CONTENTS OF THE OPERATING MANUAL

1. GENERAL OVERVIEW
1.1 Cracking
1.2 Modes of Cracking
1.3 Trends in Hydrocracking
1.4 OHCU at Haldia Refinery

2. PROCESS ACHEIVEMENTS
2.1 General Information
2.2 FEED characteristics
2.3 Block Flow Diagram
2.4 Product Characteristics
2.5 Expected Battery Limit Conditions

3. DESCRIPTION OF PROCESS
Process Reactions Overview
3.1 Process flow Diagrams
3.2 Process Flow Description
3.2.1 Reaction Section
3.2.2 H2S Stripper
3.2.3 Fractionation Section
3.2.4 Naphtha Stripper
3.2.5 Amine Scrubber
3.2.6 Absorber – DeEthanizer
3.2.7 LP Amine Absorber
3.2.8 Debutanizer
3.2.9 Naphtha Splitter
3.2.10 LPG caustic wash
3.2.11 Lean Amine Storage
3.2.12 Precautions on Feed Storage

3.3 P&IDs

4. PROCESS FLOW DIAGRAMS

The process flow diagram datasheets

5. PROCESS LIMIT CONDITIONS

5.1 Safety Valves
5.2 Alarm and Trip Settings
5.3 List of Interlocks
6. CONTROL AND OPERATING CONDITIONS
6.1 Method of control
6.2 Operating Conditions
6.2.1 Reactors 91R01 and 91R02
6.2.2 Feed Surge Drum 91V01
6.2.3 Reactor Feed Heater 91F01
6.2.4 HP Separator 91V05
6.2.5 MP Separator 91V06
6.2.6 Wash Water Surge Drum 91V09
6.2.7 Stripping Section
6.2.8 Naphtha Stripping Section
6.2.9 Fractionator Section
6.2.10 Gas Plant Section
6.2.11 Amine Section
6.3 Process Variables
6.3.1 Independent Variables
6.3.2 Hydrotreating
6.3.3 Hydrocracking
6.3.4 Summary
6.4 Instrument List
6.5 Control Panel

7. UTILITY AND CHEMICAL REQUIREMENTS

7.1 Fuel
7.1.1 Fuel Gas (FG)
7.1.2 Fuel Oil (FO)
7.2 Steam
7.2.1 MHP Steam
7.2.2 MP Steam
7.2.3 LP Steam
7.3 electrical Power
7.4 Chemicals
7.5 Plant Air
7.6 Instrument Air
7.7 Cooling Water
7.8 D.M. Water

8. PREPARATION FOR INITIAL STARTUP

8.1 Units Check out
8.1.1 Equipment inspection
8.1.2 Unit Inspection
8.2 Line Flushing
8.3 Leak Testing
8.4 Feed Heater and Reaction Section Dryout
8.4.1 Refractor Dryout 91F01 and 91F02
8.4.2 Reaction Section Drying

8.5 Catalyst Loading

 8.5.1 Preliminary Checking
8.5.2 Points to be noted
8.5.3 Special Loading Devices
8.5.4 Loading of the Reactor
8.5.5 Leak test after Catalyst Loading
8.5.6 High Density Loading
8.6 Passivation
8.7 Steam or Air Blowout Procedure
8.8 Safety Valve Settings
8.9 System blowout
8.10 Electric Equipment test
8.10.1 Electrical Motors
8.10.2 Fans
8.10.3 Pumps
8.10.4 Compressors

9. NORMAL START UP
9.1 Summary of Start Up
9.1.1 Status of the Unit
9.2 Final Preparation
9.3 Purging
9.3.1 Prerequisites
9.3.2 Steam out procedure
9.4 Cold Circulation
9.4.1 Procedure for establishing Vessel Levels
9.4.2 Dewatering pump out to slops
9.4.3 Start closed loop ( short circulation )
9.4.4 Naphtha Circulation in Gas Plant
9.4.5 Catalyst treatment
9.4.6 General Comments
9.4.7 Prewetting
9.4.8 Activation Procedure
9.4.9 Activation procedure Problem troubleshooting
9.5 Streaming products / Intermediate Streams
9.6 Normal Operation
9.6.1 Switch to normal Feedstock (60% capacity)
9.6.2 Increase throughput to design
9.6.3 Stripper and fractionators adjustments
9.6.4 Start Up Gas plant
9.7 Instrument Calibration
9.8 Safety system checking
9.9 Protection relay setting
9.10 Log Sheet preparation

10. NORMAL OPERATION

 10.1 Normal Routine Operation
10.1.1 Operating Parameters
10.2 Adjustment of operating conditions
10.2.1 Reaction Section
10.2.2 Fractionation Section
10.2.3 Auxiliary Systems
10.3 Catalyst trouble shooting
10.3.1 Feed Quality
10.3.2 Recycle Gas Purity
10.3.3 Nitrogen Content
10.3.4 Asphaltenes

11. NORMAL SHUTDOWN

11.1 Summary of Shutdown
11.2 Vacuum Gas Oil Flush
11.3 Re-circulate Start UP Gas Oil
11.4 Shut Off the Liquid Feed to the Reaction Section / Hydrogen Stripping
11.5 Reduce the reaction section temperature and pressure
11.6 Shutdown stripper / Fractionation Section
11.7 Shut Down Gas Plant / LPG Caustic Wash
11.8 Steam Out (Separation / Stripping / Fractionation)
11.9 Normal Shutdown (For Limited Maintenance Work)
11.9.1 Vacuum Gas Oil Flush
11.9.2 Re-circulate Low Nitrogen Gas Oil
11.9.3 Shut Off Liquid Feed to the Reaction Section
11.9.4 Reduce Reaction Section Temperature and Pressure
11.9.5 Shutdown of Stripper and Fractionation Section
11.9.6 Shutdown of Gas Plant / LPG Caustic Wash

12. EMERGENCY SHUTDOWN

12.1 General Information
12.2 Automatic emergency shutdown / Safety logic sequences
12.3 Emergency Depressurization system
12.4 Reaction section shutdown after emergency depressurization
12.5 Unscheduled shutdown
12.5.1 Fire in the unit
12.5.2 Feed Pump failure, 91P01
12.5.3 Wash water pump failure, 91P02
12.5.4 RGC failure, 91K02
12.5.5 MUG failure, 91K01 A/B/C
12.5.6 Temperature Excursions
12.5.7 Reaction Heater Shutdown, 91F01
12.5.8 Fractionator Feed heater shutdown, 91F02
12.5.9 Utility Failures
12.5.10 Reactor Heater tube rupture, 91F01
12.5.11 Fractionator heater tube rupture, 91F02
12.5.12 Start UP after Emergency Shutdowns
12.5.13 Important Shutdown notes
 12.5.14 Lean Amine pump failure

13. SAMPLE ANALYSIS

13.1 Sample Taking
13.2 Quality tests
13.3 Quantity Tests
13.4 Analytical Methods
13.4.1 Recommended methods and frequency
13.4.2 Description of IFP Analytical Methods

13.5 Laboratory Equipment

14. HAZARDOUS SUBSTANCES

14.1 Chemical and Catalyst Hazards
14.2 Detailed Listing, Precautionary Measures and Special Procedures
14.2.1 Catalyst Specifications
14.2.2 Special Procedures

15. PROCESS INTERLOCK DIAGRAMS

16. CAUSE AND EFFECT DIAGRAMS
17. FIRE PROTECTION SYSTEMS
18. FLARE LOAD SUMMARY

Appendix A: Master Blind List

Appendix B: Work Permit System
Appendix C: Equipment Handover Takeover Procedure
Appendix D: Critical Equipment Startup procedure
Appendix E: OHCU Trip Settings