
found in refinery processing units, and need no further explanation. This document describes in more detail
the atypical process control schemes. It is not intended to provide a comprehensive description of the
implementation of the control strategy.

1. Philosophy for introducing feed to the First Stage Feed Surge Drum

A. Normal Feed Basis and Feed Control Strategy

The normal feed basis to Unit 214 is:

MAB Hot (182°C) VGO/TGO from VRU-213 (21,000 bpsd) on ISBL flow control †;
MAB Hot (190°C) Heavy Diesel from CDU-111 (10,000 bpsd) on ISBL flow control †;
MAA/MAB Cold (52-82°C) VGO/Heavy Diesel from Storage (19,000 bpsd) on ISBL flow control
reset by first stage feed surge drum level control.

There is no VRU-13 feed and no coker gas oil in the normal feed blend to the hydrocracking unit.

† With possible override by feed surge drum level control upon high level condition.
See Paragraph 1.C, First Stage Feed Surge Drum Level Control Strategy, for details.

Since the upstream units supply the hot feeds at constant temperatures, and since the cold feed from
storage temperature is relatively constant, the total feed blend temperature is expected to be fairly
constant, near 146 °C, without the need for pre-heating cold feed by the Cold Feed Steam Heater.

B. Alternate Feed Basis and Feed Control Strategy

The alternate feed basis to Unit 214 consists of:

MAB Hot VGO/TGO (28,200 bpsd) from VRU-213 on ISBL flow control †;
MAB Hot Heavy Diesel (10,000 bpsd) from CDU-111 on ISBL flow control †;
MAB Hot (260°C) CGO from DCU-20 (11,800 bpsd) on ISBL flow control reset by first stage feed
surge drum level control.

The VGO/TGO and Heavy Diesel will be supplied hot such that the normal feed drum temperature of
146°C is maintained. There is no VRU-13 feed and no feed from storage in the alternate feed blend to
the hydrocracking unit.

† With possible override by feed surge drum level control upon high level condition.
See Paragraph 1.C, First Stage Feed Surge Drum Level Control Strategy, for details.

The alternate feed basis with CGO is a short-term operating mode of approximately three weeks
duration during a planned / unplanned shutdown of MAB HCR Unit 114, which is expected to occur
once every two years. The design ratio of CGO to straight-run VGO/TGO/Heavy Diesel is 23.6 to 76.4
or a ratio of about 0.3. A ratio indicator with high alarm is provided to alert the operators when the
design ratio is exceeded. Because of the short-term operation, a ratio control is not provided.

Form QUA-06-4
Revision
Indication
UOP LLC
PROCESS DESIGN INFORMATION
25 E. Algonquin Road
Des Plaines, Illinois 60017-5017, USA PROJECT 953000 B2. SHEET 2
REV DATE BY APVD REV DATE BY APVD
O 14Aug09 CVZ JQ
PROCESS CONTROL PHILOSOPHY A 22Sep09 JQ JQ

C. First Stage Feed Surge Drum Level Control Strategy

The First Stage Feed Surge Drum level controller maintains level as follows:

Normal Feed Basis:

i.) Via a hand switch, route one level control split range signal to reset the flow controller for
cold feed from storage, and route another split range signal to the MAB Hot CGO override
loop.
ii.) Rising level first decreases cold feed from storage.
iii.) Rising level next, via the split range level control, overrides flow controllers to
simultaneously throttle flow control valves for MAB Hot VGO / TGO feed from
VRU-213, and for MAB Hot Heavy Diesel feed from CDU-111, and as a contingency, for
MAB Hot CGO feed from DCU-20 (normally no flow).

Alternate Feed Basis:

i.) Via a hand switch, deactivate the level control split range signal to the flow controller for
cold feed from storage, and route that signal instead to the MAB Hot CGO override loop.
ii.) Rising level first decreases MAB Hot CGO feed from DCU-20 by overriding the flow
controller to throttle the flow control valve.
iii.) Rising level next, via the split ranged level control, overrides flow controllers to
simultaneously throttle the flow control valves for MAB Hot VGO / TGO feed from VRU-
213 and for MAB Hot Heavy Diesel from CDU-111.

2. Philosophy for introducing feed to the first stage reactor section and second stage reactor section

Feed to each reactor section is controlled by straight flow control because constant feed rate to the
reactor helps maintain stable reactor operation.

3. Philosophy regarding bypass of feed around the first and second stage effluent - hot/cold feed
exchangers

The reactor feed flow control and effluent-feed heat exchanger bypass control scheme includes a FIC
(flow controller) to the control the feed rate to the reactor section, and a TIC (temperature controller) to
control the feed-effluent exchanger outlet temperature by throttling the feed bypass valve (TCV) around
the feed-effluent exchanger.

The feed-effluent exchanger outlet TIC, by maintaining a stable feed-effluent exchanger outlet
temperature, assists in keeping the recycle gas heater duty requirement at a stable value. This helps the
reactor inlet temperature controller and recycle gas heater outlet temperature controller provide more
stable control of the reactor inlet temperature by regulating the recycle gas heater fuel firing.

The feed-effluent exchanger bypass valve (TCV) is sized such that, when wide open, it can pass the
design feed rate to the reactor section. The valve is sized this way because, in certain situations, the
reactor effluent may be hot enough to heat the feed too much for good reactor inlet temperature control.
In these situations it is necessary to bypass all of the feed around the feed-effluent exchanger.

Form QUA-06-4
Revision
Indication
UOP LLC
PROCESS DESIGN INFORMATION
25 E. Algonquin Road
Des Plaines, Illinois 60017-5017, USA PROJECT 953000 B2. SHEET 3
REV DATE BY APVD REV DATE BY APVD
O 14Aug09 CVZ JQ
PROCESS CONTROL PHILOSOPHY A 22Sep09 JQ JQ

Due to margins applied when sizing the TCV, it could bypass more than the design feed rate to the
reactor section. This could result in an undesirably high feed flow rate.

To prevent an undesirably high feed from going through the TCV, the feed FIC is split ranged so that,
as the TIC increases the bypass rate / feed flow rate, the FIC first closes the normal feed FCV, and after
having closed the FCV, the FIC overrides the TIC via a low signal selector (LSS) and takes control of
the feed-effluent exchanger bypass TCV.

4. Recycle Gas Heater Pass Flow Balancing

Flow balancing control is used to split the total recycle gas flow equally among the recycle gas heater
passes with the lowest practical pressure drop through the heater pass control valves. Equal flow
splitting assures that each pass receives adequate flow and distributes the heat load evenly among the
passes. Low pressure drop reduces operating energy costs for the recycle gas compressor.

The pass flow balancing system consists of a flow controller (FIC) and control valve (FCV) on each
heater pass, a signal selector to select the output signal from the FIC with the most open FCV, and a
valve position controller (GIC).

Each FIC output is sent to the signal selector that selects the output of the FIC whose valve is most
open. The signal selector output (the most open valve position) is the process variable signal to the
GIC. The GIC output resets the heater pass FIC’s, providing them all with the same set point.

In normal operation, operators set the GIC set point at a value corresponding to a valve opening of
about 90 %. If the most open valve is less than 90 % open, the GIC increases the FIC set points until
the most open valve is 90 % open. The system eventually reaches a state with all of the FIC’s
controlling at the same flow rate, and with the most open valve running 90 % open, and the other valves
running at the somewhat lower openings that their FIC’s require to control the flow rate in the other
passes.

This operation achieves the two goals of providing equal flow to each pass with minimal pressure loss.
The pressure loss corresponds approximately to the pressure drop of a 90 % open valve, typically about
0.2 to 0.6 bar in the pass with the 90 % open control valve.

5. Cold Separator Pressure Control

The reactor circuit pressure is controlled by a pressure controller (PIC) on the Cold Separator. The PIC
is split ranged. Upon rising pressure, the PIC first closes the makeup gas valve and secondly opens the
recycle gas purity purge valve via a high signal selector (HSS) to vent gas from the reactor section.

A flow controller (FIC) on the recycle gas purity purge line can also open the recycle gas purity purge
valve via the HSS.

In normal operation, because of the high hydrogen purity of the make-up gas from the PSA unit, no
purge gas is required from the reactor circuit to maintain the desired recycle gas purity and hydrogen
partial pressure in the reactors. Consequently, the purge gas FIC set point is normally zero. The
separator PIC normally controls the separator pressure by throttling the makeup gas pressure control

Form QUA-06-4
Revision
Indication
UOP LLC
PROCESS DESIGN INFORMATION
25 E. Algonquin Road
Des Plaines, Illinois 60017-5017, USA PROJECT 953000 B2. SHEET 4
REV DATE BY APVD REV DATE BY APVD
O 14Aug09 CVZ JQ
PROCESS CONTROL PHILOSOPHY A 22Sep09 JQ JQ

valve, and does not open the purge valve during normal operation. So neither the purge gas FIC nor the
separator PIC is expected to open the purge valve during normal operation.

At startup, when feed is first introduced in the reactor circuit, incoming feed displaces gas that tends to
increase the separator pressure. When this happens, the PIC responds by first closing the makeup gas
valve completely, and next opening the purge gas flow control valve via the HSS to vent gas in order to
prevent the separator pressure from rising above the PIC set point.

6. Wash Water Controls

Wash water for injection to control fouling caused by ammonium bisulfide salt deposition is sourced
from the Product Fractionator (PF) Receiver and the Low Pressure Boiler Feed Water (LP BFW)
system as primary makeup wash water. A secondary makeup water source is pumped low pressure
condensate (CL).

The Wash Water Drum level controller accomplishes the following:

• Always accepts the water pumped from the PF Receiver

• Normally imports make-up water first from the LP BFW system to maintain level, and next from
the CL header
• Protects against high level that could occur if the wash water pumps stop. In this situation, the
wash water surge drum level controller first closes the makeup water valve from the CL header,
then closes the makeup water valve from the LP BFW system, and lastly opens the water outlet
valve from the Wash Water Surge Drum to the Oily Drips Sewer (ODS).

7. Fractionation Column Overhead Liquid Quality Control

For most fractionation columns that produce a significant amount of net overhead liquid product, one of
the two following controlling schemes is used to control the quality of the overhead product.

a. Conventional control scheme.

In the conventional control scheme, a fractionation column temperature (composition) controller adjusts
the reflux and the column’s overhead receiver level controller adjusts the net overhead liquid flow.

This is the preferred configuration when the receiver serves as a surge drum that feeds downstream
columns or process units because the control system does not introduce rapid variations in the net
overhead liquid flow rate. This configuration may also be used if desired for columns whose overhead
liquid goes to storage.

This system is well known in the refining industry and details of its operation are not provided in this
control philosophy description.

b. UOP’s Material Balance Control scheme (applied on the Naphtha Splitter column)

In UOP’s material balance control scheme, the column temperature (composition) controller (TIC)
adjusts the net overhead liquid product flow. The receiver level controller (LIC) adjusts a total

Form QUA-06-4
Revision
Indication
UOP LLC
PROCESS DESIGN INFORMATION
25 E. Algonquin Road
Des Plaines, Illinois 60017-5017, USA PROJECT 953000 B2. SHEET 5
REV DATE BY APVD REV DATE BY APVD
O 14Aug09 CVZ JQ
PROCESS CONTROL PHILOSOPHY A 22Sep09 JQ JQ

overhead liquid (reflux plus net overhead liquid) flow controller (FIC) that adjusts the reflux. The
receiver LIC resets the total overhead liquid FIC.

The system controls the overhead liquid quality in the following manner. When temperature rises,
indicating that the overhead liquid may contain too much heavy material, the TIC decreases the net
overhead liquid rate. The total overhead liquid FIC senses this as a decrease in the net overhead liquid
rate, so the FIC immediately increases the reflux by the same amount to maintain the same total
overhead liquid flow rate. The increased reflux rate causes the temperature at the TIC to fall back to the
set point, resulting in the appropriate composition of material in the top of the column.

Conversely, when temperature falls, indicating that the overhead liquid contains too little heavy
material, the TIC increases the net overhead liquid rate. The total overhead liquid FIC senses this as an
increase in the net overhead liquid rate, so the FIC immediately decreases the reflux by the same
amount to maintain the same total overhead liquid flow rate.

UOP applies this system to fractionation columns whose design reflux to net overhead liquid ratio is
between 1 and 10. However, since this system’s TIC may cause significant short-term variations in the
net overhead liquid rate, UOP applies this system only to columns where its overhead liquid flows to a
destination, such as storage, that is not adversely affected by flow rate changes.

Where applicable, UOP prefers this system because, upon sensing a high temperature in the column, the
TIC immediately both reduces the net overhead liquid export rate and causes the reflux to increase, and
these combined actions tend to minimize the amount of off-specification material exported as net
overhead product.

8. Naphtha Splitter Column Overhead Pressure Control

The Naphtha Splitter column overhead vapor is totally condensed to liquid. Almost all of the
condensation occurs in an air cooled condenser located above the receiver. A small amount of the
overhead vapor condenses to liquid on the inside walls of piping or the receiver. The column and its
overhead receiver produce no net overhead vapor.

The pressure control system for this column is designed and operates as described below.

A pressure controller (PIC) on the column overhead vapor line controls a pressure control valve (PCV)
at the vapor inlet to the condenser. By controlling vapor flow through this valve, the PIC controls the
column pressure.

The PCV is sized for a pressure drop of approximately half the pressure drop of the condenser. Typical
pressure drops are about 0.14 bar for the PCV, and 0.2 to 0.35 bar for the condenser

A pressure differential controller (PDIC) between the overhead vapor line and the overhead receiver
controls the pressure difference between those points by throttling a control valve (PDV) in the hot
vapor bypass line from the overhead vapor line to the receiver. The PDIC assures a stable differential
pressure between the column and the receiver. This results in a stable pressure drop at the PCV, which
permits the PCV to operate at a reasonable opening under the wide range of cooling conditions
expected from an air cooled condenser.

Form QUA-06-4
Revision
Indication
UOP LLC
PROCESS DESIGN INFORMATION
25 E. Algonquin Road
Des Plaines, Illinois 60017-5017, USA PROJECT 953000 B2. SHEET 6
REV DATE BY APVD REV DATE BY APVD
O 14Aug09 CVZ JQ
PROCESS CONTROL PHILOSOPHY A 22Sep09 JQ JQ

Without the PDIC controlled hot vapor bypass, the receiver pressure could approach the vapor pressure
of the condenser outlet liquid. If the condenser subcools the liquid, the liquid vapor pressure and the
receiver pressure will fall, and the pressure difference between the column and the receiver will
increase, forcing the PCV to drop more pressure. This could cause the PCV to operate too far closed
for best control. By providing a hot vapor bypass flow to maintain the receiver at a constant pressure,
the PDIC prevents this problem.

A non-condensable vent line with a valve controlled by an HIC in the control center is provided to vent
non-condensable vapor from the receiver to the relief header at startup. Non-condensables must be
vented at startup (or if they accumulate for any reason during normal operation) because the presence of
non-condensables can interfere with performance of the air cooled condenser and can adversely affect
pressure control of the column.

9. Vacuum Drier Pressure Control

Continuous removal of process vapor by the ejector maintains a vacuum in the vacuum drier and in
vacuum condenser 214-A-0101-E01.

If no pressure control is provided for the vacuum condenser, and if process load (non-condensable gas
leakage into the vacuum system) is lower than the ejector capacity, the vacuum condenser may operate
at a pressure lower than the desired pressure. The operating pressure would vary with the vapor
pressure of the subcooled liquid in the vacuum condenser, which in turn may vary due to fluctuations in
the cooling water supply temperature or due to heat exchange performance (or fouling) of the vacuum
condenser.

To obtain pressure control of the vacuum drier, a pressure controller throttles the cooling water flow
rate to the vacuum condenser. Reducing the cooling water flow affects the vacuum condenser in two
ways. First, lower cooling water flow results in a greater cooling water temperature rise in the
condenser, thus lowering the LMTD (log mean temperature difference) between the cooling water and
the oil. Secondly, lower cooling water flow reduces the heat transfer coefficient of the vacuum
condenser. Both effects serve to reduce the subcooling and condensing capacity of the vacuum
condenser, and increase the vapor pressure of the condensed oil, and enable pressure control.

Parts of this description are based on information provided in bulletin entitled VacAdemics, Applying
Vacuum Technology, Issue 2, page 4, by Graham Manufacturing.

10. Heater Fuel Firing Control System

The control system is designed to control the temperature at the heater outlet by adjusting the flow rates
of fuel gas and combustion air to the heater.

The following abbreviations are used in the description below:

TIC for temperature controller

FIC for flow controller
HIC for hand control (ratio) station
HSS for signal selector
LSS for low signal selector

Form QUA-06-4
Revision
Indication
UOP LLC
PROCESS DESIGN INFORMATION
25 E. Algonquin Road
Des Plaines, Illinois 60017-5017, USA PROJECT 953000 B2. SHEET 7
REV DATE BY APVD REV DATE BY APVD
O 14Aug09 CVZ JQ
PROCESS CONTROL PHILOSOPHY A 22Sep09 JQ JQ

System Operation

The remote setpoint to the combustion air FIC is either the heater outlet TIC output signal (i.e., the
TIC’s demand for fuel gas in kg/hr), or the measured fuel gas flow signal in kg/hr, whichever is greater
as determined by an HSS, multiplied by the Air to Fuel Ratio HIC setting of 15.5 kg air / kg fuel. This
assures that the remote setpoint to the combustion air flow controller is high enough to maintain the
desired quantity of excess air. It also assures that when the TIC demands more fuel, air flow increases
before the measured fuel flow increases, and that when the TIC demands less fuel, air flow does not
decrease until after the measured fuel flow has decreased.

The combustion air flow measurement signal (kg air/hr) is divided by the Air to Fuel Ratio HIC setting
of 15.5 kg air / kg fuel to obtain the allowable fuel gas kg/hr flow set point signal.

The remote setpoint of the fuel gas FIC is either the heater outlet TIC output signal (i.e., the TIC’s
demand for fuel gas in kg/hr), or the calculated allowable fuel gas kg/hr flow set point signal,
whichever is lower as determined by an LSS. This assures that when the TIC demands more fuel, the
fuel flow does not increase until after the measured air flow increases, and that when the TIC demands
less fuel, the fuel gas flow set point decreases before measured air flow decreases.

11. Cascade Temperature Control at Reactor R-0101 inlet

The cascaded temperature control provides a faster response time rather than having R-0101 inlet TC
directly reset the fuel gas to the heater. The primary purpose of this temperature cascade is to avoid
overfiring the heater and avoid increasing the reactor inlet too much since the material from the heater
outlet is the hotter material fed to R-0101.

12. Split-range Level Control at 1st Stage / 2nd Stage Hot Separators

The Hot Separator split-range level control maintains level by first opening the A valve to the Power
Recovery Turbine (PRT), which takes ~85% of the lowest normal liquid from the separator, and opens
B valve (normally 20-50% open) to export balance. If the PRT is out of service, the LIC first opens the
B valve fully and then opens the C valve to export the balance. The C valve is sized to handle the full
liquid rate plus design margin.

13. Redundant Level Controllers at 1st Stage / 2nd Stage Cold Separators

Water level control – Redundant level transmitters and controllers are specified for high pressure (level
glass not allowed) and dirty sour water service. Redundant level control valves are provided to ensure
the bypass valve is exactly the same as the primary control valve in this high pressure drop service. A
selector switch allows operator selection of A or B controller to be in service. A second selector switch
allows operator selection of A or B control valve to be in service.

Hydrocarbon level control – Redundant level transmitters and controllers are specified for high pressure
hydrocarbon liquid service (level glass not allowed). Both controllers are active, and a high signal
selector automatically selects the level controller with the higher level output. This minimizes liquid
carryover during depressurization due to high liquid level.

Form QUA-06-4
Revision
Indication
UOP LLC
PROCESS DESIGN INFORMATION
25 E. Algonquin Road
Des Plaines, Illinois 60017-5017, USA PROJECT 953000 B2. SHEET 8
REV DATE BY APVD REV DATE BY APVD
O 14Aug09 CVZ JQ
PROCESS CONTROL PHILOSOPHY A 22Sep09 JQ JQ

Redundant level control valves are provided to ensure the bypass valve is exactly the same as the
primary control valve in this high pressure drop service. Split range level control is provided to provide
additional capacity for liquid removal during depressurization. In normal operation, one control valve is
adequate to pass the required flow.

14. Reflux Measurement at Product Fractionator Sidedraws

The kerosene and diesel sidedraws are taken from accumulator trays. These are total accumulator trays
and the internal reflux overflows a weir and is withdrawn via a separate nozzle and flows through a
pitot type flow meter. The internal reflux is returned through a distributor onto the tray below. The
measurement of the internal reflux provides additional data for column troubleshooting.

Form QUA-06-4