3.13 C2H4C2H6 Separation and Ethylene Refrigeration Cycle PDF

DAHEJ PETROCHEMICAL
COMPLEX
Dual Feed Cracker Unit
ONGC Petro additions Ltd. EIL
SEZ, Dahej, Gujarat, India & Associated Units JOB NO. 6987
Page: 1 of 46
3.13 C2H4/C2H6 Separation

and
Ethylene Refrigeration Cycle
X 01 17.05.2010 First Issue T. Schmidt O. Lex B. Sasse

Status Issue Date Reason for Issue / Remark Prepared Checked Approved OPaL/EILo
ENGINEERING Linde Proj. No.: 3110 A9NK

DIVISION Linde Project Code : DAHEJ
Samsung Proj. No.: SC 2252

Samsung Job Code : OPaL
Contract No / PO No.: Item No.:

MR/OW/MM/DFC/02/2007 N/A
Contractor Doc. No.: Company Doc. No.:
&AA-00-P-MC 1002.313 6987-LEPC1-AA-00-PO-MC 1002.313
Intellectual property rights reserved - refer to protection Important Notice ISO 16016
Dahej Petrochemicals Complex DFCU & AU Page 2of 46
6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01
Contents:
Figure Index:
Table Index:
3.13.1 The Process at Normal Operation ............................................................................................3
3.13.2 Functionality of Control Loops ................................................................................................13
3.13.3 Start-up and Shut-down ..........................................................................................................14

3.13.3.1 Basic Requirements for Start-Up ............................................................................................14
3.13.3.2 Preparations for Start-up.........................................................................................................15
3.13.3.3 Start-up ...................................................................................................................................19
3.13.3.4 Shut-down ...............................................................................................................................28
3.13.4 Unit Upsets and Safety Devices .............................................................................................31

3.13.4.1 Upsets .....................................................................................................................................31
3.13.4.2 Switches..................................................................................................................................36
3.13.4.3 Mechanical Interlocking Devices ............................................................................................37
3.13.5 Special Operating Procedures ................................................................................................37
3.13.1 The Process at Normal Operation
The aim of the process unit 43 "C2H4/C2H6 Separation", PID No.: 11-441 to 11-444 is to split the
C2 fraction into C2H4, the ethylene product, and C2H6, ethane, which is recycled to the Cracking
Furnaces.
The aim of the process unit 44 "Ethylene Refrigeration Cycle", PID No.: 11-451 to 11-461 is to
supply cooling duty in the low temperature range. The different cooling temperatures are achieved
by vaporization of liquid ethylene at different pressure and temperature levels.
The operation of the "Ethylene Refrigeration Cycle" always involves the operation of the
"C2H4/C2H6 Separation", since the Ethylene Refrigeration Cycle is an open loop system. It is
possible to operate process unit 43 "C2H4/C2H6 Separation" and process unit 44 "Ethylene
Refrigeration Cycle" in internal recirculation, but it is not possible to operate each unit separately.
The C2 fraction from the bottom of the Demethanizer 11-CC-402 is split into C2H4 (the ethylene
product) and C2H6 (recycle ethane) in the C2 Splitter 11-CC-403. The operation of the C2 Splitter
11-CC-403 is based on the heat pump principle where the overhead gas (ethylene) is compressed
in the 3rd stage of the Ethylene Compressor 11-KC-401. A part of the ethylene gas is precooled in
the CC Exchanger C2 Splitter 11-EP-407 and condensed in Reboiler C2 Splitter 11-EP-406. The
stream is than routed back to the CC Exchanger C2 Splitter 11-EP-407 where it is subcooled
before it is returned to C2 Splitter 11-CC-403 as reflux.
The Ethylene Refrigeration Cycle is an open loop system and serves as a supplier of cooling duty
for the plant. It supplies cooling duty in the low temperature range. The different cooling
temperatures are achieved by vaporization of liquid ethylene at different pressure and temperature
levels.
• LP Ethylene Refrigerant: expansion from 8.3barg to 0.26barg minus 100°C
• MP Ethylene Refrigerant: expansion from 8.3barg to 2.4barg minus 80°C
• HP Ethylene Refrigerant: expansion from 8.5barg to 7.3barg minus 56°C
In the Ethylene Refrigeration Cycle System:

• The reflux for the C2 Splitter 11-CC-403 is generated
• The Ethylene Refrigerant streams to the low temperature section are supplied
• The ethylene product is compressed to the required BL pressure
• If necessary the ethylene product is liquefied and send to BL storage.
The gaseous ethylene streams returning from the Ethylene Refrigerant consumers at different
pressure levels and the overhead product of the C2-Splitter 11-CC-403 are compressed in the first
3 stages of the Ethylene Compressor 11-KC-401. The 4th stage of the Ethylene Compressor 11-
KC-401 serves as booster stage. In the 4th stage the pressure of the ethylene product is raised to
approximately 36barg and sent to BL.
The initial filling and start-up of the "Ethylene Refrigeration Cycle" and the "C2H4/C2H6
Separation" is done with ethane via a special filling line from the "Feed Preheating" to the suction
line of the 3rd stage of the Ethylene Compressor 11-KC-401. In order to remove the impurities in the
ethane, an ethane cleaning cycle for the filling and subsequent cooling down and liquefying steps is
provided. The ethane is routed from the discharge side of the 3rd stage of the Ethylene Compressor
11-KC-401 to the Caustic Scrubber 11-CC-301. From overhead of the Caustic Scrubber 11-CC-
301 the gas is routed via the Cracked Gas Cooler 11-EE-309 and the Cracked Gas Drier 11-VD-
301A/B/S back to the suction side of the 3rd stage of the Ethylene Compressor 11-KC-401. The
initial filling and start-up of the "Ethylene Refrigeration Cycle" and the "C2H4/C2H6 Separation"
with ethane is described in section "3.14.5 Special Operating Procedures" of this Operating
Manual.
C2 Splitter 11-CC-403
The C2 Splitter 11-CC-403 is equipped with 100 sieve trays, operated at a pressure of 7,4barg. In
the column the C2 Fraction is split into the gaseous ethylene product which leaves the column over
top and liquid ethane the bottom product of the column.
The C2 Fraction is generated in the Demethanizer 11-CC-402. The liquid is routed level/flow
controlled from the bottom of the Demethanizer 11-CC-402 to the C2 Splitter 11-CC-403. The
pressure is significantly reduced over the flow control valve and the liquid flashes as it passes
through the valve. The C2 Fraction stream is further vaporized and heated in the Low Temperature
CC. Exchanger I 11-EP-401 before it is fed to the C2 Splitter 11-CC-403.
In addition to the C2 Fraction off spec. ethylene from the OSBL Offspec Ethylene Tank can get
mixed flow controlled into the feed stream to the C2 Splitter 11-CC-403.
The operation of the column is based on the heat pump principle where the overhead gas
(ethylene) is compressed in the 3rd stage of the Ethylene Compressor 11-KC-401. Part of the gas
is send to the Countercurrent Exchanger C2 Splitter 11-EP-407 where it is precooled and routed to
the Reboiler C2 Splitter 11-EP-406 where it is condensed. The condensing ethylene serves as heat
source in the Reboiler C2 Splitter 11-EP-406. The stream is than routed back to the Countercurrent
Exchanger C2 Splitter 11-EP-407 where it is subcooled before it is returned to the C2 Splitter 11-
CC-403 as reflux.
Approximately 1/4 of the overhead gas mass flow of the C2 Splitter 11-CC-403 is ethylene product
gas. During normal operation it is send as gaseous product to BL., but it can also get liquefied and
send to storage tanks OSBL.
C2 Splitter 11-CC-403 operates at a pressure of approx. 7,4barg. The column pressure
corresponds to the suction pressure of the 3rd stage of the Ethylene Compressor 11-KC-401. The
suction pressure of the 3rd stage of the Ethylene Compressor 11-KC-401 is controlled via a
pressure/speed controller cascade which keeps the suction pressure at the 3rd stage of the
Ethylene Compressor 11-KC-401 constant by varying the speed of the driving turbine of the
compressor.
The bottom product of the C2 Splitter 11-CC-403 consists of ethane and a very small amount of C3
components. The stream of so called Recycle Ethane is routed level controlled to the Deethanizer
Condenser 11-EP-302 where it is vaporized. The Recycle Ethane is further heated up in the
Cracked Gas Countercurrent Exchanger 11-EP-301 before being routed into the Ethane Feed Way
upstream the Propylene Refrigerant Subcooler 11-EE-407.
The level in the bottom of the C2 Splitter 11-CC-403 is controlled via a level/flow cascade. If for any
reason the Recycle Ethane can not get vaporized in the Deethanizer Condenser 11-EP-302 or not
sufficiently superheated in the downstream Cracked Gas Countercurrent Exchanger 11-EP-301
respectively Propylene Refrigerant Subcooler 11-EE-407, a gaseous ethane stream can get
withdrawn from the gas phase of the C2 Splitter 11-CC-403 bottom. During normal operation a
small stream of gaseous ethane is withdrawn from the C2 Splitter 11-CC-403 bottom and routed
directly into the Ethane Feed Way upstream the Propylene Refrigerant Subcooler 11-EE-407.
The operation conditions of the C2 Splitter 11-CC-403 can get observed by the following remote
indications:
• 11-TI-44201 bottom temperature
• 11-TI-44206 temperature below tray 10
• 11-TI-44205 overhead gas temperature
• 11-PDI-44201 differential pressure over the column (by manual operation of the isolation
valves at the tapping points the differential pressure over the individual
sections column of the column can get measured, normal line up: differential
pressure over entire column)
The overhead gas of the C2 Splitter 11-CC-403 is analyzed online and indicated via 11-AI-44202.
The measured and indicated values are:
• 11-AI-44202A CH4 content
• 11-AI-44202B C2H2 content
• 11-AI-44202C C2H6 content
• 11-AI-44202D Sum of CH4 & C2H6 content
Below tray 82 the C2H6 content is analyzed online and indicated via 11-AI-44207.
The C2H4 content of the bottom product of the C2 Splitter 11-CC-403 is analyzed online and
indicated via 11-AI-44201.
Since it is the ethylene product gas, at the discharge 3rd stage the Ethylene Compressor 11-KC-
401 the ethylene gas is also analyzed online and indicated via 11-AI-45801 The measured and
indicated values are:
Additionally several local indications and manual sampling points allow the observation/check of
the operation conditions of the C2 Splitter 11-CC-403 in the field.
In case of pluggage of the C2 Splitter Reboiler 11-EP-406 or the upstream strainer, due to
formation of ice or gas hydrates, methanol can get injected via methanol injection line.
In case the C2 Splitter 11-CC-403 itself is plugged by formation of ice or gas hydrates methanol
can get injected into the reflux line, the feed line and directly into the column below tray 79.
Countercurrent Exchanger C2 Splitter 11-EP-407

The overhead gas of the C2 Splitter 11-CC-403 is upstream the Countercurrent Exchanger C2
Splitter 11-EP-407 combined with the HP Ethylene Refrigerant vapour coming from the Low
Temperature CC. Exchanger I 11-EP-401 and the Deethanizer Condenser 11-EP-302 and the flash
gas from the Ethylene Collecting Drum 11-VV-406. This stream is then heated up to 10°C in the
Countercurrent Exchanger C2 Splitter 11-EP-407 (passage 5) before it enters the 3rd stage of the
Ethylene Compressor 11-KC-401. Due to this the 3rd stage of the Ethylene Compressor 11-KC-
401 can be operated at ambient temperature.
In the 3rd stage of the Ethylene Compressor 11-KC-401 the pressure of the ethylene gas is raised
from 8.3barg to 19.0barg. The gas is cooled against cooling water in the Ethylene Cooler 3rd Stage
11-EE-404A/B to 37°C. The main part of this stream is routed back to the Countercurrent
Exchanger C2 Splitter 11-EP-407 (passage 4), where it is cooled to approx. minus 10 °C and split
into the following two streams:
• Ethylene vapour as heating medium to the C2 Splitter Reboiler 11-EP-406
• Ethylene vapour to the Ethylene Condenser 11-EP-408
Ethylene vapour as heating medium to the C2 Splitter Reboiler 11-EP-406 and Operation of the C2
Splitter 11-CC-403
In the C2 Splitter Reboiler 11-EP-406 approximately 60wt% of the ethylene flow coming from the
Countercurrent Exchanger C2 Splitter 11-EP-407 is condensed. The condensing ethylene serves
as heat source in the C2 Splitter Reboiler 11-EP-406. The main part of the condensed ethylene is
routed through passage 2 of the Countercurrent Exchanger C2 Splitter 11-EP-407, where it is
cooled to minus 50°C. From the Countercurrent Exchanger C2 Splitter 11-EP-407 the cold ethylene
is returned to the C2 Splitter 11-CC-403 under flow control as the main reflux.
The stream of ethylene circulated via the Ethylene Compressor 11-KC-401 3rd stage, the
Countercurrent Exchanger C2 Splitter 11-EP-407, the C2 Splitter Reboiler 11-EP-406 and the C2
Splitter 11-CC-403 is reflux flow (to the C2 Splitter 11-CC-403) and heat duty (at the C2 Splitter
Reboiler 11-EP-406) at the same time. If this flow is changed by changing the reflux, the heat duty
of the C2 Splitter Reboiler 11-EP-406 is changed simultaneously. To increase the reflux of the C2
Splitter 11-CC-403 without simultaneously increasing the reboil duty and vice versa an auxiliary
reflux is foreseen. As auxiliary reflux serves condensed ethylene from the Ethylene Condenser 11-
EP-408, fed via passage 3 of the Countercurrent Exchanger C2 Splitter 11-EP-407, as reflux to the
C2 Splitter 11-CC-403.
To be able to increase the reboil duty of the C2 Splitter Reboiler 11-EP-406 without simultaneously
increasing the reflux and vice versa an auxiliary reboil is foreseen. During normal operation only
approximately 5wt% of the ethylene flow condensed in the C2 Splitter Reboiler 11-EP-406 is fed
under flow control to the Ethylene Collecting Drum 11-VV-406. Changing this flow changes the duty
of the C2 Splitter Reboiler 11-EP-406 without changing the reflux flow to the C2 Splitter 11-CC-403.
Ethylene vapour to the Ethylene Condenser 11-EP-408

Approximately 40wt% of the ethylene flow coming from the Countercurrent Exchanger C2 Splitter
11-EP-407 is routed to the Ethylene Condenser 11-EP-408 and is condensed against vaporizing
LP Propylene Refrigerant.
A small part of this stream, the auxiliary reflux, is routed to the C2 Splitter 11-CC-403 via the
Countercurrent Exchanger C2 Splitter 11-EP-407 where it is subcooled to approximately -51°C in
passage 3 of the exchanger. During normal operation this stream serves as auxiliary reflux. During
start up the stream can get increased a lot in order to cool down the system during start up.
The main part of this stream is routed as Ethylene Refrigerant make up to the "Ethylene
Refrigeration Cycle". The flow of liquid ethylene from the Ethylene Condenser 11-EP-408 to the
Ethylene Collecting Drum 11-VV-406 is controlled by the level controller of the vessel.
MP Ethylene Refrigerant coming from MP Ethylene Refrigerant consumers first passes the
Ethylene Subcooler 11-EP-409 before it is directed to passage 6 of the Countercurrent Exchanger
C2 Splitter 11-EP-407. This stream is warmed up from minus 56°C to 10°C and by this provides
additional cooling in the Countercurrent Exchanger C2 Splitter 11-EP-407. The MP Ethylene
Refrigerant stream leaving the Countercurrent Exchanger C2 Splitter 11-EP-407 is routed to the
2nd stage of the Ethylene Compressor 11-KC-401. The temperature of 10°C allows the operation
of the 2nd stage the Ethylene Compressor 11-KC-401 at ambient temperature.
Additionally the hydrogen rich fraction coming from the Cracked Gas Countercurrent Exchanger
11-EP-301 is heated up further to 25°C in passage 1 of the Countercurrent Exchanger C2 Splitter
11-EP-407 before being routed to the PSA Plant 11-LZ-402.
Ethylene Product Export

Approximately 1/4 of the overhead gas mass flow of the C2 Splitter 11-CC-403 is ethylene product
gas and is not routed back to the Countercurrent Exchanger C2 Splitter 11-EP-407. This excess
gas from the 3rd stage of the Ethylene Compressor 11-KC-401 is further compressed in the 4th
stage of the Ethylene Compressor 11-KC-401. The ethylene from the 4th stage is than cooled in
the Ethylene Cooler 4th Stage 11-EE-405 against cooling water and send as gaseous product at a
temperature of 45°C and a pressure of 36barg to BL.
During normal operation the entire ethylene production is exported gaseous to BL. If for some
reason the export of gaseous ethylene is not possible or reduced, the ethylene product can get
liquefied and send to the OSBL storage facilities. The liquid ethylene is withdrawn from the
Ethylene Collecting Drum 11-VV-406 under flow control. The liquid ethylene is subcooled against
MP Ethylene Refrigerant in the Ethylene Subcooler I 11-EE-403 and further subcooled against LP
Ethylene Refrigerant in the Ethylene Subcooler II 11-EE-402. Afterwards the subcooled liquid
ethylene is routed pressure controlled at a temperature of minus 98°C and a pressure of 7,5barg to
the OSBL storage facilities.
The capacity for liquefaction is 30% of the ethylene production at 100% plant load or 100% of the
ethylene production at 50% plant load respectively. The ethylene gas is liquefied in the Ethylene
Condenser 11-EP-408 against vaporizing LP Propylene Refrigerant. Therefore changes in the
liquefaction have a significant impact on the load of the Propylene Compressor 11-KC-402.
Even if during normal operation when the entire ethylene production is exported gaseous to BL. a
continuous flow of 13,75t/h of liquefied ethylene is sent to BL. under flow control. 3t/h thereof are to
compensate the boil off gas of the OSBL Ethylene Tank and 10,75t/h are used to keep a minimum
flow via the Ethylene Product Pumps in order to keep them cold and in operation to allow for a
immediate supply of ethylene from OSBL if required. The minimum flow of the Ethylene Product
Pumps is routed to upstream of the Ethylene Subcooler II 11-EE-402.
The boil off gas from the OSBL Ethylene Tank is routed to the suction line of the 1st stage of the
Ethylene Compressor 11-KC-401.
The total amount of gaseous ethylene product exported to BL. is measured, indicated and counted
by 11-FQI-45906B. The amount of ethylene boil off gas from the OSBL Ethylene Tank is
measured, indicated and counted by 11-FQI-45507B. The total amount of liquid ethylene product
exported to the OSBL Ethylene Tank is measured, indicated and counted by 11-FQI-45301B.
The ethylene product gas exported to BL. is analyzed online downstream the Ethylene Cooler 4th
Stage 11-EE-405 and indicated via 11-AI-45901 and 11-AI-45901.
The measured and indicated values are:
• 11-AI-45901A Methanol content
• 11-AI-45901B CO2 content
• 11-AI-45901C CO content

If for some reason the ethylene product fails to meet the required specifications, liquid off spec
ethylene (max. 68,75t/h) can get withdrawn under flow control from the Ethylene Collecting Drum
11-VV-406 and get routed to the OSBL Offspec Ethylene Tank.
Ethylene Refrigeration Cycle

The Ethylene Refrigeration Cycle is an open loop system. In the Ethylene Refrigeration Cycle:
• The reflux for the C2 Splitter 11-CC-403 is generated
• The Ethylene Refrigerant streams (HP, MP and LP Ethylene Refrigerant) for the separation
sections are generated
• The ethylene product is compressed to the required BL pressure
• If necessary the ethylene product is liquefied and send to the OSBL Ethylene Tank.
• In case the ethylene product is off spec. the liquefied ethylene can get send to the OSBL
Offspec Ethylene Tank.
The "Ethylene Refrigeration Cycle" serves as a supplier of cooling duty for the plant. It supplies
cooling duty in the low temperature range. The different cooling temperatures are achieved by
vaporization of liquid ethylene at different pressure and temperature levels.
• LP Ethylene Refrigerant: expansion from 8.3barg to 0.26barg minus 100°C
• MP Ethylene Refrigerant: expansion from 8.3barg to 2.4barg minus 80°C
• HP Ethylene Refrigerant: expansion from 8.5barg to 7.3barg minus 56°C
The gaseous ethylene streams returning from the Ethylene Refrigerant consumers at different
pressure levels and the overhead product of the C2 Splitter 11-CC-403 are compressed in the first
3 stages of the Ethylene Compressor the Ethylene Compressor 11-KC-401.
Downstream of Ethylene Cooler 3rd Stage 11-EE-404A/B the main ethylene stream is routed to the
Counter Current Exchanger C2-Splitter 11-EP-407. In this multi stream exchanger the gas is
cooled to approximately -10°C by warming up the counter current streams of HP Ethylene
Refrigerant and MP Ethylene Refrigerant returning to the Ethylene Compressor 11-KC-401. The
cooled ethylene vapour is then split into the following two streams:
• Ethylene vapour as heating medium to the C2 Splitter Reboiler 11-EP-406
• Ethylene vapour to the Ethylene Condenser 11-EP-408
The ethylene vapour is then condensed in these two exchangers and the liquid is distributed as
follows:
From the C2 Splitter Reboiler 11-EP-406:
• The main fraction of the condensed ethylene is routed via the Countercurrent Exchanger C2
Splitter 11-EP-407, to the C2 Splitter 11-CC-403 under flow control as the main reflux.
• A small fraction of the condensed ethylene is routed under flow control as the auxiliary reboil
and ethylene make up to the Ethylene Collecting Drum 11-VV406.
From the Ethylene Condenser 11-EP-408:
• The main fraction of the condensed ethylene is routed under level control of the Ethylene
Collecting Drum 11-VV-406 as ethylene make up to the Ethylene Collecting Drum 11-VV-406.
• A small fraction of the condensed ethylene is routed if necessary under flow control as
auxiliary reflux via the Countercurrent Exchanger C2 Splitter 11-EP-407, to the C2 Splitter 11-
CC-403.
The Ethylene Collecting Drum 11-VV-406 is the storage vessel of the liquid ethylene used in the
"Ethylene Refrigeration Cycle". The Ethylene Collecting Drum 11-VV-406 is fed with liquid ethylene
from:
• The main supply is generated in the Ethylene Condenser 11-EP-408.
• A small stream is coming from the C2 Splitter Reboiler 11-EP-406 (auxiliary reboil)
The liquid ethylene streams to the Ethylene Collecting Drum 11-VV-406 are expanded over the
respective control valves into the Ethylene Collecting Drum 11-VV-406. The flash gas generated is
routed under pressure control into the overhead gas stream from the C2 Splitter 11-CC-403
upstream of the Countercurrent Exchanger C2 Splitter 11-EP-407. The pressure in the Ethylene
Collecting Drum 11-VV-406 is controlled at the HP Ethylene Refrigerant supply pressure of
8,5barg.
The level in the Ethylene Collecting Drum 11-VV-406 is controlled by three level controllers. The
SPN controller controls in split range the flow of ethylene liquid from the process to the Ethylene
Collecting Drum 11-VV-406 respectively from the Ethylene Collecting Drum 11-VV-406 to the
OSBL storage. The SPL controller prevents too low levels in the Ethylene Collecting Drum 11-VV-
406 by reducing the flow to the OSBL storage. The SPH controller prevents too high levels and the
risk of liquid carry over to the downstream aluminium plate fin exchanger by reducing the flow of
ethylene liquid from the process to the Ethylene Collecting Drum 11-VV-406.
The liquid ethylene from the Ethylene Collecting Drum 11-VV-406 is used for two purposes:
• As Ethylene Refrigerant in the separation sections and in the "Ethylene Refrigerant Cycle"
itself
• As ethylene product which is after subcooling in the Ethylene Subcooler I 11-EE-403 and
Ethylene Subcooler II 11-EE-402 routed to the OSBL storage facilities.
The Ethylene refrigerant withdrawn from the Ethylene Collecting Drum 11-VV-406 is routed to the
following consumers:
• Directly as HP Ethylene Refrigerant to the Deethanizer Condenser 11-EP-302 and the Low
Temperature CC Exchanger I 11-EP-401
• Via the Ethylene Subcooler 11-EP-409 as MP Ethylene Refrigerant to the Low Temperature
CC Exchanger IIA 11-EP-402 and the Ethylene Product Subcooler I 11-EE-403
• Via the Ethylene Subcooler 11-EP-409 as LP Ethylene Refrigerant to the Low Temperature
CC Exchanger IIB 11-EP-403, the Ethylene Phase Separator 11-VV-405 (supplying the
Demethanizer Condenser 11-EP-405) and the Ethylene Product Subcooler II 11-EE-402
The HP Ethylene Refrigerant is sent to the Deethanizer Condenser 11-EP-302 and the Low
Temperature CC Exchanger I 11-EP-401 where it is vaporized at a temperature of minus 56°C.
The flow is controlled by the respective temperature controllers controlling the process gas
temperatures at the outlet of the exchangers and via the respective differential temperature
controllers, which ensure no liquid is carried over into the vapor return lines. After vaporizing in the
Deethanizer Condenser 11-EP-302 and the Low Temperature CC Exchanger I 11-EP-401 the HP
Ethylene Refrigerant gas is mixed with the flash gas from the Ethylene Collecting Drum 11-VV-406
and routed to the overhead gas of the C2 Splitter 11-CC-403. The combined ethylene gas is then
superheated to 10°C in the Countercurrent Exchanger C2 Splitter 11-EP-407 and fed to suction
side of the 3rd stage of the Ethylene Compressor 11-KC-401.
The liquid ethylene serving as MP and LP Ethylene Refrigerant is first subcooled in the Ethylene
Subcooler 11-EP-409 to approximately minus 57°C by warming up in counter current flow the
returning gas streams from the MP and LP Ethylene Refrigerant consumers. From the outlet of the
Ethylene Subcooler 11-EP-409 the cooled liquid Ethylene Refrigerant is sent to the different
consumers.
A part of the MP Ethylene Refrigerant is fed to the Low Temperature CC Exchanger IIA 11-EP-402.
The flow is controlled by the respective temperature controller controlling the process gas
temperature at the outlet of the exchanger and via the respective differential temperature controller,
which ensures no liquid is carried over into the vapour return line. The other part of the MP
Ethylene Refrigerant is fed to the Ethylene Product Subcooler I 11-EE-403 under level control.
After vaporization in the consumers the MP Ethylene Refrigerant gas is superheated first in the
Ethylene Subcooler 11-EP-409 than in the Countercurrent Exchanger C2 Splitter 11-EP-407 to
approximately 10°C and returned to suction side of the 2nd stage of the Ethylene Compressor 11-
KC-401.
A part of the LP Ethylene Refrigerant is fed to the Low Temperature CC Exchanger IIB 11-EP-403.
The flow is controlled by the respective temperature controller controlling the process gas
temperature at the outlet of the exchanger and via the respective differential temperature controller,
which ensures no liquid is carried over into the vapour return line. Another part of the LP Ethylene
Refrigerant is fed to the Ethylene Phase Separator 11-VV-405 under level control. Another part of
the LP Ethylene Refrigerant is fed to the Ethylene Product Subcooler I 11-EE-403 under level
control. After vaporization in the consumers the LP Ethylene Refrigerant is superheated in the
Ethylene Subcooler 11-EP-409 and returned to the 1st stage of the Ethylene Compressor 11-KC-
401 at a temperature of approximately minus 56°C.
A Plant Minimum Flow Line branches off downstream the Ethylene Cooler 3rd Stage 11-EE-404A/B.
In case the plant load is decreased to the minimum load ethylene can get routed via this line into
the cracked gas line upstream the Primary Fractionator 11-CC-201.
Separation" is done with ethane via a special filling line. Every subsequent filling of the "Ethylene
Refrigeration Cycle" and the "C2H4/C2H6 Separation" e.g. after a restart is done via the Filling Line
branching off from the ethylene product line to BL. Via this line ethylene can get imported from BL
and routed to the suction side 1st stage of the Ethylene Compressor 11-KC-401.
Ethylene Compressor 11-KC-401

The Ethylene Compressor 11-KC-401 is a centrifugal compressor with four stages placed in three
individual casings. Stage 1 and 2 are accommodated in one casing, stage 3 and 4 in individual
casings. The discharge gas of 3rd and 4th stage is routed through the respective interstage cooler
Ethylene Cooler 3rd Stage 11-EE-404A/B respectively Ethylene Cooler 4th Stage 11-EE-405. The
gas routed through the tube side of the respective interstage cooler and is cooled against cooling
water on the shell side. The cooled gas is than routed into the suction line of the following stage of
the Ethylene Compressor 11-KC-401 or to the "Ethylene Refrigeration Cycle" and the "C2H4/C2H6
Separation".
The temperature of the gas at 1st stage discharge is only 25°C, therefore no cooling is required and
the gas is internally routed to the 2nd stage of the Ethylene Compressor 11-KC-401. The
temperature of the gas at 2nd stage discharge is only 8°C, therefore no cooling is required and the
gas is routed to the suction line 3rd stage of the Ethylene Compressor 11-KC-401.
The suction pressure of the 3rd stage of the Ethylene Compressor 11-KC-401 is controlled via a
pressure/speed controller cascade which keeps the suction pressure of the 3rd stage of the
Ethylene Compressor 11-KC-401 constant by varying the speed of the driving turbine. The
remaining intermediate pressures and the suction pressure of the 1st stage of the Ethylene
Compressor 11-KC-401 will vary between their tolerance values dependent on the stage loads and
the compressor speed. The discharge pressure of the 4th stage of the Ethylene Compressor 11-
KC-401 is controlled via the product flow rate of gaseous ethylene to BL.
During normal operation the suction pressure of the 1st stage of the Ethylene Compressor 11-KC-
401 floats between 30mbarg and 50mbarg and the discharge pressure of the 4th stage of the
Ethylene Compressor 11-KC-401 is kept by the SPN discharge pressure controller at 37barg.
The suction pressure of the 1st stage of the Ethylene Compressor 11-KC-401 is controlled by a 1st
stage SPL and a SPH suction pressure controller. If the suction pressure of the 1st stage of the
Ethylene Compressor 11-KC-401 falls to 30mbarg the 1st stage SPL suction pressure controller
opens the kick back valves and charges gas from the discharge side of 3rd stage to the suction side
of the 1st stage. This SPL pressure controller operates in split range and first opens a small valve
for controlling a small kick back flow. If a larger flow is required the controller opens the main kick
back valve.
If the suction pressure of the 1st stage of the Ethylene Compressor 11-KC-401 rises above
50mbarg the 1st stage SPH suction pressure controller initiates step wise/in split range the following
actions:
• First, the set point of the 4th stage SPN discharge pressure controller is increased from 37barg
to finally 40barg.
• Second, the set points of the 3rd and 4th stage SPL turndown flow controllers are equally in
proportion to their max values.
All these actions from the 1st stage SPH suction pressure controller lead to an increasing suction
pressure at the 3rd stage of the Ethylene Compressor 11-KC-401. The pressure/speed controller
cascade will keep the suction pressure of the 3rd stage of the Ethylene Compressor 11-KC-401
constant by increasing the speed of the driving turbine. This will than result in a decrease of suction
pressure at the 1st stage of the Ethylene Compressor 11-KC-401.
The 3rd and 4th stage of the Ethylene Compressor 11-KC-401 are provided with SPL turndown flow
controllers to enable the loads of these stages to be increased independent and above the
minimum flow (anti surge) requirements. These controllers open the kick back valves in the
minimum flow lines of the respective stage via maximum selector.
Additionally to the pressure and flow controllers described above the Ethylene Compressor 11-KC-
401 is equipped with an Anti-Surge-Control-System (minimum flow control) to prevent surging of
the compressor. The minimum flow for the 1st, 2nd and 3rd stage is drawn off from the discharge
side 3rd stage downstream the Ethylene Cooler 3rd Stage 11-EE-404A/B. The minimum flow for the
4th stage is drawn off from the discharge side 4th stage downstream the Ethylene Cooler 4th Stage
11-EE-405.
The flow through each stage of the Ethylene Compressor 11-KC-401 is controlled by an individual
Anti-Surge Controller.
The Ethylene Compressor the 11-KC-401 is driven by the Ethylene Compressor Turbine 11-KT-
401.
Ethylene Compressor Turbine 11-KT-401

Ethylene Compressor Turbine 11-KT-401 is a condensing type turbine with an intermediate
extraction of steam at the LP Steam pressure level. HP Steam serves as live steam.
The Ethylene Compressor Turbine 11-KT-401 is equipped with an oil-hydraulic speed control
system. HP Stream is charged to the high pressure section of the Ethylene Compressor Turbine
11-KT-401 based on the demand of the speed controller. The steam from the high pressure section
of the Ethylene Compressor Turbine 11-KT-401 is partially charged to LP Steam Header and
partially sent via the low pressure section of the Ethylene Compressor Turbine 11-KT-4011 to the
Ethylene/Propylene Compressor Turbine Condenser 11-LZ-401. The Steam Condensation Unit
"Ethylene/Propylene Compressor Turbine Condenser 11-LZ-401" is a common unit for the exhaust
steam of the Ethylene Compressor Turbine 11-KT-401 and the Propylene Compressor Turbine 11-
KT-402.
The amount of steam routed from the high pressure section of the Ethylene Compressor Turbine
11-KT-401 to the low pressure section of the Ethylene Compressor Turbine 11-KT-401 is controlled
via the control valve in the turbine extraction line. The SPN pressure controller of the LP Steam
Header controls the opening of the valve in the turbine extraction line and varies the steam flow
towards the LP Steam Header. By this the pressure in the LP Steam Header is kept constant. If the
opening of the control valve in the extraction line is increased less stream is routed to the low
pressure section of the Ethylene Compressor Turbine 11-KT-401, thus more steam is extracted
and charged to the LP Steam Header, the pressure in the LP Steam header increases and vice
versa.
The speed of the Ethylene Compressor Turbine 11-KT-401 is controlled via suction pressure/speed
controller cascade. During normal operation the set point of the speed controller is led by the
suction pressure controller, which controls the suction pressure of the 3rd stage of the Ethylene
Compressor 11-KC-401. The speed controller acts on the HP Steam inlet control valves of the
Ethylene Compressor Turbine 11-KT-401. In order to increase the speed the valve opening is
increased, more HP Steam is routed to the Ethylene Compressor Turbine 11-KT-401 the turbine
accelerates and vice versa.
During start up the speed is controlled by the turbine control system. Only after the minimum
governor speed is reached it is possible to enable the suction pressure/speed controller cascade.
In case the controller cascade is not enabled the speed of the Ethylene Compressor Turbine 11-
KT-401 can get controlled via the speed controller directly.
For design reasons always a certain flow from the high pressure section of the Ethylene
Compressor Turbine 11-KT-401 to the low pressure section of the Ethylene Compressor Turbine
11-KT-401 is ensured to avoid inadmissible thermal stress. Therefore it is not possible to operate
the Ethylene Compressor Turbine 11-KT-401 with 100% of the steam being charged as extraction
to the LP Steam Header.
During start up the valve in the extraction line is fully closed (Start Interlock). Only after the
minimum governor speed of the turbine is reached it is possible to enable the pressure controller
varying the opening of this valve.
3.13.2 Functionality of Control Loops
Level Control
11-LIC-44201 Level Control C2 Splitter 11-CC-403

The bottom level of the C2 Splitter 11-CC-403 is controlled by 11-LIC-44201 (master) which leads
the setpoint of 11-FIC-44202 (slave). The 11-FIC-44202 is acting via the minimum selector 11-FY-
44202 on the flow control valve 11-FV-44202.
In case the level in the C2 Splitter 11-CC-403 rises, the output of the 11-LIC-44201 rises and the
setpoint of the 11-FIC-44202 is increased. In order to adjust the flow to the increased setpoint, the
11-FIC-44202 in turn increases the opening of the 11-FV-44202 via minimum selector 11-FY-
44202. In case the Recycle Ethane can not get fully vaporized in the Deethanizer Condenser 11-
EP-302, resulting in a low differential temperature, the 11-TDIC-38513 will throttle the 11-FV-44202
via minimum selector 11-FY-44202.
Conditions for functionality

Controller Mode Action
11-LIC-44201 automatic direct
11-FIC-44202 cascade reverse
Master Controller 11-LIC-44201
Control Loop
Slave Controller 11-FIC-44202

Control Valve 11-FV-44202
Level Control Ethylene Collecting Drum 11-VV-406

The level of the Ethylene Collecting Drum 11-VV-406 is controlled by three level controllers, a SPL,
a SPN and a SPH level controller.
The SPN level controller 11-LIC-45102 controls the level in the Ethylene Collecting Drum 11-VV-
406 by acting in split range and via several minimum and maximum selectors on the 11-LV-45102
(liquid ethylene from the Ethylene Condenser 11-EP-408) and the 11-FV-45104 respectively 11-
FV-45301 (off spec. respectively on spec. ethylene product to OSBL storage).
In case the level in the Ethylene Collecting Drum 11-VV-406 is decreasing the output of the SPN
level controller 11-LIC-45102 rises. Between a controller output of 0% to 45% the 11-LIC-45102 will
open 11-LV-45102, in order to increase the flow of liquid ethylene from the Ethylene Condenser 11-
EP-408 to the Ethylene Collecting Drum 11-VV-406.
Between a controller output of 55% to 100% the 11-LIC-45102 will close 11-FV-45104 or 11-FV-
45301, off spec. or on spec. ethylene to OSBL storage, depending which path is selected via 11-
HS-45101. Nevertheless the flow selected via the respective flow controller 11-FIC-45104A (off
spec. ethylene product to OSBL storage, 11-FV-45104) or 11-FIC-45301A (off spec. ethylene
product to OSBL storage, 11-FV-45301) is kept since the SPN level controller 11-LIC-45102 only
acts via maximum selector 11-FY45104B respectively 11-FY-45301B on the valves.
The SPH level controller 11-LIC-45101 will prevent a too high level in the Ethylene Collecting Drum
11-VV-406 (and the risk of liquid carry over via the flash gas vent line) by closing 11-LV-45102 via
minimum selector 11-LY-45102B. By this the flow of liquid ethylene from the Ethylene Condenser
11-EP-408 to the Ethylene Collecting Drum 11-VV-406 is reduced regardless of the output of the
SPN level controller 11-LIC-45102.
The SPL level controller 11-LIC-45103 will prevent a too low level in the Ethylene Collecting Drum
11-VV-406 (and the risk of loosing the Ethylene Refrigerant supply for the plant ) by closing 11-FV-
45104 or 11-FV-45301, off spec. or on spec. ethylene to OSBL storage, depending which path is
selected via 11-HS-45101. The minimum selectors 11-FY-45104C respectively 11-FY-45301C
ensure that the valves are closed regardless of the flow selected via the respective flow controller
11-FIC-45104A (off spec. ethylene product to OSBL storage, 11-FV-45104) or 11-FIC-45301A (off
spec. ethylene product to OSBL storage, 11-FV-45301) or the output of the SPN level controller 11-
LIC-45102.
The pressure controller 11-PIC-45906 (pressure in the header "Gaseous Ethylene to BL") acts via
the minimum selector 11-LY-45102A on the 11-LV-45102 (liquid ethylene from the Ethylene
Condenser 11-EP-408 to the Ethylene Collecting Drum 11-VV-406). In case the pressure in the
header "Gaseous Ethylene to BL" rises, e.g. shut-down or trip of a consumer OSBL, the pressure
controller 11-PIC-45906 increases the opening of 11-LV-45102, the level in the Ethylene Collecting
Drum 11-VV-406 will rise and the SPN level controller 11-LIC-45102 will open 11-FV-45104 or 11-
FV-45301, off spec. or on spec. ethylene to OSBL storage, depending which path is selected via
11-HS-45101. By this the surplus of ethylene production which can not get exported as gaseous
ethylene to BL will get liquefied and send to OSBL storage.
3.13.3 Start-up and Shut-down
The start-up of the "Ethylene Refrigerant Cycle" always involves the start-up of the "C2H4/C2H6
Separation", since the "Ethylene Refrigeration Cycle" is an open loop system. It is possible to
operate process unit 43 "C2H4/C2H6 Separation" and process unit 44 "Ethylene Refrigeration
Cycle" in internal recirculation, but it is not possible to operate each unit separately.
The start up of the "Ethylene Refrigerant Cycle" and the "C2H4/C2H6 Separation" is done before
the start-up of the entire plant. First the "Propylene Refrigerant Cycle" and than the "Ethylene
Refrigerant Cycle" is started. Before start up of the "C2/C3 Separation" and the "Low Temperature
Section" the "Ethylene Refrigerant Cycle" must be in operation. As a result of the start-up of the
"Ethylene Refrigerant Cycle" the C2 Splitter 11-CC-403 will be in internal recirculation and ready to
receive feed.
For the start-up sequence of the entire plant please also refer to chapter 1 "Start-up and Shut-down
Summary" of this Operating Manual.
Separation" is done with Ethane. Every subsequent filling of the "Ethylene Refrigeration Cycle" and
the "C2H4/C2H6 Separation" e.g. after a restart is done with Ethylene from the OSBL ethylene
storage. Since the initial filling and start-up of the "Ethylene Refrigeration Cycle" and the
"C2H4/C2H6 Separation" with Ethane is a one time only operation, this is described in the section
5 "Special Operating Procedures" of this chapter of the Operating Manual.
3.13.3.1 Basic Requirements for Start-Up
• All precommissioning work has been done successfully.

• All safety systems / equipment in the entire plant are in service respectively their functionality
is ensured
• All LO/LC devices are installed and the respective valves in the position as indicated in the
P&ID.
• All blinds/spacers or spectacle blinds are in the position as indicated in the P&ID.
• All drain and all vent valves are closed and the blind flanges installed
• All Utility Systems are in operation (e.g. Instrument Air, Cooling Water, Sewer System,
Electrical Power, Demin. Water)
• Cold Gas Flare System is under working condition
• Cold Liquid Flare System is under working condition
• Warm Gas Flare System is under working condition.
• Steam System is under working condition
• Condensate System is under working condition
• All Ethylene Refrigerant consumers are ready for being charged with ethylene gas
• Preferably the "Propylene Refrigerant Cycle" is in operation
For the initial Start-up with Ethane additionally:

• The Propylene Refrigerant Cycle must be in operation
• The Caustic Scrubbing is in operation
• The Spent Caustic Oxidation is in operation
• The Regeneration System is in operation
• The Precooling and Drying system is ready for operation with the Cracked Gas Driers 11-VD-
301A/B/S regenerated
For basic requirements regarding the start up of the Ethylene Compressor Turbine 11-KT-401 and
the Ethylene Compressor 11-KC-401 please refer to the vendor documentation and instructions
(Linde to insert Doc-No. of OM 11-KT-401 and 11-KC-401).
The vendor documentation must get adhered to and is authoritative.
3.13.3.2 Preparations for Start-up
The Ethylene Cooler 3rd Stage 11-EE-404A/B and Ethylene Cooler 4th Stage 11-EE-405 are filled
with cooling water by opening the 1" high point vent at the CWR line and slowly opening the
butterfly valve in the CWS line. Once CW spills out clean from the 1" high point vent it is closed and
first the butterfly valve in the CWS line fully opened and than the butterfly valve in the CWR line.
• All block valves up- and downstream of the control valves are opened. The control valves
themselves and their bypasses remain closed. Except:
All block valves up- and downstream of the control valves at the Ethylene Refrigerant
consumers are CLOSED. The control valves themselves and their bypasses remain closed as
well.
The C2 Splitter 11-CC-403 inlet valve 11-HV-44103 stays CLOSED as well as the block valves
up- and downstream of this valve.
In the following basic information for the start-up preparation of the Ethylene Compressor Turbine
11-KT-401, the Ethylene Compressor 11-KC-401 and the Ethylene/Propylene Compressor Turbine
Condenser 11-LZ-401 are given. Regarding the required detailed start-up preparation of the
Ethylene Compressor Turbine 11-KT-401 and the Ethylene Compressor 11-KC-401 please refer to
the vendor documentation and instructions (Linde to insert Doc-No. of OM 11-KT-401 and 11-
KC-401).

First the Seal Gas System of the Ethylene Compressor Turbine 11-KT-401 and the Ethylene
Compressor 11-KC-401 is taken into service as per vendor instructions and vendor operation
manual. The vendor documentation must get adhered to and is authoritative. Only after the
separation gas, a part of the Seal Gas System, is in service the Lube Oil System can get taken into
service, otherwise there is a risk of entrainment of lube oil into the compressor housing and/or the
turbine housing.
Once the above mentioned systems are in stabile operation the Ethylene Compressor Turbine 11-
KT-401 and the Ethylene Compressor 11-KC-401 can get started. Without Seal Gas System and
Lube Oil System in service the start of the Turning Gear will be interlocked. The start of the Turning
Gear is carried out as per vendor instructions and vendor operation manual. The vendor
documentation must get adhered to and is authoritative.
Before taking the ejectors of the Ethylene/Propylene Compressor Turbine Condenser 11-LZ-401 in
service the sealing steam to the labyrinth seals of Ethylene Compressor Turbine 11-KT-401 has to
get taken in service. This is to avoid the entrainment of air/non condensable gas once the pressure
in Ethylene/Propylene Compressor Turbine Condenser 11-LZ-401 drops to the operation pressure /
vacuum of approximately -0.8barg.
Since the Ethylene/Propylene Compressor Turbine Condenser 11-LZ-401 is a common unit for the
Ethylene Compressor Turbine 11-KT-401 and the Propylene Compressor Turbine 11-KT-402, the
same preparation has to be carried out for the Propylene Compressor Turbine 11-KT-402 and the
Propylene Compressor 11-KC-402 prior to taking the ejectors of the Ethylene/Propylene
Compressor Turbine Condenser 11-LZ-401 in service.
Ethylene Compressor Turbine 11-KT-401

As a prerequisite process unit 80 "Steam System" is in operation and the HP Steam Header is
warmed up.
• Open the Service Water supply for the Relaxation Tube
• Open the hand control valve in the warming up line upstream the HP Steam inlet block valve
11-MV-62101 of the Ethylene Compressor Turbine 11-KT-401 and vent the HP Steam to the
silencer 11-WL-61801 until line is warmed up.
• Drain the condensate from the boot leg upstream the HP Steam inlet block valve 11-MV-
62101 of the Ethylene Compressor Turbine 11-KT-401 to the Relaxation Tube. Adjust the
service water flow to not exceed the maximum waste water temperature, watch local indication
11-TI-62202.
Warm up the HP Steam supply line of the Ethylene Compressor Turbine 11-KT-401 up to the trip
and throttle valve 11-XV-83401:
• Open the bypass of the HP Steam inlet block valve 11-MV-62101
• Open the hand control valve in the warming up line upstream the trip and throttle valve 11-XV-
83401 and vent the HP Steam to the silencer 11-WL-61801 and warm up the line.
• Drain the condensate from the boot leg upstream the trip and throttle valve 11-XV-83401 of
the Ethylene Compressor Turbine 11-KT-401 to the Relaxation Tube. Adjust the service water
flow to not exceed the maximum waste water temperature, watch local indication 11-TI-62202.
Once the HP Steam supply line of the Ethylene Compressor Turbine 11-KT-401 is warmed up to
minimum 310°C, indicated at 11-TI-62101A, the HP Steam flow to the silencer 11-WL-61801 is
throttled. If the pressure downstream the HP Steam inlet block valve 11-MV-62101 has reached
approximately 36barg, indicated at 11-PI-62101A the HP Steam inlet block valve 11-MV-62101 is
opened.
Warm up the LP Steam extraction line on the "Steam System" side means downstream the trip and
throttle valve 11-XV-83401 in the extraction line.
• Open the bypass of the LP Steam outlet block valve
• Open the block valve in the condensate drain line from the boot leg upstream the trip and
throttle valve 11-XV-83401 in the extraction line of the Ethylene Compressor Turbine 11-KT-
401 to the Relaxation Tube. Adjust the service water flow to not exceed the maximum waste
water temperature, watch local indication 11-TI-62202.
Warm up the line up to the check valve to a temperature of 180°C, indicated at 11-TI-62201A. Than
throttle block valve in the condensate drain line from the boot leg to the Relaxation Tube. If the
pressure upstream the LP Steam outlet block valve has reached approximately 5barg, indicated at
11-PI-62201A the LP Steam outlet block valve is opened.
Ensure the boot legs are always drained. Take the steam traps in the HP Steam supply line as well
as in the LP Steam extraction line in service. Regarding the commissioning of the steam traps
please refer to chapter 6, "General Operating Notes" of this Operating Manual.
Prior to warming up of the Ethylene Compressor Turbine 11-KT-401 itself the Turning Gear of the
Ethylene Compressor 11-KC-401 and the Ethylene Compressor Turbine 11-KT-401 has to get
taken in service. This requires taking the Seal Gas System and Lube Oil System in service.
The warming up of the Ethylene Compressor Turbine 11-KT-401 itself is carried out as per vendor
instructions and vendor operation manual. The vendor documentation must get adhered to and is
authoritative. Ensure that during the warming up all drain lines of the turbine which are required to
be open are open and the condensate is drained to the Ethylene/Propylene Compressor Turbine
Condenser 11-LZ-401 respectively the Relaxation Tube.
Ethylene/Propylene Compressor Turbine Condenser 11-LZ-401

The general start up sequence is given below, for detailed instructions of the Ethylene/Propylene
Compressor Turbine Condenser 11-LZ-401, please refer to the vendor instructions and vendor
operation manual. The vendor documentation must get adhered to and is authoritative.
• The Ethylene/Propylene Compressor Turbine Condenser 11-LZ-401 is filled with BFW via
filling line.
• The Condensate Pumps 11-PC-451A/S are prepared for the start up (sealing system, valve
setting) and one pump is taken in service
• The water is circulated via the Ejector Condenser 11-EE-452 back to the Surface Condenser
11-EE-451
• One Ejector Set 11-JA-452A / 11-JA-453A or 11-JA-452S / 11-JA-453S is taken in service and
by this the non condensable gas is removed from the Surface Condenser 11-EE-451.
• The pressure in the Surface Condenser 11-EE-451 will drop to the normal operation pressure
of approximately-0.8barg. The Ethylene/Propylene Compressor Turbine Condenser 11-LZ-401
is ready for operation.
Important Notice:
Ensure the sealing water to the safety valve 11-SV-83905 of the Surface Condenser 11-EE-451 is
in service. Ensure the sealing water to the shaft seal of the Condensate Pumps 11-PC-451A/S is in
service. These points are the major source of air / non condensable gas inleakage and therefore a
"poor vacuum". Ensure the steam traps of the Ejector Set 11-JA-452A / 11-JA-453A or 11-JA-452S
/ 11-JA-453S are working properly otherwise the ejectors are not working a "poor vacuum" is the
result.
Gassing up
As a result of the shut-down activities the "C2H4/C2H6 Separation" and the "Ethylene Refrigerant
Cycle" as well as the connected consumers are under nitrogen pressure. Nitrogen is an inert gas
and has to get released to flare before the start-up.
Since the vapour return lines of the consumers are connected to the "Ethylene Refrigerant Cycle"
without isolation by block valves, the respective side of the ethylene refrigerant consumers are
charged with ethylene gas as well.
Important Notice:
During the gassing up the seal gas and lube oil system as well as the turning gear of the Ethylene
Compressor 11-KC-401 and Ethylene Compressor Turbine 11-KT-401 has to be in operation, since
it is possible that the rotor turns when gas passes through the compressor stages.
The nitrogen pressure in the system is lowered to 0.5barg:

• Open the pressure control valve 11-PV-45105 of the Ethylene Collecting Drum 11-VV-406.
• Open the flow control valves 11-FV-44206 and 11-FV-44401 in the reflux line to the C2 Splitter
11-CC-403
• Ensure all the kick back valves of the Ethylene Compressor 11-KC-401 are open.
• Release the nitrogen via 11-PV-45902C to the Warm Gas Flare by decreasing the set point of
the SPH pressure controller 11-PIC-45902C at the 4th stage discharge of the Ethylene
Compressor 11-KC-401 slowly to 0barg.
Once the pressure in the system reached 0.5barg 11-PV-45902C is closed and the set point of 11-
PIC-45902C set back to the normal operation set point.
The system is now pressurized with ethylene from BL. to 5barg.

• Ensure the ethylene available at BL complies with the specifications for the ethylene product.
• Open the block valve in the "Ethylene Gaseous Product" at the BL.
• Open the switch valve 11-XV-45905
• The block valve in the "Purge/Filling Line" downstream 11-XV-45905 is carefully opened.
• By opening the valve in the "Purge/Filling Line" to the suction line 1st stage of the Ethylene
Compressor 11-KC-401 the system is filled with ethylene.
Once the pressure in both systems ("C2H4/C2H6 Separation" and the "Ethylene Refrigerant
Cycle") has reached 5barg the valve in the "Purge/Filling Line" to the suction line 1st stage of the
Ethylene Compressor 11-KC-401 is closed.
The ethylene gas is released via 11-PV-45902C to the Warm Gas Flare by decreasing the set point
of the SPH pressure controller 11-PIC-45902C at the 4th stage discharge of the Ethylene
The pressurization with ethylene and afterwards releasing the gas to the Warm Gas Flare is carried
out in total 3 times. Now the concentration of nitrogen remaining in both systems ("C2H4/C2H6
Separation" and the "Ethylene Refrigerant Cycle") should be less than 1vol% and is confirmed by
sampling the gas at various low and high point vents.
After the gassing up of the both systems ("C2H4/C2H6 Separation" and the "Ethylene Refrigerant
Cycle") is completed, the systems are pressurized via the "Purge/Filling Line" to the suction line 1st
stage of the Ethylene Compressor 11-KC-401 to 7barg.
3.13.3.3 Start-up
In the following basic information for the start-up of the Ethylene Compressor Turbine 11-KT-401,
the Ethylene Compressor 11-KC-401 and the Ethylene/Propylene Compressor Turbine Condenser
11-LZ-401 are given. Regarding the required detailed start-up procedure of the Ethylene
Compressor Turbine 11-KT-401 and the Ethylene Compressor 11-KC-401 please refer to the
vendor documentation and instructions (Linde to insert Doc-No. of OM 11-KT-401 and 11-KC-
401).
Regarding the start-up of the aluminum plate fin heat exchangers within the "C2H4/C2H6
Separation" and the "Ethylene Refrigeration Cycle" as well as the aluminum plate fin heat
exchangers which are supplied with Ethylene Refrigerant, please also refer to chapter 1 "Start-up
and Shut-down Summary" of this Operating Manual.
Cooling down
Prior to every start up of the Ethylene Compressor 11-KC-401 especially after a long term shut
down, the drains at the suction lines to the individual stages as well as all casing drains have to be
opened and accumulated liquid has to be drained to Cold Liquid Flare.
• The SPH pressure controller 4th stage discharge of the Ethylene Compressor 11-KC-401, 11-
PIC-45902C is in automatic with the normal set point.
• The SPN pressure controller 4th stage discharge of the Ethylene Compressor 11-KC-401, 11-
PIC-45902B is in automatic with the normal set point.
• The 1st stage SPL suction pressure controller of the Ethylene Compressor 11-KC-401, 11-PIC-
45504B is in automatic with the normal set point
• The 1st stage SPH suction pressure controller of the Ethylene Compressor 11-KC-401, 11-
PIC-45504D and the 3rd stage SPN suction pressure controller of the Ethylene Compressor
11-KC-401, 11-PIC-45701B are kept in manual mode, means the controllers do not take any
action.
• The pressure controller of the Ethylene Collecting Drum 11-VV-406, 11-PIC-45105 is in
automatic with the normal set point. The block valves up- and downstream the corresponding
control valve are open.
• All control valves in the "Ethylene Refrigerant Cycle" and the "C2H4/C2H6 Separation" are
closed via the respective controller on manual closed.
Once the Ethylene Compressor Turbine 11-KT-401 and the Ethylene Compressor 11-KC-401 are
prepared for the start-up as per the vendor instructions and all start-up Interlocks are cleared the
Ethylene Compressor Turbine 11-KT-401 and the Ethylene Compressor 11-KC-401 are started
according to the vendor instructions and vendor operation manual. The vendor documentation
must get adhered to and is authoritative.
in stabile operation the Anti Surge Control can get taken in operation according to the vendor
instructions and vendor operation manual.
Observe the suction pressure of the 1st stage of the Ethylene Compressor 11-KC-401. Ensure it
does not drop below the set point of the suction pressure low protection 11-PSLL-45501A/B/C.
During the following cool down the suction pressure of the 1st stage is kept way above the normal
suction pressure of 50mbarg to prevent a trip of the Ethylene Compressor 11-KC-401 due
activation of the suction pressure low protection 11-PSLL-45501A/B/C in case of an upset during
the cool down. Since the Ethylene Refrigerant Consumers are not in service, the temperature
levels of the Ethylene Refrigerant supply streams do not have reach normal operation levels during
the cooling down.
The suction pressure 3rd stage of the Ethylene Compressor 11-KC-401, is controlled at the normal
operation pressure via the 3rd stage SPN suction pressure controller of the Ethylene Compressor
11-KC-401, 11-PIC-45701B. The controller is taken in automatic control (and the speed controller
11-SIC-83401 in cascade) once the Ethylene Compressor Turbine 11-KT-401 and the Ethylene
Compressor 11-KC-401 are in stabile operation at a speed above minimum governor speed.
If the suction pressure 3rd stage of the Ethylene Compressor 11-KC-401 drops and the speed
reaches minimum governor speed, means the suction pressure 3rd stage can not get increased
further by slowing down the compressor, this is an indication that more gas has to get charged to
the system via the "Purge/Filling Line" to the suction line 1st stage of the Ethylene Compressor 11-
KC-401. During the cooling down the ethylene gas in the system will liquefy, this amount of gas has
to get constantly made up in order to keep the pressure stabile. During the cooling down keep the
suction pressure 3rd stage stabile by controlling the ethylene gas stream via the "Purge/Filling Line"
to the suction line 1st stage of the Ethylene Compressor 11-KC-401. Do not wait until the speed of
the compressor reaches minimum governor speed.
During the following cooling down of the "C2H4/C2H6 Separation" and the "Ethylene Refrigeration
Cycle" it is extremely important to that the aluminum plate fin heat exchangers are cooled down
slowly and evenly and that the allowable temperature gradients are never exceeded. Please also
refer to chapter 1 "Start-up and Shut-down Summary" of this Operating Manual.
To achieve a slow and even cool down of the aluminum plate fin heat exchangers within the
"C2H4/C2H6 Separation" and the "Ethylene Refrigeration Cycle", the Countercurrent Exchanger
C2 Splitter 11-EP-407, the Reboiler C2 Splitter 11-EP-406, the Ethylene Subcooler 11-EP-409 and
the Ethylene Condenser 11-EP-408, the cooling down of the following cycles is done
SIMULANOUSLY:
• Cooling down of the C2-Splitter 11-CC-403, together with the Countercurrent Exchanger C2
Splitter 11-EP-407, the Reboiler C2 Splitter 11-EP-406 by circulation of the ethylene over the
3rd stage of the Ethylene Compressor 11-KC-401.
• Cooling down of the Ethylene Condenser 11-EP-408 with ethylene by circulation of the
ethylene via the Countercurrent Exchanger C2 Splitter 11-EP-407 over the 3rd stage of the
• Cooling down of the Ethylene Subcooler 11-EP-409 by routing ethylene via the Start-Up Line,
from overhead of the C2 Splitter 11-CC-403 to the passage 1 of the Ethylene Subcooler 11-
EP-409 and from there via the Ethylene Product Cooler I, 11-EE-403 and Ethylene Product
Cooler II, 11-EE-402 back to the Ethylene Subcooler 11-EP-409 passage 2 and 3.
Cooling down of the C2-Splitter 11-CC-403, together with the Countercurrent Exchanger C2 Splitter
11-EP-407 and the Reboiler C2 Splitter 11-EP-406
The cooling down of the C2 Splitter 11-CC-403 is started by slowly opening the Main Reflux Valve
11-FV-44206 thus routing the ethylene gas from the 3rd stage discharge of the Ethylene
Compressor 11-KC-401 via the Countercurrent Exchanger C2 Splitter 11-EP-407 to the Reboiler
C2 Splitter 11-EP-406. Since the Auxiliary Reboil Valve 11-FV-45202 (ethylene from the Reboiler
C2 Splitter 11-EP-406 to the Ethylene Collecting Drum 11-VV-406) is closed, the entire gas stream
is routed via the Countercurrent Exchanger C2 Splitter 11-EP-407 and the 11-FV-44206 to the C2
Splitter 11-CC-403.
At the Main Reflux Valve 11-FV-44206 the gas expands from discharge pressure 3rd stage of the
Ethylene Compressor 11-KC-401 to suction pressure 3rd stage of the Ethylene Compressor 11-KC-
401 and due to this cools down. The gas leaves the C2 Splitter 11-CC-403 as overhead gas
passes though the Countercurrent Exchanger C2 Splitter 11-EP-407 and is routed to the suction
side 3rd stage of the Ethylene Compressor 11-KC-401. In the Countercurrent Exchanger C2 Splitter
11-EP-407 the gas from overhead of the C2 Splitter 11-CC-403 cools down the gas stream from
the discharge side 3rd stage of the Ethylene Compressor 11-KC-401 to the Reboiler C2 Splitter 11-
EP-406.
By recycling the ethylene gas as described over the C2 Splitter 11-CC-403, the column as well as
the Countercurrent Exchanger C2 Splitter 11-EP-407 and the Reboiler C2 Splitter 11-EP-406 cools
down to normal operation temperature. The slow cooling down ensures the admissible temperature
gradients for the Countercurrent Exchanger C2 Splitter 11-EP-407 and the Reboiler C2 Splitter 11-
EP-406 are not exceeded.
Once the temperature downstream 11-FV-44206 and in the C2 Splitter 11-CC-403 reaches the
liquefaction temperature the trays in the C2 Splitter 11-CC-403 slowly start filling with liquid
ethylene. As soon as ethylene is condensing the pressure in the system will drop and ethylene gas
has to get charged into the system again via the "Purge/Filling Line" to the suction line 1st stage of
the Ethylene Compressor 11-KC-401. Keep the suction pressure 3rd stage stabile by controlling the
ethylene gas stream via the "Purge/Filling Line" to the suction line 1st stage of the Ethylene
Compressor 11-KC-401. Do not wait until the speed of the compressor reaches minimum governor
speed. If necessary slow down the cooling.
The C2 Splitter 11-CC-403 will cool down, the trays will slowly start filling with liquid and finally the
bottom of the column will fill up. The level of the C2 Splitter 11-CC-403 indicated via 11-LIC-44201
will rise. Once the bottom level of the C2 Splitter 11-CC-403 increases, the Reboiler C2 Splitter 11-
EP-406 (passage 1) also starts filling with liquid ethylene and the ethylene gas from the
Countercurrent Exchanger C2 Splitter 11-EP-407 will condense in the Reboiler C2 Splitter 11-EP-
406 (passage 2).
• Reduce the reflux flow via the Main Reflux Valve 11-FV-44206 by setting the controller 11-
FIC-44206 to automatic with the normal set point.
• Start venting the inert gas from the header 11-WI-402 of the Reboiler C2 Splitter 11-EP-406
(passage 2) to the Cold Gas Flare. This is done until 11-LAL-44302 the low level alarm in the
header 11-WI-402 below the Reboiler C2 Splitter 11-EP-406 (passage 2) clears.
• Repeat venting of inert gases from the header 11-WI-402 of the Reboiler C2 Splitter 11-EP-
406 (passage 2) any time 11-LAL-44302 becomes active.
Important Notice:
During the first start up of the C2 Splitter 11-CC-403 dirt and particles will be washed from the
column trays and the column walls and will accumulate in the strainer upstream the Reboiler C2
Splitter 11-EP-406. Flush back the strainer (see section 5 "Unit Upsets and Safety Devices") during
the cooling down phase. In any case flush back the strainer if the performance of the Reboiler C2
Splitter 11-EP-406 decreases.
As soon as the bottom level of the C2 Splitter 11-CC-403 reaches normal operation level indicated
via 11-LIC-44201, ethylene which condenses in the Reboiler C2 Splitter 11-EP-406 (passage 2)
can get charged via the Auxiliary Reboil Valve 11-FV-45202 to the Ethylene Collecting Drum 11-
VV-406 if necessary.
Since the Ethylene Condenser 11-EP-408 is cooled down and taken in service in parallel to the C2
Splitter 11-CC-403 the level in the Ethylene Collecting Drum 11-VV-406 might be already sufficient.
Do not fill the Ethylene Collecting Drum 11-VV-406 too much; avoid liquid carry over to the
downstream aluminum plate fin heat exchangers.
Important Notice:
Before charging liquid ethylene to the Ethylene Collecting Drum 11-VV-406 ensure the 11-XV-
45108 and 11-XV-45113 are OPEN. The block valve in the 8" liquid ethylene line from the Ethylene
Collecting Drum 11-VV-406 to the Ethylene Subcooler 11-EP-409 MUST BE CLOSED. Ensure also
that 11-FV-45104 and 11-XV-45110 are closed.
During the subsequent operation of the C2 Spiltter 11-CC-403 in internal circulation and with
ethylene only the heat duty of the Reboiler C2 Splitter 11-EP-406 will be too low to reboil the
ethylene in the bottom of the C2 Splitter 11-CC-403 sufficiently and the level in the bottom will rise.
In order to increase the reboil duty during the internal circulation DO NOT use the Auxiliary Reboil
Valve 11-FV-45202, but carefully open the hand control valve in the bypass line of the ethylene gas
from the Ethylene Cooler 3rd Stage 11-EE-404 around the Countercurrent Exchanger C2 Splitter
11-EP-407. By this the temperature of the ethylene gas routed to the Reboiler C2 Splitter 11-EP-
406 is increased and therefore the temperature difference and the reboil duty. Once the C2 Splitter
11-CC-403 is fed with C2 Fraction and the bottom liquid becomes ethane the hand control valve in
the bypass is carefully closed again.
Important Notice:
Always open or close the hand control valve in the bypass line of the ethylene gas from the
Ethylene Cooler 3rd Stage 11-EE-404 around the Countercurrent Exchanger C2 Splitter 11-EP-407
in a slow and controlled way. Ensure the allowable temperature differences and temperature
gradients at the Countercurrent Exchanger C2 Splitter 11-EP-407 and the Reboiler C2 Splitter 11-
EP-406 are not exceeded.
Cooling down of the Ethylene Condenser 11-EP-408

The Ethylene Condenser P1_E-4411 is cooled down in parallel to the C2 Splitter 11-CC-403. Gas
from downstream the Countercurrent Exchanger C2 Splitter 11-EP-407 passage 4 is routed via the
aluminum plate fin exchanger block in the kettle of the Ethylene Condenser 11-EP-408 and via the
Countercurrent Exchanger C2 Splitter 11-EP-407 passage 3 and the Auxiliary Reflux Valve 11-FV-
44401 to the C2 Splitter 11-CC-403.
• Ensure the level control valve 11-LV-45102 in the liquid ethylene supply line from the Ethylene
Condenser 11-EP-408 to the Ethylene Collecting Drum 11-VV-406 is closed
• Slowly open the Auxiliary Reflux Valve 11-FV-44401 to the C2 Splitter 11-CC-403.
Now ethylene gas is routed from downstream the Countercurrent Exchanger C2 Splitter 11-EP-407
passage 4 is routed via the aluminum plate fin exchanger block in the kettle of the Ethylene
Condenser 11-EP-408 and via the Countercurrent Exchanger C2 Splitter 11-EP-407 passage 3
and the Auxiliary Reflux Valve 11-FV-44401 to the C2 Splitter 11-CC-403.
Once the temperature of the ethylene gas leaving the Ethylene Condenser 11-EP-408 reaches a
temperature of minus 25°C, check 11-TI-45201, LP Propylene Refrigerant can get charged to the
kettle of the Ethylene Condenser 11-EP-408.
Open the block valves up and downstream of the level control valve 11-LV-45201 in the LP
Propylene Refrigerant supply line. Start filling the kettle of the Ethylene Condenser 11-EP-408 by
slowly opening the level control valve 11-LV-45201.
As soon as LP propylene refrigerant is charged to the Ethylene Condenser 11-EP-408 ethylene will
condense on the tube side and collect in the header 11-WI-403 below the Ethylene Condenser 11-
EP-408.
• Slowly close the Auxiliary Reflux Valve 11-FV-44401 to the C2 Splitter 11-CC-403
• Start filling the header 11-WI-403 below the Ethylene Condenser 11-EP-408.
• If necessary vent inert gas from the header 11-WI-403 below the Ethylene Condenser 11-EP-
408 to the Cold Gas Flare. This is done in case the low level alarm 11-LAL-45204 in the
header 11-WI-403 below the Ethylene Condenser 11-EP-408 does not clear.
• Repeat venting of inert gases from the header of 11-WI-403 below the Ethylene Condenser
11-EP-408 any time 11-LAL-45204 becomes active.
Fill the kettle of the Ethylene Condenser 11-EP-408 until the normal operation level is reached,
afterwards the level controller 11-LIC-45201 can get put in automatic control.
Important Notice:
If LP Propylene Refrigerant is charged to the Ethylene Condenser 11-EP-408 it will vaporize and
the vapor flows back to the 1st stage suction of the Propylene Compressor 11-KC-402. In order to
avoid large changes in the gas flows to the 1st stage suction of the Propylene Compressor 11-KC-
402, open the level control valve of the LP Propylene Refrigerant supply slowly. Since the speed of
the Propylene Compressor 11-KC-402 is controlled in by the suction pressure controller 1st stage,
large fluctuations in the vapor flows to the 1st stage resulting in large fluctuations of the suction
pressure will cause the compressor speed fluctuate. This will affect the entire "Propylene
Refrigerant Cycle" and the connected consumers.
During the normal operation avoid sudden and large changes in the liquid ethylene flow withdrawn
from the Ethylene Condenser 11-EP-408 since this will also result in the vaporization of large
amounts of LP Propylene Refrigerant and the above described problems.
The ethylene condensed in the Ethylene Condenser 11-EP-408 can get charged via the 11-FV-
45202 as auxiliary reflux to the C2 Splitter 11-CC-403 or to the Ethylene Collecting Drum 11-VV-
406 to increase the level. Do not fill the Ethylene Collecting Drum 11-VV-406 too much; avoid liquid
carry over to the downstream aluminum plate fin heat exchangers.
Important Notice:
Before charging liquid ethylene to the Ethylene Collecting Drum 11-VV-406 ensure the 11-XV-
45108 and 11-XV-45113 are OPEN. The block vale in the 8" liquid ethylene line from the Ethylene
Collecting Drum 11-VV-406 to the Ethylene Subcooler 11-EP-409 MUST BE CLOSED. Ensure also
that 11-FV-45104 and 11-XV-45110 are closed.
When liquefying ethylene in the Ethylene Condenser 11-EP-408, the pressure in the system will
drop and ethylene gas has to get charged into the system again via the "Purge/Filling Line" to the
suction line 1st stage of the Ethylene Compressor 11-KC-401. Keep the suction pressure 3rd stage
stabile by controlling the ethylene gas stream via the "Purge/Filling Line" to the suction line 1st
stage of the Ethylene Compressor 11-KC-401. Do not wait until the speed of the compressor
reaches minimum governor speed. If necessary slow down the cooling.
Cooling down of the Ethylene Subcooler 11-EP-409 together with the Ethylene Product Cooler I,
11-EE-403 and Ethylene Product Cooler II, 11-EE-402
The Ethylene Subcooler 11-EP-409 together with the Ethylene Product Cooler I, 11-EE-403 and
Ethylene Product Cooler II, 11-EE-402 are cooled down in parallel to the C2 Splitter 11-CC-403.
Gas from downstream the pressure control valve 11-PV-45105 of the Ethylene Collection Drum 11-
VV-406 is charged via a start-up line into the HP Ethylene Refrigerant supply header.
Important Notice:
The HP Refrigerant supply header is isolated. The block valve in the 8" liquid ethylene line from the
Ethylene Collecting Drum 11-VV-406 to the Ethylene Subcooler 11-EP-409 MUST BE CLOSED.
The gas from downstream the pressure control valve 11-PV-45105 of the Ethylene Collection Drum
11-VV-406 is routed via the passage 1 of the Ethylene Subcooler 11-EP-409 to the shell sides of
Ethylene Product Cooler I, 11-EE-403 and Ethylene Product Cooler II, 11-EE-402. From Ethylene
Product Cooler I, 11-EE-403 the gas is returned via passage 2 of the Ethylene Subcooler 11-EP-
409 and the Countercurrent Exchanger C2 Splitter 11-EP-407 passage 6 to the suction nozzle 2nd
stage of the Ethylene Compressor 11-KC-401. From the Ethylene Product Cooler II, 11-EE-402 the
gas is returned via passage 3 of the Ethylene Subcooler 11-EP-409 to the suction nozzle 1st stage
of the Ethylene Compressor 11-KC-401.
• The block valves up and downstream the 11-LV45302 of Ethylene Product Cooler I, 11-EE-
403 and 11-LV45303 of Ethylene Product Cooler II, 11-EE-402 are opened. The control valves
and the corresponding bypasses stay closed.
• Ensure the block valve in the 8" liquid ethylene line from the Ethylene Collecting Drum 11-VV-
406 to the Ethylene Subcooler 11-EP-409 is CLOSED.
• Ensure the 11-FV-45301 in the line from Ethylene Product Cooler I, 11-EE-403 to Ethylene
Product Cooler II, 11-EE-402 is CLOSED.
• Ensure the 11-XV-45306 in the liquid ethylene line from BL. and the 11-XV-45304 to BL. are
CLOSED.
• Ensure the HP Ethylene Refrigerant Consumers Low Temperature CC. Exchanger I, 11-EP-
401 and the Deethanizer Condenser 11-EP-302 are isolated, means the respective
temperature control valves are CLOSED. The 11-XV-45113 in the supply header stays OPEN.
• The "Start-Up Line" is pressurized by opening the block valve in the 3" start-up line. The HP
Ethylene Refrigerant supply header is slowly pressurized to approximately 7barg, afterwards
the block valve is fully opened.
By slowly opening -LV45302 of Ethylene Product Cooler I, 11-EE-403 ethylene gas is routed from
downstream the pressure control valve 11-PV-45105 of the Ethylene Collection Drum 11-VV-406
via the passage 1 of the Ethylene Subcooler 11-EP-409 to the shell side of Ethylene Product
Cooler I, 11-EE-403. The gas returns via passage 2 of the Ethylene Subcooler 11-EP-409 and the
Countercurrent Exchanger C2 Splitter 11-EP-407 passage 6 to the suction nozzle 2nd stage of the
Watch the pressures, flows and load of the Ethylene Compressor 11-KC-401. With increasing flow
towards the 2nd stage suction of the Ethylene Compressor 11-KC-401 the minimum flow valve of
the 2nd stage 11-FV-45602 will close.
By slowly opening -LV45303 of Ethylene Product Cooler II 11-EE-402 ethylene gas is routed from
downstream the pressure control valve 11-PV-45105 of the Ethylene Collection Drum 11-VV-406
via the passage 1 of the Ethylene Subcooler 11-EP-409 to the shell side of Ethylene Product
Cooler II, 11-EE-402. The gas returns via passage 3 of the Ethylene Subcooler 11-EP-409 to the
suction nozzle 1st stage of the Ethylene Compressor 11-KC-401.
Watch the pressures, flows and load of the Ethylene Compressor 11-KC-401. With increasing flow
towards the 1st stage suction of the Ethylene Compressor 11-KC-401 the minimum flow valve of the
1st stage 11-FV-45501 will close.
During the cool down of the Ethylene Subcooler 11-EP-409 watch the suction and discharge
pressures of the Ethylene Compressor 11-KC-401 as well as the suction temperatures. Also
ensure the allowable temperature gradients for the Ethylene Subcooler 11-EP-409 and the
Countercurrent Exchanger C2 Splitter 11-EP-407 are not exceeded.
Once all 3 passages of the Ethylene Subcooler 11-EP-409 are cooled down to approximately
normal operation temperature:
• Close the 11-LV45302 of Ethylene Product Cooler I, 11-EE-403 and the 11-LV45303 of
Ethylene Product Cooler II, 11-EE-402.
• Close the block valve in the 3" start-up line.
• Ensure the MP Ethylene Refrigerant Consumer Low Temperature CC. Exchanger IIA, 11-EP-
402 is isolated, means the respective temperature control valve is CLOSED.
• Ensure the LP Ethylene Refrigerant Consumers Low Temperature CC. Exchanger IIB, 11-EP-
403 and Condenser Demethanizer 11-EP-405 are isolated, means the respective temperature
respectively level control valves are CLOSED.
By slowly opening the block valve in the 8" liquid ethylene line from the Ethylene Collecting Drum
11-VV-406 to the Ethylene Subcooler 11-EP-409 the HP Refrigerant supply header is filled with
liquid ethylene. Once the lines are filled, means the level in the Ethylene Collecting Drum 11-VV-
406 does not drop anymore, the block valve in the 8" liquid ethylene line is fully opened.
Slowly fill the shell sides of the Ethylene Product Cooler I, 11-EE-403 and the Ethylene Product
Cooler II, 11-EE-402 by slowly opening the respective level control valves. Once the normal
operation level is reached, but the respective level controller in automatic mode.
During the filling of the HP Refrigerant supply header and the Ethylene Subcooler 11-EP-409 watch
the suction and discharge pressures of the Ethylene Compressor 11-KC-401 as well as the suction
temperatures. Also ensure the allowable temperature gradients for the Ethylene Subcooler 11-EP-
409 and the Countercurrent Exchanger C2 Splitter 11-EP-407 are not exceeded. Keep the level in
the Ethylene Collecting Drum 11-VV-406 by charging liquid ethylene from the Ethylene Condenser
11-EP-408 to the vessel.
The cooling down of the "Ethylene Refrigerant Cycle" and the "C2H4/C2H6 Separation" is
completed if:
• The C2 Splitter 11-CC-403 operates in internal recycle. The main reflux via 11-FV-44206 is
adjusted to the normal operation value. The bottom level indicated via P111-LIC-44201 is
stabilized. If necessary the reboil duty of the Reboiler C2 Splitter 11-EP-406 is increased by
routing gas via the bypass line of the ethylene gas from the Ethylene Cooler 3rd Stage 11-EE-
404 around the Countercurrent Exchanger C2 Splitter 11-EP-407.
Important Notice:
Always open or close the hand control valve in the bypass line of the ethylene gas from the
Ethylene Cooler 3rd Stage 11-EE-404 around the Countercurrent Exchanger C2 Splitter 11-EP-
407 in a slowly. Ensure the allowable temperature differences and temperature gradients at
the Countercurrent Exchanger C2 Splitter 11-EP-407 and the Reboiler C2 Splitter 11-EP-406
are not exceeded.
• The Ethylene Condenser 11-EP-408 is in stand-by, filled with liquid ethylene and the liquid LP
Propylene Refrigerant level in the kettle is at normal operation level and the level controller in
automatic mode with the normal operation setpoint.
• The Ethylene Collecting Drum 11-VV-406 is filled with ethylene to the normal operation level,
the level controllers, SPL, SPN and SPH are in automatic mode with the normal operation
setpoints and also the pressure controller 11-PIC-45105 is in automatic mode with the normal
set point.
• The Ethylene Subcooler 11-EP-409 is in operation with the liquid LP Ethylene Refrigerant
supplied to the Ethylene Product Subcooler 11-EE-402 and the vapor returning from this
exchanger to the 1st stage suction of the Ethylene Compressor 11-KC-401
• The Ethylene Product Subcooler II 11-EE-403 is in operation with the minimum flow from/to
the OSBL Liquid Ethylene Storage Tank.
• The Ethylene Product Subcooler I 11-EE-402 is in stand-by with the shell side filled with MP
Ethylene Refrigerant.
• The "on spec. ethylene product" export line and the OSBL Liquid Ethylene Storage Tank are
kept cold respectively at normal operation temperature by the minimum flow circulated over
the Ethylene Product Subcooler II 11-EE-403 and the boil off gas charged back via the OSBL
Boil Off Compressors to the 1st stage suction of the Ethylene Compressor 11-KC-401.
• The "off spec. ethylene" export line and the OSBL Off Spec. Tank are kept cold respectively at
normal operation temperature as per vendor instructions.
Flaring upstream C2 Splitter 11-CC-403

Once the flow of the C2 Fraction from the bottom of the Demethanizer 11-CC-402 to the C2 Splitter
11-CC-403 is stabilized put the level / flow controller cascade to control the bottom level of the
Demethanizer 11-CC-402 in service.
In case the bottom liquid of the Demethanizer 11-CC-402 is "off specification" during the start-up or
becomes "off specification":
• Close 11-HV-44103 in the feed line of the C2 Splitter 11-CC-403
• Decrease the set point of the pressure controller 11-PIC-44102 upstream the C2 Splitter 11-
CC-403 to 1barg below the operation pressure of the C2 Splitter 11-CC-403
The C2 Fraction is released via 11-PV-44102 to the Cold Gas Flare.
Important Notice:
The capacity of the Cold Blow Down Drum 11-VV-705 is limited. At a plant load of 100% the Cold
Blow Down Drum 11-VV-705 can only hold the C2 Fraction released via 11-PV-44102 for
approximately 45min. If the level in the Cold Blow Down Drum 11-VV-705 is too high, the flaring
has to get shifted back to "upstream of the Guard Drier 11-VD-303", means the operation of the
"Low Temperature Section" and "C1/C2 Separation" is stopped.
Therefore it is advisable to operate the Demethanizer 11-CC-402 with a slightly increased bottom
temperature during the start up period to avoid "off specification" bottom product.
Starting up the Ethylene Refrigerant Cycle / Feeding the C2 Splitter 11-CC-403

The "Ethylene Refrigerant Cycle" and the "C2H4/C2H6 Separation" are cooled down as part of the
start-up of the entire plant or the system is basically in the same condition after a short term shut
down, e.g. Trip of the Cracked Gas Compressor 11-KC-301 or Shut-down of the C2
Hydrogenation.
Once the "C2/C3 Separation" is started up the Condenser Deethanizer 11-EP-302 is taken in
service with HP Ethylene Refrigerant. The respective control valve is opened slowly to not exceed
the allowable temperature gradients of the aluminium plate fin exchangers and to not cause load
fluctuations at the Ethylene Compressor 11-KC-401.
Once process gas is sent to the Low Temperature Section the Ethylene Refrigerant Consumers,
the Low Temperature CC. Exchangers 11-EP-401, 11-EP-402, 11-EP-403 have to get taken in
service with liquid Ethylene Refrigerant from the Ethylene Collection Drum 11-VV-4406. The
respective control valves are opened slowly to not exceed the allowable temperature gradients of
the aluminium plate fin exchangers and to not cause load fluctuations at the Ethylene Compressor
11-KC-401.
Once the "C1/C2 Separation" is started up the Condenser Demethanizer 11-EP-405 is taken in
service with LP Ethylene Refrigerant. The respective control valve is opened slowly to not exceed
the allowable temperature gradients of the aluminium plate fin exchangers and to not cause load
fluctuations at the Ethylene Compressor 11-KC-401.
During the start up of the "C1/C2 Separation" the bottom liquid of the Demethanizer 11-CC-402 is
routed via the Low Temperature CC. Exchanger I 11-EP-401and is sent upstream the C2 Splitter
11-CC-403 to flare via the flare controller 11-PIC-44102. The setpoint of the 11-PIC-44102 is set
0.5bar below the operation pressure of the C2 Splitter 11-CC-403.
Once the bottom of the Demethanizer 11-CC-401 is "on specification" the pressure in the feed line
towards the C2 Splitter 11-CC-403 is slowly raised by increasing the setpoint of the 11-PIC-44102
to the operation pressure of the C2 Splitter 11-CC-403. Once the pressure is reached the feed
valve 11-HV-44103 to the C2-Splitter 11-CC-403 can get opened. The block valves up and
downstream the 11-HV-44103 are opened and by slowly opening the 11-HV-44103 the C2 fraction
from the bottom of the Demethanizer 11-CC-401, warmed up in Low Temperature CC. Exchanger I
11-EP-401 is fed to the C2 Splitter 11-CC-403. Once the 11-HV-44103 is fully open the set point of
the 11-PIC-44102 is set to the normal operation set point, the controller remains in automatic.
As soon as C2 Fraction is sent to the C2 Splitter 11-CC-403 the ethylene in the bottom of the
column is slowly replaced by ethane. The bottom temperature indicated by 11-TI-44201 will
increase.
The temperature profile of the C2 Splitter 11-CC-403 is adjusted as follows:
First the reboil duty of the Reboiler C2 Splitter 11-EP-406 is adjusted (decreased) carefully closing
the hand control valve in the bypass line of the ethylene gas from the Ethylene Cooler 3rd Stage 11-
EE-404 around the Countercurrent Exchanger C2 Splitter 11-EP-407.
In order to increase the reboil duty the flow of condensed ethylene from the Reboiler C2 Splitter 11-
EP-406 to the Ethylene Collecting Drum 11-VV-406 is increased by increasing the set point of 11-
FIC-45202.
In order to increase the reflux ethylene from P1_E-4411 is routed via P1_E-4312 to the C2 Splitter
P1_T-4301 by increasing the set point of P1_FIC-43115.
Important Notice:
Do not adjust the reflux by varying the set point of 11-FIC-44206 (main reflux) since this will also
change the reboil duty at the same time.
As soon as the bottom of the C2 Splitter 11-CC-403 is "on specification", the bottom temperature
11-TI-44201 has reached normal operation temperature, the ethane can be sent as recycle ethane
to the Cracking Furnaces.
First route the ethane to the Deethanizer Condenser 11-EP-302. Slowly open the 11-FV-44202 in
the bottom line of the C2 Splitter 11-CC-403, ensure the allowable temperature gradients at the
Deethanizer Condenser 11-EP-302 are not exceeded. The ethane stream vaporizing in the
Deethanizer Condenser 11-EP-302 serves as supplier of cooling duty at the same level as the LP
Propylene Refrigerant. Therefore as soon as ethane is charged to the Deethanizer Condenser 11-
EP-302 the vaporization rate of LP Propylene Refrigerant will decrease. Observe the Propylene
Refrigerant level in the Propylene Phase Separator 11-VV-320 and the temperature of the ethane
at the outlet of the Deethanizer Condenser 11-EP-302. Via the vaporization pressure of the LP
Propylene Refrigerant the cooling duty supplied by the LP Propylene Refrigerant is controlled, NOT
by the level in the Propylene Phase Separator 11-VV-320. The cooling duty supplied by the LP
Propylene Refrigerant is adjusted so the ethane leaving the Deethanizer Condenser 11-EP-302 is
fully vaporized.
If the vaporization capacity of the Deethanizer Condenser 11-EP-302 is not sufficient to vaporize
the ethane and the outlet temperature is too low even with minimal LP Propylene Refrigerant
cooling duty supply, the level in the bottom of the C2 Splitter 11-CC-403 can be lowered by routing
gaseous ethane directly to the "Feed Preheating".
As soon as the overhead gas of the C2 Splitter 11-CC-403 is "on specification", indicated via 11-AI-
44202A/B/C/D and also the ethylene gas discharge 4th stage of the Ethylene Compressor 11-KC-
401 indicated via 11-AI-45901A/B/C and 11-AI-45902A/B/C/D fulfils the requirements for the
ethylene product the excess ethylene gas is sent via 11-PV-45902B to as Ethylene Gaseous
Product to BL.
• Open the block valves upstream and downstream of 11-PV-45902B
• The block valve in the ethylene product header at BL. as well at the switch valve 11-XV-45905
is already, respectively still open from the "gassing up" respectively "cooling down" activities. If
not the lines are pressurized and the valves are opened.
• Slowly open 11-PV-45902B.
• Once the pressures and the flow is stabilized put the SPN pressure controller 11-PIC-45902B
in automatic with the normal set point.
In case not all ethylene can get exported to BL. the pressure in the export line will rise, the
discharge pressure 4th stage of the Ethylene Compressor 11-KC-401 will rise and the excess
ethylene will get released to the Warm Gas Flare via the SPH pressure controller 11-PIC-45902C.
The start up of the liquefaction way via the Ethylene Product Subcooler I, 11-EE-403 and the
Ethylene Product Subcooler II, 11-EE-402 to the OSBL Ethylene Storage Tank is done in
combination with the cooling down of the OSBL Ethylene Storage Tank. Please also refer to the
vendor manual and instructions for the OSBL Ethylene Storage Tank. Common practice for
atmospheric pressure liquid ethylene storage tanks is the cool down with gaseous ethylene to a
temperature of -80°C, afterwards the tank is cooled down with liquid ethylene to a temperature of -
100°C before the filling with liquid ethylene can start.
As soon as the nitrogen content is below the allowable limits for the ethylene product, the ethylene
gas from the OSBL Ethylene Storage Tank can get charged as boil off gas back to the 1st stage
suction of the Ethylene Compressor 11-KC-401.
Operation Notes
The Ethylene Compressor Turbine 11-KT-401 and the Ethylene Compressor 11-KC-401 are
operated as per vendor instructions and vendor operation manual. The vendor documentation must
get adhered to and is authoritative.
Vent inert gas from the headers below the C2 Splitter Reboiler 11-EP-406 and the Ethylene
Condenser 11-EP-408 via the inert vent line to Cold Gas Flare if required.
If the indicated temperatures 11-TI-44201 and/or 11-TI-44301 are low or the reboiling of the C2
Splitter 11-CC-403 is insufficient it is a indication that the flow though the Reboiler C2 Splitter 11-
EP-406 is restrained. In this case the strainer upstream the Reboiler C2 Splitter 11-EP-406 has to
get back flushed:
• Close the butterfly valve in the line from the C2 Splitter 11-CC-403 to the Reboiler C2 Splitter
11-EP-406
• Open the valve in the drain line of the strainer and drain the liquid to the Cold Liquid Flare until
it is audible that gas is released via the drain line.
• Close the valve in the drain line of the strainer
• Open the butterfly valve in the line from the C2 Splitter 11-CC-403 to the Reboiler C2 Splitter
11-EP-406
After the back flushing the temperatures 11-TI-44201 and/or 11-TI-44301 should normalize and the
reboiling duty increase. If this is not the case the back flushing has to get repeated.
In case the plugging of the strainer is caused by ice or gas hydrates methanol can get injected
upstream the strainer. In order to avoid the contamination of the bottom of the C2 Splitter 11-CC-
403 with methanol close the butterfly valve in the line from the C2 Splitter 11-CC-403 to the
Reboiler C2 Splitter 11-EP-406 BEFORE the injection of methanol. The injected methanol should
get drained as much as possible. For removal of pluggages caused by ice or gas hydrates, please
refer to chapter 6 "General Operating Notes" of this Operating Manual.
If off spec ethylene from the OSBL Off Spec. Ethylene Storage Tank has to get reprocessed the off
spec. ethylene can only get fed directly into the feed line of the C2 Splitter 11-CC-403 if the
ethylene is "contaminated" with ethane. In order to remove other impurities but ethane the off spec.
ethylene has to get fed to the KO Drum Precooling 11-VV-318.
3.13.3.4 Shut-down
The "Ethylene Refrigerant Cycle" is the supplier of low temperature cooling duty for the plant.
Without the supply of Ethylene Refrigerant several process units, especially the "Low Temperature
Section" can not get operated without the "Ethylene Refrigerant Cycle" in operation. The shut down
of this system therefore results in the shut down of the "Low Temperature Section" of the plant and
interruption/stop of ethylene production.
During a short interruption of production or during plant upsets the "Ethylene Refrigerant Cycle"
and the "C2H4/C2H6 Separation", means the C2 Splitter 11-CC-403 is operated in internal
circulation. The "Ethylene Refrigerant Cycle" is only shut-down if the entire plant is shut-down, e.g.
turn around.
Short term stop of the "Ethylene Refrigerant Cycle"

If the Ethylene Compressor Turbine 11-KT-401 / Ethylene Compressor 11-KC-401 are tripped via
the Plant ESD System or Machine ESD System the aim is to rectify the problem/reason for the trip
and restart the Ethylene Compressor Turbine 11-KT-401 / Ethylene Compressor 11-KC-401 as
soon as possible.
For explanations of the switch functions of the ESD System (Emergency Shut Down System), EBS
(Emergency Block-In System) and BDS (Blow Down System) please refer to chapter 5 "Shut-down
Systems" of this Operation Manual.
For explanations of the switch functions of the EPF System (Electrical Power Failure System)
please refer to chapter 4 "Failure of Key Components" of this Operation Manual.
For the internal switches related to Vendor Equipment and Package Units, please refer to the
vendor instructions and vendor operation manual. The vendor operation manuals have to be
followed and are authoritative. For the list of the vendor operation manuals please refer to the
"Bibliography" of this Operation Manual.
Besides the automatically initiated actions which are mainly:

• Stop of the feed to the C2 Splitter 11-CC-403 by closing the 11-HV-44103
• Isolation of all consumers
• Opening of all control valves in the minimum flow lines of the Ethylene Compressor 11-KC-401
it is extremely important to check the streams to the system from/to the OSBL Storage Tanks and
ensure the allowable temperature gradients at the equipment of the "Ethylene Refrigerant Cycle"
are not exceeded.
Further required measures are determined by the reason for the shut-down and the expected shut-
down period. These measures are essentially related to the shut-down of the Separation Section of
the Plant and for the conservation of the status of the plant at the time of the shut-down. Please
also refer to chapter 4 "Failure of Key Components" of this Operation Manual.
For measures to be taken after a trip of the Ethylene Compressor Turbine 11-KT-401 / Ethylene
Compressor 11-KC-401 and the consecutive restart please refer also to the vendor instructions and
vendor operation manual. The vendor documentation must get adhered to and is authoritative.
Short term stop of the feed stream to the C2 Splitter 11-CC-403

If the feed to the C2 Splitter 11-CC-403 becomes "off spec." indicated and alarmed via 11-AI-
43201A/B or due to upsets in the upstream systems (e.g. "C2 Hydrogenation" effluent off spec.) the
contamination of the C2 Splitter 11-CC-403 and especially the open loop ethylene cycle is
prevented by manually closing the 11-HV-44103. Once the 11-HV-44103 is closed decrease the
set point of the upstream pressure controller 11-PIC-44102 to 0.5 bar below the operation pressure
of the C2 Splitter 11-CC-403. The C2 fraction will get released via 11-PV-44102 to the Cold Liquid
Flare.
Important Notice:
In the Cold Blow Down Drum 11-VV-706 only 60% of the design feed stream of the C2 Splitter 11-
CC-403 which is charged via 11-PV-44102 to the Cold Liquid Flare can get vaporized. At 100%
load the Cold Blow Down Drum 11-VV-706 fills up. In case it is foreseeable that the C2 fraction can
not get sent to the C2 Splitter 11-CC-403 for a longer period the process gas stream towards the
"Low Temperature Section" has to get decreased in order to avoid the complete shut down of the
"Low Temperature Section" respectively the shut down of the entire plant due to overfilling of the
Cold Blow Down Drum 11-VV-706.
If the 11-HV-44013 is closed, either manually or via ESD system the C2 Splitter 11-CC-403 is
operated in internal circulation.
• If necessary the flow of ethylene towards the OSBL Ethylene Tank is stopped by taking the
controllers in manual mode and closing them in order to keep the ethylene in the system.
• Keep the temperature profile of the C2 Splitter 11-CC-403 by adjusting the auxiliary reboil via
11-FV-45202 and the auxiliary reflux via 11-FV-44401.
• If necessary the controller cascade of 11-LIC-44201 is opened and the ethane flow from the
bottom of the C2 Splitter 11-CC-403 is stopped to avoid draining or too low level in the C2
Splitter 11-CC-403. The same applies to the 11-FIC-44203, the corresponding flow control
valve has to get manually closed as well.
• In case of a longer stand by operation "internal circulation" of the C2 Splitter 11-CC-403 it

might be necessary to open the hand control valve in the bypass line of the ethylene gas from
the Ethylene Cooler 3rd Stage 11-EE-404 around the Countercurrent Exchanger C2 Splitter
11-EP-407. By this the temperature of the ethylene gas routed to the Reboiler C2 Splitter 11-
EP-406 is increased and therefore the temperature difference and the reboil duty. Once the
C2 Splitter 11-CC-403 is fed with C2 Fraction and the bottom liquid becomes ethane the hand
control valve in the bypass is carefully closed again.
• Since pressure discharge side 4th stage of the Ethylene Compresor 11-KC-401 will decrease
11-PV-45902B will close and stop the export of Ethylene Gaseous Product to BL.
Once the feed stream to the C2 Splitter 11-CC-403 is available and/or "on specification " again the
setpoint of the pressure controller 11-PIC-44102 is raised to the operation pressure of the C2
Splitter 11-CC-403 again, the 11-HV-44103 is carefully opened and the C2 Splitter 11-CC-403 fed
with liquid as per section "3.13.3.3 Start-up".
Shut-down of the "Ethylene Refrigerant Cycle"

A planned shut down of the "Ethylene Refrigerant Cycle" and the "C2H4/C2H6 Separation" as part
of a complete plant shut down is done as follows:
• The levels in all consumers are reduced to the achievable minimum level in order to transfer
all ethylene into the Ethylene Collecting Drum 11-VV-406 and from there to the OSBL
Ethylene Storage Tank
• The feed stream to the C2 Splitter 11-CC-403 is stopped by closing the 11-HV-44103
• The bottom level of the C2 Splitter 11-CC-403 is reduced to the minimum level, afterwards the
11-LIC-44201 is taken in manual and the ethyne flow is stopped by closing the 11-FV-44202.
• The speed of the Ethylene Compressor Turbine 11-KT-401 / Ethylene Compressor 11-KC-401
is taken to minimum governor speed and afterwards the Ethylene Compressor Turbine 11-KT-
401 / Ethylene Compressor 11-KC-401 are stopped by activation of the respective hand
switch.
• The Turning Gear of the Ethylene Compressor Turbine 11-KT-401 is started as soon as the
speed reached the allowable speed for engaging the turning gear..
• The Lube Oil System and the Seal Gas System must remain in service until the turbine is
cooled down completely.
For the shut down procedure of the Ethylene Compressor Turbine 11-KT-401 / Ethylene
Compressor 11-KC-401 and measures to be taken afterwards refer also to the vendor instructions
and vendor operation manual. The vendor documentation must get adhered to and is authoritative.
The Ethylene/Propylene Compressor Turbine Condenser 11-LZ-401 is a common unit and can only
get shut down if the Propylene Compressor Turbine 11-KT-402 AND the Ethylene Compressor
Turbine 11-KT-401 are shut down and cooled down.
A general shut down sequence for the Ethylene/Propylene Compressor Turbine Condenser 11-LZ-
401 is given below, for detailed instructions please refer to the vendor instructions and vendor
operation manual. The vendor documentation must get adhered to and is authoritative.
• Break the vacuum in the Surface Condenser 11-EE-451
• The sealing steam flow to the labyrinth seals of the Propylene Compressor Turbine 11-KT-402
AND the Ethylene Compressor Turbine 11-KT-401 is stopped
• The Ejector Sets 11-JA-452A / 11-JA-453A or 11-JA-452S / 11-JA-453S are taken out of
service
• The Condensate Pumps 11-PC-451A/S are stopped
• The Cooling water to the Propylene Condenser 11-EE-406A/B/C/D, the Surface Condenser
11-EE-451 and the Lube Oil Coolers can get stopped if necessary and the coolers drained. It
is advisable keeping the coolers in service in order to avoid fouling and deposits on the cooling
water side.
After the shut down:

• The Ethylene Compressor 11-KC-401 can get blocked in by closing the motor valves in the
suction lines of the individual stages, the discharge of the 3rd stage and the switch valve 11-
XV-45905 in the discharge line to the BL. If necessary the Ethylene Compressor 11-KC-401
can be depressurized via casing drains to the Cold Liquid Flare
• The "Ethylene Refrigerant Cycle" and the connected consumers itself remain filled
respectively pressurized.
• The C2 Splitter 11-CC-403 and the connected heat exchangers remain filled respectively
pressurized.
• As a result of the shut down all level and temperature controllers of the consumers and the
"Ethylene Refrigerant Cycle" are in manual forced closed.
• If control valves are leaking internally, the block valves upstream of the control valve must be
closed.
• The pressure in the "Ethylene Refrigerant Cycle" and the connected consumers will rise over
the time due to vaporization of the liquid ethylene remaining in the equipment and the
consumers. In order to avoid lifting the safety valves observe the pressure of the system via
the various remote and local pressure indications and if necessary release the gas via the 2"
bypass lines of the safety valves to the Cold Gas Flare
A prerequisite for draining and depressurization of the "Ethylene Refrigerant Cycle" and/or the C2
Splitter 11-CC-403 is that the levels in all equipment (e.g. column bottom, shell sides, vessels) got
reduced to the achievable minimum level.
• Block in the equipment to be drained and depressurized if possible.
• Drain the liquid ethylene remaining in the equipment or piping via drain line to the Cold Liquid
Flare.
• Depressurize the equipment or piping via drain or vent line to the Cold Liquid Flare or Cold
Gas Flare.
• Purge the equipment or piping with nitrogen if required.
3.13.4 Unit Upsets and Safety Devices
3.13.4.1 Upsets
In case of an alarm also general problems, such as fault of the controller, lack of instrument air or
other type of general disturbances shall be considered. For controllers it must be checked whether
they are on manual, or if the bypass of the respective control valve is possibly open. These types of
general problems, which can occur for all instruments, will not be considered in the following
paragraphs.
For alarm and automatic switch devices of this system and their set points, please refer to the
"Alarm and Switch Point", listed in the "Further relevant Contractor Documents" of this Operation
Manual.
Feed to the C2 Splitter 11-CC-403 "off spec."

If the feed to the C2 Splitter 11-CC-403 becomes "off spec." indicated and alarmed via 11-AI-
43201A/B (bottom of the Demethanizer 11-CC-402) or due to upsets in the upstream systems (e.g.
"C2 Hydrogenation" effluent off spec.) the contamination of the C2 Splitter 11-CC-403 and
especially the open loop ethylene cycle is prevented by manually closing the 11-HV-44103. Please
refer to section "3.13.3.4 Shut-down", Short term shut down of the C2 Splitter 11-CC-403.
Overhead gas of the C2 Splitter 11-CC-403 "off specification"

In case the overhead gas of the C2 Splitter 11-CC-403 is off specification in regards to the
methane (CH4), acetylene (C2H2) or ethane (C2H6) content, an alarm alerts the operator.
In order to detect a possible ethane (C2H6) carry over into the overhead gas the online analyzer
11-AI-44207 measures the gas below tray 82 of the C2 Splitter 11-CC-403 and alerts the operator
via high alarm.
In case of a too high ethane content in the overhead gas of the C2 Splitter 11-CC-403, the reflux
must be increased as a first measure.
Important Notice:
Increasing the reflux flow via 11-FIC-44206 (main reflux) changes the flow to the C2 Splitter
Reboiler 11-EP-406 at the same time Therefore to increase the reflux flow only, change the setting
of 11-FIC-44401 (auxiliary reflux)
Also check the temperature profile of the column as well as the feed flow and temperature and the
reboil duty.
Alarms at the bottom of the C2 Splitter 11-CC-403

In case of a too low or a too high level in the bottom of the C2 Splitter 11-CC-403 an alarm alerts
the operator. Check the level/flow controller cascade and the downstream system for restrictions.
In case of a too low temperature of the liquid in the bottom of the C2 Splitter 11-CC-403 an alarm
alerts the operator. A low temperature indicates insufficient reboiling, check the performance of the
Reboiler C2 Splitter 11-EP-406. If necessary back flush the reboiler, refer to next paragraph.
The online analyzer 11-AI-44201 measures the ethylene content of the gas in the bottom of the C2
Splitter and alerts the operator in case of a too high ethylene content in the bottom gas. Check the
temperature of the bottom gas, usually the column bottom is too cold and the reboil must be
increased as a first measure. Also check the temperature profile of the column as well as the feed
flow and temperature and the reflux flow.
Poor performance of the Reboiler C2 Splitter 11-EP-406

If the indicated temperatures 11-TI-44201 and/or 11-TI-44301 are low or the reboiling of the C2
Splitter 11-CC-403 is insufficient it is a indication that the flow though the Reboiler C2 Splitter 11-
EP-406 is restrained. In this case the strainer upstream the Reboiler C2 Splitter 11-EP-406 has to
get back flushed:
• Close the butterfly valve in the line from the C2 Splitter 11-CC-403 to the Reboiler C2 Splitter
11-EP-406
• Open the valve in the drain line of the strainer and drain the liquid to the Cold Liquid Flare until
it is audible that gas is released via the drain line.
• Close the valve in the drain line of the strainer
• Open the butterfly valve in the line from the C2 Splitter 11-CC-403 to the Reboiler C2 Splitter
11-EP-406
After the back flushing the temperatures 11-TI-44201 and/or 11-TI-44301 should normalize and the
reboiling duty increase. If this is not the case the back flushing has to get repeated.
In case the plugging of the strainer is caused by ice or gas hydrates methanol can get injected
upstream the strainer. In order to avoid the contamination of the bottom of the C2 Splitter 11-CC-
403 with methanol close the butterfly valve in the line from the C2 Splitter 11-CC-403 to the
Reboiler C2 Splitter 11-EP-406 BEFORE the injection of methanol. The injected methanol should
get drained as much as possible. For removal of pluggages caused by ice or gas hydrates, please
refer to chapter 6 "General Operating Notes" of this Operating Manual.
Differential pressure alarm "high" at the C2 Splitter 11-CC-403

In case of high differential pressure over the C2 Splitter 11-CC-403an alarm alerts the operator.
During normal operation the differential pressure is measured over the entire column. In order to
locate the source for the high pressure drop, the differential pressure can be measured over the top
section or lower section only. This is done by opening respectively closing the block valves in the
respective impulse lines.
Possible causes for a high differential pressure over the C2 Splitter 11-CC-403 are:
• Reflux flow too high.
Important Notice:
Changing the reflux flow via 11-FIC-44206 (main reflux) changes the flow to the C2 Splitter
Reboiler 11-EP-406 at the same time and therefore the reboil duty. If the reflux flow is
indented to get changed only, change the setting of 11-FIC-44401 (auxiliary reflux)
• Fouling of the trays in the C2 Splitter 11-CC-403
• Formation of ice or gas hydrates on the trays and/or internals of the C2 Splitter 11-CC-403.
A methanol injection line is provided in order to inject methanol into the feed line, the reflux line
and onto tray 78. For removal of pluggages caused by ice or gas hydrates, please refer to
chapter 6 "General Operating Notes" of this Operating Manual.
Important Notice:
The methanol injected into the C2 Splitter 11-CC-403 respectively the reflux or feed line will
end up in the ethane which is routed from the bottom of the C2 Splitter 11-CC-403 to the
Cracking Furnaces. Methanol will form in the Cracking Furnaces CO which affects the C2
Hydrogenation. When injecting methanol preferably route the recycle ethane from the C2
Splitter 11-CC-403 to the Cold Liquid Flare.
Temperature alarm "high" at the top of the C2 Splitter 11-CC-403

In case of too high temperature of the gas leaving the C2 Splitter 11-CC-403 overhead, an alarm
alerts the operator.
Check the reflux flow to the C2 Splitter 11-CC-403 as well as the temperature of the reflux liquid.
Pressure alarm "high" or "low" at the top of the C2 Splitter 11-CC-403

In case of too high or a too low pressure overhead of the C2 Splitter 11-CC-403, an alarm alerts
the operator.
The column pressure is determined by the suction pressure 3rd stage of the Ethylene Compressor
11-KC-401. Check the operation respectively the suction pressure 3rd stage of the Ethylene
Compressor 11-KC-401 and the setting of the pressure controller 11-PIC-45701B. If the suction
pressure 3rd stage of the Ethylene Compressor 11-KC-401 is normal check the system for
restrictions (e.g. valve openings, suction strainer).
Reflux flow alarm "low" at the C2 Splitter 11-CC-403

In case the main reflux flow and/or the auxiliary reflux flow drop below the alarm value, an alarm
alerts the operator. Besides the controller settings and the control valves check the system for
restrictions. Remember that the main reflux flow is "connected" to the reboil duty.
Level alarm "low" in the header below the Reboiler C2 Splitter 11-EP-406 or the Ethylene
Condenser 11-EP-408
In case of a low level in the header below the Reboiler C2 Splitter 11-EP-406 or the Ethylene
Condenser 11-EP-408 an alarm alerts the operator.
The alarm indicates insufficient condensation in the heat exchanger most likely caused by the
accumulation of inert gases in the header and the "ethylene side" of the exchanger. Open the vent
line on top of the header fully for 1Minute. Afterwards close the vent line again and observe the
system. If the low level alarm does not clear respectively reoccur repeat the venting.
Temperature alarms at the Countercurrent Exchanger C2 Splitter 11-EP-407

At the Countercurrent Exchanger C2 Splitter 11-EP-407 various temperature alarms alert the
operator of operation irregularities.
The heat duty in the Countercurrent Exchanger C2 Splitter 11-EP-407 is mainly supplied by the hot
ethylene gas stream from the 3rd stage of the Ethylene Compressor 11-KC-401 which is precooled
in the Ethylene Cooler 3rd Stage 11-EE-404A/B. Therefore check the flow and temperature of this
stream. Too low temperatures of the streams leaving the Countercurrent Exchanger C2 Splitter 11-
EP-407 are either caused by a too low heat duty supply or too high flows or too low inlet
temperatures of the respective stream showing the low temperature alarm.
A too high temperature of the gas stream leaving passage 4 of the Countercurrent Exchanger C2
Splitter 11-EP-407 is caused by a (too large) opening of the valve in the bypass line. The bypass
line is used during start-up respectively internal circulation of the column with ethylene or mainly
ethylene only. During normal operation the valve in the bypass line is CLOSED.
Level Alarms at the Ethylene Collecting Drum 11-VV-406

In case of a too high or a too low level in the Ethylene Collecting Drum an alarm alerts the operator.
Check the level controller settings and prevent overfilling of the drum by stopping the liquid
ethylene flow from the Ethylene Condenser 11-EP-408 by closing 11-LV-45102. Closing of the 11-
FV-45202 will affect the auxiliary reboil stream of the C2 Splitter Reboiler 11-EP-406
In case of a low level prevent loosing the Ethylene Refrigerant supply by stopping the liquid
ethylene export to the OSBL Liquid Ethylene Storage Tank if in operation. Reduce the Ethylene
Gaseous Product export if possible and increase the liquefying in the Ethylene Condenser 11-EP-
408.
Level alarms at the Ethylene Product Subcooler I and II 11-EE-403 and 11-EE-402
In case of a too high or a too low level of Ethylene Refrigerant on the shell side of the Ethylene
Product Subcooler I and II 11-EE-403 and 11-EE-402 an alarm alerts the operator.
A too low level will lead to insufficient subcooling and therefore increased boil off in the OSBL
Ethylene Storage Tank and also flow restriction in the liquid ethylene export line. Check the flow of
ethylene product to the exchangers, the level controllers and the system for restrictions.
If the high level alarm at the Ethylene Product Subcooler I 11-EE-403 becomes active immediate
action is required to avoid the activation of the 2oo3 level high switch which interrupts the Ethylene
Refrigerant supply. Check the level controller and reduce the supply of Ethylene Refrigerant
supply.
Temperature "low" alarms at the Ethylene Subcooler 11-EP-409

At the Ethylene Subcooler 11-EP-409 various temperature "low" alarms alert the operator of
operation irregularities.
All temperature low alarms around the Ethylene Subcooler 11-EP-409 are due to possible liquid
carry over from the upstream exchangers respectively phase separator. Therefore check the
upstream system for liquid carry over, e.g. level controller settings.
Immediate action is required in case the low temperature alarm 11-TI-45401 (MP Ethylene
Refrigerant vapour from passage 2) becomes active. The activation of the 2oo3 11-TSLL-
45506A/B/C temperature low switches which would lead to an automatic interruption of the MP
Ethylene Refrigerant supply to the Low Temperature CC Exchanger IIA 11-EP-402 has to get
avoided since this would cause a major operation upset in the Low Temperature Section.
In case the low temperature alarm 11-TI-45401 (MP Ethylene Refrigerant vapour from passage 2)
becomes active check the operation of the Low Temperature CC Exchanger IIA 11-EP-402 and the
Ethylene Product Subcooler 11-EE-403.
Temperature alarm "low" 1st Stage Suction of the Ethylene Compressor 11-KC-401
In case of low temperature of the ethylene gas charged to the 1st Stage Suction of the Ethylene
Compressor 11-KC-401 an alarm alerts the operator.
Immediate action is required to avoid the activation of the 2oo3 11-TSLL-45502A/B/C temperature
low switches which would lead to an automatic shut down of the Ethylene Compressor 11-KC-401.
As a first measure the minimum flow control valve 11-FV-45501 is opened via the manual control
function in the anti surge control system. By this hot gas from downstream the Ethylene Cooler 3rd
Stage 11-EE-404A/B is routed to the suction side 1st stage and warms up the gas coming from the
process. Afterwards check the upstream system for the source of the cold gas, means boil off gas
temperature and flow and the operation of the Ethylene Subcooler 11-EP-409 respectively the
streams to and from this exchanger.
Pressure alarm "low" 1st Stage Suction of the Ethylene Compressor 11-KC-401
In case of low suction pressure 1st Stage Suction of the Ethylene Compressor 11-KC-401 an alarm
alerts the operator.
Immediate action is required to avoid the activation of the 2oo3 11-PSLL-45501A/B/C pressure low
switches which would lead to an automatic shut down of the Ethylene Compressor 11-KC-401.
As a first measure the minimum flow control valve 11-FV-45501 is opened via the manual control
function in the anti surge control system. By this gas from downstream the Ethylene Cooler 3rd
Stage 11-EE-404A/B is routed to the suction side 1st stage and increases the gas flow to the 1st
stage suction side. If necessary take the speed controller of cascade control and reduce the speed
of the compressor. Afterwards check the upstream system why the flow from the process side is
low and also check the SPL pressure controller 11-PIC-45504B which should prevent a low suction
pressure 1st stage by opening 11-PV-45504B.
Temperature "low" alarms in the suction lines of the Ethylene Compressor 11-KC-401
In case of low temperature of the ethylene gas charged to the different suction nozzles of the
Ethylene Compressor 11-KC-401 the respective alarm alerts the operator.
The suction temperatures of the Ethylene Compressor 11-KC-401 depend on the operation of the
upstream equipment. In case of too low suction temperatures check the upstream equipment for
e.g. liquid carry over and also check the suction pressures of the Ethylene Compressor 11-KC-401.
The pressures determine the vaporization temperature of the Ethylene Refrigerant.
Pressure "high" or "low" alarms in the suction lines of the Ethylene Compressor 11-KC-401
In case of high or low suction pressures at the different suction nozzles of the Ethylene
Compressor 11-KC-401 the respective alarm alerts the operator.
The suction pressure of the 3rd stage of the Ethylene Compressor 11-KC-401 is controlled by a
pressure controller acting on the speed controller of the driving turbine, Ethylene Compressor
Turbine 11-KT-401. If the suction pressure of the 3rd stage is too low or too high check the pressure
controller. All other suction pressures are a result of the flows to the respective stage, if necessary
the pressure profile of the compressor can get adjusted by manually increasing the kick back flows
to the individual stages, e.g. the minimum flow is opened the suction pressure of the stage
increases.
Ethylene Gaseous Product gas "off specification"

The Ethylene Gaseous Product is monitored via the online analyzer 11-AI-44202 and 11-AI-45901
which check the gas downstream the Ethylene Cooler 4th Stage 11-EE-405. In case one or more
impurity concentrations exceed the alarm value, an alarm alerts the operator.
The operation of the C2 Splitter 11-CC-403 has to get checked as well as the boil off gas charged
from the OSBL Ethylene Storage Tank to the 1st stage suction of the Ethylene Compressor 11-KC-
401.
In case the Ethylene Gaseous Product becomes "off specification" the gas is either send to the
Warm Gas Flare or liquefied to the OSBL Off. Spec. Ethylene Storage Tank.
In order to send the gas to the flare and not disturb the operation of the Ethylene Compressor 11-
KC-401 the setpoint of the SPH pressure controller 11-PIC-45902C is lowered to the normal
operation pressure discharge 4th stage and the setpoint of the SPN pressure controller is
increased. By this the flow of gas is shifted to the Warm Gas Flare. The OSBL Ethylene Gaseous
Product header is than supplied by vaporized ethylene from the OSBL Ethylene Storage Tank.
In order to send the "off spec" ethylene to the OSBL Off. Spec. Ethylene Storage Tank charge the
liquid ethylene from the Ethylene Collecting Drum 11-VV-406 via flow controller 11-FIC-45104A to
the OSBL Off. Spec. Ethylene Storage Tank. Since the ethylene gas to get liquefied the load on the
Ethylene Condenser 11-EP-408 and therefore also the Propylene Compressor 11-KC-402
increases significantly.
3.13.4.2 Switches
For detail to switch signals see following "Further relevant Contractor Documents":
• "Cause and Effect Diagram"
• "Alarm- and Trip Setting List"
• Current set of P&FD
For each mentioned switch signal the P&ID number is given as reference and for fast follow up of
the respective effects which are caused by activation of the listed switches.
For explanations of the switch functions of the ESD System (Emergency Shut Down System), EBS
(Emergency Block-In System) and BDS (Blow Down System) please refer to chapter 5 "Shut-down
Systems" of this Operation Manual.
For explanations of the switch functions of the EPF System (Electrical Power Failure System)
please refer to chapter 4 "Failure of Key Components" of this Operation Manual.
For the internal switches related to Vendor Equipment and Package Units, please refer to the
vendor instructions and vendor operation manual. The vendor operation manuals have to be
followed and are authoritative. For the list of the vendor operation manuals please refer to the
"Bibliography" of this Operation Manual.
Cooling Water Pressure Low 11-PSLL-77101

In case the "Cooling Water Pressure Low" switch 11-PSLL-77101 is activated, a "C2CSD: Ethylene
Compressor Shutdown" is initiated since the exhaust steam of the Ethylene Compressor Turbine
11-KT-401 can not get condensed anymore.
The automatically initiated actions which are mainly:
• Isolation of all consumers
• Stopping the feed to the C2 Splitter 11-CC-403 by closing the 11-HV-44103 and stopping the
ethane flow from the bottom of the C2 Splitter 11-CC-403 by closing the 11-XV-44204 and 11-
XV-44209
• Opening of all control valves in the minimum flow lines of the Ethylene Compressor 11-KC-401
• The loss of level in the Ethylene Collecting Drum is prevented by automatically taking the SPL
level controller 11-LIC-45103 in forced manual closed.
The activation of the "Cooling Water Pressure Low" switch 11-PSLL-77101 also causes the shut
down of the other two Main Compressors and the shut-down of various reboilers and pumps
throughout the plant. The Ethylene Compressor Turbine 11-KT-401 / Ethylene Compressor 11-KC-
401 should be the second Main Compressor to be restarted in order to stabilize the plant and
restart the plant efficiently (first start the Propylene Compressor 11-KC-402 and at last the Cracked
Gas Compressor 11-KC-301).
Ethane Feed Gas downstream Propylene Refrigerant Subcooler 11-EE-407 Temperature

"low" 11-TSLL-48004
In case the "Propylene Refrigerant Subcooler 11-EE-407 Temperature low switch" 11-TSLL-48004
is activated, the ethane liquid flow from the bottom of the C2 Splitter 11-CC-403 is stopped by
automatically closing the switch valve 11-XV-44204 in the bottom line of the C2 Splitter 11-CC-403.
The ethane gas flow from the gas phase in the bottom of the C2 Splitter 11-CC-403 is stopped by
automatically closing the switch valve 11-XV-44209.
The temperature low switch protects the Ethane Preheater 11-EE-205 from freezing.
In order to avoid upsetting the operation of the C2 Splitter 11-CC-403 and flooding of the bottom of
the column:
• Cut the Ethane Feed Gas streams from BL., clear the temperature low switch and first
establish the ethane liquid flow from the bottom of the C2 Splitter 11-CC-403 before opening
the ethane flows from BL.
• If the level in the bottom of the C2 Splitter 11-CC-403 is rising and the 11-XV-44204 can not
get opened since the temperature low switch can not get cleared, it is possible to drain the
bottom liquid to the Cold Liquid Flare via the drain line of the strainer upstream the Reboiler
C2 Splitter 11-EP-406
3.13.4.3 Mechanical Interlocking Devices
Not applicable.
3.13.5 Special Operating Procedures
Separation" is done with ethane via a special filling line from the "Feed Preheating" to the suction
line of the 3rd stage of the Ethylene Compressor 11-KC-401. In order to remove the impurities in the
ethane, an ethane cleaning cycle for the filling and subsequent cooling down and liquefying steps is
provided. The ethane is routed from the discharge side of the 3rd stage of the Ethylene Compressor
11-KC-401 to the Caustic Scrubber 11-CC-301. From overhead of the Caustic Scrubber 11-CC-
301 the gas is routed via the Cracked Gas Cooler 11-EE-309 and the Cracked Gas Drier 11-VD-
301A/B/S back to the suction side of the 3rd stage of the Ethylene Compressor 11-KC-401.
Separation" with ethane is a one time only operation and is described below.
Initial filling and start-up of the "Ethylene Refrigeration Cycle" and the "C2H4/C2H6
Separation" with ethane
For the initial filling and start-up of the "Ethylene Refrigeration Cycle" and the "C2H4/C2H6
Separation" with ethane the same "Basic Requirements for Start-Up" and "Preparations for Start-
Up" as described in the sections 3.14.3.1 and 3.14.3.2 apply. The "gassing up" and "cooling down"
is in parts different and described below as well as the start-up and subsequent operation during
which all ethane in the "Ethylene Refrigeration Cycle" and the "C2H4/C2H6 Separation" and the
connected consumers is replaced by ethylene.
Important Notice:
Ethane has different physical properties as Ethylene. Check that all instrumentation and especially
the Anti-Surge-Control-System of the Ethylene Compressor 11-KC-401 is set for the operation with
Ethane
Gassing up with Ethane

The ethane used for the initial gassing up and cooling down of the "C2H4/C2H6 Separation" and
the "Ethylene Refrigerant Cycle" is supplied as liquid ethane from BL. and is vaporized in the
Ethane Start-up Evaporator 11-EE-206 and than fed pressure controlled via the respective filling
and start-up lines to the "C2H4/C2H6 Separation" and the "Ethylene Refrigerant Cycle":
• Ensure the ethane available at BL complies with the specifications for the ethane permitted for
the initial filling of the "C2H4/C2H6 Separation" and the "Ethylene Refrigerant Cycle":
• Nitrogen: 0.0 mole% (max)
• Methane: 1.5 mole% (max)
• Ethane: 98 mole% (min)
• Propane: 0.5 mole% (max)
• Butanes: 0.0 mole% (max)
• Pentane: 0.0 mole% (max)
• H2S: 10 ppm (w/w) max
• Total Sulphur: 50 ppm (w/w) max
• CO2: 10 ppm (w/w) max
• O2: 5 ppm (w/w) max
• Isolate the normal operation Liquid Ethane Feed way towards the Cracked Gas CC Exchanger
11-EP-301 by closing the block valves up and downstream the Strainer 11-WG-201A/S and
setting the spectacle blinds (including the ones in the bypass lines) to closed position.
• Isolate the normal operation vaporized Ethane Feed way towards the Ethane Feed header by
closing the block valves up and downstream the 11-PV-21303 as well as the bypass and the
control valve itself.
• Close the block valve and set the spectacle blind in CLOSED position in the start-up line
(pressurization) from the Ethane Start-up Vaporizer 11-EE-206 to upstream the Cracked Gas
CC Exchanger 11-EP-301.
• Ensure the Ethane Start-up Vaporizer 11-EE-206 is ready for operation, warmed-up and the
LP-Steam supply is ensured as well as the removal of the LP-Condensate.
The ethane used for the initial gassing up and cooling down of the "C2H4/C2H6 Separation" and
the "Ethylene Refrigerant Cycle" contains sour gases such as CO2 and H2S which is harmful
during long term operation of the system and therefore has to get removed during the gassing up
and subsequent cooling down of the "C2H4/C2H6 Separation" and the "Ethylene Refrigerant
Cycle".
The sour gases such as CO2 and H2S are removed from the ethane in the Caustic Scrubber 11-
CC-301. Therefore the process unit 34 "Caustic Scrubbing" as well as the process unit 35 "Spent
Caustic Oxidation" have to be ready for operation, means the Caustic Scrubber 11-CC-301 is
under circulation with caustic solution, the respective caustic concentrations (same as for the
normal operation) are adjusted, the "Spent Caustic Oxidation" is in stand-by operation ready to
receive effluent from the Caustic Scrubber 11-CC-301. The Caustic Stripper 11-CC-302 is
bypassed during this operation step due to lack of heavy hydrocarbons which have to get stripped
from the spent caustic.
The "Caustic Scrubbing" is lined up as follows:

• Remove the spool piece in the cracked gas line from the Inlet Separator Acid Gas Removal
11-VV-305 to the Caustic Scrubber 11-CC-301 and blind the line.
• Remove the spool piece in the cracked gas line downstream the Cracked Gas Suction Drum
5th Stage 11-VV-306 and the suction 5th stage of the Cracked Gas Compressor 11-KC-301
and blind the line.
• Close the block valve in the line "C2 Fraction from 11-EP-301" which ties in upstream the
Cracked Gas Suction Drum 5th Stage 11-VV-306
• Ensure the Gasoline/Spent Caustic Separator 11-VV-309 pressure control is lined up to "fuel
gas supply" and "discharge to the Warm Gas Flare".
• Ensure all PSV´s are lined up as per PID for normal operation.
Once the ethane gas passes through the Caustic Scrubber 11-CC-301 it is saturated with water.
Water would cause major operation problems in the "C2H4/C2H6 Separation" and the "Ethylene
Refrigerant Cycle" respectively would make the operation impossible due to icing and plugging with
ice/hydrates. Therefore the water has to get removed in the process unit "Precooling and Drying".
This means in consequence that process unit 37 ""Precooling and Drying" has to be ready for
operation, as well as process unit 46 "Propylene Refrigerant Cycle" in order to supply HP
Propylene Refrigerant to the Cracked Gas Cooler I 11-EE-309 and the process unit 86
"Regeneration System" in order to supply regeneration gas for the regeneration of the Cracked
Gas Drier 11-VD-301A/B/S.
The "Precooling and Drying" is lined up as follows:

• Remove the spool piece in the cracked gas line between the Cracked Gas 5th Stage
Intercooler 11-EE-305A/B and the Cracked Gas Cooler I 11-EE-309 and blind the line.
• Open the block valves in the start-up line between the Cracked Gas Suction Drum 5th Stage
11-VV-306 and the Cracked Gas Cooler I 11-EE-309.
• Line up the Separator Precooling 11-VV-317 as for normal operation, but close 11-XV-36302
in the cracked gas condensate way and set a blind. In case the process unit 28 "Water
Scrubbing" is ready for receiving the water from the Separator Precooling 11-VV-317 and
potentially ethane gas (in case of a malfunction of the level controller or valve) the process
water way is lined up as per normal operation. If not the block valve downstream the 11-LV-
36303 is removed and a temporary connection made to a system where the water can get
safely drained to (potential release of ethane gas)
• Close the block valve upstream 11-FV-32201 and set a blind. Close the block valve
downstream 11-TV-31905 and set a blind.
• Line up the Cracked Gas Driers 11-VD-301A/B/S as for normal operation, means two driers in
operation and one in stand-by and the drier regeneration sequence is set accordingly. In case
the Cracked Gas Suction Drum 1st Stage 11-VV-301 is not ready to receive the ethane gas
during the "depressurizing step" during the regeneration, the block valve downstream the
respective switch valve has to get closed and a blind set. The gas during the "depressurizing
step" is released via temporary connections from the 1" drains to the flare.
• Remove the spool piece in the line downstream the Strainer 11-WG-301A/S towards the
Cracked Gas CC Exchanger 11-EP-301 and blind the line.
• Install the spool piece in the start-up line which ties off downstream the Strainer 11-WG-
301A/S towards the Ethylene Compressor 11-KC-401 and the Regeneration Gas Heater I 11-
EE-702 and open the block valve upstream.
The "Regeneration System" is lined up as follows:

• Close the block valves in the methane gas, nitrogen and hydrogen supply line to the
Regeneration Gas Heater 11-EE-702 and set blinds.
• Open the block valve in the ethane gas start up line.
• Ensure the "Regeneration System" is lined up to the Cracked Gas Drier 11-VD-301A/B/S only,
all other driers are isolated.
• Ensure the flow measurements are set for ethane gas (physical properties e.g. density)
• In case the "Fuel Gas System" is not ready to receive the ethane "exhaust" gas from the
Regeneration Gas Cooler 11-EE-703 during the regeneration, line up the outlet gas line of the
Regeneration Gas Cooler 11-EE-703 to the Warm Gas Flare.
• Ensure the spectacle blind in the outlet gas line of the Regeneration Gas Cooler 11-EE-703 to
atmosphere is set to CLOSE position.
The "Ethylene Refrigerant Cycle" is lined up as follows:

• Open the block valves up and downstream 11-FV-37003 as well at the control valve, ensure
the valve in the bypass is closed.
• Open the block valve in the Ethane Recycle Line During Start-Up from downstream the
Ethylene Cooler 3rd Stage 11-EE-404A/B to the cracked gas inlet line of the Caustic Scrubber
11-CC-301
• Open the block valve in the "Purge/Filling Line" to the 1st stage suction of the Ethylene
Compressor 11-KC-401.
As a result of the precommissioning activities the "C2H4/C2H6 Separation" and the "Ethylene
Refrigerant Cycle" as well as the connected consumers are under nitrogen pressure. Nitrogen is an
inert gas and has to get released to flare before the start-up.
Since the vapor return lines of the consumers are connected to the "Ethylene Refrigerant Cycle"
without isolation by block valves, the respective side of the ethylene refrigerant consumers are
charged with ethane gas as well.
Important Notice:
During the gassing up the seal gas and lube oil system as well as the turning gear of the Ethylene
Compressor 11-KC-401 and Ethylene Compressor Turbine 11-KT-401 has to be in operation, since
it is possible that the rotor turns when gas passes through the compressor stages.
The nitrogen pressure in the system is lowered to 0.5barg:

• Open the pressure control valve 11-PV-45105 of the Ethylene Collecting Drum 11-VV-406.
• Open the flow control valves 11-FV-44206 and 11-FV-44401 in the reflux line to the C2 Splitter
11-CC-403
• Ensure all the kick back valves of the Ethylene Compressor 11-KC-401 are open.
• Release the nitrogen via 11-PV-45902C to the Warm Gas Flare by decreasing the set point of
the SPH pressure controller 11-PIC-45902C at the 4th stage discharge of the Ethylene
The system is now pressurized with ethane from BL. to 5barg.

• Ensure the ethane available at BL complies with the specifications for the specifications for the
ethane permitted for the initial filling of the "C2H4/C2H6 Separation" and the "Ethylene
Refrigerant Cycle" as given above.
• Open the switch valve 11-XV-21101 in the "Liquid Ethane Feed" line at the BL.
• Open the block valve in the "Liquid Ethane Feed" line at the BL and fill the line up to 11-PV-
21304 at the Ethane Start-up Evaporator 11-EE-206
• Open the switch valve 11-XV-21305 and afterwards slowly fill and pressurize the Ethane Start-
up Evaporator 11-EE-206 by opening the 11-PV-21304.
• Open the block valves up and downstream 11-PV-21306
• By slowly opening the 11-PV-21306 the entire loop, process units 34,37,43,44, are
pressurized with ethane gas to 5barg
Once the pressure in all systems involved has reached 5barg the 11-PV-21306 is closed.
The ethylene gas is released via 11-PV-45902C to the Warm Gas Flare by decreasing the set point
of the SPH pressure controller 11-PIC-45902C at the 4th stage discharge of the Ethylene
The pressurization with ethane and afterwards releasing the gas to the Warm Gas Flare is carried
out in total 3 times. Now the concentration of nitrogen remaining in all systems involved should be
less than 1vol% and is confirmed by sampling the gas at various low and high point vents.
After the gassing up of all the systems involved is completed, the systems are pressurized via the
11-PV-21306 to 7barg.
Starting-up and cooling down with ethane

In the following basic information for the start-up of the Ethylene Compressor Turbine 11-KT-401,
the Ethylene Compressor 11-KC-401 and the Ethylene/Propylene Compressor Turbine Condenser
11-LZ-401 are given. Regarding the required detailed start-up procedure of the Ethylene
Compressor Turbine 11-KT-401 and the Ethylene Compressor 11-KC-401 please refer to the
vendor documentation and instructions (Linde to insert Doc-No. of OM 11-KT-401 and 11-KC-
401).
Important Notice:
Ethane has different physical properties as Ethylene. Check that all instrumentation and especially
the Anti-Surge-Control-System of the Ethylene Compressor 11-KC-401 is set for the operation with
Ethane
Regarding the start-up of the aluminum plate fin heat exchangers within the "C2H4/C2H6
Separation" and the "Ethylene Refrigeration Cycle" as well as the aluminum plate fin heat
exchangers which are supplied with Ethylene Refrigerant, please also refer to chapter 1 "Start-up
and Shut-down Summary" of this Operating Manual.
Prior to start up of the Ethylene Compressor 11-KC-401 the drains at the suction lines to the
individual stages as well as all casing drains have to be opened and accumulated liquid has to be
drained to Cold Liquid Flare.
• The SPH pressure controller 4th stage discharge of the Ethylene Compressor 11-KC-401, 11-
PIC-45902C is in automatic with the normal set point.
• The SPN pressure controller 4th stage discharge of the Ethylene Compressor 11-KC-401, 11-
PIC-45902B is in manual mode and the corresponding control valve closed.
• The 1st stage SPL suction pressure controller of the Ethylene Compressor 11-KC-401, 11-PIC-
45504B is in automatic with the normal set point
• The 1st stage SPH suction pressure controller of the Ethylene Compressor 11-KC-401, 11-
PIC-45504D and the 3rd stage SPN suction pressure controller of the Ethylene Compressor
11-KC-401, 11-PIC-45701B are kept in manual mode, means the controllers do not take any
action.
• The pressure controller of the Ethylene Collecting Drum 11-VV-406, 11-PIC-45105 is in
automatic with the normal set point. The block valves up- and downstream the corresponding
control valve are open.
• All control valves in the "Ethylene Refrigerant Cycle" and the "C2H4/C2H6 Separation" are
closed via the respective controller on manual closed.
• Close the flow control valve 11-FV-37003 in the "Ethane Recycle Line During Start-up" from
the Cracked Gas Driers 11-VD-301A/B/S to the 3rd stage suction of the Ethylene Compressor
11-KC-401.
• Close the block valve in the "Ethane Recycle Line During Start-Up" from downstream the
Ethylene Cooler 3rd Stage 11-EE-404A/B to the cracked gas inlet line of the Caustic Scrubber
11-CC-301
• Keep the block valve in the "Purge/Filling Line" to the 1st stage suction of the Ethylene
Compressor 11-KC-401 open.
• Close the 11-PV-21306 in the ethane supply line from the Ethane Start-up Evaporator 11-EE-
206.
prepared for the start-up as per the vendor instructions and all start-up Interlocks are cleared the
Ethylene Compressor Turbine 11-KT-401 and the Ethylene Compressor 11-KC-401 are started
according to the vendor instructions and vendor operation manual. The vendor documentation
must get adhered to and is authoritative.
in stabile operation the Anti Surge Control can get taken in operation according to the vendor
instructions and vendor operation manual.
Observe the suction pressure of the 1st stage of the Ethylene Compressor 11-KC-401. Ensure it
does not drop below the set point of the suction pressure low protection 11-PSLL-45501A/B/C.
During the following cool down the suction pressure of the 1st stage is kept way above the normal
suction pressure of 50mbarg to prevent a trip of the Ethylene Compressor 11-KC-401 due
activation of the suction pressure low protection 11-PSLL-45501A/B/C in case of an upset during
the cool down. Since the Ethylene Refrigerant Consumers are not in service, the temperature
levels of the -in this case Ethane- Refrigerant supply streams do not have reach normal operation
levels during the cooling down.
Once the Ethylene Compressor 11-KC-401 is in stabile operation with ethane first the loop via the
Caustic Scrubber 11-CC-301 and the "Precooling and Drying" is established in order to remove the
sour gases such as CO2 and H2S from the ethane:
• Slowly open the block valve in the "Ethane Recycle Line During Start-Up" from downstream
the Ethylene Cooler 3rd Stage 11-EE-404A/B to the cracked gas inlet line of the Caustic
Scrubber 11-CC-301
By this the Caustic Scrubber 11-CC-301 and two of the lined up Cracked Gas Driers 11-VD-
301A/B/S and the connected equipment of the "Precooling and Drying" is pressurized to the
discharge pressure of the Ethylene Compressor 11-KC-401.
Once the pressure in the lined up path and equipment has reached the discharge pressure of the
Ethylene Compressor 11-KC-401 the minimum gas load for the Caustic Scrubber 11-CC-301 is
adjusted by slowly opening the 11-FV-37003. By this gas is routed back to the 3rd stage suction of
the Ethylene Compressor 11-KC-401. Once the required minimum gas load for the Caustic
Scrubber 11-CC-301 is reached take the flow controller 11-FIC-37003 in automatic control with the
respective setpoint.
The feeding point for fresh Ethane from the Ethane Start-up Vaporizer 11-EE-206 to the
"C2H4/C2H6 Separation" and the "Ethylene Refrigeration Cycle" is changed to "upstream the
Caustic Scrubber 11-CC-301 by:
• Ensure the block valve in the Filling Line/Start-up Line to the cracked gas inlet line of the
Caustic Scrubber 11-CC-301 is open.
• Close the block valve in the "Purge/Filling Line" to the 1st stage suction of the Ethylene
Compressor 11-KC-401.
The suction pressure 3rd stage of the Ethylene Compressor 11-KC-401, is controlled at the normal
operation pressure via the 3rd stage SPN suction pressure controller of the Ethylene Compressor
11-KC-401, 11-PIC-45701B. The controller is taken in automatic control (and the speed controller
11-SIC-83401 in cascade) once the Ethylene Compressor Turbine 11-KT-401 and the Ethylene
Compressor 11-KC-401 are in stabile operation at a speed above minimum governor speed.
If the suction pressure 3rd stage of the Ethylene Compressor 11-KC-401 drops and the speed
reaches minimum governor speed, means the suction pressure 3rd stage can not get increased
further by slowing down the compressor, this is an indication that more gas has to get charged to
the system via the "Purge/Filling Line" by opening 11-PV-21306 to the inlet line of the Caustic
Scrubber 11-CC-301. During the cooling down the ethane gas in the system will liquefy, this
amount of gas has to get constantly made up in order to keep the pressure stabile. During the
cooling down keep the suction pressure 3rd stage stabile by controlling the ethane gas stream via
the "Purge/Filling Line" by opening 11-PV-21306 to the inlet line of the Caustic Scrubber 11-CC-
301. Do not wait until the speed of the compressor reaches minimum governor speed.
The following cooling down of the "C2H4/C2H6 Separation" and the "Ethylene Refrigeration Cycle"
is done similar to the cooling down with ethylene, please refer to section 3.13.3 Start-up.
During the cooling down of the "C2H4/C2H6 Separation" and the "Ethylene Refrigeration Cycle"
the ethane will liquefy. The amount of ethane which liquefies has to get made up with ethane gas
from the Ethane Start-up Vaporizer 11-EE-206.
The sour gas removal (CO2 and H2S) is controlled via the online analyzer 11-AI-33101 overhead
of the Caustic Scrubber 11-CC-301. Since H2S reacts with the caustic much easier than the CO2 it
is sufficient to monitor the CO2 content of the ethane.
The temperature of the ethane gas downstream the Cracked Gas Cooler I 11-EE-309 is kept at
15°C. Higher temperatures would lead to higher moisture contents of the ethane gas being send to
the Cracked Gas Driers 11-VD-301A/B/S and therefore short runtimes. Lower temperatures would
lead to the formation of gas hydrates and plugging of the downstream KO Drum Precooling I 11-
VV-316.
The condensate which is separated in the KO Drum Precooling I 11-VV-316 and drains into the
Separator Precooling 11-VV-317 is drained level controlled from the boot to the "Water Scrubbing
or via temporary piping to a suitable point in the process.
Important Notice:
In case of male function of the level controller 11-LDIC-36303 or the corresponding level control
valve 11-LV-36303, ethane gas will get released via this line. Operating pressure of the KO Drum
Precooling I 11-VV-316 during the ethane filling approximately 19barg.
The Cracked Gas Driers 11-VD-301A/B/S are regenerated according to need via the "Regeneration
System". As regeneration gas dry ethane gas from downstream the Cracked Gas Driers 11-VD-
301A/B/S is used. The ethane gas is routed via "Start-up Line" to the "Regeneration System".
(Since the regeneration of the Cracked Gas Driers 11-VD-301A/B/S is done in countercurrent
direction and the cool down is done by the regeneration gas, dry gas has to be used in order to not
load the dryer bed during the cooling down step.)
Once all equipment of the "Ethylene Refrigerant Cycle" and the "C2H4/C2H6 Separation" is cooled
down and sufficiently filled with ethane, the OSBL Off Spec Ethylene Tank has to get filled with
liquid ethane.
Important Notice:
Once the DFCU is prepared for the start-up, means the Caustic Scrubber 11-CC-301 is lined up for
the normal operation (all spool pieces are installed and blind removed), the "Ethylene Refrigerant
Cycle" and the "C2H4/C2H6 Separation" can NOT get fed with ethane gas from the Ethane Start-
up Vaporizer 11-EE-206 anymore. If ethane make up during this start-up phase is required, ethane
from the OSBL Off Spec Ethylene Tank can get fed via the liquid off spec ethylene line and via a
special start-up line into the feed line of the C2 Splitter 11-CC-403.
Important Notice:
The ethane from the Ethane Start-up Vaporizer 11-EE-206 contains heavy components such as
propane. The heavy components will accumulate in the bottom of the C2 Splitter 11-CC-403 and
can not get vaporized by the Reboiler C2 Splitter 11-EP-406. The bottom of the C2 Splitter 11-CC-
403 therefore has to get drained to the Cold Liquid Flare periodically to avoid too high
concentrations of heavy components.
The ethane from the Ethane Start-up Vaporizer 11-EE-206 contains also light components such as
methane and nitrogen (of which small amounts are also still in the system from the gassing up
step). The light components will not condense and will accumulate in the header below the
Reboiler C2 Splitter 11-EP-406 or the Ethylene Condenser 11-EP-408. The corresponding "low
level alarm" is usually the indication for this. Open the vent line on top of the header fully for
1Minute. Afterwards close the vent line again and observe the system. If the low level alarm does
not clear respectively reoccur repeat the venting.
The cooling down of the "Ethylene Refrigerant Cycle" and the "C2H4/C2H6 Separation" is
completed if:
• The C2 Splitter 11-CC-403 operates in internal recycle. The main reflux via 11-FV-44206 is
adjusted to the normal operation value. The bottom level indicated via P111-LIC-44201 is
stabilized. If necessary the reboil duty of the Reboiler C2 Splitter 11-EP-406 is increased by
routing gas via the bypass line of the ethane gas from the Ethylene Cooler 3rd Stage 11-EE-
404 around the Countercurrent Exchanger C2 Splitter 11-EP-407.
Important Notice:
Always open or close the hand control valve in the bypass line of the ethane gas from the
Ethylene Cooler 3rd Stage 11-EE-404 around the Countercurrent Exchanger C2 Splitter 11-EP-
407 in a slowly. Ensure the allowable temperature differences and temperature gradients at
the Countercurrent Exchanger C2 Splitter 11-EP-407 and the Reboiler C2 Splitter 11-EP-406
are not exceeded.
• The Ethylene Condenser 11-EP-408 is in stand-by, filled with liquid ethane and the liquid - in
this case LP Propane - Refrigerant level in the kettle is at normal operation level and the level
controller in automatic mode with the normal operation setpoint.
• The Ethylene Collecting Drum 11-VV-406 is filled with ethane to the normal operation level,
the level controllers, SPL, SPN and SPH are in automatic mode with the normal operation
setpoints and also the pressure controller 11-PIC-45105 is in automatic mode with the normal
set point.
• The Ethylene Subcooler 11-EP-409 is in operation with the liquid - in this case LP and MP
Ethane - Refrigerant supplied to the Ethylene Product Subcooler I and II 11-EE-402 and 11-
EE-403 and the vapor returning from these exchangers to the 1st and 2nd stage suction of the
• The Ethylene Product Subcooler II 11-EE-403 is in stand-by with the shell side filled with - in
this case LP Ethane - Refrigerant. The OSBL Liquid Ethylene Storage Tank remains isolated.
DO NOT charge ethane to the On Spec Ethylene Tank.
• The Ethylene Product Subcooler I 11-EE-402 is in stand-by with the shell side filled with - in
this case MP Ethane – Refrigerant.
• The "off spec. ethylene" export line and the OSBL Off Spec. Tank are kept cold respectively at
normal operation temperature as per vendor instructions.
• The OSBL Off Spec Ethylene Tank is filled with liquid ethane.
Once the above criteria fulfilled the Caustic Scrubber 11-CC-301 and the "Precooling and Drying"
can get disconnected from the Ethylene Compressor 11-KC-401. Preferably the Cracked Gas
Driers 11-VD-301A/B/S are regenerated before to avoid the possible necessity to regenerate the
driers with nitrogen.
• Stop the ethane gas supply from the Ethane Start-up Evaporator 11-EE-206 by closing the 11-
PV-306 and close also the block valves up and downstream the control valve and the block
valves in the "Filling Line/Start-up Line"
• Slowly close Close the block valve in the "Ethane Recycle Line During Start-Up" from
downstream the Ethylene Cooler 3rd Stage 11-EE-404A/B to the cracked gas inlet line of the
Caustic Scrubber 11-CC-301
Since the 11-FV-37003 to the 3rd stage suction of the Ethylene Compressor 11-KC-401 is still open
the Caustic Scrubber 11-CC-301 and the lined up equipment in the "Precooling and Drying" will
depressurize to suction pressure 3rd stage suction of the Ethylene Compressor 11-KC-401. Once
this pressure of approximately 7barg is reached:
• Close 11-FV-37003 and close also the block valves up and downstream the control valve.
• Depressurize the isolated Caustic Scrubber 11-CC-301 and the lined up equipment in the
"Precooling and Drying", purge the lines and equipment with nitrogen to the Warm Gas Flare
until free of hydrocarbons. Afterwards all spool pieces are reinstalled, the respective blinds
removed, the spectacle blinds turned in the required position and the system lined up as per
PID for the normal operation case respectively start-up.
Operation of the "Ethylene Refrigerant Cycle" and the "C2H4/C2H6 Separaton" with Ethane
and consecutive replacement of the Ethane with Ethylene
The "Ethylene Refrigerant Cycle" and the "C2H4/C2H6 Separation" and the consumers are
operated with ethane until the C2 Splitter 11-CC-403 is fed with C2 Fraction from the bottom of the
Demethanizer 11-CC-401.
Important Notice:
During the operation of the "Ethylene Refrigerant Cycle" with ethane instead of ethylene the
achievable temperatures of the – in this case Ethane Refrigerant – is approximately 20°C higher
than if the system is operated with ethylene. The operation of all consumers is therefore different to
the normal operation.
Once feed (C2 Fraction) is send to the C2 Splitter 11-CC-403 the level in the bottom will rise as
well at the pressure in the "Ethylene Refrigerant Cycle" respectively 4th stage discharge of the
Ethylene Compressor 11-KC-401. In order to remove the ethane from the "Ethylene Refrigerant
Cycle" and the "C2H4/C2H6 Separation":
• Start releasing the ethane liquid from the bottom of the C2 Splitter 11-CC-403 as recycle
ethane to the Cracking Furnaces. The removal of the ethane as liquid from the bottom of the
C2 Splitter 11-CC-403 is the most efficient and the flow should be as large as possible
Important Notice:
Ensure the downstream systems, especially the Deethanizer Condenser 11-EP-302 can
handle the ethane recycle stream. Avoid low temperatures and possible trips due to "too low
temperatures"
• Via the Ethylene Start-up Line/min Flow Line from the Ethylene Cooler 3rd Stage 11-EE-
404A/B to the cracked gas line upstream the Primary Fractionator 11-CC-201 gas can get
routed flow controlled via 11-FIC-45801 back to the process.
Important Notice:
By sending the gas from the "Ethylene Refrigerant Cycle" back into the process the volume
flow as well as the composition of the cracked gas will change. Observe the process, and
adjust the operation especially the "C2/C3 Separation" and the "C2 Hydrogenation".
• By draining liquid, preferably from the bottom of the C2 Splitter 11-CC-403 or from the header
below the Reboiler C2 Splitter 11-EP-406 to the Cold Liquid Flare liquid ethane can get
removed from the "Ethylene Refrigerant Cycle"
• Via the SPH pressure controller gas from the 4th stage discharge of the Ethylene Compressor
11-EE-401 can get released to the Warm Gas Flare. This is the least preferable location to
remove gas from the system since at this location the ethane concentration is the lowest,
means the most ethylene is lost to the flare.
During the operation "Replacement of Ethane with Ethylene" the following has to be considered:
• With increasing ethylene concentration in the "Ethylene Refrigerant Cycle" and the consumers
the operation parameters such as the suction temperatures of the Ethylene Compressor 11-
KC-401 will shift towards the normal operation parameters.
• The vaporization temperatures of the Ethane respectively Ethylene Refrigerant will change as
well (the higher the concentration of ethylene the lower the vaporization temperature).
Observe the operation of the Ethylene Refrigerant consumers and adjust the Refrigerant flow
respectively operation parameters accordingly.
The composition of the gas in the "Ethylene Refrigerant Cycle" and the "C2H4/C2H6 Separation" is
measured by the online analyzers. Once the overhead gas of the C2 Splitter 11-CC-403 and also
the gas downstream the Ethylene Cooler 4th Satge 11-EE-405 fulfils the specification of the
ethylene product gas the operation "Replacement of Ethane with Ethylene" is completed.

3.13 C2H4C2H6 Separation and Ethylene Refrigeration Cycle PDF

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3.13 C2H4C2H6 Separation and Ethylene Refrigeration Cycle PDF

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DAHEJ PETROCHEMICAL

3.13 C2H4/C2H6 Separation

X 01 17.05.2010 First Issue T. Schmidt O. Lex B. Sasse

ENGINEERING Linde Proj. No.: 3110 A9NK

Samsung Proj. No.: SC 2252

Contract No / PO No.: Item No.:

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

3.13.1 The Process at Normal Operation ............................................................................................3

3.13.2 Functionality of Control Loops ................................................................................................13

3.13.3 Start-up and Shut-down ..........................................................................................................14

3.13.4 Unit Upsets and Safety Devices .............................................................................................31

3.13.5 Special Operating Procedures ................................................................................................37

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

3.13.1 The Process at Normal Operation

In the Ethylene Refrigeration Cycle System:

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

Countercurrent Exchanger C2 Splitter 11-EP-407

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

Ethylene vapour to the Ethylene Condenser 11-EP-408

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

Ethylene Product Export

• 11-AI-45902A CH4 content

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

Ethylene Refrigeration Cycle

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

Ethylene Compressor 11-KC-401

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

Ethylene Compressor Turbine 11-KT-401

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

3.13.2 Functionality of Control Loops

11-LIC-44201 Level Control C2 Splitter 11-CC-403

Conditions for functionality

Master Controller 11-LIC-44201

Slave Controller 11-FIC-44202

Level Control Ethylene Collecting Drum 11-VV-406

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

3.13.3 Start-up and Shut-down

3.13.3.1 Basic Requirements for Start-Up

• All precommissioning work has been done successfully.

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

For the initial Start-up with Ethane additionally:

3.13.3.2 Preparations for Start-up

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

Ethylene Compressor 11-KC-401

Ethylene Compressor Turbine 11-KT-401

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

Ethylene/Propylene Compressor Turbine Condenser 11-LZ-401

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

The nitrogen pressure in the system is lowered to 0.5barg:

The system is now pressurized with ethylene from BL. to 5barg.

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

Cooling down of the Ethylene Condenser 11-EP-408

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01

Flaring upstream C2 Splitter 11-CC-403

6987-LEPC1-AA-00-PO-MC 1002.313 C2H4/C2H6 Sep. and Eth. Ref. Cyc. Issue: 01