Qatar Petroleum Ngl-1 Operating Manual: 1. General

QATAR PETROLEUM VOL : 1
SEC. : 5
NGL-1 OPERATING MANUAL PAGE : 1
MOLECULAR SIEVE ADSORBERS
1. GENERAL
1.1 Process Description

a. Regeneration Gas Supply
b. Operating Pressures
c. Adsorbing/Regeneration Cycles
d. Regeneration
e. Product Separators
1.2 Operating Variables and Process Controls

a. Master Cycling Timer
1. Regeneration
2. Sequences, Trips and Stoppage Notes.
3. Alarm and System Malfunction
b. Instruments and Functions for C-1307 A/B.
c. Instruments and Functions for C-1308 A/B.
d. Regeneration Gas Furnace F-1301.
e. Product Separators
2. PREPARATION FOR START-UP

3. START-UP
3.1 Propane Molecular Sieves

3.2 Butane Molecular Sieves
3.3 Start up of Regeneration Furnace
a. Prestart up inspection
b. Purging and Final Tightness Testing of Fuel System
c. Purging Combustion Chamber
d. Gas Testing
SEC. : 5
e. Open Common Trip Valve

f. Set Air Register to start up position for pilot burner.
g. Start ignition torch
h. Start up pilot burner.
i. Start up of main burner
4. SHUTDOWN
5. EMERGENCY SHUTDOWN
5.1 Depressurising
5.2 Liquid Levels
5.3 Shutdown Causes
a. Cooling Water Failure
b. Instrument Air Failure
c. Power Failure
d. Hot Oil Failure
e. Fire
f. Tube Burst in F-1301.
5.4 Shutdown Activities
6. EQUIPMENT/INSTRUMENT SUMMARY
SEC. : 5
MOLECULAR SIEVE ADSORBERS
Reference Drawings.
F11W-0180-01
F11W-0180-02
F11W-0181-01
F11W-0181-02
F11W-0181-03
F11W-0181-04
F11W-0181-05
F11W-0181-06
NG-1069/0
NG-1070/0
NG-076
1. GENERAL
The propane molecular sieve adsorbers C-1307A/B and the butane molecular
sieve adsorbers C-1308A/B are fixed bed units filled with molecular sieves.
The molecular sieves adsorb the water and possibly some mercaptan molecules
from the liquid streams.
The bed of sieves are held on a fixed grid, a 20 mesh wire screen. Layers of 1/4”
and 1½” ceramic balls are placed on the wire mesh.
The propane and butane adsorbers are similar except that the fixed grid on the
butane absorber is lighter.
The propane adsorber is filled with 17m 3 of type RK-29- Union Carbide - Molecular
sieves 1/16” pellets.
The butane adsorber is filled with 13m3 of type 9453- Union Carbide - Molecular
sieves.
Above the beds of sieves is a floating grid and screen. It allows movement in the
bed but also contains it.
Above the bed is a further layer of ceramic balls.
The ceramic balls form a trap for any dust and dirt particles.
Both inlet and outlet lines have special devices which prevent any sieves or balls
passing into piping and equipment.
SEC. : 5
Molecular sieves provide a means of selectively removing and holding specific

molecules from a fluid stream which is passing through the sieve bed.
This physical phenomenon is termed adsorption. The molecules are adsorbed in

the pores of the molecular sieves.
The amount of a certain component that can be adsorbed by the sieves is a

function of both temperature and pressure. The higher the temperature, the less
will be adsorption. The higher the pressure, more will be adsorption. The design
operating parameters should be followed for best results.
Normally, while one bed is in adsorption service the other bed is being
regenerated.
The propane and butane leaving their respective adsorbers contain less than 1
ppm wt of water and less than 5 ppm wt of sulphur.
The frequency of change over of the adsorbers will be dependant upon the
efficiency of the treating units, ADIP and Merox.
Since molecular sieve material is very expensive, particular care should be taken
to ensure that they remain in good condition.
SEC. : 5
1.1 Process Description
The molecular sieve treating sections contains two units, propane and butane.
They each consist of two adsorbers with identical equipment and functions.
Configuration and operation of the two units is identical. They differ only in actual
size. The present operating conditions are shown in brackets.
a. Regeneration Gas Supply
In addition to all the other common features the adsorbers also share a
common regeneration gas heater F-1301.
Gas from the HP fuel gas system passes through the Adip gas treating unit at
21.0 barg and at approximately 11,000 kg/hr and 30°C.
The temperature increases over C-1305, in the ADIP gas treating unit, to 43°C.
The gas passes through the Gas Drying Unit S-1305 to remove moisture.
The gas is then heated in the regeneration gas furnace F-1301 to 316°C
(310°C).
The gas is then supplied as required to the regeneration cycles of either the
propane molecular sieve C-1307A/B or the butane molecular sieve C-1308A/B.
b. Operating pressures
The operating pressure of the molecular sieves during the adsorption cycle is
determined by the back pressure controllers in the product rundown lines to
storage and the differential pressure controllers on the product lines
immediately downstream of the sieve beds.
The back pressure controllers are 13-PIC-53 for propane and 13-PIC-54 for
butane.
The differential pressure controllers are 13-PDRC-25 for propane and

13-PDRC-31 for butane.
The PDRC’s will not open until the pressure in the bed is 1.7 barg above the
pressure in the product rundown line.
c. Adsorbing/Regeneration Cycles
Information applies to both systems based on 8 hour cycle.
However with current operation after installation of Merox Unit, space capacity is
available in the beds and cycle length of 4-5 days is achieved.
SEC. : 5
1) Liquid adsorption 8 hours Downflow

Regeneration total 8 hours
2) Bed displacement 27 minutes Downflow product
3) Bottom head 7 minutes Downflow displacement

to flare through product-recovery
system. (V-1351/1352)
4) Regeneration heating 5 hours Upflow
5) Regeneration gas 77 minutes Upflow

purge to flare
6) Cooling and vessel fill 11 minutes Upflow
7) Idle time 54 minutes
The gas is vented through product recovery system while filling the absorbers
vessel.
To avoid overlap of the heating periods for butane and propane sieves, the two
cycles are displaced by a 4 hour period.
In addition, a half hour interval between the required operation of the heater allows
for some variation in the relative times between the two cycles.
1) At the end of the adsorbing period of 8 hours the valves for the units are
repositioned to place the regenerated adsorber on line.
2) To start the displacement of product from the spent adsorber, sweetened and
dehydrated gas is admitted to the top of the bed.
Product is displaced from the free void volume in the bed into the main product
outlet line.
The flow of gas is controlled by a variable orifice set to extend the

displacement of product over a 27 minute period.
SEC. : 5
3) There is a differential pressure cell at the base of the adsorber that detects the
level of liquid within the bed.
When the level has reached the bottom tangent line of the adsorption column
the cell will be set to reposition the valve to displace the liquid product
remaining in the bottom to the flare system through product recovery system
and starts the interval timer controlling displacement to flare.
When the timer (7 minutes) runs out, the adsorber is shut in until the sequence
control repositions the valves to the heating position.
4) Regeneration gas is taken from the regeneration gas heater at 316°C (310°C)
and passed into the base of the absorber. It exchanges heat with the
adsorbent, vaporizing adsorbed product and contaminants from the bed.
The gas plus de-adsorbed material from the bed is routed through an air cooler
to the fuel system through a back pressure regulator.
SEC. : 5
5) At the end of the 5 hour period the sequence control will reposition the valves
for the purge step and start the purge interval timer.
During purge, clean product is admitted to the base of the adsorber with the
flow limited through a hand valve. It is vaporized by the hot molsieve bed and
the vapours displace regeneration gas out of the absorber through the air-in
cooler to the LP flare through product recovery system. 77 minutes have been
set for this step to keep the flow requirements low enough to prevent lifting of
the bed.
Product vapours generated by the purge liquid are about twice the total void
volume in the absorber.
When the purge interval time runs out, the valves are positioned for the cooling
and filling step.
6) Clean product passing through a larger hand valve enters the bed. As the
liquid rises, heat is transferred from the bed vaporizing the product.
Vaporized product leaves the adsorber and passes to the air cooler where it is
condensed.
After condensation it is returned to the main product line going to the product
cooling units.
Rates are specified that will cool the bed and refill it with liquid product in about
11 minutes.
SEC. : 5
7) At the end of this time the sequence control will reposition the valves to
block in the bed to stand idle for 54 minutes before starting the adsorption
cycle.
This 54 minutes idle time is available for remedial action in the event of a
malfunction.
8) Flow rates for the various streams for each regeneration step are given in
the stream property tables.
These rates should be used as a guide for the initial settings on the various
hand valves and flow controls in the units.
The product recovery system consisting of V-1351/V-1352 has been added

as a modification by QP to avoid loss of product (propane or butane) during
liquid displacement form molsieves and purge/filling of molsieves beds.
The recovered product (propane or butane) contains dissolved gas is
vented form V-1351/V-1352 respectively to the flare and the recovered
product is routed to the respective columns in the fractionation unit.
Combustion protection of the regeneration heater is based on one large

pilot (approx. 50% of a main burner) for the main burner. The pilot is
individually observed by a flame detector.
d) Regeneration
Information applies to both system.
1) Fuel gas is dried to a dew point of -18°C (80 ppm vol) in the gas dryer
S-1305, before passing to the regeneration gas heater.
S-1305 is a two tower fixed bed dryer, one tower drying and the other
regenerating or on standby, employing a high capacity alumina desiccant
(A 2-5).
The dryer is a fully automated unit, (see the Delair book for detailed
instructions).
2) The operating pressure of the propane and butane molecular sieves during
the regeneration step is determined by the back pressure controllers
13-PICA-23 (set at 18.0 barg) and 13-PICA-29 (set at 5.5 barg)
respectively.
The temperature of the gas from the regeneration gas heater,F-1301, is

held at 316°C (310°C) by 13-TRCA-12, mounted in the heater outlet, which
acts to reset the fired heater fuel gas pressure controller, 13-PIC-126.
SEC. : 5
3) During the automatic regeneration of a molecular sieve, the sequence and

phase through which the sieve is passing is indicated by an illuminated
status light on the panel display. In the transition from one phase to
another both status lights of the relevant phases are illuminated.
4) In the butane molecular sieves, 13-PIC-58 and 13-PIC-59 have been

added to prevent over pressurization of the system on introduction of
regeneration gas to avoid opening of relief valves.
SEC. : 5
e) Product Separators
Displacement of product from the spent molecular sieve absorbers is carried

out using sweet dry gas. This stream is first routed to liquid product through
regeneration cooler. Subsequently on detection of low low level. In adsorber,
the displacement stream from regeneration cooler was originally designed to
go to flare / burn pit. This resulted in product loss.
Similarly during filling stage also the excess liquid product which may come
from absorbers was also going to flare/burnpit.
In order to reduce hydrocarbon liquid losses, product recovery unit is added.
Propane Separator
Propane stream from molsieves after cooling in regeneration fin fan cooler
E-1314 A/B is diverted to propane separator V-1351, where liquid is retained
and gas is sent to flare system.
Recovered liquid is recycled back to depropaniser column C-1302 under flow

control cascaded with separator level control. Flow is by pressure difference
available between separator arid depropaniser. Offspec propane produced
during start-up is manually diverted to depropaniser for recovery.
Butane Separator
Butane stream from molsieves after cooling in regeneration fin fan cooler
E-1315 diverted to the butane separator V-1352, where liquid is retained and
vapours are routed to flare system.
Liquid from separator is sent back to debutaniser column C-1303 by butane

transfer pump P-1352 A/B under flow control reset by separator level. Bypass
facility is also kept for butane transfer pumps P-1352A/B which can be used
depending as per process requirement.
SEC. : 5
1.2 Operating Variables and Process Controls
a. Master Cycling Timer
The regeneration and changeover sequences are initiated and synchronized

by a master clock.
Operation of the molecular sieve units consist of the step wise programme as
detailed in drawings NG-1070/0 for propane and NG-1069/0 for butane.
This is initiated by the master cycling timer which keeps the proper order of
sequences and required time spacing between the two cycles.
The following features are in the design
1. Regeneration
a) Once initiated this is normally fully automatic. As the sequence goes

through each phase, the appropriate status light is illuminated on a
panel display.
During transition from one step to the next, both status lights of the
relevant steps are illuminated.
b) The valves used are tight shut off. Valve actuators are
of the double acting piston type. On air failure they maintain the existing
position ‘STAY PUT’.
c) During the displacement step, molecular sieve product valves Nos. 7 or

8 for propane and Nos. 27 or 28 for butane, fail closed.
d) Permanent interlocks are provided to prevent opening of product valves

Nos. 7 or 8 for propane and Nos. 27 or 28 for butane, on low-level.
e) Permanent interlocks are also provided on valves Nos. 1 or 2 for

propane and Nos. 21 or 22 butane unless the high level function is for
satisfied.(bed is full of product).
The valves will remain closed.
f) The system has semi automatic panel operation and manual local
operation.
SEC. : 5
2. Sequences, trips and stoppage notes
Reference should be made to logic timer.
a) Displacement to product will stop when;
1. 13-LE-53/57-L for C-1307A/B and 13-LE-61/65-L

for C-1308A/B reach 50% (0.6 barg signal).
2. There is a default in the program, if program stops or a valve does

not go fully to the open/close position required as per the sequence.
3. 13-LE-54/58-LL for C-1307A/B and 13-LE-62/66-LL for C-1308A/B

if levels are on low low.
b) Program stops at end of cooling and filling steps, if 13-LE-52/56-H for

C-1307A/B and 13- LE-60/64-H have not been reached.
c) Regeneration timer will start on receipt of signal - FURNACE ON from

F-1301 and signal regeneration temperature reached from 13-TRCA-12
to commence regeneration time in conjunction with regeneration flow.
d) ‘VALVE CLOSED’ lamps stay illuminated until valve is closed. ‘VALVE

OPENED’ lamp to stay illuminated until the valve is open. Both lamps
will be illuminated when valves are in intermediate position.
e) If one bed of molecular sieves is out of service, the

master timer must be overridden to allow automatic operation of the
next sequence.
3. Alarm and system malfunction
They are primarily - with a common fault alarm for each unit - as follows
a) Master timer to initiate liquid adsorption- unit not idling.
b) Displacement period has elapsed level has not actuated valves.
c) Filling and cooling time elapsed level has not actuated valves.
d) To start heating - furnace in service for other unit.

SEC. : 5
b) Instruments and functions for C-1307A/B
TAG NO. FUNCTION PHASE

13-XV-1 INLET C-1307A C3 LIQUID
13-XV-2 INLET C-1307B C3 LIQUID
13-XV-3 TO E-1314 REGEN. GAS/ C3 VAPOUR
13-XV-4 TO E-1314 REGEN. GAS/ C3 VAPOUR
13-XV-5 TO C-1307A REGEN GAS IN
13-XV-6 TO C-1307B REGEN GAS IN
13-XV-7 OUTLET C-1307A C3 LIQUID
13-XV-8 OUTLET C-1307B C3 LIQUID
13-XV-9 TO C-1307A/B DISPLACING GAS
13-XV-10 TO C-1307A/B COOLING C3 LIQUID
13-XV-11 TO C-1307A/B REGEN GAS
13-XV-12 TO C-1307A/B PURGE C3 LIQUID
13-XV-13 INLET E-1314 C3 LIQUID
13-XV-14 INLET E-1314 (EX C-1307A/B) FUEL GAS C3 VAPOUR
13-XV-15 OUTLET E-1314 (TO C3 LINE) C3 LIQUID
13-XV-16 OUTLET E-1314 (TO C3 LINE) FUEL GAS
13-XV-17 OUTLET E-1314 (TO FLARE) FUEL GAS/C3 LIQUID/C3
VAPOUR
TAG No. FUNCTION

13-HC-13 Depressurization C-1307A to LP Flare
13-HC-14 Depressurization C-1307B to LP Flare
13-LI-51/55 Differential pressure cell over C-1307A/B
13-LE-52/56 Top levels C-1307A/B
13-TR-8-5/6 Bed temperature C-1307A/B middle
13-LE-53/57 Low level C-1307A/B
13-LE-54/58 Low low level C-1307A/B
13-TR-8-2/4 Bed bottom temperature
13-TR-8-1/3 Bed top temperature
13-PI-55/56 Bed outlet pressure
13-TR-26 Temperature outlet of E-1314 regen. Cooler
13-PI-27 Pressure outlet of E-1314 regen. Cooler
SEC. : 5
13-PICAL-23-1/2 Split range control.
13-PICAL-23-1 in conjunction with 13-XV-16 during heating cycle allows ‘regen.’ gas
to flow to LP fuel gas.
13-PICAL-23-2 in conjunction with 13-XV-17 during displacement/purging/cooling,

allows fuel gas C3 vapour to flow to LP Flare.
Low alarm signal to control room on 16.0 barg(13-PICAL-23).
Both valves have bypass valves.
13-XFV-53 Variable orifice flow valve to control rate of product during cooling and
filling in conjunction with opening of 13-XV-10.
13-XFV-54 Variable orifice flow valve to control displacement flow to rundown

and then to flare via E-1314 A/B.
13-XFV-55 Variable orifice flow valve to control purge rate in conjunction with
13-XV-12.
13-PDRC-25 Controls the differential pressure over the bed. It will control the
pressure of the bed at 1.5 barg higher than the pressure of the
product rundown line.
13-QR-25 Records H2S in propane to storage.
13-PI-28 indicates pressure from C-1307A/B at 19.5 barg
13-PR-28 records pressure from C-1307A/B at 19.5 barg
13-TR-27 records temperature from C-1307A/B at 29°C
13-TA-13 alarms on high temperature from C-1307 A/B of 50C
17-PI-006 indicates propane pressure from Merox at 20.3 barg.
17-TI-014 indicates propane temperature to Merox at 28.4°C.
17-FR-021 indicates propane flow to Merox at 34561 kg/hr (54167 kg/hr).
13-RV-50/51 Protects C-1307A/B from over pressure. Set at 29.0 barg.
13-HC-17 Regulates set point to 13-FIC-30.
Will set the amount of flow of regeneration gas from F-1301.
The valve will only open on a signal from dryer logic via solenoid
13-X-54 and will close on completion of regeneration.
SEC. : 5
c) Instruments and functions for C-1308A/B
TAG NO FUNCTION PHASE
13-XV-21 INLET C-1308A C4 LIQUID
13-XV-22 INLET C-1308B C4 LIQUID
13-XV-23 TO E-1315 REGEN. GAS/C4 VAPOUR
13-XV-24 TO E-1315 REGEN. GAS/C4 VAPOUR
13-XV-25 TO C-1308A REGEN. GAS IN
13-XV-26 TO C-1308B REGEN. GAS IN
13-XV-27 OUTLET C-1308A C4 LIQUID
13-XV-28 OUTLET C-1308B C4 LIQUID
13-XV-29 TO C-1308A/B DISPLACING GAS
13-XV-30 TO C-1308A/B COOLING C4 LIQUID
13-XV-31 TO C-1308A/B REGEN. GAS
13-XV-32 TO C-1308A/B PURGE C4 LIQUID
13-XV-33 INLET E-1315 C4 LIQUID
13-XV-34 INLET E-1315
(EX C-1308A/B) FUEL GAS/C4 VAPOUR
13-XV-35 OUTLET E-1315
(TO C4 CLINE) C4 LIQUID
13-XV-36 OUTLET E-1315
(TO FUEL GAS) FUEL GAS
13-XV-37 OUTLET E-1315 FUEL GAS/C4 LIQUID/C4

(TO FLARE) VAPOUR
SEC. : 5
TAG NO FUNCTION
13-HC-15 Depressurization C-1308A to LP Flare
13-HC-16 Depressurization C-1308B to LP Flare
13-LI-59/63 Differential pressure cell over C-1308A/B
13-LE-60/64 Top levels C-1308A/B
13-TR-9-5/6 Bed Temperature C-1308A/B
13-LE-61/65 Low Level C-1308A/B
13-LE-62/66 Low low level C-1308A/B
13-TR-9-1/3 Bed bottom temperature
13-TR-9-2/4 Bed top temperature
13-PI-58/59 Bed outlet pressure
13-TR-24 Bed temperature
13-PI-29 Pressure outlet of E-1315 regen. Cooler
13-PICAL-29-1/2 Split range control.
13-PICAL-29-1 in conjunction with 13-XV-36 during heating cycle allows ‘regen’

gas to flow to LP fuel gas.
13-PICAL-29-2 in conjunction with13-XV-37during displacement/ purging/

cooling, allows fuel gas/C4 liquid/C4 vapour to flow to LP Flare.
Low alarm signal to control room on 3.5 barg.
Both valves have bypass vales.
13-XFV-56 Variable orifice flow valve to control rate of product during

cooling and filling in conjunction with opening of 13-XV-30.
13-XFV-57 Variable orifice flow valve to control displacement flow to

rundown and then to LP flare via E-1315.
13-XV-58 Variable orifice flow valve to control purge rate in conjunction

with 13-XV-32.
SEC. : 5
13-PDRC-31 Controls the differential pressure over the bed. It will control the
pressure of the bed at 1.7 barg higher than the pressure of the
product rundown line.
13-PI-44 indicates pressure from C-1308A/B at 7.0 barg
13-PR-33 records pressure from C-1308A/B at 7.0 barg
13-TR-25 records temperature from C-1308A/B at 22°C
13-TA-14 alarms on high temperature from C-1308A/B at 50°C
17-PI-012 indicates butane pressure from Merox Unit at 7.3 barg
17-TI-018 indicates butane temperature to Merox Unit at 25 °C
17-FRC-011/013 indicates butane flow to Merox Unit at 24933 kg/hr (39580 kg/hr).
13-PIC-58/59 On top of C-1308A/B, prevents over pressurization of the system on

introduction of regeneration gas to avoid the opening (lifting) of
relief valves 13-RV-52/53. They are set at 13.8 barg.
13-RV-52/53 Protects C-1308A/B from over pressure. Set at 13.79 barg.
13-HIC-20 Regulates set point to 13-FIC-32.
Will set the amount of flow for regeneration of regeneration gas

from F-1301.
The valve will only open on a signal from the dryer logic via
solenoid 13-X-55 and will close on completion of regeneration.
d) Regeneration Gas Furnace F-1301
F-1301 is a small, vertical, petrochem, natural draught furnace manufactured by

J.G.C.
Design temperature is based on 40°C inlet and 329°C outlet. The normal operating
outlet temperature is 316C (310C).
Design pressure is based on 21.0 barg. The normal operating pressure is 19.0
barg.
Normal flow on regeneration is 8532 kg/hr.
Temperature of flue gas outlet is 800°C.
Number of coils 1
Number of tubes 22
Burner - John Zink - PVYD22 1

SEC. : 5
Located in furnace floor.
Supplemented by a single tube pilot burner. Facility for inserting a mobile ignition
unit.
LOGIC CIRCUIT COMPRISES
Ignition burner for pilot burner permissive
Common safeguarding circuit with trip inputs
Start stop pilot burner circuit.
High temperature and burner on, signal to 10-PR-1 and 10-PR-2 to continue.
THE FOLLOWING INSTRUMENTS
13-XE-176 Pilot burner cock ‘CLOSED’
13-X-180 Tight shut off valve to pilot.
13-PIC-130 Supply to pilot
13-XEA-179 Flame detection ignition burner
13-PEA-128H Permissive signal to pilot closes 13-X-180, 2.0 barg
13-XA-175 Pilot vent not closed
13-X-195 Main fuel gas supply tripped by common safeguard reset.
13-PEA-027L Low pressure signal to burners closes 13-X-195, 0.6 barg.
13-XE-113 Tight shut off valve, 13-X-194, reset to 2.5 barg
13-PIC-126 Pressure Control to main burner, 0.4 barg.
13-PEA-127H High pressure signal closes 13-X-194, 1.2 barg.
13-XE-181C Burner cock closed.
13-PA-129H High Pressure between valves, 2.0 barg.
13-TRCA-12HL To 13-PIC-126 (ARWU) High-330 Low -300 °C
13-XI-120 Limit switch on damper Full open

SEC. : 5
13-FEA-31 Low flow of regen. Gas to F-1301. 27.5t/d closes 13-X-194.
13-TEA-11HH To heater relay Closes 13-X-195.
13-X-119 Low select relay from either 13-HC-122 or from 13-TRCA-12
to 13-PIC-126
13-HC-122 Regulates set point for 13-PIC-126, 0.4 barg
13-HI-120 Test override switch
13-HE-115 Emergency shutdown-Control Room
13-HE-119 Emergency Shutdown – Local
13-XEA-173 Pilot burner common alarm
13-H-12 Mechanical adjustment of Stack damper

SEC. : 5
e) Product Separators
During displacement of product from the spent molecular Sieve absorbers using
sweet dry gas, this stream is first routed to liquid product through regeneration
cooler. Subsequently on detection of low low level in adsorber the displacement
stream from regeneration cooler was originally designed to go to flare/burn pit.
This resulted in product loss.
Similarly during filling stage also the excess liquid product which may come from
absorbers was also going to flare/burn pit.
In order to reduce hydrocarbon liquid losses, facilities had subsequently been

added for product recovery from these streams.
Propane Separator
Propane stream from absorbers after cooling in regeneration cooler E-1314 A/B is
diverted to propane separator V-1351 where liquid is retained and gas is sent to
flare system. Recovered liquid is recycled back to depropaniser C-1302 under flow
control cascaded with separator level control. Flow is by pressure difference
available between separator and depropaniser. Offspec propane produced during
start-up is manually diverted to depropaniser for recovery.
13-LICA-700 controls the level in the separator by regulating set point to

13-FIC-700 which controls 13-FIC-700. The controller gives alarm on high and low
levels.
13-LEA-700 will alarm on low low level in separator and close separator outlet
SDV 13-XV-701. This will avoid gas passing to depropaniser.
13-LEA-701 will alarm on high high level and stop flow to separator by closing
13-XV-701 and open bypass valve 13-XV-702 diverting flow directly to flare
system.
13-LG-700 locally indicates level in the separator.
13-TG-700 locally indicates temperature.
13-PG-700 indicates pressure in vessel.
13-LG-701 indicates level in the vessel boot.
V-1351 is protected by 13-PSV-700 A set at 24.0 barg and relieving to LP flare.

SEC. : 5
Butane separator
Butane stream from molsieve bed after cooling in regeneration cooler E-1315 is
diverted to butane separator V-1352, where liquid is retained and gas is sent to
flare system. Recovered liquid is recycled back to debutaniser C-1303. Offspec
butane produced during start-up is manually diverted to debutaniser for recovery.
13-LICA-702 controls the level in the separator by regulating set point to

13-FIC-701 which controls 13-FCV-701. The controller gives alarm on high and
low levels.
13-LEA-702 will alarm on low low level in separator and close separator outlet
valve 13-XV-703 as well as trip the butane transfer pump P-1352 A/B.
13-LEA-703 will alarm on high high level and stop flow to separator by closing
13-XV-704 and open bypass valve 13-XV-705 diverting flow directly to flare
system.
13-LG-703 locally indicates level in the separator and 13-TG-701 locally indicates
temperature.
13-PG-701 indicates pressure in vessel.
13-LG-702 indicates level in the vessel boot.
Vessel is protected by 13-PSV-701A set at 13 barg and relieving to LP flare.
Molecular Sieve Units Modifications

Both propane and butane Molecular Sieves operate in the same way. In each set,
one Molecular Sieve is on line (adsorbing) while the other is on regeneration or
idling (standby after regeneration).
The regeneration cycle has been modified since it’s original installation, to recover
product which is displaced from the molecular sieve immediately prior to
regeneration of that adsorber.
This modification has not been integrated into the existing sequence and therefore
the regeneration/recovery cycle requires operator intervention to successfully
operate.
The existing sequence is based on a mechanical cam type sequencer. The valves
included with the product recovery upgrade are not included in the overall logic,
(eg. Valves 13-XV-702, 13-XV-701 for propane and 13-XV-704, 13-XV-705 for
butane).
Manual intervention is required on the pressure control of vessels V-1351

(Propane Recovery) and V-1352 (Butane Recovery), to displace product to the
respective columns.
SEC. : 5
SEC. : 5
6.1 ALARM & TRIP SETTINGS
TAG NO. EQUIPMENT ALARM TRIPS

SETTING
13-LEH-52 TOP LEVEL C-1307A PROPANE 41% STOPS SYSTEM
MOL. SIEVE
13-LEH-56 TOP LEVEL C-1307B PROPANE 41% STOPS SYSTEM
MOL. SIEVE
13-LEL-53 LOWER LEVEL C-1307A 50% STOPS SYSTEM
PROPANE MOL. SIEVE
13-LEL-57 LOWER LEVEL C-1307B 50% STOPS SYSTEM
PROPANE MOL. SIEVE
13-LELL-54 BOTTOM LEVEL C-1307A 82% STOPS SYSTEM
PROPANE MOL. SIEVE
13-LELL-58 BOTTOM LEVEL C-1307B 82% STOPS SYSTEM
PROPANE MOL. SIEVE
13-LEH-60 TOP LEVEL C-1308A BUTANE 41% STOPS SYSTEM
MOL. SIEVE
13-LEH-64 TOP LEVEL C-1308B BUTANE 41% STOPS SYSTEM
MOL. SIEVE
13-LEL-61 LOWER LEVEL C-1308A BUTANE 50% STOPS SYSTEM
MOL. SIEVE
13-LEL-65 LOWER LEVEL C-1308B BUTANE 50% STOPS SYSTEM
MOL. SIEVE
13-LELL-62 BOTTOM LEVEL C-1308A 82% STOPS SYSTEM
BUTANE MOL. SIEVE
13-LELL-66 BOTTOM LEVEL C-1308B 82% STOPS SYSTEM
BUTANE MOL. SIEVE
13-LEA-105HH V-1320 LP FUEL GAS 50% FURNACE
HEATER RELAY
13-LA-106H V-1320 LP FUEL GAS 20% N/A
13-FEA-31L LOW REGENERATION GAS TO 27.44 t/d FURNACE
F-1301
13-TRCA-12H F-1301 OUTLET TEMPERATURE 330°C N/A
13-TEA-11HH F-1301 OUTLET TEMPERATURE 350°C FURNACE
HEATER RELAY
13-TRCA-12L F-1301 OUTLET TEMPERATURE 300°C N/A
13-TA-13H LIQUID PROPANE EX. V-1307 50°C N/A
A/B
13-TA-14H LIQUID BUTANE EX. V-1308 A/B 50°C N/A
13-PICA-23L LIQ. PROPANE EX.V-1307 A/B TO 16 barg N/A
LP FLARE
13-PICA-29L LIQ. BUTANE EX. V-1308 A/B TO 3.5 barg N/A
LP FLARE FUEL GAS
13-PEA-27L FUEL GAS TO F-1301 3.0 barg TRIP FUEL.GAS
TO FURNACE
13-PEA-127H FUEL GAS TO F-1301 TO MAIN 1.2 barg TRIP MAIN.
BURNER BURNER F-1301
SEC. : 5
TAG NO. EQUIPMENT ALARM TRIPS

SETTING
13-PEA-128H F. GAS TO F-1301 TO PILOT 2.0 barg CLOSE X-180 TO
PILOT & TRIP
FURNACE
13-PA-129H F. GAS TO F-1301 BURNER 2.0 barg ALARM
13-LEA 700LL V-1351 SEPARATOR LEVEL CLOSE XV-700
13-LEA-701HH V-1351 SEPARATOR LEVEL CLOSE XV-701
OPEN XV-702
13-LICA-700H V-1351 SEPARATOR LEVEL ALARM
13-LICA-700L V-1351 SEPARATOR LEVEL ALARM
13-LEA-702LL V-1352 SEPARATOR LEVEL CLOSE XV-703 &
TRIP P-1352
13-LEA-703HH V-1352 SEPARATOR LEVEL CLOSE XV-704
OPEN XV-705
13-LICA-701H V-1352 SEPARATOR LEVEL ALARM
13-LICA-701L V-1352 SEPARATOR LEVEL ALARM
6.2 EQUIPMENT LIST
TAG NO. SERVICE

C-1307 A PROPANE MOL. SIEVE ADSORBER
C-1307 B PROPANE MOL. SIEVE ADSORBER
C-1308 A BUTANE MOL. SIEVE ADSORBER
C-1308 B BUTANE MOL. SIEVE ADSORBER
E-1314 A/B PROPANE MOL. SIEVE REGENERATION COOLER (AIR FIN FAN)
E-1315 BUTANE MOL. SIEVE REGENERATION COOLER (AIR FIN FAN)
F-1301 MOL. SIEVE REGENERATION HEATER
V-1351 PROPANE SEPARATOR
V-1352 BUTANE SEPARATOR
P-1352 A/B BUTANE TRANSFER PUMPS
6.3 RELIEF VALVES
TAG NO. EQUIPMENT RELIEF TO SET NORMAL

PRESSU OPERATING
RE Barg PRESSURE
13-RV-50 PROPANE FROM C-1307 A LP FLARE 29.0 19.5 barg
13-RV-51 PROPANE FROM C-1307 B LP FLARE 29.0 19.5 barg
13-RV-52 BUTANE FROM C-1308 A LP FLARE 13.8 7.0 barg
13-RV-53 BUTANE FROM C-1308 B LP FLARE 13.8 7.0 barg
13-RV-55 F-1301 INLET LP FLARE 25.5 18.0 barg
SEC. : 5
13-PSV-700A PROPANE FROM V-1351 LP FLARE 24. 0 18.0 barg

13-PSV-701A BUTANE FROM V-1352 LP FLARE 13.0 7.0 barg
6.4 EMERGENCY VALVES
TAG NO. EQUIPMENT ACTUATED BY ACTION

13-X-195 FUEL GAS SUPPLY T.S.O. MAIN FUEL GAS CLOSE
VALVE SUPPLY
13-X-194 MAIN BURNER FUEL GAS START / STOP OPEN/CLOSE
SUPPLY T.S.O VALVE MAIN BURNER
FUEL GAS SUPPLY
13-X-180 PILOT BURNER FUEL GAS START /STOP OPEN/CLOSE
SUPPLY T.S.O VALVE PILOT BURNER
FUEL GAS SUPPLY
13-XV-700 PROPANE FROM V-1351 LEA-700LL CLOSE
13-XV-701 PROPANE TO V-1351 LEA-701HH CLOSE
13-XV-702 PROPANE SEPARATOR LEA-701HH OPEN
BY-PASS
13-XV-703 BUTANE FROM V-1352 LEA-702LL CLOSE
13-XV-704 BUTANE TO V-1352 LEA-703HH CLOSE
13-XV-705 BUTANE SEPARATOR BY LEA-703HH OPEN
PASS
SEC. : 5
6.5 PRESSURE CONTROL VALVES
TAG NO. EQUIPMENT ACTING ON BODY C/R ACTION

SIZE ALARM ON AIR
FAIL.
13-PICA-23/1L OUTLET OF E-1314 PICA-23 SPLIT 3” L CLOSE
A/B REGN. COOLER RANGE
A/B REGN. COOLER RANGE
13-PDRC-25 OUTLET OF C-1307 PDRC-25 3” -- OPEN
A/B TO PRODUCT
LINE
REGN. COOLER RANGE
REGN. COOLER RANGE
13-PIC-58 C-1308A TOP PIC-58 6” -- CLOSE
OUTLET
13-PIC-59 C-1308B TOP PIC-59 6” -- CLOSE
OUTLET
13-PDRC-31 OUTLET OF C-1308 PDRC-31 3” -- OPEN
A/B TO PRODUCT
LINE
13-PIC-126 F. GAS TO MAIN PIC-126 1” -- CLOSE
BURNER
F-1301
13-PIC-130 F. GAS TO PILOT PIC-130 1” -- CLOSE
BURNER F-1301
6.6 FLOW CONTROL VALVES
TAG NO. EQUIPMENT ACTING ON BODY C./R ACTION

SIZE ALAR ON AIR
M FAIL.
13-FIC-30 REGN.GAS TO FIC-30 6” CLOSE
C-1307A/B
13-FIC-32 REGN.GAS TO FIC-32 3” CLOSE
C-1308A/B
13-FIC-700 PROPANE FROM LICA-700 1” CLOSE
V-1351
13- FIC-701 BUTANE FROM LICA-701 1” CLOSE
V-1352
SEC. : 5
6.7 LEVEL CONTROL VALVES
TAG NO. EQUIPMENT ACTING ON BODY C.R ACTION

SIZE ALAR ON AIR
M FAIL.
13-LICA-700 PROPANE FCV-700 1” H/L CLOSE
SEPARATOR V-1351
13-LICA-701 BUTANE FCV-701 1” H/L CLOSE
SEPARATOR V-1352
SEC. : 5
2. PREPARATION FOR START-UP
The commissioning of a new plant, section of plant or a modified system

requires essential, detailed and organized procedures, tasks and activities.
Reference should be made to section 1 of this volume of the manual for a

comprehensive explanation of guidelines to Precommissioning.
This section outlines the relevant points of attention for the molecular sieve
adsorber section
a) A full detailed check of all equipment for details of installation in

accordance With the piping and instrument diagrams (P&IDs) must be
made.
This must be checked and checked again. a list of faults, no matter how
small or insignificant the, may seem, must be made. The faults must be
corrected, then removed from the list. This is sometimes referred to as a
‘Punch’ list i.e. “This section is checked ‘PUNCHED OUT’ !”.
b) Flushing, cleaning, drying, filling etc. should be carried out in ,a controlled

and organized manner.
Spare sets of P&IDs may be used for this purpose. As each section is
completed it can be marked off on the P&ID. Sections should not be
missed out if done in this manner.
During water flushing a constant check must be made for dirt, scale and oil.
Ensure that all drains and vents are capped.
c) Plant line up must be thoroughly checked and equipment checked for

correct installment. Check that all instrumentation has been commissioned
externally and in the control room. Ensure all instrument tapping are open.
d) Ensure that the vessels containing molecular sieves have been filled to the
proper levels etc. This should be an operational duty to supervise the
filling, etc. and check levels prior to ‘boxing up’.
SEC. : 5
e) 1. Ensure that all safety procedures are carried out.
2. Ensure that all fire fighting and safety equipments are available and in
there proper locations.
3. Ensure that all debris and unnecessary equipments are removed.
4. Check relief valve installation, ensuring that all block valves on duty
relief valves are CAR SEAL OPEN.
5. Verify fire and gas detection systems.

SEC. : 5
f) 1. Ensure that the power supply is available to all equipments.
2. Check air fans.
3. Check analyzer systems.
g) 1. Check flare knock out drums and fuel gas.
2. Check furnace as listed in furnace start-up.
3. Check that all accessories are available.
If molecular sieve adsorbers have to be loaded the following is an outline of

procedure. The procedure and systems for loading should be described
and followed :
1. Safety items and protective clothing for loading team should be

available. They should include dust masks, safety helmets, special
shoes, safety harness etc.
2. Correct type of molecular sieves should be collected and clearly

identified to avoid any confusion between propane and butane
systems.
3. Only one system at a time should be loaded.
4. Weights and amounts of molecular sieves should be recorded and

records retained.
5. The internals, grids, trays, wire mesh, level tapping etc. should be
checked for correct installation.
6. Entry permits should be obtained and all safety rules strictly adhered to.
7. Correct types and sizes of ceramic balls should be available.
8. Sieves should be loaded slowly in order to avoid sintering (breaking).
9. Cranes, loading chutes and weighing scales will be required.
10. When loading, ensure that level of pellets is uniform.
11. Floating screen should be installed correctly and inspected.
12. When replacing manways use new gaskets.
13. Pressure test with nitrogen.
14. Programmer and logic should be checked by instrument department.

SEC. : 5
15. After filling, pressurizing with air and depressurising, purge all lines and
systems with nitrogen.
16. Ensure that line up is correct for normal use except that system should
be isolated from product rundowns and Merox Unit.
17. Commission fuel gas from fuel gas system and commence tightness
test in steps .
3 barg - 7 barg - 12 barg - 13 barg for propane 3 barg - 5 barg - 10 barg

for butane.
18. Return pressure to 5 barg throughout by slowly relieving to fuel gas.
19. Line up system for normal regeneration.
In progression C-1307A, when complete C-1308A then C-1307A and

finally C-1308B.
20. Commission F-1301 as normal start-up.
21. Programmer may have to be advanced on manual.
22. Regenerate each bed twice as in the above sequence.
23. It should be realized that this will have to be carried out well in advance
of anticipated feed from the Merox Unit as each step will take time.
24. The pilot can be retained in F-1301.
25. Thoroughly check system to ensure that all valves are in their
correct positions.
26. Maintain a constant watch for any pressure drop.
27. If any of the sequential valves have to be placed in the hand wheel
position, care must be taken to ensure that it is done correctly.
28. Variable orifice flow valves should be returned to a position for normal
operation.
29. Electrical tracing on fuel gas lines should be checked.
30. All safety equipment should be checked.
31. Fire and gas detection systems should be verified.
32. Relief valves and Car Seals should be checked.
33. Finally ensure that there are no unwanted items like drums etc.
remaining on site.
SEC. : 5
3. START-UP -- MOLECULAR SIEVES
3.1 Propane Molecular Sieves
When the ADIP treating section has been commissioned and the
charcoal filters are taken into operation the propane molecular sieves
should be started up in the following sequence
a) Put panel/local switch 13-H-40-1 to “Local” and override master

timer
b) Close the following valves :

XV-9, XV-14, XV-16, XV-11, XV-15.
Close 13-PDRC-25 block valves and bypass, also main 6” inlet

valves.
c) Open the following valves :
XV-1, XV-7, XV-3, XV-4, XV-5, XV-6, XV-2, XV-8 , XV-13 , XV-17,
XV-10, XV-12.
Check: set point of 13-PIC-23. This should be set at 20.0 barg.
d) Pressure up whole system by opening XV-9. Check proper function

of 13-PIC-23.
e) Close XV-9, XV-13.
f) Open valve upstream XV-1 and XV-2 slowly.
g) Open XV-7 and XV-8.
h) Line up to burnpit and slowly fill vessels with a small flow to burn pit.
i) When the vessels are filled with propane, (observe local indicators of
13-LIE-30, 31, 34, 35).
j) Open slowly the block valve in the inlet line until fully open.
k) Line up system for normal operation.
1) Line up 13-PDRC-25.
m) The programme can now be switched to “panel” “manual advance”

by H-40-1 and H-40-2.
SEC. : 5
n) If C-1307A should be regenerated first, pushbutton H-41-2 should be

pressed in.
If C-1307B is to be regenerated first, pushbutton H-42-2 has to be

pressed.
The programme will automatically continue until the next lights

(H-41-3 or H-42-3) are on.
o) The next step can now be initiated by pressing the push-button

H-41-3 or H-42-3.
p) When satisfied that programme steps are correctly performed

switch-to “auto advance” by H-40-2 .
r) Bring the sequence of steps in line with the butane molecular sieve
programme and have master timer set to appropriate time relative to
total cycle and remove master timer override.
NOTE:
If one bed of molecular sieve absorbers is out of operation the master

timer must be overridden to allow automatic sequence operation of the
next sequence.
3.2 Butane Molecular Sieves
As soon as debutaniser top product is on specification and treated gas

is available, the butane molecular sieves have to be started-up in the
following sequence:
a) Put panel/local switch 13-H-43-1 to “Local” and override master

timer.
b) Close the following valves :

XV-29, XV-34, XV-31, XV-35, XV-36.
Close 13-PDRC-31 block valves and main product inlet valve.
c) Open the following valves :

XV-21, XV-27, XV-22, XV-28, XV-23, XV-24, X:V-25,
XV- 26, XV-33, XV-37, XV-30, XV-32.
Check set point of 13-PIC-29.
This should be set at 6.5 bang.
d) Pressure up whole system by opening XV-29.

Check proper function of 13-PIC-29.
e) Close XV-29, XV-33.

SEC. : 5
f) Open valve upstream XV-21 and XV-22 slowly.
g) Open XV-27 and XV-28.
h) Line up to burnpit and slowly fill vessels with a small flow to burn pit.
i) When the vessels are filled with propane, (observe local indicators of
13-XV-32, 33, 36, 37).
j) Open slowly the block valve in the inlet line until fully open.
k) Line up system for normal operation.
1) Line up 13-PDRC-31.
m) Switch the programme to “panel” “manual advance” by H-43-1 and

H-43-2.
n) If C-1308A has to be regenerated first, press pushbutton H-44-2.
If C-1308B has to be regenerated first press push button H-45-2.
o) Bring the sequence of steps in line with the propane molecular sieve
programme and have master timer set to appropriate time relative to
total cycle, remove master timer override.
p) When satisfied that programme steps are correctly executed switch

to “auto advance” using H-43.
NOTE:
If one bed of molecular sieve adsorbers is out of operation the master

timer must be overridden to allow automatic sequence operation of the
other pair of dryers.
SEC. : 5
SEC. : 5
3.3 START-UP OF REGENERATION FURNACE
a) Pre-Start-up Inspection
1. Check all alarm conditions are satisfied. Check; burners, paying

particular attention to guns. Check furnace generally, inside and
outside, it should be clean, and any debris and foreign matter
removed before start-up.
2. Check that furnace is properly boxed up (all access panels

closed).
3. Check that air registers, the air damper, and flaps of observation
windows are clean, lubricated, and able to move freely.
4. Check that the ignition burner is available and in a serviceable

condition. Check that the butane bottle is present and showing
the correct pressure. Check that face shields or goggles are
available.
5. Check that minimum stops have been set correctly on the air
damper and fuel gas control valves.
6. Check that all associated fire fighting facilities are present and in
useable condition.
b) Purging and final tightness testing of fuel system.
1. Check that start-up bleed line for pilots and that burner cocks for
pilots and main burners are closed.
2. Remove fuel gas blind at battery limit and open battery limit cock
valve.
3. Check that there is no visible pressure build-up downstream of

common trip TSO valve in 5 minutes.
4. Press reset push button to open common trip valve.
5. Vent at high/low points and dead ends to purge headers for

pilots and main burners of inert gas.
6. Open all manual burner cock.
7. Close off incoming fuel gas supply at supply header.
8. Check that there is no fall in pressure in furnace headers, over a

5 minute period (to confirm that individual trip valves are not
passing). Close individual burner cocks.
9. Check the operation of the safeguarding system by simulation of

the various emergency conditions, in conjunction with Instrument
Department.
SEC. : 5
c) Purging Combustion Chamber
1. When all burner cocks are closed on pilot and main burner, the
lamp ‘ready for purge’ light will be on, lights will also be on local
panel until the furnace purge is completed.
2. Open stack damper fully with burner valves closed.
3. Open the air registers manually.
4. The purge timer starts when burner cocks for all pilot and vain
burners are closed and stack damper is fully open.
5. “Ready for purge” lamp is on local panel. At the end of the 5

minutes purge, the purge completed, lamp comes on.
6. This provides a minimum purging requirement, extra precautions

in the form of a longer purge time and/or purging with inert gas
should be taken as necessary.
d) Gas Testing
Although the purge timer of the interlock system prevents any

ignition before the required purge timer has elapsed, it is essential to
perform a gas test after the signal ‘ignition torch deblocked’ has
been received. The combustion chamber atmosphere should be
checked with an explosive meter as follows:
1. in the throat of the first burner to be lit.
2. through the observation window for this burner on the furnace

platform.
3. in the outlet of the furnace cell.
Note that the term ‘gas free’ denotes that the concentration of
hydrocarbons in air is not more than 4% of the lower explosion limit
as measured by an approved and accurately calibrated explosive
meter.
If gas is found, remedial action by repurging must be taken. If the

test indicates the absence of combustible gas, proceed to light the
first pilot.
SEC. : 5
e) Open Common Trip Valve
1. The common trip valve TSO 13-X-195 can be opened when
a. The level in the fuel gas KO Drum is below the trip value.
b. The manual emergency trip switches are not activated.
c. Process conditions are satisfied.
2. Open the common trip valve by pressing the reset button. If it is

released before minimum fuel gas pressure of 2.5 barg is
reached, the common on trip valve will close again. In this event
repeat sequence.
3. Open the 1” start-up bleed line to atmosphere on the pilot burner

header to obtain the required pressure. This enables
13-PEA-128 condition to be satisfied for start-up of the pilots
(setting 1.2.barg).
4. Check that the electrical heat tracing is switched on.
f) Set air register to start-up position for pilot burner.
g) Start ignition torch
1. Insert ignition torch alongside the pilot burner, and secure. To

start the ignition sequence, the interlock system requires that:
a. the ignition torch is secured at the burner.
b. the pilot burner flame eye is not activated.
c. the common trip valve is open.
d. the ‘purge completed lamp’ is lit.
2. Press the “start ignition torch” button on the local panel. This
will :
a. admit butane to ignition torch.
b. activate the sparker for 8 seconds.
After 10 seconds the flame rod holds the propane trip valve open
if a flame is detected, otherwise it will be closed. Flame detection
by the flame rod is indicated by the local panel lamp ignition on.
SEC. : 5
3. A quick restart in the case of an unsuccessful ignition is

prevented by a timer. It is not necessary to repurge and gas test
after an unsuccessful ignition of the ignition burner, but it is
recommended that after 3 unsuccessful ignition attempts, the
system should be checked for faults before proceeding any
further.
h) Start-up of pilot burner
1. Check that fuel gas pressure on the pilot header is correct for
burner start-up i.e. 0.3 barg. Ensure that stack damper and air
registers are in correct positions for start-up.
2. Before the burner can be taken into operation, the interlock

system requires that
a. the ignition torch be in operation for at least 10 seconds, and

be placed at the burner to be lit.
b. the relevant burner cock be open.
c. the fuel gas pressure on the pilot header is not above the
high trip limit of 1.2 burg.
Adjust vent to atmosphere.
3. Open the burner cock; and press the ‘start burner’ button on the
local panel. This will:
a. open the burner trip valve for 8 seconds.
b. extinguish the ignition burner after the burner flame is

detected.
After 8 seconds the flame eye holds the burner trip valve open if
a flame is detected, otherwise it will be closed and the furnace
must be repurged (starting from step 3).
The atmospheric start-up bleed must be closed after the pilot

burner has been lit.
SEC. : 5
i) Start-up of Main Burner
With the pilot in operation, and when the furnace is warmed up, the
furnace can be placed in readiness to start the main burner.
1. Set air register in position for main burner operation and throttle
damper to about 60% open position.
2. Check that 13-PRC-126 in control roots is in automatic mode

and on ‘external set point’.
3. Set the maximum set point limited of 13-PRC-126 (13-HC-122)

at 1.0 barg (50% output). This maximum gas flow for burner
over-firing control.
4. Check the position of the minimum stop of 13-PRCV-126

(recommended to be adjusted to 10% opening) and the air
register positions.
5. Open main burner cock.
The main burner trip valve will open, admitting fuel gas to the
burners when
a. PEA-127 is less than high (0.2 barg).
b. FEA-31 is greater than minimum flow.
c. the flow through the furnace tube is above the low trip limit.
d. the gas outlet temperature is below the high trip limit.
e. the flame eye of the pilot burner registers a flame.
f. the main burner cock is not closed.
The valve is slow opening and quick closing to give a good

safeguarding function on shutdown, and to prevent the supply
pressure being placed on the burner during start-up.
6. When the main burner is in operation check if flames are all right
and adjust air register if necessary.
7. When the main burner has been lit, and the regeneration gas
temperature at the furnace outlet is above the low temperature
alarm, a signal is given to the molecular sieve programmer to
start the heating timer.
SEC. : 5
4. SHUTDOWN - MOLECULAR SIEVES
If the molecular sieves are to be stopped for a period longer than one week, the
vessels should be regenerated before the fractionation plant is stopped.
As soon as feed is stopped the molecular sieves should be bypassed and

blocked in.
Stop the automatic programme by putting switch 13-H-132/236 to ‘Local’.
Displace the liquid in the adsorbing bed to flare by adjusting the relevant local
valves.
If an adsorber is blocked in hot, immediately after regeneration, the bed should

first be cooled. down by adjusting the relevant local valves.
Then block in the vessels and depressurize via the depressurising valves
13-H-13, 14, 15, 16.
Depending on what has to be done the vessels should be purged with inert gas
and spaded off.
SEC. : 5
5. EMERGENCY SHUTDOWN
Emergency shutdown of the molecular sieve unit or any section of it would be

required in the event of a fire, major leak or a failure of power, instrument air or
cooling water to the unit.
General guide lines exist within the Emergency Shutdown Procedures (ESD) for
all the possible causes and types of shutdown.
The types of shutdown can be categorized into three different types i.e.
Emergency Shutdown - extreme emergency and may entail

shutdown from remote or control room
action.
Crash Shutdown - plant has to be shutdown very quickly and

is normally from automatic action.
Normal Shutdown - a planned shutdown done in a

programmed orderly manner.
Reference should be made to Volume 4 Section 3 of the manual and the

relevant cause and effect matrix drawings F11W-0500-01 to 21.
5.1 Depressurizing
In the event of any shutdown and consequent increase of system

pressure, such as would occur in a cooling water failure, the excess
pressure should be relieved to flare manually.
Isolation of systems, particularly levels within this system, is highly

important.
This serves to facilitate a quick restart and to enable regeneration to

recommence.
Depressurising facilities exist within the system.
13-HIC-13 - Top of C-1307A (Propane) - To LP flare.
13-HIC-14 - Top of C-1307B (Propane) - To LP flare.
13-HIC-15 - Top of C-1308A (Butane) - To LP flare.
13-HIC-16 - Top of C-1308B (Butane) - To LP flare.
13-PIC-58 - Top of C-1308A (Butane) - Set at 10.0 barg.
13-PIC-59 - Top of C-1308B (Butane) - Set at 10.0 barg.

SEC. : 5
Fuel gas to F-1301 pilot has a 1” vent line to atmosphere. This line is
used when commissioning the pilot burner.
When the valve is open an alarm sounds in Control Room (13-XA-175).
5.2 Liquid Levels
The liquid level valves in the molecular sieve beds are net recognized as
actual shutdown valves but if their functions are not correct and carried
out properly then they can cause some inconvenience by delaying or
stopping the logic timer and programmer.
a) 13-LE-52/56-H (C-1307A/B) and 13-LE-60/64-H (C- 1308 A/B) will

stop programmer if level is not above 41% of the top level leg.
b) 13-LE-53/57-L (C-1307A/B) and 13-LE-61/65-L (C- 1308A/B) will

stop programmer if level in the lower level leg falls below 50%.
c) 13-LE-54/58-LL (C-1307A/B) and 13-LE-62/66-LL (C- 1308A/B) will

stop programmer if level in the bottom level leg falls below 82%.
If the level in V-1320, LP fuel gas drum, rises above 50% it will trip
13-X-195, the fuel gas main supply valve to F-1301.
Other functions will stop the furnace or the programmer. They are
explained in the operational description.
Trip functions are listed in the section.

SEC. : 5
5.3 Shutdown Causes
a) Cooling Water Failure
The failure of cooling water on the molecular sieves has no direct

effect.
Indirectly the procedure for cooling water failure within the Merox
Units and Adip Unit will affect the molecular sieves.
b) Instrument Air Failure
Can be considered one of the main emergencies in the system since

we lose remote control facility of all valves except HIC’s which would
be supplied from the secured air system.
All the sequential valves 13-XV-1 to 13-XV-37 inclusive are ORBIT

valves.
The ORBIT valve action on air failure is to ‘STAY PUT’ i.e. they will
stay in the position they were in when the air failure occurred.
Should the valve be moving at the time of failure it would remain in

the ‘in between’ position. It would be necessary therefore to
manually operate the valve or valves to place the system in the
sequence it was at just prior to the failure. This would ensure that
when restarting, the system can be manually advanced to restart at
a safe programme step.
Care should always be taken in manual operation.
All valves in fuel gas to furnace will close including 13-X-180,

13-X-194, 13-X-195 and 13-PIC-126 which have an air facility for
slow opening.
Regeneration gas flow 13-FIC-30 and 13-FIC-32 will close but have
a bypass facility.
Depressurising valves 13-HC-14, 15, 16 fail open.
13-PIC-58 and 13-PIC-59 have a hand wheel, valves fail closed.
13-PDRC-25 and 13-PDRC-31 open on air failure.
The action of all control valves on air failure would be known by

operators. They are listed and identified by a colour code. Valves
which go to the OPEN position on air failure are painted GREEN.
Valves which go to the CLOSED position on air failure are painted
RED.
It is important that the information on sequential valves and variable

orifice valves are well known to operators and action taken
according1y.
SEC. : 5
c) Power Failure
All NGL-1 power is supplied by Sub-station SS-1600 except for the

Merox Unit, which is supplied from SS-1660 and the cooling water
pumps supplied from SS-3401.
1. If the failure is within Sub-station SS-3401 then the effect and

action will be the same as for a cooling water failure.
2. If the failure is within Sub-station SS-1600 then all pumps will

stop.
Emergency power for lighting and essential instrumentation will

be provided, by emergency diesel generator DG-101.
The unit will be shutdown.
Pressures can be controlled by venting to flare.
Draining if necessary must be done with care.
Furnace and programme will stop.
Instrument air will be provided by K-3201E, Emergency Instrument

Air Diesel Compressor.
d) Hot, oil Failure
Molecular sieves have to be bypassed and products diverted to

burnpit when off grade.
e) Fire
In the event of a serious fire the unit will have to be shutdown and
depressurized.
All fire fighting facilities and protection methods should be used.

SEC. : 5
f) Tube Burst in F-1301
1. Estimate area and severity of burst.
2. Stop gas flow - Close 13-FIC-30/32.
3. Depressurize regeneration gas dryer.
4. Bypass molecular sieve dryers.
5. Stop programmer and depressurize system.
6. Isolate furnace regeneration gas.
7. Allow gas to burn off.
8. Leave pilot on.
9. When all gas has burned off, ensure that no gas is passing to
F-1301
10. After furnace has cooled down-approximately 4 hours, isolate

fuel gas.
11. Purge furnace with Nitrogen.
12. Purge tubes with Nitrogen.
13. Purge furnace with air prior to any entry for repair etc.
SEC. : 5
5.4 Shutdown Activities
The main faults that can affect the molecular sieve dryers have been
covered.
The seriousness of the failure, other than that which affects the rest of
NGL-1, should be considered.
a) Because of the spare capacity of the molecular sieves, it may well

be possible to run both propane and butane systems for some time
before they require to be regenerated.
This decision would be taken with the Senior Supervisor.
b) If, in the case of a tube rupture, the furnace shutdown may be

prolonged, then a planned shutdown of the plant could take place.
c) In the case of air failure and power failure, the nature of the failure
and the position of the rest of the system would have to be taken into
account when making decisions.
d) If shutdown of the molecular sieves is prolonged, a check must be

made to ensure that all systems are isolated in a safe manner.
SEC. : 5
P&IDs DRAWINGS FOR MOLECULAR SIEVES
VOLUME 1 SECTION 5
F11W-0180-01 Gas Dehydration System PFD

F11W-0180-02 Gas Dehydration System PFD
F11W-0181-01 Regeneration Gas Heater
F11W-0181-02 Molecular Sieves
F11W-0181-03 Molecular Sieves
F11W-0181-04 Propane Separator
F11W-0181-05 Butane Separator
F11W-0181-06 Compressed Gas Dryer
F11W-0361-01 Fuel Gas
F11W-0361-04 Fuel Gas

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QATAR PETROLEUM VOL : 1

MOLECULAR SIEVE ADSORBERS

1.1 Process Description

1.2 Operating Variables and Process Controls

2. PREPARATION FOR START-UP

3.1 Propane Molecular Sieves

e. Open Common Trip Valve

MOLECULAR SIEVE ADSORBERS

Above the bed is a further layer of ceramic balls.

Molecular sieves provide a means of selectively removing and holding specific

This physical phenomenon is termed adsorption. The molecules are adsorbed in

The amount of a certain component that can be adsorbed by the sieves is a

1.1 Process Description

a. Regeneration Gas Supply

The differential pressure controllers are 13-PDRC-25 for propane and

1) Liquid adsorption 8 hours Downflow

2) Bed displacement 27 minutes Downflow product

3) Bottom head 7 minutes Downflow displacement

4) Regeneration heating 5 hours Upflow

5) Regeneration gas 77 minutes Upflow

6) Cooling and vessel fill 11 minutes Upflow

7) Idle time 54 minutes

The flow of gas is controlled by a variable orifice set to extend the

The product recovery system consisting of V-1351/V-1352 has been added

Combustion protection of the regeneration heater is based on one large

Information applies to both system.

The temperature of the gas from the regeneration gas heater,F-1301, is

3) During the automatic regeneration of a molecular sieve, the sequence and

4) In the butane molecular sieves, 13-PIC-58 and 13-PIC-59 have been

Displacement of product from the spent molecular sieve absorbers is carried

In order to reduce hydrocarbon liquid losses, product recovery unit is added.

Recovered liquid is recycled back to depropaniser column C-1302 under flow

Liquid from separator is sent back to debutaniser column C-1303 by butane

1.2 Operating Variables and Process Controls

a. Master Cycling Timer

The regeneration and changeover sequences are initiated and synchronized

The following features are in the design

a) Once initiated this is normally fully automatic. As the sequence goes

c) During the displacement step, molecular sieve product valves Nos. 7 or

d) Permanent interlocks are provided to prevent opening of product valves

e) Permanent interlocks are also provided on valves Nos. 1 or 2 for

The valves will remain closed.

2. Sequences, trips and stoppage notes

Reference should be made to logic timer.

a) Displacement to product will stop when;

1. 13-LE-53/57-L for C-1307A/B and 13-LE-61/65-L

2. There is a default in the program, if program stops or a valve does

3. 13-LE-54/58-LL for C-1307A/B and 13-LE-62/66-LL for C-1308A/B

b) Program stops at end of cooling and filling steps, if 13-LE-52/56-H for

c) Regeneration timer will start on receipt of signal - FURNACE ON from

d) ‘VALVE CLOSED’ lamps stay illuminated until valve is closed. ‘VALVE

e) If one bed of molecular sieves is out of service, the

3. Alarm and system malfunction

a) Master timer to initiate liquid adsorption- unit not idling.

b) Displacement period has elapsed level has not actuated valves.

d) To start heating - furnace in service for other unit.

b) Instruments and functions for C-1307A/B

TAG NO. FUNCTION PHASE

TAG No. FUNCTION

13-PICAL-23-1/2 Split range control.

13-PICAL-23-2 in conjunction with 13-XV-17 during displacement/purging/cooling,

Low alarm signal to control room on 16.0 barg(13-PICAL-23).