GAS CRACKER PLANT OPERATING MANUAL FEED HANDLING, CRACKING FURNACE AND QUENCH WATER SYSTEM U INDIAN PETROCHEMICALS CORPORATION LIMITED GANDHAR PETROCHEMICALS COMPLEX DAHEJPREFACE This Operating Manual cover Feed Handling, Cracking Furnace And Quench Water System of the Gas Cracker Plant of IPCL Gandhar Petrochemicals Complex - Dahej The chapters covered are process description, normal operation, start-up Procedure, shutdown procedure, emergency procedure safety procedures of the above said area. The relavent drawings are also attached for reference. These instructions are based on the experience gained and may subsequently call for minor changes as per the situation faced during the Start-up and the emergencies. The informations given in the manual are strickly for using them in the operations of this plant and should not be disclossed to any outsiders without the prior permission of the undersigned. —— G. R. NANDAGOPALAN Senior Manager (Chem.) Gas Cracker Unit (Gandhar)10 2.0 Contents FEED HANDLING SYSTEM. 1.1. INTRODUCTION 1.2 PROCESS DESCRIPTION 1.2.1. ETHANE/ PROPANE FEED 1.2.2 LPG FEED 1.3.1 NORMAL OPERATION CONDITIONS 13.2 OPERATION OF LPG VAPORISER 1.4 E/P OVERHEAD TEMPERATURE IMPORTANCE : 1.5 ONLINE ANALYSERS 1.6 E/P TOWER START UP WITH PIPE LINE FEED 1.7 E/P TOWER SHUTDOWN PROCEDURE 1.8 EMERGENCIES 1.8.1 TOTAL FEEDFAILURE 1.8.2 PROPYLENE REFRIGERATION FAILURE 1.8.3 QUENCH WATER SYSTEM FAILURE 1.84 FAILURE OF REFLUX. 18.5 TRIPPING OF ETHANE FURNACE, 19 DEPENTANISER SYSTEM CRACKING FURNACES 2.1 INTRODUCTION 2.2 PROCESS DESCRIPTION 2.2.1 ZONE OPERATION 2.2.2 HOT STEAM STAND BY (HSS) NORMAL CONTROL PHILOSOPHY: FEED CONTROL AND UNIFORM DISTRIBUTION RADIANT SECTION CONTROL. STEAM DRUM LEVEL CONTROL FURNACE DRAFT CONTROL. [CMO SHCHOCEOHYEHOKEDLE3.0 2.4 24.1 242 243 24.4 25 2.5.1 2.5.2. 2.5.3 2.5.4 2.6 27, 2.8 2.8.1 2.8.2 2.8.3 28.4 2.9 2.9.1 29.2 2.9.3 2.9.4 29.5 2.9.6 NORMAL OPERATION CRACKING DECOKING HIGH STEAM STANDBY (HSS) CHEMICAL INJECTION SYSTEM EMERGENCIES, ALARMS AND TRIPS ‘VHP STEAM DRUM LOW LEVEL TOTAL SHUTDOWN : SD? OTHER EMERGENCIES ACTION FOLLOWING EMERGENCY FURNACE START UP FURNACE SHUT DOWN STEAM AIR DECOKING STEAM + AIR DECOKING CHECK LIST FURNACE STEAM + AIR DECOKING PROCEDURE FOR FURNACE DRYOUT OPERATION OF LD. FAN SPECIAL EQUIPMENT : FURNACES USX EXCHANGER TRANSFER LINE EXCHANGERS TLX-1 TLX-2 INDUCED DRAFT FAN BURNERS ON LINE ANALYSERS WATER QUENCH TOWER : C-40 31 3.2 33 33.1 3.4 3.5 3.5.1 36 INTRODUCTION PROCESS DESCRIPTION NORMAL OPERATION NORMAL CONDITIONS NORMAL START UP OF QW CIRCULATION. NORMAL SHUTDOWN. SHUTDOWN OF THE TURBINE (10-PT-41 A) AMMONIA INJECTION 23 30 33 33 35 35 37 38 39 41 47 51 51 92 60 66 66 68 0 70 70 n 5 8 8 7 19 80 82 82 834.0 5.0 6.0 DILUTION STEAM GENERATION 4d 42 43 43.1 432 44 45 INTRODUCTION 84 84 PROCESS DESCRIPTION AND NORMAL OPERATION : 84 INJECTION OF CHEMICALS MEA 10-C-35 FEED. CAUSTIC INTO 10-C-30. DILUTION STEAM GENERATION START UP NOTES BOILER FEED WATER SYSTEM. 5.1 5.2 5.2.1 5.2.2 5.23 53 53.1 5.3.2 5.33 5.4 55 5.6 5.6.1 5.6.2 5.6.3 5.7 5.7.1 5.1.2 INTRODUCTION PROCESS DESCRIPTION DEMINERALISED WATER THE DEAERATOR BFW SYSTEM NORMAL OPERATION DEAERATOR HP BFW SYSTEM MP BFW SYSTEM TRIPS AND ALARMS P-211 A/B/C LUBE OIL CIRCULATION SYSTEM : DEAERATOR SYSTEM START-UP. BFW PUMP START UP CHECK LIST : P-211A START UP PROCEDURE FOR TURBINE PUMP. 86 86 87 87 88 91 1 m1 91 a 92 92 92 93 93 94 94 95 97 97 CHANGING OVER OF MOTOR PUMP TO TURBINE PUMP 98 NORMAL SHUTDOWN STOPPING ONE BFW PUMP OUT OF TWO PUMPS RUNNING TOTAL SHUTDOWN BASIC THEORY OF CRACKING REACTIONS 61 62 63 INTRODUCTION CRACKING REACTIONS REACTION CONDITIONS 99 99 99 100 100 100 102°1.0 FEED HANDLING SYSTEM 1.1 INTRODUCTION The feed to gas cracker plant is mainly a mixture of Ethane and propane (also called C,/C,) to be supplied from Ethane propane recovery unit, There is also provision for handling a small quantity of propane/butane mixtures (LPG), which can be received as liquid, vaporised, superheated and fed directly to the furnace for cracking. The Ethane/Propane feed stock is separated into ethane and propane streams, superheated and delivered to the furnace for cracking. The C,/C, feed stock is stored in two spheres in the GC (OSBL) area. During normal operation 90% of C,/C, feed to the gas cracker unit is supplied directly from EPRU as saturated liquid. The remaining 10% is sup- plied from spheres storage facilities to keep the OSBL supply system alive and ready to supply the entire feed in case of stoppage from EPRU. 1.2 PROCESS DESCRIPTION 1.2.1 ETHANE / PROPANE FEED E/P column feed comes through E/P feed vaporiser into the column tower overhead is partially condensed against propylene refrigerant -24°C & flows to reflux drum. Reflux is pumped on flow control to the column. Ethane feed for the furnace is drawn as vapour from the.reflux drum. The recycle ethane from Ethylene tower (vapourised in the Ethane Recycle Vaporizer 10-E-70) and the fresh ethane drawn from the reflux drum. The total stream is then superheated against propylene and quench water in exchangers 10-E-05 and £-06 then sent to furnaces, for cracking The tower bottoms are reboiled against quench water in the reboilers 10-E-02 A/B. Propane liquid is drawn from the bottom and flashed into the propane feed/recycle vaporiser drum 10-V-04, Recycle propane from Propy- Iene strippet bottom also comes to this drum. Liquid propane in 10-V-04 is vaporised by quench water in exchangers 10-E-04 and by steam in E-177. The saturated vapour from.the drum over- head goes to the propane recycle heater 10-E-07, where it is superheated byQuench water. The superheated propane then is sent to furnaces for cracking The E/P fractionator column is 27.84 meters tall and 2.3 m in diameter, has 36 valve trays and is made of killed carbon steel. The tower operates at 14.4 Kg/Cm’g, with a differential pressure of 0.1 Kg/Cm?(PDI 1401). Feed to the tower is expected to be dry, and the tower is designed to handle feed compositions as below. Component Alternatives Design Methane 05 05 Ethane 60 70.00. * Propane 36.3 26.00 « Butane-1 3.0 3.0 CS & heavier 0.2 0.2 CO, is also present in the feed stream, to the extent of 300 ppm (max.). The tower is operated to separate ethane and propane. 1.2.2 LPG FEED In addition to Ethane / Propane cracking in furnaces, LPG cracking also can be done in the furnaces. LPG can be fed to 10-H-11/12/13. Typical LPG composition is as follows: . Components Mole % “Carbondioxide 0.01 Ethane 1.04 Propane 56.65 i-Butane 20.51 n-Butane 20.51 i-Pentane 1.10 n-Pentane 0.18 At normal conditions the flow of C, - C,LPG = 35.0 T/HR. Supply press = 11.0 Kg/Cm?g Supply temperature = 30°CFeed comes as liquid and directly goes to V-08 (LPG vapourising drum) through FV-1502 as per the flow requirement. This system comprises of the following. a) CJC, LPG feéd vapourising drum — 10-V-08 b) LPG feed vaporiser 10-E-08 ©) LPG feed superheater 10-E-09 4) LPG vaporiser condensate pot 10-V-06 Normal operation of E/P column : E/P feed from EPRU comes to tower through FIC-1401. Reflux drum level controller LIC-1402 resets FIC-1401 to open or close if V-01 level goes down or goes up respectively. The feed temperature is controlled by TV - 1450 which resets the flow of propylene refrigerant to 10-E-176. The feed enters into the column at the 17th tray. The column bottom is reboiled in 10-E-02 A/B using Q.W, under flow con- trol FIC 1413. In case of very high pressure in the column FIC1413 gets closed thus preventing any further pressure increase. The column or reflux drum pressure in controlled.by PIC 1402 which con- trols the C,R refrigerant to the condenser (10-E-03) with high level override from 10-V-170 (C,R refrigerant condenser flash pot). In case of very high pressure PV 1408 opens and controls the pressure by dumping into flare. The ethane header pressure is controlled by PIC1403. PIC 1402 overrides PIC 1403 in case of low pressure in 10-V-01. The-column bottom is con- trolled by LIC-1403 which resets FIC-1403 by putting feed to propane va- poriser V-04. In case of increase of ethane header pressure and after PIC- 1403 closes fully, if the header pressure does not come down, PIC 1406 opens and controls by dumping ethane to flare. There is provision for con- troiling the F.G. pressure by dumping ethane to FG through PIC 1410. The level in propane vapouriser (10-V-04) is indicated by LIC 1401. On high level it overrides FIC 5603 on propane recycle flow from propylene stripper bottom by closing it. Normally the propane header pressure is controlled by PV 1404/1 which throttles Q.W. flow through 10-E-04. In case of S/D'of -3-propane furnace LIC 1401 takes over the control of propane header from PV 1401/1. Propane header pressure can be controlled by dumping Propane to Ethane through PV-1404/2. In case of very high pressure, the dump control valve PIC-1409 is controlled by dumping into flare. The tower overhead is provided with two safety valves (PSV 1401, 1402) and are set at 17.0 Kg/ Cm’g and discharge to dry flare. 1.3.1 NORMAL OPERATION CONDITIONS 1. Operating pressure 14.9 Kg/Cmg : (reflect set 17.0 Kg/Cm*g) 2. Pressure drop 0.1 Kg/em’g 3 Overhead temperature -17°C 4. Bottom Temperature 45 °C. 5. Reflux flow 32.46 Tihr. 1.3.2 OPERATION OF LPG VAPORISER. ‘The LPG vaporiser is operated, to maintain 10-V-08 pressure at less than 9 Ke/cm’g, since 10 KG/Cm’g the set pressure of PSV. The superheated vapours at 70°C are supplied to furnaces for cracking. During initial stages, hydrocarbon is taken into 10-V-08 by slowly opening FV1502. The inerts present are purged out by pressurising 10-V-08 to 5 kg/ emg and depressurising. when inerts are driven out, 10-V-08 can be pres- surized to 7 kg/cm?g at which point, liquid will accumulate in 10-V-08. Va- poriser 10-B-08 and superheater 10-E-09 are to be taken in service very slowly. In case of tripping of the LPG furnace, FV1501 is to be closed. Pressure build up, if unacceptable, should be released through safety valve by pass. 1.4 E/P OVERHEAD TEMPERATURE IMPORTANCE : E/P overhead design temperature is -17°C at 14.4 kg/Cm*g. As E/P overheads warms up C,’s get lifted to the overhead, As ethane is cracked at higher temperature the propane which is in E/P overheads is also cracked at higher temperature. So when propane is cracked at high temperature formation of acetylene and methane is more. So ethylene yield comes down. This addi 4.tional methane and acetylene will disturb cold section and acetylene con- verter. Higher methane in cold section feed will disturb demethaniser system reboiling and C-75 O/H gets warmed up. Whenever E/P overhead goes warms look for following things 1) 2) 3) 4) 5) CJC, feed compositions. Trim C-O1 reboiling If possible the ethane/Propane recycles. Increase Propane through put if margin.is available. Tn extreme problematic situations Propane is put to fuel gas from C- 120 bottom of FCC, through put is reduced, The following table shows propane composition in C-01 O/H at different O/ H temperatures. The data is at EP pressure 13. 9 Kg/em*g, Dew Point(°C) - 19.5 - 15.4 -1L Els - 3.8 -0.4 +28 5.9 8.9 11.9 39.2 1.5 ONLINE ANALYSERS 15.1 TAG NO 10-AT-1401 a) Tag No 10-AT-1401 b) No of streams - Two c) Component being analysed - % Propane 0.0 45 9.5 14.5 19.5 24.5 29.5 34.5 39.5 44.5 94.5 Methane (0-3%) Ethane (0-100%) Propane (0-50%) iC, 0-3% nC, 0-1% C,+0-1% .1.5.2 1.6 10. (d) Sample point - Stream J - I/L HC feed to ’ E/P fractionator columns. Stream 2 - E/P fractionator column bottoms e) Sample State Stream 1 - Liquid (17 Kg/cm*g, -3.5°C) Stream 2 - Liquid (14.5 kg/cm?g, 45°C) f) ‘Type - Gas chromatograph (thermal conductivity detection) 2) Cycle time - 10 minutes TAG. NO. 10-AT-1402 a) Tag. No. 10-AT-1402 b) No, of streams - ONE c) Components being analysed Methane (0-5%) Propane (0-5%) d) Sample point - E/P fractionator reflux drum overhead e) Sample state - Vapour (13.95 Kg/em’g -18.9°C) f) Type - gas chromatograph. (Thermal conductivity detector) g) Cycle time -10 minutes E/P TOWER START UP WITH PIPE LINE FEED : Stroke checking of control valves, FV 1401, FV1403, FV 1404, FV 1413, PV1403, PV1406, PV1409, PV1402, PV1408. Leak test of all disturbed flanges and check pressure drop of the sys- tem. It should be < 0.5 Kg/em*/hr. Inertise the system with N,, Oxygen should be < 0.2% & moisture < 5 ppm. - Disconnect all hoses from the system. Lineup PSV 1401, PSV 1402, PSV 1403, TSV 1403, PSV1404 PSV 1408, PSV1410, PSV1450. Lineup PV1406, FV1401, PV1402, PV1410, PV1409, PV1406, PV1408, PV1403. 2 Check healthiness of P-01 A/B. If ethane BOG available then pressurise system with Ethane up to 10 Kg/em? Start Q.W in E-02 A/B only after pressurising column upto 19 Kg/ cm’, so that if tube leak is there, quench water will not ingress into the tower. Pressurise the line upto B/L MOV with ethane BOG (8 Kg/cm?) from we -6- geecolumn. 11. Take clearance from OSBL/EPRU for C,/C, feed through pipe line. and ensure up to B/L B/V line is pressurised from OSBL. 12. Open eq. valve of feed B/V and slowly open MOV eg, valve. Pres- surise line upto FV1401 25K g/cm? pressure. 13, Line up pipe line feed B/V and MOV1401. 14. Slowly open FV1401 and take CC, liquid in to the column. 15. Start taking C,R in to V-170 by opening PV1402 16. Keep PIC1408 on auto with set point 14.4 kg/em*g, 17. Slowly increase reboiling by increasing Q.W. flow in E02 A/B. 18. As level appears in V-01 start P-O1 A or P-O1 B on miniflow after sufficient chilling and then line up discharge B/V. 19. — Start reflux to tower by opening FV1404. and establish tower on total reflux. 20. Put FIC 1404 on cascade made with LIC1402 set point 50% 21, Ensure PV1410 Ethane to FG shut & PIC1406 ethane to flare on auto with set point 11.kg/em’g 22. _ Pressurise propane header through, PV 1402-2 upto 4 Kg/cm? and then slowly pressurise the header upto 8 Kg/cm? by vaporising propane feed in 10-V-04. 23. Line up Q.W. to E-06/E-07/E-04. 24. As level appears in C-01 bottom then line up FV 1403 & take liquid into V-04. 25. Put PIC1409 on auto with set point 10 Kg/em’g. 26. - Maintain propane header pressure with HIC1406 by adjusting Q.W. flow & Keep on auto with set point 9 Kg/om?g. 1.7 E/P TOWER SHUTDOWN PROCEDURE : Whenever E/P system is going for shut down following actions to be taken. Inform OCG, OSB] and EPRU about shutdown planning well before. Reduce inventory in C-01 and V-04 before last furnace is brought to HSS so that less Flaring is done. 2, Once in all the furnace feed is taken out cut the feed rate through FIC 1401 slowly and flare it through PV 1408, it required divert the feed to fuel gas header through PV 1410. Maintain column pressure at 12 Kg/cm?g with PV 1408. Close MOV 1401 after closing FIC 1401 and inform OSBL. : 3. Keep sufficient reboilng is 10-E-02 /04. 7a 10. ll Close both Ethane / propane recycle and of the C/C, BOG. Close C3R to E-03 by closing PIC 1402. Once V-01 level depletes to minimum level stop reflux pump and close FIC 1404. Start blowing down the remaining liquid inventory from C-01, V-04 and V-01. Watch the tower bottom and V-04 bottom temperature. Hold the pressure in the column and the vessels. Drain the line of any liquid remaining in the line by opening dry blow down line U/S and d/s of FV-1401. After draining the remaining liquid in the system, depressrurise the column through PV-1408 till the pressure in the line reduces to 0.1 Kg/em’g, Close PV- 1408 after line pressure reduces to 0.1 Kg/em?g. Connect Nitrogen hose at B/L and FV-140 U/S bladers. If welding is planned on pipe line sufficient nitrogen purging is to be done. Note :- As C-01/V-04 bottom reboiling is done by Q.W. ensure no icing is on reboiler liquid inlet and outlet. 18 EMERGENCIES. The emergencies that may occur are listed below: 1.8.1 Total feed stoppage Propylene refrigeration failure Quench water failure. E/P tower reflux pumps failure Tripping of ethane furnace Tripping of Propane furnace Flare valves malfunctioning. NOE After informing GC(OSBL), OCG, EPRU. and CPP, further action to be taken depending on the emergency as described below : TOTAL FEED FAILURE when the pump out feed line pressure drops to below about 45 kg/em’g, furnace feed rates to be reduced and firing adjusted to hold COTS. If avaliable ethane/propane recycles to be increased. In case the pressure at pump outline drops to below about 42 kg/em’g, one ethane furnace to be taken on SD-1 and kept on HSS conditons. “8. A @e@ @ wa wtFeed rates and zone feed type to be adjusted in other furnace/furnaces to maintain pipe line pressue. D. SLM header, CG machine, Quench tower, Caustic tower operation to be carefully wateched and monitored. During change in feed type furnace, number of bumers in the respec- tive zone to be initially reduced and later sterilized at required COT. F. If the pressure feed line irom ONGC continues to drop to below 45 kg/em’g, take all cracking furnaces on HSS and shut MOV 1401 and MOV 1402. G. Isolate C,/C, BOG line. 1.8.2, PROPYLENE REFRIGERATION FAILURE 1.8.2.1 Short duration (about 10 minutes) 1. Cut down the reflux to the E/P tower. Run the reflux pump on mini- mum flow circulation, close PIC1402 and TIC1403 immediately. 2. Line up ethane feed to propane furnace and monitor propane header pressure carefully, 3. Watch E-05 outlet temperature. 2 Longer duration (More than about 10 minutes) Take cracking furnace on SD-1 and keep the furnace on HSS condi- tion. 2. Stop the feed to E/P tower. 3. Isolate C2/C3 BOG line. 1.8.3 QUENCH WATER SYSTEM FAILURE. Operate the system as in case of CR failure. 1. Hold C-01 and V-04 pressure. 2. * Remove liquid from C-01 and V-04 by blowdown. 3. Watch C-01 and V-04 bottom temperature. 1.8.4 FAILURE OF REFLUX. Operate the system as in the case of C,R failure except point 1 i.e. Shut the réflux C/V FIC1404. 1.8.5 TRIPPING OF ETHANE FURNACE A. Incase of trip of ethane furnace on SD-1 line up ethane to propane -9-furnace and cut off recycle ethane. In case of level build up in E/P tower, Note : Note : 19 give below down from tower, Control propane header pressure care- fully. In case of trip of ethane furnace on SD-2 reduce the feed to E/P tower and line up the feed to the cracking furnaces to crack ethane in one furnace and propane in one furnace, if only two furnaces are on crack- ing initially. In E-05, Ethane from V-01 overhead is heated to 25°C using C3R from surge down to 2nd stage. Ethylene tower bottom ethane recycle after getting vaporised in E-70 joins the line from V-01 to E-05 with block valve and NRV. Due to more recycle some times there will be some liquid carry over from E-70 to ethane header which causes some times furnace tripping and leakage of flanges of ethane recycle B/V or NRY. So if E-05 outlet TIC-1403 shows low temperature about 10°C check E-70 level indication. If required blow down to be given from E-70 When E/P tower pressure PIC 1408 reaches it high alarm limit (PVHITP= 15.4 Kg/em?) the reboiling C/V FIC 1413 will trip. Then Close Q.W. C/V FIC 1413 on manual Allow pressure to come down fo 14.8 Kg/em? Reset the reboiler by using HS1408 and see the trip status PS1408 has changed to NORMAL. Once rebolier is “reset” then open Q.W. C/V FICI413 as per requirement. Field SOV On C/V FV1413 is auto reset type DEPENTANISER SYSTEM This is an existing system designed by SWEC to fractionate C/C, feedstock received from EPRU, into ethane and propane streams, which are the routed to cracking furnaces. This system shall now be processing revised feedstock from EPRU, with minor modifications in reboiler circuit. Revised feedstock consists of C1 to C6 range of hydrocarbons. The feed- stock is routed to EPF column through existing lines, B/L arrival tempera- ture is 12°C as against - 35°C of CJC, as per original design. Exchanger 10- -10-E-176 is used to heat up and partially vaporise the feedstock to about 15°C. Ethane product is drawn from reflux drum in vapor form at-18.9 °C. con. denser is employing 3rd stage C,R liquid as per original design and no change/ modification is envisaged in this section. Due to heavies present in the revised feedstock, reboiler temperature has gone up from 46°C to 60°C. Consequently, existing quench water reboiler using 67°C quench water shall not work. To use the existing reboiler system, quench water @ 80°C from upstream of 10-E-120 A/B (Propylene stripper reboilers) shall be diverted to 10-E-02 (EPF reboilers). This shall provide enough MTD for reboilers to perform satisfactorily. Any short fall in reboil- ing duty for propylene stripper shall be made up using steam reboiler for propylene stripper column. EPF column bottom product, mainly C, to C,, shall be routed to new column, Depentaniser 10-C-02. This is a 40 tray column, similar in operation to 10- C-01, Overhead vapor are routed to condenser 10-E-270 which uses cooling water as condensing media. Here vapors are partially condensed and routed to Depentaniser reflux drum 10-V-275. Column operates at 9.5 Kg/cm?g and 51.5°C overhead condition Condenser outlet is maintained at 40°C. Uncondensed vapors are routed out of reflux drum under column back pres- sure control. These vapors. The C/C, product from column, are then routed to LPG vaporiser system, to be routed to cracking furnaces. Column employs a thermosphyon type reboiler system with two reboilers (10-E-271 A/B) cach designed for 100% duty, using LMP steam. Column bottom operates at 9.8 Kg/Cm*g and 144°C. Steam is supplied to reboilers under flow control, reset by column temperature. Condensate is drawn from reboiler condensate pot 10-V-276 under level control. Condensate shall be diverted to existing MP condensate header in GCU for LP steam/condensate recovery. Bottom product from column is then pumped under flow control, reset by column level control, to be touted to lean gas pipeline. This stream, consist- ing mainly of C,+ stream is cooled to 40°C in depentaniser bottoms cooler 10-E-272, before sending for injection in lean gas. -ll-2.0 CRACKING FURNACES : 2.1 INTRODUCTION An outline of cracking conditions and reactions taking place is dealt with separately (Sec 7.0). The equipment provided in this section achieve the ob- jective of maintaining suitable conditions for obtaining a desirable product mix. ‘The feeds to the cracking furnaces are supplied in vapor form to the convec- tion section of the furnaces, where preheating is achieved. Cracking occurs in the radiant section of the furnace. The furnace effluent is quenched in the Ultra selective Exchangers (USX) to arrest the cracking reactions, then fur- ther cooled in transferline exchangers TLX-1 and TLX-2, in which most of the energy imparted to this stream is recovered. This stream then goes to the quench water tower. 2.2 PROCESS DESCRIPTION ‘There will be five furnaces of stone & Webster design in Gas cracker plant for producing 400,000 TPA of Ethylene Presently four of these are installed and the 5th furnace is in the process of being constructed. Of the four, nor- mally three furnaces shall be in operation to produce 300.000 TPA of ethyl- ene and the 4th fumace shall be standby: When the Sth fumace comes up later, 4 furnaces shall be on live with one stand by to produce 400.000 TPA of a ethylene. All the four installed furnaces have a capability of cracking Ethane and Propane. IN addition, H-11,12,13 can crack LPG (as per the pip- ing arrangement in existence). Each Ultra selective cracking (USC) furnace consists of two parts. The bot- tom radiant section uses the radiant heat obtained from fuel combustion and has coils through which the hydrocarbon being cracked flows. The top con- vection section recovers the heat from the flue gases leaving the radiant sec- tion and has 6 banks Each furnace radiant section consists of 24 coils of ‘W? configuration Each “W” comprises of 4 tubes each 36 ft. Long. The coils are eeof swaged design with each successive tube having increased diameter. Hy- drocarbon feed enters the furnace via 3 hydrocarbon feed control valves. Each of feeds splits into two parallel passes, for a total of six parallel passes of HC preheat in the convection section. Likewise, dilution steam enters via 3 control valves and splits into a total of six parallel passes of dilution steam super heating coils. The dilution steam coils are located in the hottest section of convection bank shielding the tubes carrying hydrocarbon from the in- tense radiant heat thus guarding against coking in the convection system. Afler the hydrocarbon and steam are independently preheated, they are com- bined into 6 parallel passes of steam and hydrocarbon preheat. Two parallel passes of hydrocarbon and steam preheat zones into one mixer. There are three mixers in total. The mixers equalise temperature and pressure of the two passes. Four outlets are taken from each mixer and each split into two radiant coils. There is a nozzle at the inlet to each coil to ensure critical flow i.e. where the flow is function on upstream pressure only and is not affected by the downstream pressure. Eventhough the pressure drop vary in the radi- ant coils due to uneven coking the flow to all coils remains equal. The cracked gas leaves the furnace at a pressure of about 1.0 Kg/cm?g and temperature 830°C. However, The COT shall be specified as per feed type, load and type of operation during cracking. The outlets from each pair of coils passes through a single USX quench exchanger making a total of 12 USXs per furnace. The outlets from 12 USXs.are combined into a primary TLX (Transfer Line Exchanger) The gas is cooled to approximately 400°C in this exchanger. The USX and TLX (primary) produce very high pressure steam (VHP). After primary TLX the cracked gas flows through a secondary TLX where it is further cooled to around 232°C by boiler feed water before entering quench tower. In the conyection section, there is a VHP steam superheater coil which su- perheats VHP steam to 490°C with attemperation for steam temperature con- trol. The hydrocarbon preheat coil in convection section is split to make optimum use of temperature difference between the process and the flue gas. A BFW preheat coil is located between the two hydrocarbon coils. -B-The furnace is gas fired with 72 radiant wall bumers on each side of the furnace (total 144 burners) and 24 gas burners installed on furnace floor. Each of the 24 floor burners has a pilot burner. These furnaces are of Induced Draft type and have a ID fan provided in the stack above the damper. 2.2.1 ZONE OPERATION The USC furnaces are operated on a zone philosophy. Zone operation in- volve treating single furnace as if it is made of 3 individual small furnac each smaller furnace being a zone. Each has its own HC feed, a dilution steam flow controller and individual burner controls. However, there is no physical barrier between zones. In the radiant section, each zone consists of 8 radiant coils each with 4 swaged tubes. The furnaces are capable of zone cracking any combination of the feeds (Ethane, Propane and LPG). In Zone operation, The adjacent zone temp. is affected by the other zone, for example if we crack EEP(Z-1 ethane, Z-2 Ethane and Z-3 Propane), the third zone COT control becomes difficult. If we want to maintain the propane COT in particular zone, then Z-2 ethane COTs are to be maintained at lower side. . The USC pyrolysis system when operated in zone mode, can achieve effec- tive steam only decoking of one zone of a furnace while allowing the other zones to continue on normal cracking. The decoke effluent passes into the cracked gas stream. The plant recovery system can accommodate the result- ant carbon dioxide gas without great care (142.16 Kg/hr CO, in caustic tower inlet design). Caustic make up to CT must be increased to 14 lit/min. The net advantage offered by the USC system equipped for zone operation, is the ability to achieve much longer online operational periods to maximise in- stalled furnace capacity utilization and to achieve smoother loading of down- stream recovery section. 2.2.2, HOT STEAM STAND BY (HSS) : During hot stand by the furnace operates with same steam flow Tate as with steam only decoke mode, but the coil outlet temperature is around 800°C. After the start up and warming up of a furnace is complete the furnace is oeusually put on hot stand by until hydrocarbon is introduced in to the furnace. A furnace may also be put on hot standby prior to decoking. In HSS, effluent is to QT and SVH is to header, 2.3 NORMAL CONTROL PHILOSOPHY: 2.3.1 FEED CONTROL AND UNIFORM DISTRIBUTION During normal operation, the hydrocarbon feed to each zone is controlled by individual flow control valves. The dilution steam flow to each Zone is also individually controlled by flow control valves. The coil outlet temperature is controlled by adjusting fuel gas flow-through two control valves one each on the base load and temperature controlled headers in each zone. Critical flow distribution nozzles ensure that the flow through each radiant coil is equal. As long as critical flow is assured any pressure variation in downstream of the nozzle will not affect the quantity flowing through the nozzle and will depend on the inlet pressure only. At Critical flow, the flow at the throat of the nozzle is at sonic velocity, and the pressure is approximately half the inlet pressure. In the divergent porion of the nozzle there is pressure regain to the extent of more than 90% Thus critical flow can be ensured by maintaining the downstream pressure lower than 85% of the in'et pressure. for this calculation, the absolute Pressure of the incoming and outgoing streams should be used. Coil inlet pressure (Absolute) Kg/Cm?A Mixer Pressure (Absolute)Kg/Cm?A Coil Pressure ratio = Pressure ratio’s of all the coils are computed and displayed in schematics At the start of run, PR is about 0.7 and at the end of run, PR is 0.85. This is the point where decoking is to be done (Nature of decoking SOA/SAD depends on total run length or number of coils having higher pressure ratio). 2.3.2 RADIANT SECTION CONTROL The instrumentation and pipings are provided so that each zone in the fur- nace can be controlled independently either on cracking or steam decoking. There are three separate headers (one for each zone) for hydrocarbon feed “15-and dilution steam. Each stream splits into two streams downstream of con- trol valve. Thus, there are six streams flowing through convection section. The six stream of dilution steam flow though convection shock bank, which faces the hottest flue gases leaving the firebox. Each dilution steam pass from the shock bank, combines with one hydrocarbon pass from the hydro- carbon preheat coils and enters the mixed preheat coils. From this section sets of two passes per zone enter the mixer drum. In the mixer drum, convec- tion section differences in pressure and temperature are equalised. This con- tributes to good control of cracking in the radiant section. The mixture of HC and steam exits from the mixer drum of a given zone in four passes, with each pass supplying feed to two radiant coils. At the inlet to each radiant coil a flow distribution nozzle is provided to ensure equal distribution of flow to all radiant coils in the relevant zone. FURNACE ‘THROUGHPUT VS. COIL OUTLET TEMPERATURE DESIGN CASE 1 - FRESH ETHANE FEED FURNACE FEEDRATE cor (% OF DESIGN) (DEG C) 100 848.0 90 845.7 80 842.7 70 839.2 DESIGN CASE | - FRESH PROPANE FEED FURNACE FEEDRATE cor (% OF DESIGN) (eC) 100 828.0 90 824.4 80 820.1 70 815.1 NOTE COT indications which are available in DCS are actually about 12°C less than the actual COT because TC’s are situated slightly away from the actual point of coil outlet so a correction of 12°C is to be made for getting actual COT. For example, at 100% feed rate, COT to be maintained at 836°C (max), and for 100% propane feed, cot to be maintained at 816°C (max). -16-Get XSN @) O ‘LOO oF ETHANE 9% CONVERSION-8I- SX Inlet) C@vU % CONVERSION OF PROPANE6°-0t: g0 PERCENTAGE OF DESIGN FEEDThe heat release in the furnace is controlled in three zones. Two coils outlets are combined and enter one USX (total 12 USXs per furnace). Each zone consists of eight radiant coils with pairs flowing to one USX (4 USX per zone). Coil outlet temperature (COT) indications are provided at inlet to USX. In a zone, out of four COTS, one can select either second or third tempera- ture points or average of all four temperatures for controlling purposes. This controls the fuel gas supplied to each zone. However the pressure in each fuel gas header should not go to extremely low levels, since there is a possi- bility of flashback of flame. A low pressure override is provided to guard against this occurrence. The furnace effluent is cooled in the USXs by generating VHP steam. The outlet streams from all 12 USXs combine and enter the primary exchanger TLX-1 where itis partially cooled by generating VHP steam in the exchanger. The outlet flows to a secondary exchanger, TLX-2, where it is further cooled against boiler feed water prior to entering the quench tower. A two step shut down system is provided in each furnace, i.e., partial shut- down (SD-1) and total-shutdown (SD-2). In case of SD-1, the fuel gas supply is cut off for floor burners and 2,4, and 6th row of wall burners. In case of SD-2 the entire fuel gas supply is cut off. 1) COT CONTROL : All the COT thermocouples are duplex one so each ications. One indication is going for control thermocouple will give two in and other one for indication In each zone of the four COT indications. For controlling, second and third can be selected for control. An average tem- perature of the all the four COTS can also be used for controlling. There is “TSEL” selector switch in DCS by which the selection of COT can be made. The selected Temperature indication will go as “PV” of the “TIC” which resets the calorific controller. 2) Firing Control : The heat release in each zone is controlled by two head- ers, base load and temperature control headers. Base load (BL) header sup- plies fuel gas, to all floor bumers and 2,4 and 6th row wall burners. Tempera- ture controlled (TC) header supplies fuel gas to Ist, 3rd and Sth row wall -21-bumers only, For a particular zone each BL and TC has a flow meter which measures flow of fuel gas and this flow is compensated for pressure, density and temperature. This compensated flow rate is converted to heat duty value by using fuel gas LHV value. There is a low pressure override to ensure fuel gas control value d/s pressure will not go below the set point of PIC. (Nor- mally PIC set point is 1.0 Kg/Cm’g). 2.3.4 STEAM DRUM LEVEL CONTROL In case the steam drum pressure drops, the water in the drum will vaporise and level in the drum will appear to increase since calibration of level is done at normal operating conditions. The corrected level signal goes to a summer block. The steam flowing out from the drum will also go to the summer block through lead/lag block. Any variation in this summer block indicates a need for more water to maintain the same level in dram even before the level in the drum decreases. This enable feed forward control; That is even before the level gets affected, incoming BFW flow will be adjusted. The output of the summer block will provide setpoint for BFW flow controller. The level is also controlled by simple LIC and FIC (auto-cascade). The output of BFW flow controller will go to BFW control valve for feed back. The CBD of the steam drum is on a flow control which goes through a selector to the final control value. The selector allows selection of the higher signal between the Outputs of the flow controller and a second level indicator controller on the drum. Normal blowdown rate is 4% of total BFW to drum CBD should not be used for controlling steam drum level. 2.3.5. FURNACE DRAFT CONTROL The present draft control has simple closed loop control with PIC. For moni- toring stack flue gas 02, CO, NO SO analysers are provided Conversion Control : The conversion is controlled in two steps : i) The first step is selection of “PV” of COT. There is selector switch on DCS which selects to COT among USX-2, USX-3 or average of all four USX’s. There is a provision that the operator can also set this temperature. This temperature signal goes to the TIC which resets the FIC of base load 22fuel gas. ii) The FIC of temperature control and base load are in bias control, ~ Control receives signal 0 to 10°C higher than the TIC of base load, which is set by operator. This temp. control TIC then resets the temp. control FIC. The higher value is given to the TIC of TC fuel gas so that fine tuning is done by the temperature control FIC and main load is taken by base load bumers. 2.4 NORMAL OPERATION 2.4.1 CRACKING The furnace can be operated to get different conversion of the feedstock. The exact conditions will depend on the actual flow through the convection sec- tion coils and the radiant section and on the extent of coking in the tubes. Typical operating conditions are given, for ethane and propane cracking. Itis seen that with lay down of coke, the operating conditions change from Start of Run (SOR) to End of Run (EOR). The wall burner assembly has one primary and two secondary air registers and normally develops a thin fan shaped flame. Proper operation of primary and secondary air registers is important to avoid smoky flames. Soot covered convection tubes will reduce heat transfer causing higher fuel input, All wall burners are gas fired and air inspirated type. The fuel gas under pressure flows through a venturi throat at high velocity, creating a suction effect which sucks air along with it. The amount of air inspirated may be adjusted by the air registers opening and the resulting air gas mixture burns around a series of peripheral slots. During normal operation, primary air register should be adjusted for a blue flame. When the heater is on cracking, almost all the burners are required to be on line. For floor bumers, primary air must be adjusted to get a proper flame pattern at burner tip. The secondary air regis- ters aie to be adjusted to achieve excess O, of about 2.5% to ensure complete combustion of fuel gas. First two passes of “W” coil are made of HP 4W and last two passes are made of HP-4W MOD. 23 -TMT Pass-I Pass-2 s-3 Pass-4 Design °C) 1040 1040 1070 1100 (Max.) Allowable °C) 1030 1030 1060 1090 The tube metal temperature is to be measured by optical pyrometer. The most convenient instrument for this purpose is a filament type optical pyrometer, with which the readings are reproducible, accuracy is adequate and varia- tions in readings taken by different operators is fairly low. The tube metal temperature measured with an optical pyrometer is always higher than the actual value due to the reflection of unabsorbed radiation from the tube sur- face. If the emissivity of the tube surface is known, correction can be made. =24-2.4.1.1 Typical Operating Condition for ethane cracking (SOR) Process Flow Flue gas Duties Temp.CC) Ke/Hr. ‘Temp.CC) MMKCALr. Hydrocarbon In 54 26991 153 17 Preheat Bank Out __144 26991 102 NumberT BFW In 116 23050 350 4.63 Out__295 23050 153 Hydrocarbon In 144 26991 549 491 Out 510 44645 549 HPSS In 318 42011 883 8.23 Out 510 44645 549 Attemperation 2634 Water HC&STM2 In 453 35088 1120 6.52 Out 692 35088 883 DILSTM In 177 8097 1133 1.72 Out 591 8097 1120 Radiant In 692 35088 1181 219 Section Out 848 35088 1181 USX In 847 35088 8.42 (fubeside) Out 555 35088 TLX-1 In 555 35088 37 Out 340 35088 TLX-2 In 340 35088 37 Out 177 35088 HP Steam Gen 44645 Fuel Fired 3402 51.85 Losses Stack 1.62 Convection 0.14 Radiant 0.52 -25-2.4.1.2 Typical Operating Condition for ethane cracking (EOR) Process Flow Flue gas Duties Temp.(C) _ Ke/Hr. ‘Temp.CC) MMKCAL/IK Hydrocarbon In 54 26991 163 131 Pheheat Bank Out 153 26991 107 Number BFW In 16 18256 368 . 5.05 Out 318 18256 163 Hydrocarbon In 153 26991 S71 5.22 Out 443 26991 368 HPSS In 318 37713, a7 9.47 Out 510 42431 571 ‘Attemperation 4718 Water HC&STM-2 In 472 35088 1156 6.89 Out 719 35088 917 DILSTM =n 177 8097 1170 1.82 Out __ 616 8097 1156 Radiant In 719 35088 1217 218 Section 0 Out 850 35088 1217 usx In 849 35088 5.92 (Cfubeside) Out 647 35088 TLX-1 In 647 35088 54 Out 456 35088 TLX-2 In 456 35088 3.79 Out 306 35088 HP steam Gen 42431 Fuel Fired 3542 53.98 Losses Stack 1.74 Convection 0.15 Radiant . 0.54 -26-2.4.1.3 Typical Operating Condition for Propane Cracking (SOR) Process Flow Flue gas Daties Temp.CC) _Kg/Hr. Temp.CC) MMKCAL/B Hydrocarbon In 54 29739 141 0.99 Preheat Bank Out 126 29739 87 Number BFW In 116 19344 291 2.19 Out_251 19344 1 Hydrocarbon In 144 29739 498 4.04 Out 352 29739 291 HPSS In 318 38850 196 6.13 Out 498 38850 498 Attemperation 0 Water HC&STM-2 In 385 38661 1058 S71 Out 589 38661 796 DILSTM Ih 177 8922 1073 1.61 Out 526 8922 1058 Radiant In 589 38661 1130 18.7 Section 0 Out 828 38661 1130 usx In 828 38661 8.13 (Tubes Out_573 38661 TLX-1 In 573 38661 6.03 Out 352 38661 TLX-2 in 392 38661 38 Out 352 38661 HP steam Gen 38850 Fuel Fired 2722 415 Losses Stack 1.02 Convection 0.11 Radiant 0.42 -27-Typical Pressure profiles in ethane and propane cracking. Case : 1 Pressure in KSCA ETHANE : PROPANE, SOR BOR SOR EOR PL 1.56 1.56 1.56 1.56 P2 1.70 177 1.70 1.84 P3 1.82 1.93 1.83 2.03, P4 1.89 2.01 1.90 211 PS 3.28 3.56 3.06 3.89 P6 4.96 5.09 4.23 4.47 P7 5.17 5.30 4.44 4.68 P8 6.34 6.50 - 5.28 5.56 P9 7.05 1.24 5.78 6.08 P10 791 8.12 6.42 6.73 PLL 6.64 6.81 5.58 5.87 282.4.1.4 Typical Operating Condition for Propane Cracking (EOR) Process Flow Flue gas Duties Temp.CC) _Kg/Hr. ‘Temp.(C) MMKCAL/H Hydrocarbon In 54 29739 in 1.36 Preheat Bank Out 151 29739 98 Number BFW In 116 13310 315 2.76 Out__299 13310 172 Hydrocarbon In 151 29739 319 4.09 Out 372 29739 315 HPSS In 318 33373 829 65 Out 510 34915 519 Attemperation 1541 Water HC&STM-2 In 406 38661 1095 . 597 Out 615 38661 829 DIL‘STM In 17 3922 1110 1.72 Out 552 8922 1095 In 615 38661 1169 18,23 0 Our 828 38661 1169 USX In 828 38661 5.7 (Tubeside) Our 629 38661 TLX-1 In 629 38661 5.47 Out 438 38661 TLX-2 In 438 38661 3.9 Out 285 38661 HP steam Gen 34915 Fuel Fired 2791 42.54 Losses Stack 1,27 Convection ou Radiant 7 0.43 The very High pressure (SVH) steam drum should be operating with steady level and steady steam flow. The BFW flow and blow down flow are to be monitored. The continuous blow down is to be adjusted to maintain PH and conductivity of steam. Intermittent blow down for TLX exchangers to be operated at least twice in a shift to remove any accumulated deposition for -29-about 4 seconds. Lab sample results should be referred for IBD frequency. A blowdown valve is provided to give IBD from drum at the grade level. When the furnace has operated for some time and coking results in changing operating conditions which are no longer acceptable, then furnace should be scheduled for decoking. The decoking is to be done when absolute pr. ratio across venturi of any coil reaches 0.85. 2.4.2 DECOKING ‘This is an expected and recurring feature in furnace operation. That is the reason for providing several furnaces for production with one additional fur- nace acting as a standby. Decoking is planned, so that production can con- tinue at the rated plant capacity, with furnaces taken off one by one for decoking periodically. The coils need decoking when : a. The tube metal temperature as determined by optical pyrometer readings, exceeds the maximum allowable for the material. b. The absolute pressure ratio across the radiant inlet distribution nozzles approaches critical ratio. The limit is 0.85. c. Progressive fouling of USX or TLX exchangers causes outlet temperature to exceed design limitations specified 4. Local hot spots appearing on the surface of radiant coil and optical pyrom- eter indicates that the temperature of these spots is close to maximum allow- able on occasions, a tube wall hot spot can be rectified by adjustment of burners in the area of the hot spot delaying an immediate need for decoking. e. A furnace is shutdown due to such emergencies as power failure, feed failure, dilution steam failure or fan failure. Coil healthiness to be checked by opening the peep doors after such emergency shutdown. Periodic removal of the coke deposit should be adopted as a routine proce- dure and furnace should be decoked on regular basis, providing operations are steady and furnace capacity is available to allow decoke. In the long run premature decokings will result in easier overall furnace operation and longer coil life. Large cyclic temperature changes in radiant coils will develop stresses which will eventually reduce coil life. Many decoke operations with very little coke inside are very likely to cause less erosive damage on “V” bends compared with fewer decks where presence of coke is heavy. It is advisable that a decoke should be carried out prior to keeping a furnace on hot steam stand-by, Following cracking, it is usual some spilling of the coke will occur. =30-The coke spilling will be excessive, if the furnace is allowed to cool and then later recommissioned. The tube metal and coke do not shrink or expand at same rate during cooling or heating and subsequently coke chips o flakes away from the tube metal. ‘These coke particles if sufficiently large or present in sufficient quantity can plug “W" coil bends or the inlets to transfer line exchangers in particular primary TLX exchangers In most cases of unplanned shut down, prior to decoking some spilling wiil occur. The degree of spilling will depend on quality of how heavily coked the tubes were prior to shutdown and how cold the tubes became during the shutdown. Occasionally coke deposition prohibits a normal decoke type operation from taking place. It may be necessary to remove the inlet head of primary TLX exchanger to allow blow of coke from the coils. When this happens, it is advisable to clean TLX exchanger as well even though there is no fouling in the tube. DECOKING is carried out by either of two methods depending upon the degree of coke laydown and the time available. ‘The method of decoking S.O.D. or S.A.D is also decided by run length and number of coils having high pressure ratio across venturi. After every emer- gency shutdown or before any planned shutdown, steam air decoking is done 2.4.2.1 Steam only decoking (SOD) Several advantages exist if steam only decoking is employed. The furnace effluent can be routed directly to quench tower. The water in effluent can be condensed and recycled back. There is no possibility of any atmospheric pollution. In case of entire furnace decoking, the heater effluent may be sent to atmosphere via decoking pot. Zone wise steam only decoking can be done while cracking continues for the other zones, COT 1000°C (max). 2.4.2.2 Steam air decoking (SAD) Steam air decoking has the advantage of being carried out of lower coil out- let temperature. It is to be noted that the burning reactions are exothermic and if the coils are heavily coked, there is a risk of tube burn out. For this operation the furnace effluent must be diverted from quench water tower to atmosphere before air is introduced. Because of this limitation the combina -31-tion of one zone on steam air decoking and other two zones on cracking is not possible. Air is to be introduced very slowly in steps observing the extent of buming (increase in COT). Decoke sample is to be given immediately after introducing air, then every four hours till two consecutive samples re- port <0.2 % CO. During decoking by either method, the coil metal temperatures can go up beyond the values of normal operation. It is essential that operation to be monitored carefully. The following points are to be noted:- a. Tube metal temperature readings are to be taken for every unit of air intro- duced, b. Maximum number of burners used to mirror image pattern to reduce localised heating. c. Alternate burners to be lighted. In steam air decoking, COT should never cross 900°C, (normally it should be 870°C). During the decoking operation VHP steam generation will continue. How- ever, due to higher level of excess air, overheating of BFW economiser coil can occur. If it happens, BFW flow.through economiser can be increased by increasing steam drum blow down. Using either method of decoking, some spilling of coke will occur. This coke i highly abrasive and can cause ero- sion especially at the USX inlet if the steam velocity is high. For this reason, a recommended maximum steam flow is included in the decoking proce- dure. If there is evidence of severe coking, a lower then recommended dilu- tion steam flow rate should be used at the start of decoking. Even thougl this will give poor temperature control, a lower flow rate will reduce the danger of spilling of coke and erosion. The flow rate should be as low as Possible as long as it is high enough to keep the convection section outlet temperature under control and to keep uniform temperature in radiant sec- ton. Decoking must be carried out before the coke gets so thick that exces- sive spalling is likely to occur, plugging the downstream exchanger inlets. It is particularly important to avoid excessive draft during decoking, Excessive draft can cause a high crossover temperature. During the HC removal, the furnace outlet temperature should be maintained -32-aS constant as possible about 30°C below the cracking temperature in order ‘0 minimize thermal shock to the radiant coil. Firing control is to be done by adjusting FG supply from control room, at the same time lighting additional burners in field 2.4.3 HIGH STEAM STANDBY (HSS) This is the operating condition of a furnace in transition, which has been brought up for cracking, or which has been taken out of cracking mode to prepare for decoking. It is the condition to which a furnace will be brought {0 in case of partial shutdown (SD-1), so that it can be held for a while under ondition before it go S to the desired operating mode, or is brought down. Conditions to be maintained for HSS condition of a furnaces are: Dilution steam per zone 3000 Kgs/nr Decoke steam per zone 5000 Kgs/hr Coils outlet 800°C Steam drum pressure Around 103 Kg/em? SVH coil outlet temperature 450°C-500°C . CBD to be continuously on from the steam drum Draft -4Omm of WC (When the furnace is on HSS it is advisable to reset SD-1 parameters and actuate base load burners (Minimum one burner per zone) to avoid delay in cracking). 2.4.4 CHEMICAL INJECTION SYSTEM 2.4.4.1 DMDS injection ‘To enhance run length of an operating furnace, Dimethyl disulphide (DMDS) is injected into the cracker feed, DMDS :-CH3 - $-$-CH3 DMDS is a pale yellow liquid with a foul odour with, SP. gravity = 1.063, Boiling Point = 109.6°C Molecular weight = 94 DMDS is injected into feed hydrocarbon (Ethane, Propane. LPG) to reduce coke formation inside the tubes, thereby increasing the furnace run length. For a fresh start up or after air steam decoking, the inside surface of tubes are pure and if tubes are not passivated initial hydrocarbon can cause coke formation. Because of this tubes are passivated with DMDS by putting it through dilu- tion steam. . “33002~CDMDS is supplied in 200 Itrs drum, which is to be unloaded into 10-V-05. Nitrogen blanketing is provided for this drum. Split range control is pro- vided by which if pressure comes down N2 can go in and if pressure goes up this can be put to flare. This can be controlled from control room, Calibra- tion pot is also provided in suction for injection purpose. 10-P-05 A/B/C/D/ E, “A” pump is for H-10 “B” pump is for H-I1 “C” pump is for H-12 “D” pump is for H-13 and “E” pump is the common for all feed pump and future farnace (H-14). DMDS Dosage in hydrocarbon feed : Basis:80 ppm of sulfur in ethane/ Propane feed. Feed (T/hr) DMDS (1vhr) Stroke length (%) 27 3.05 25 36 4.07 34 54 6.105 48 72 8.14 65 36 Provisions are made to inject DMDS in dil steam headers of individual fur- nace on continuous basis 2.4.4.2 Phosphate Injection Trisodium Phosphate (TSP) is dissolved in DMW in 10-V-260 and injected in to each steam drum by individual dosing pumps 10-P-260 A to 10-P-260 F, The Phosphate added forms a thin protective layer, which protects the waste heat boiler system from corrosion. It should be closed to maintain approximately 2 ppm of phosphate in the blowdown from the steam drums. Depending on the analysis, amount of b/d, IBD as phosphate/ hydrazine in- jection rates are adjusted. Phosphate Solution Preparation Mol. wt of Na,PO4. 12H20 = 380 Ratio of PO4-2 : T SP = P04? = 95 = 0.25 TSP 380 (62) ie. 1 Kg of TSP = 0.25 Kg of POS? V - 260 Volume is 150 lits. For 3% solution PO4-2 in V - 260 = 150 x 0.03 = 4.5 Its. in V-260 =_4.5 = 18 Kg of TSP. 0.25 -34-Total steam generation in 4 furnaces = 160 T/ hr. For 5 ppm PO4-2 in b/d ++ PO4-2 in blow down = 16x 5x 10° = 0.08 Ke/hr (10% of st gen.) 10° Total phosphate Sol. to be pumped = 150 x 0.08 45 = 2.67 ItMhr. (For four furnaces) Pump. Cap. = 1.5 L/H. “For I furnace = 0.67 Lvhr =>17% Stroke. * 2.5 EMERGENCIES, ALARMS AND TRIPS Emergency system is Provided together with alarms to Protect the furnace from abnormal or unsafe operating conditions, The two stage shutdown sys- tem SDI partial shut down and SD2 total shut down is activated either by emergency operating condition or manually by panel operator. After the emergency. The panel operator should check all systems operated correctly for shutdown system, If an unavoidable emergency can be anticipated it is preferable that the operator activate the shutdown system rather than rely upon sequential shutdown brought about by failure, Some emergencies classified as non ‘critical will cause a partial shutdown (SDI) shutting off about 55% of the heat input to the furnace, stopping hy- drocarbon feed and automatically providing access to admit detoke steam to second hydrocarbon convection coil (crossover) steam. If emergency devel- ops into a situation classified as critical, a total shutdown (SD2) is activated. SD2 will shutoff fuel to all burners stop ID fan and bring the damper to minimum stop position in addition to actions caused by $D-1. Activa SD-2 Automatically activates SD-1. 2.5.1 VHP STEAM DRUM LOW LEVEL Fach steam drum is provided with high and low-level alarm on drum level, When alarm appears, the operator should visually check and if necessary, adjust BFW rate manually to avoid a trip. If the level goes low SDI (20%) -35-will be activated by low level alarm. This is to protect USX’s and primary TLX from BFW starvation which can result in dry run. 2.5.1.2 Low Hydrocarbon Flow to any Zone In case the hydrocarbon in a particular zone comes below safe operating level due to any problem, to protect the radiant coils from coking and con- vection section from overheating, the furnace SD1 is activated automati- cally. 2.5.1.3 Low FG Header Pressure for base load burners If the FG supply head pr. for base load burners drops below the given limit, there is possibility of flash back or bumers getting put off. To avoid any hazardous situation the furnace SD1 is activated on low fuel gas pressure (0.15 Kg/Cm?g) on baseload. 2.5.1.4 VHP steam superheater outlet temp. high Due to low steam flow of” high flue gas temperature the VHP steam superheater outlet temp. will cross the design limits and cause damage to the convection section. To avoid this a high temp. SD-1 trip is given at 650°C. 2.5.1.5 Quench tower overhead temperature high. This indicates a high load on the quench section, which should be taken care of as the Cracked gas compressor would otherwise trip on high discharge temperature. If quench tower overhead goes 65°C. Trip a (Se) Furnace, oth- erwise SD-1 will be activated. Detailed trip logic is attached in QW section of this manual. 2.5.1.6 SD-1 is activated if decoke MOV is moved from open position dur- ing normal operation and prevents reset activated trip if decoke MOV is not fully closed at start-up or after decoke. 2.5.1.7, SD1 is activated when SD-2 is activated. 2.5.1.8. SD-I of furnace can be activated by operating users witch US 1601/ 1701/1801/1901. from control room or by US 1601 A/ 1701 A/ 1801 A/ 1901 A. from field. -36-When SD-1 occurs following actions should occur: a) _ All zones hydrocarbon feed is cut off. b) All zones base load control valve is shut off temperature control fur- ther reduces fuel gas flow to other burner. c) The decoke switch will get unlatched. It will put automatically decoke steam as per the output opening given. d) Sec - TLX C/V will be shut. NOTE : If decoke switch is not in normal mode and cracking completed and SD1 occurs, decoke steam valves do not open automatically. It is to be opened from control room. 2.5.2. TOTAL SHUTDOWN : SD2 2.5.2.1. High flue gas pressure In case furnace pressure increases, there is a chance of pressure build up in the furnace which is hazardous. To protect the furnaces, the high flue gas pressure sensed by pressure switches will activate SD2. the high furnace pressure may be the result of lack of draft, wrong draft adjustment or damper getting stuck up to high use of secondary air. 2.5.2.2 ID fan failure : In case ID fan trips, the furnace can get over pressurised due to less draft. to avoid such a situation ID fan tripping automatically activates SD2. 2.5.2.3 Low dilution steam flow : If the dilution steam flow is low, it may result in over heating of dilution steam preheating coil and mixed preheat section as well as severe coking in radiant coils, To protect the furnace from overheating and coking a low flow alarm is provided on dilution steam flow. This alarm will activate SD2 auto- matically. 2.5.2.4 Low fuel gas pressure for temperature control header. If the fuel gas pressure goes low in temp. controlled header the burners may get put off which can result in hazardous situation, To avoid such a situation, the low flow pressure alarm on T.C. header will activate SD2 automatically, at 0.15 Kg/Cm?. : eaTeNOTE :- To avoid the mistake of not giving Tequired decoke FIC out put when furnace is on cracking following measures are incorporated: a) Asa preventive measure, in furnace zone feed control schematics a message will appear to check decoke output if the FIC out put is <45% b). If SD2 occurs and decoke flow is less than 3T/h one flag point is con- figured, which in turn will give high priority alarm to operator. In that case operator has to check all the 3 zones decoke flows for that fur- nace. 2.5.2.7 SD2 can be activated by DCS switch US 1602/1702/1802/1902, from control room or by US 1602A/1702A/1802A/1902A, from field When SD? is activated the following actions should occur - a SD1 is activated automatically, all actions for SD1 should occur. b. Fuel gas main UV valve will get closed cutting off all fuel being sup- plied. c. ID fan will be stopped. 4, Damper will be closed to minimum stop position (10%) e Subsequent to SD2 dilution steam flow is to be maintained at SDI even though it will cause more rapid cooling of the furnace. This will Prevent coke spilling which can plug the U bends, Dil steam and decoke steam are to be slowly reduced as COT comes down below 400°C. At 200 COT/Arch temp. steam to be totally cut. 2.5.3 OTHER EMERGENCIES 2.5.3.1 Fire In Fire Box The fire box can withstand moderate fire within its enclosure. If fire is Pro- duced due to radiant coil Tupture. Activate SD-1 and let the accumulated gas bum off. 2.5.3.2 Instrument Air Failure In case of local failure of instrument air for a closed loop, and no shutdown SDI or SD2 occurs. taken control valve on bypass or handjack and maintain normal operating conditions till the fault is rectified. If instrument air supply for whole plant fails, al control valves will go to fail safe position, Plant will be shutdown. If anticipated earlier, it is preferble to trip the plant instead of some critical parameter activating the trip. -38-2.5.3.3 Steam Failure In case steam failure, dil steam flow will come down and SD2 will be acti- vated. 2.5.3.4 BFW Failure : In case of BFW failure, low level of steam drum will activate SD1 and low level of steam drum will activate SD2.(10%) 2.5.3.5 Power Failure : Power failure lead to total instrument air failure and steam failure. Action are similar. If it is a partial power failure, ID fan failure will lead to SD2. 2.5.4 ACTION FOLLOWING EMERGENCY 2.5.4.1 Partial shutdown SD1: Check all base load burner valves are closed. Also close burner cocks. Cut some of the temp control burners also to maintain 800°C COT. Maintain dilution steam flow at required level Ensure decoke steam has come inline. ‘The furnace operation can be continued at SD1 for longer period. The extent of coking in the coils, prior to SD1 trip will decide the period of operation at SDI condition. If coke spilling occurs, decoking of the furnace may be re- quired. If conditions are normal, the furnace can be taken on cracking after rectifying the reason on which SD1 has occurred. After SD1 conditions the heater can be taken on cracking or decoking depending on extent.of coking FURNACE FEED TYPE CHANGING 1. Take HC FIC on manual (of the particular zone) 2. If TIC is controlling COT, Remove it form TIC and take on PIC con- trol, Bypass HC FSLL of the particular Zone. 4. Change the feed type from DCS from ethane > Propane or pro- pane ——> Ethane as the case may be . Whenever feed type is changed, ensure HC FT range is also changed automatically, (Ethane 0- 8200 nm3/hr and propane O-7400 nm‘/hr). 5. HC block valves of the new feed (ethane or propane) to be lined up slowly and after that HC block valve of the old feed line to be closed slowly, keeping a watch on the feed header pressure. 6. Adjust the feed flow as per the new FT and adjust the COT (some tS -39-burners may have to cut down if feed in changed over from ethane > Propane or the vice versa). ; At normal feed rate check healthiness of FSLL, take C/V on auto and then take FSLL online. 2,5.4.2 Total shutdown SD: The reason for SD2 trip is to be identified and eliminated and it should be confirmed prior to restarting the furnace. It is preferable to relight the burn- ers as quickly and safely as possible to minimize coke spalling from coil shrinkage. Check that individual valves of each burner, of temp. controller header as well as base load header are closed. Dilution steam flow to be maintained to avoid coke spalling in the coils. The damper will remain at minimum stop position to contain heat in radiant coil. Check reason for SD2 trip and eliminate the fault. Before relighting the burners ensure sufficient damper opening. Check the steam drum water level. IF VHP steam drum pressure is below header pressure, vent the steam drum. Proceed to light the burners as quickly as possible and bring the heater to SD1 conditions. Pressurise the steam drum, then divert steam to SVH header after informing CPP. If it is decided that the furnace is not to be started after SD2 trip. Follow the procedure given below: — Check all FG individual valves are closed and both block valves on HC feed are closed. — Close secondary air registers of individual all burners. — __ Dil steam flow will be on. The heater coils will have to be sufficiently hot before turning effluent to atmosphere. — Turn VHP steam to atmosphere slowly. Check steam drum level when COTS are about 700°C, Stop dilution steam and allow the coils to cool slowly. Stop phosphate pump. 2.5.4.3 After BFW pump failure i) If there are no chances of starting the pump immediately, SD2 is to be taken immediately without letting LSLL to create SD-1 & SD-2 to save BFW. In case of SD-2 the following action to taken. a) Close the feed control valves on manual and temperature, Base load FG. control valves as well. 5) Close ali the Blow downs from steam drum including IBD’s to save water. ©) — Close BFW attemperator TIC on manual. -40-d) Close see. TLX FV on manual, e) Close feed B/V’s at the field fy Close main FG SOV U/S B/V and shut all the burners cocks including hearth burners and pilots 8) Try to reduce the dilution steam and decoke steam to conserve some water. Ensure that P-TLX & S-TLX O/L temp. are within range. h) . Start ID fan and open the damper and try to cool the furnaces to avoid overheating of USX and TLX tubes. i) Point is to be remembered that decoke pot can handle only three heat- ers load. If at all fourth heater is to be put to decoke pot, steam flows can be adjusted to a total of 63 t/hr. J) Once the arch temperature comes to down around 400°C, slowly stop decoke steam and dilution steam. 2.5.4.5 After Dilution steam failure Once the dilution steam flow comes down due to steam failure or Dil stm. C/ V. malfunctioning automatically SD-2 will get actuated. Afterwards the fol- lowing actions to be taken:- a) Stop dilution steam C/V’s on manual, and shut block valve. b) Main purge steam B/V can be closed, c) Close main FG B/V and shut all the burner cocks. d) Close HC C/V’s gn manual and B/V’s of all the three zones. e) Take out furnace off to decokepot & SVH to atm. fy Remaining jobs of SD-2 activity to be taken up. 2.5.4.6 After Fuel Gas Failure Once the F.G. Pressure.comes down automatically SD2 will take place and afterwards all SD-2 activities can be taken up. 2.6 FURNACE START UP During the furnace start up the water level indicated by displacement type level indications on steam drum are not correct unless the drum is operating under normal conditions. This happens as water density varies with temp thereby affecting displacement. Instruments relying on differential pressure due to liquid head are also affected for the same reason. Level gauge unaf- fected by density changes are the preferred means of checking the drum level During start up the steam drum level. is to be made up manually. Pressure compensation is given for steam drum level indication still it is preferable to fill up steam drum before starting the furnace. . -41-Gas cracker - ISBL Gandhar petrochemicals complex ‘Two burners lighting check list for furnaces FURNACE : 10-H- Date: (S.Nq__ Description Yes__ No] T. | He feed to all three zones blinded (ethane/propane/LPG) 2.__|-Dil steam main B/V DiS deblinded 3, | Purge steam main B/V D/S deblinded & all purge points on line, (Mov, Usx, Thx) &._|_DmDS to dil steam deblined 5.__ |All hose connection to FG/HC system removed (6._| Fuel gas main B/V DiS deblinded '7__| Peep door and burner cocks shut 8. instrument tapping in steam drum online 9.__[_ Steam drum level app. 50% in LG Main BFW B/V & BQ. valve shut 10._|_ID fan running & Damper is in min. stop position (10%), TI. |_Decoke air spool piece removed & Blinded 12, | Effluent to MOV operation checked & Moy. B/V shut. 13,_| Effluent to DC Pot mov operation checked & Mov. B/V open 14, | No cover should be there on stack 15,_|_No debris in furnace plate forms 16. | Silencer vent is full open & header side BIV fully shut along with EQ valve Cond. drain from SVH header O/L of furnace Primary & secondary TLX safety guards are in position ‘Steam drum CBD C/V is isolated ‘Steam drum vent close All bumers secondary air part shul. ‘Check for Hic inside the furnace box with explosive meter Lighting torch with tube connection provided ‘Match box/ lighter available TD fan motor oil level & temp normal 26. LG bulbs are blo 27. Usx collector header drain bleeders are deblinded & water drained PART - B : CONTROL ROOM Stroke checking of : Dil steam C/V_zone 1/273 He feed CIV__zone 1/273 Decoke C/V__zone 1/273 ‘Biw C/V/ HiC/Convections. TLX/Attemp. FGTeCW zone 1/273 FGBLCchW zone 1/273 OFS =>] Damper CV Trip testing of furnace carried out = 3. [All trips on Tine except dil steam FSLL & HC RI j4._[ "Steam / FG Clearance from epp Taken. FIELD TECH SIGN SHIFT ENG. SIGN. -42-FURNACE BRINGING UP FOR HSS FROM TWO BURNERS (1) Two bumer checklist should be filled both field & C/R without fail (2) Contact CPP for steam & FG clearance (3) Phosphate solution should be ready. (4) Phosphate pump pumping status should be confirmed (5) Start warming up of dilution steam header. Continue it till condensate is fully drained. (Dil steam start coming) (©) Usx collection HDR end flanges deblinded. START-UP (1) _ Ask field operator to start putting on wall burners at the rate of @ 3 bumers/hr. so that the heating rate will be maintained at @ 60°C/hr. ‘Always put burners on mirror image pattern. (2) If the furnace is being started after a long S/D & during the S/D Fur- nace box manways were Opened then furnace Dry out Operation should be done by keeping pilot burners on for one day. 3) At 200°C of arch temp start Dil” steam at a slow rate say @ 500 Ke/hr. © Taform area Operators to start draining condensate from USX Collec- tion header. Keep dil steam FSLL by passed. Take steam drum level control on auto. (4) Once the condensate draining is over increase dil” steam flow at the rate of @ 500 Kg/15 minimum to 3 T/HR/zone. Purge steam to all points also to be commissioned (5) Once the dilution steam flow reaches @ 3 Tyhr & at COT @ 400°C, start introducing Decoke steam at the same rate as dil steam. Once dil. steam flow is 3T/hr. check the FSLL switch healthiness & take FSLL online. Start phosphate injection into the steam drum at thé same time Finally decoke steam flow should be a 5 T/hr. (6) Maintain the heating rate at 50°C/hr. (7) With the increase in COT steam generation will start (8) Inform area Operators to start condensate draining from SVH furnace OL line. (9) As per the requirement BFW B/V to be opened. (10) Once the SVH O/L temp reaches @ 400°C. attemperator CV to be -43-lined up & Put it on auto, as the temp reaches @ 500°C, (11) (12) (13) (4) (15) (16) (17) (1g) At a COT of 750°C SVH. to be diverted into SVH plant header. For diversion start closing the silencer vent very slowly and care to be taken that at no point of time SVH generation flow goes below 7 T/hr (7T/hr of flow is to prevent SVH superheater coil from overheating and to maintain the cross over temp. of the flue gas for the protection of H/c convection bank) On closing silencer vent, steam drum, pres- sure will slowly start increasing line un one B/V in the heads. At 95 kg. of steam drum pressure start lining up of the SVH header side other valve & open it fully. Continue closing the silencer vent valve with same restriction of maintaining 7 T/hr flow. Once the steam drum pressure reaches 100 kg. pressure close the silence vent fully. Inform CPP before diverting. CBD should be kept on at @ 20% output from CBD control valve. (CBD c/v to be lined up only after COT’s are above 400°C and drum pr. 10 Kg/cm?) Diversion of furnace effluent to QT. (2) _ Reconfirm that Decoke air line is blinded. / Spool piece dropped. (b) _ Inform furnace area Operator to divert effluent to QT side. (©) _ Inform C/R area 2 panel operator about this diversion without fail. QT should be in a position to receive the effluent. (@ "Ensure in the PG’s that furnace side pressure is always higher than QT side to avoid HC backing up from QT. Once drum levels are steady take LSLL inline. Hot bolting of the venturi flanges, TLX flanges is done once the fur- nace reaches 600°C COT and before cracking. The bolts of the above mentioned flanges are tightened during hot bolting. If any of flanges like USX bottom, effluent to Q.T. flanges, COT thermowell flanges are disturbed during shutdown of the furnace, hot bolting of them to be done before cracking. USX collection header end bleeders to be blinded. Get HC CIV d/s LPD’s deblinded for condensate draining before crack- ing. Ask laboratory to collect SVH b/d sample. -44-Gas Cracker - ISBL Gandhar Petrochemicals Complex Cracking Checklist - Field FURNACE : 10-H- Date : Sr. | Deseription ‘Yes/No Remarkg Decoke Air Spool Piece Dropped & End Blinded SVH Diverted to header & silencer side both valves closed Fumace Effluent diverted to Q.T. purge steam to MOV lined up) DMDS to DIL steam lined up DMDS to DIL stein deblinded Decoke side both MOV & B/V closed QTside MOV & B/V in between drain & vent kept closed Effluent PSV Tined up Purge steam to effluent PSV started HC CIV SOV's reset & S/V's stroke checked IC Manifold Spec. blind turned to open position, HC manifold drain bleeders deblinded & heaviers drained bleeder B/V closed HC CIV's US & DIS bleeders deblinded condensate drained & 14, | Base load FG header pressurised & 3 bumers litin BLL. TS. | USX collector drain bleeder B/V closed & endblinded. 16. Tracing steam for inst, line up & steam flow through it is prope 17.| BEW main B/V fully line up T8_| Attemperator C/V full line up 19.] Sec. TLX CIV reset & lined up 20. |[ CBD CIV on line FIELD TECH SIGN Gas Cracker - ISBL Gandhar Petrochemicals Complex Cracking Checklist - Control Room FURNACE: 10-H- SHIFT ENG. SIGN. Date: Sr. [ Description ‘Yes/No Remarks T._| Pressure ratio across venturi should be normal value Hot bolting of venturi flanges, TLX flanges done Phosphate pump available & running OK Feed clearance available from OSBL/C2-C3 OSBL/ OCG/CPP informed APF C.G.MIC Ist stage PIC taken out from process mode P-211 B or P-211 C on remote mode with AOP on. P-211 A online ‘DMDS dosing done for I hour and is continuing (0. | Decoke MOV fully close SDI bypass taken on line, FIELD TECH SIGN -45- SHIFT ENG. SIGN.Furnace Feed Cut (From HSS to Cracking) Pre-requisites : (1) Cracking checklist to be filled for both C/R & field. (2) Hic CV's dis bleeders to opened é& condensate to be drained fully. (3) H/c B/V’s to be lined up as per the type of feed i.e. E/P. (4) DMDS pumps are pumping or not should be confirmed. Procedure () COT should be @ 810°C (DMDS calibration pot level depletion to be checked). . (2) Inform area Operator to start putting wall bumners slowly. Keep a watch on draft, Select feed type in DCS and check the FT range. (3) Simultaneously start putting on feed by opening H/C C/V. Ensure C/ V's are open in field. (4) While Opening H/C C/V keep a watch on mixer pressure, it should never cross 4.5 Kg/Cmm?g (5) _ As the mixer pressure touches 4 Ke/Cin?g start cutting down Decoke flow/start closing decoke CV at @ 5% at a time (6) At this point H/C CV opening & Decoke CV closing should be done almost simultaneously. Keep a close watch on MIXER pressure, Steam drum level to be maintained. (7) During this change over Operation keep a close watch on COT. Also it should not go above 840°C and below 800°C. (8) Once.all the wall bumers are lighted up. (A) Keep watching the draft pressure & open the damper by 5% or . So at required intervals. Pr. to be maintained at - 5 mmwe, (B) Watch the steam drum level & steam temp. & if required adjust the BFW by taking the FV to MAN. (©) BFW to S-TLX to be lined up when cracking is started. In case of Ethane Cracking all wall burners are lighted up except 6th row. Ask the field Operator to start putting on floor bumers as per the requirement ie. COT (Open damper according to draft). (9) _ By this time Decoke CV should be fully closed. (10) H/C CV to be kept open at about 55% output for a zone on Manual & COT @ 830 (E)/ 820 (P). (11) This status is to be maintained till inst. gives clearance (issue w/p) that HIC FT/FSLL is healthy in PLC. Put FIC on auto. (12) H/C FSLL DCS bypass switch to be taken in line. (13) Now adjust H/C feed as per the plant requirement or go upto design = 46 -feed rate Ethane 9.1 T/Propane 10.4 Thr. propane, (4) Decoke switch on DCS to be taken on NORMAL mode & ask field operator to latch the local SOVs. Once he confirms that both SOVs ate latched, Decoke control valve should be checked by giving say 20% out put from DCS “It should not open at all”. Once the Operator Confirms that valve is full shut, then give 55% out put to Decoke CV and keep it in manual only. (At 55% output it will allow @ 5 T/hr. of steam flow in case of SDI). Issue W/p to blind HC d/s LPD’s, Take pyrometer survey and physically check the coil health by opening peep doors. Adjust secondary air registers to have a proper COT and 2% O, in the flue gas (O, analyser). COT control can be taken on TIC instead of PIC control. CG can be taken back on “PROCESS”, Note : 1. 27 1) Burner lighting torch connection has been given, from temp. controlled FG header. This is to ensure fuel gas supply even though the furnace is in SDI condition. Analyser shelter vent - Steam purging to be oii - particularly before outset of monsoon. DM water line has been provided upto furnace steam drum platform for steam drum clearing / man entry before IBR TEST. Furnace load should never be less than 70% (Ethane 6.3 T/hr./Zone, propane 7.0 T/hr./Zone). Stack temp. should neve be more than 135°C, Beyond which bearing may get damaged. To take care of high stack temp. during HSS, more of BFW though economiser can be put and CBD can be opened little more. Do not reset FG main USOV before all the burner cocks are shut. FURNACE SHUT DOWN: Planned shutdown from cracking to HSS : Pre-requisite: a) Inform OSBL about reduced feed intake and CPP about more SVH import and fuel gas import. b) Inform area # 2 operator about more steam effluent. Easc) Take fluid data analyser’s (FDA’s) i) Give all there Decoke control values zero % out put. Take the decoke switches to DECOKE mode (By doing this decoke SOVs will get unlatched). Ask area-2 operator to take out CG from PROCESS mode. Take the Hydrocarbon FSLL on By Pass. Take out TIC control from Auto / CAS to PIC control. Ask field operator to put off the burners. As COTs starts falling, take all three zone hydrocarbon contro] valves on manual and start closing them. Intro- duce decoke steam and maintain COT about 800°C. vi) Reduce damper opening to keep draft - 5mmwe. vii) Cut down BFW make upto steam druny and BFW flow through S-TLX to hold the steam drum level about 50- 55%. Keep watch on stack temp. viii) Once mixer pressure starts coming down while pinching hydrocarbon C/Vs (at 40% output of HC c/v’s) start put ting decoke steam. When hydrocarbon control valves are closed keep about 4 T/hr. of decoke steam in each zone. This operation is to be done simultaneously. ix) Ask field operator to close hydrocarbon block valves (both) and adjust the COT’s by adjusting no. of the burn ers. x) While cutting burners cut all base load burners and floor burners and some of the top row temp. Controlled burners. At the end keep about 45 temp. Controlled wall burners. Action when SD1 occurs : ° 1) Inform CPP/OCG/OSBL. 2) — Close H/C C/Vs ON on manual and bypass hydrocarbon FSLL. 3) Ask field operator to close base load burner cocks (wall and floor) and reduce temperature control burners to about 40. 4) Ensure decoke steam is started and adjust the FIC opening to 4vhr in each Zone. 5) _ ASK instrument incharge to take FDA’s off line (If furnace is to be cracked immediately, then FDA’s need not be taken off line). 6) As heat load has come down steam drum level rapidly increases. Take BEW make up C/v on manual and adjust the flow. Reduce the damper opening to maintain the draft of - 5 mm/we. -48-7) 8) 9) 10) 11) 12) Check for coil healthiness by seeing through peeping doors. Seé PLC printers for the first out and get the corresponding switch attended if it has malfunctioned or rectify the alarm state. Check coil pressure ratios for any coke spalling. If furnace has to be kept in HSS condition for longer time close both the hydrocarbon block valves of all tlie three zones. If cracking is to be done follow the same procedure explained in the section HSS to cracking. Before latching HC C/V’s, ensure output is zero manually. If cracking is not to be done, reduce DMDS strokes Action when furnace goes to SD2 Condition : Inform OSBL/OCG/CPP 1) 2) 3) 4) a) b) °) qd e) 5) a) b) c) @) Close all the burner cocks and ensure sufficient dil steam and decoke steam is maintained. Take all the actions of SD1 also. Ask inst, to take FDA's off-line. . Check for coil pressure ratio for any coke spalling. If possible furnace should he lifted as early as possible to HSS condi- tion. If furnace is to be brought down, then slowly bring down the furnace to avoid any thermal shock. If due to any problem furnace is to be kept in SD2 condition only, then divert SVH to atmosphere and effluent to decoke pot (close all hydro- carbon block valves before diverting the effluent.) Close decoke steam between COT’s 400°C to 300°C. Close dil st. between COT’s 300°C to 200°C. Close Dilution steam / purge steam block valves. Get the USX collection headers deblinded and drain the condensate, keep the furnace on two bumers. If furnace is going to be brought up to HSS condition immediately then check PLC printer for first out and rectify the problem. Start ID fan, latch the fuel Gas SOV’s on main fuel gas UV and latch the damper. Hold the steam drum level and ensure no carry over of condensate to SVH header. (If level goes to very high level and super heater out let temperature comes down, divert SVH to atmosphere). First try with increase COT, IBD, CBD and definitely by closing BFW C/V’s. Ask Field operator to put temp. controlled burners. Open damper while burners are being lighted. -49-Furnace Zone wise steam only decoking (SOD) Prerequisites : (1) Inform C/R area 2 panel Operator so that he will increase caustic makeup to 12 lit/min. before decoking starts. (2) FDA's to be taken off line. (3) Inform OSBL about reduction in feed. Procedure : (1) Take H/C FSLL switch on DCS on “BYPASS” of that particular zone of which decoking is to be done. (2) Close Decoke steam CV's on Manual to zero, then take the Decoke switch on the DCS to “DECOKE” Mode. (3) Now inform field Operator regarding the decoke plan & zone in par- ticular (4) Ask field Operator to start cutting/Off all the burners of that particular zone slowly. (5) Simultaneously from C/R H/C to decoke change over to be done by keeping a close watch on Mixer pressure & COT which should be around 4 Kg./em2g and 800°C to 850°C respectively. (6) Once the field Operator confirms that he has put off all bumers of that particular zone (including floor burners). Cut down the H/C feed to- tally & maintain decoke steam @ 4.5 T/hr. (7) Due to step (6) Mixer pressure will come down to @ 3.0 Kg. & COT’s are likely to be @ 900°C. (a) Ask field Operator to take TMT (8) Due to reduction in heat duty in that zone the COT’s of the adjacent zones are likely to get affected. (9) Once the H/C c/v is fully, close ask the field Operator to close H/C B/ Vs of that particular zone. (10) Now start increasing COT of that zone by putting some burners or increasing FG pressure to @ 980°C & maintain it. (@) Ask field Operator to take TMT. (11) Try to maintain COTs of the other two zone at least 810°C. If required, HIC feed to be reduced, in consultation with shift incharge. (12) Maintain same status till the pressure ratios of all the coils of decoking (13) zone comes ‘down-to @ 0.65. During this decoking operation TMTs of all the coils to be taken at COTs of 900°C & 980°C i.e. before & after increasing the temp. Don’t allow the TMT’s to cross 1020°C. -50-Note : If all the three zones are to be steam only decoked, then slowly bring the furnace to HSS condition divert effluent to decoke pot then increese the COs to 950-980°C slowly and continue steam only decoking till pressure ratio’s become normal (0.65). Deblind HC d/s LPD’s for draining condensate before cracking. Once decoking is over, cut burners to bring down COT’s to about 800-820°C. Never introduce hydrocarbon at a COT above 840°C. 2.8 STEAM AIR DECOKING: During steam air decoke, since the reaction is exothermic care must be taken 0 avoid any excessive localised burning. If any hot spots are ‘observed, re- duce air to control the rate of burning. 2.8.1 STEAM + AIR DECOKING CHECK LIST Furnace No. :10 - H- Shift : Date: YesINo. Remarks 1. | Hydrocarbon lines Ethane / Propane / LPG blinded. 2. | QT side MOV, purge steam valve shut and blinded 3. | QT side MOV and D/S B/V closed and in between vent and bleeder kept opened, ¢ Plant Air Header Charged Decoke Air Header Spoolpiece boxed up All three zones decoke air FTs zero checked Decoke MOV U/S pressure is minimum 2 kg/em'g Decoke MOV not fully clésed SD1 by pass ._|_Both T.C. & B.L.Bumers are available, .|_Decoke POT side MOV & B/V lined up. Pyrometer is available. Effluent PSV D/S B/V is closed 13 Purge steam to effluent PSV valve is shut, 14] Short cut Effluent sample line blinded 15 FDA take off valves shut & purge steam on 16.) DMDS to DIL steam line blinded (Field Technician Sign.) (Shift Engineer-Sign;)2.8.2 FURNACE STEAM + AIR DECOKING Prerequisites : (1) Confirm that decoking checklist is filled up. (2) Inform O&U shift incharge that we want to consume plant air of the: Order of total @ 3000 nm*/hr. within a span of @ § hrs. from start of consumption. (3) SW to Decoke pot is on (4) Pyrometer should be available. (5) Decoke sample pot is clear & purging on. Procedure : (1) Check that COT is @ 850°C. (2) ° Decoke & Diln steam is @ 5T/hr. & 3.0 T/hr. respectively. (3) Ask area/field Operator to put @ 2 units of plant air in each zone (4) Observe the COT’s as the burning will start COT’s starts increasing (5) At this point give first Lab. sample for initial CO, and note down analyser reading. (6) COT may go upto 870°C, once burning is over with 2% air, COT will start coming down. This is the point at which another 2 units of plant air should be introduced. (7) CO, Lab samples to be given every 4 hrs. (8) | TMTs to be measured every 4 hrs. (9) Continue introducing air 2 units at a time till burning is observed & air is fully lined@ip or 10 units/zone. (10) During the increments of air at no point of time COT should cross 875°C. zi (11) After introducing full 10 units or 20% (w/w) air if still COTs are com- ing down then increase the COTs to @ 875°C & maintain it till we achieve two consecutive lab samples CO, Content <0.2%. (12) This pt indicates that decoking is over. (13) Next step after this is air polishing which is to be done one zone at a time to achieve maximum air flow 3400 nm3/hr through each zone i.e. @ 35% of air w.rt. to steam (w/w). It has beén observed that required amount of plant air (3400 nm*/hr.) cannot be put through each zone because of line limitation. Only about 1800 km/hr can be push through. Since O&U has got limitation of flow, the polishing to be done zonewise. (14) Continue-this air polishing step for @ 4 hrs. in each zone. (15) Also take decoke sample for CO, at the end of air polishing step for each zone and pyrometer readings. -52-In USC, cracking furnaces, ceramic fibre insulation is used in radiant box py) 2) 3) 4) 3) 6) and castable refractory bricks are used in convection section. The fol- lowing jobs should be completed prior to furnace dryout: Checking furnace instrumentation interlocks, alarm/trip systems. Boiler feed water system to be charged till B/V Dilution steam system to be charged till main B/V Fuel gas system to be charged till main B/V Instrument air and power are available Ctemical injection in Boiler Feed Water/VHP generation system avai able. Trip testing of furnace : Trip testing of all the trip parameters is di @ to check the healthiness of Switches and settings before a furnace is brought up after a long shutdown 1) Fuel gas header PSLL : If FG header is blinded and trip testing to be done for PSLL, then header to be pressurised with N, at w/s LPD of ny PG ely. Pressurise the fuel gas control value down stream by open- ing the Clv on handjack. Slowly depressutise the header by opening the individual zone burner cock and note down pressure at which cor responding PSLL alarm appears in PLC printer (Take one PSLL at a time and isolate the othe). If the value is much away from 0.15 kg/ cm? then get the switch attended by instrument people. Similar exer- cise to be done for both temperature control and base load switches of all the zones. Ensure No man entry is given in furnace box. If EG is deblinded, N, hose is not required. Ensure ID fan is running Steam drum level L-SLL : Fill the drum by opening the main BFW block valve, isolate and drain the HP of LT’s (one by one) slowly down value of LI indication at which PLC printer giving LSLL alarm for set value for both SDI and sD2. Issue work permit to instrument incharge to check the trips settings of following Switches by simulating the trip millivolts to the ‘following switches. All the hydrocarbon and dil steam FSLLS Furace draft PSHHS (done by blowing air) SVH superheater coil outlet TSHHs. -53-‘Trip Values of furnaces : SDI parameters and trip values D2 parameters and trip values 1) Low Low Hydrocarbon flow 1) Low Low Dil. st flow =>0.6 T/ For Ethane =>2.6TM. — 2) Low Low temp. For Propane =>3.1Th. control header pressure => 0.15 kg/m2 2) Low Low base load pr. = > 0.15 kg/m? 3) Low Low steam 3) Low Low steam drum level = > 20% drum level => 10% 4) High High Q.T. O/H 4) High High furnace temperature => 65°C draft +2MMWC 5) High High SVH superheater 5) ID fan failure coil outlet temperature = > 560°C Note = 1) SDlcan be actuated by switch (US 1601 for H-10) 2) SD2can be actuate by pressing push button on hardware panel (US1602 for H-10) H-10 Trip Test Records SN] TagNo. | Location Unit Values Normal____ Set T. [FSUL 1612 | HCfeedto | T/hr. (NM) AIBIC zone-1 Ethane 9.1 6700) | 2.6 (1940) Propane 10 (5300) 3.0 (1585) 2, | FSLL 1622 | HCfeedto | Tyhr. (NM/Hr.) AIBIC zone-2 Ethane 9.16700) | 2.6 (1940) Propane 9.5 (5300) | 3.01585) 3. | FSLL 1632 | HC feed to Thr. (m3/hr.) ABBIC zone-3 Ethane. 9.1 6700) | 2.6 (1940) Propane 9.5 (5300) | 3.0.(1585) 4. | LSLL2806 | V-10 Drum % 50 20% A/BIC 5. | PSLL2315 | B.L.FGzone-1 | Kg/em2g 0.15 AIBIC 6. | PSLL.2325 | B.L.FG zone-2 | Kg/cm2g 17 OS AIBIC 7, | PSLL 2355 | B.L.FGzone-3 | Ke/em2g 17 ous AIBIC 8. | TSHH 3410] Q.T.O/H Temp. | °C 40 65 AIC lo. | TSHH 2806] HPSS Coil | °C 495-500 | 565 ADBIC Outlet Temp, 10.| US 1601} DCS SDi Push Button 1. | FSLL1615 | DIL steam Thr. 3.0 0.95 AIBIC to zone-1 12,| FSLL 1625 | DIL. steam to | ‘Tir. 3.0 0.95 zone-2 13. | FSLL1635 | DIL.steamto | Téhr. 3.0 0.95 zone-3 14. | PSHH 1603 | Arch. Draft Press | MM.WC 4.0 #20 -54-ate ABIC 1S. TCSLL 2802] V-10 Daum 7% 30% 10 AIBIC 16.] PSLL2312 | TCG press to | Kg/em’g LT O15 zone-1 17. | PSLL 2322 | TC FG press to | Kg/em?g 17 Os zone-2 18. | PSLL 2332 | TCFG press | Kg/em’g 17 0.15 to zone-3 19.| PSLL 2333 | TCFG press | Kp/em’g 17 0.15 AIBIC to zone-3, 20. | US 1602 21. | B-10 Fail | Induced Draft Fan Failure LI Trip Test Records Sr. [TagNo. | Location Unit Values No. Normal Set 1 PPSCLTI2 | AC teed to] 17h GT) AIBIC zone-1 9.1 (6700) | 2.6 (1940) Propane 10 (5300) | 3.0 (1585) 2. | FSLL1722 | HCfeedto | T/r (mn) AIBIC zone-2 E 9.1 (6700) Propane 10.0 (5300)} 3.1 (1585) 3. | FSLL 1632 | HC fee ‘Taw (m/he) AIBIC 9.1 (6700) | 2.6 (1940) 10.0 (5300)] 3.0 (1585) LSLL 2906 % 50 20% AIBIC 5. | PSLL 2415 17 0.15 AIBIC 6. | PSLL.2425 Kglemg 17 0.15 ABIC 7. | PSLL 2435 Kefem’g 17 ous AIBIC 8. | TSHH 3410] QT. O/H Temp, ec 40 65 AIBIC 9. JUS 1701 | Des spi p button 10. | FSLLI7I5 | DIL. Steam | Thr 3.0 0.95 AIBIC to zone-1 11. | FSLL1725 } DIL. Steam | Thr 3.0 1 0.95 AIBIC to zone-2 12. FSLL1735 | DIL. Steam — | T/hr 30 095 AIBIC to zone-3 13. | PSHH 1703 } Arch Draft Press | MM.WC -4.0 42.0 | ABBIC 14. | PSHH 1705 (Transmeter) . 15. | LSLL 2902 | V-1 Drum % 50% 10% . -55-16. | PSLL 2412 FG press | Kgem'g TT O15 to zone-L 17. | PSLL2422 | TCFG press | Kg/cm’g 17 0.15 ABIC to zone-2 18. | PSLL 2432 | TCFG press | Kg/em’g LT 0.15 to zone-3 19. | TSHH 2906 } Sup. HTR. "c 495-500 | 565 AIBIC O/L VHP Temp| 20.] US 1702 | Manual SD2 buttion 21. | B-10 ID fan H-12 Trip Test Records Sr. ]TagNo. | Location Unit Values No. Normal __ Set 1, [FSLL1812 [HCfeedto | T/hr Gm) AIBIC zone-1 Ethane 9.1 6700) | 2.6 (1940) Propane 10.0 (5300)} 3.0 (1585) 2. | FSLL 1822 | HCfeedto | Thr (M¥mr) AJBIC zone-2 Ethane 9.1 6700) | 2.6 (1940) Propane 10.0 (5300)} 3.0 (1585) 3. | FSLL 1832 | HCfeedto | Thr (MY/nr) AIBIC vone-3 Ethane 9.1 (6700) | 2.6 41940) Propane 10.0 (5300)} 3.0 (1585) 4. | LSLL3006 | V-12Dum | % 50 20% ABIC 5. | PSLL2515 | B.L.FGZone-1 | Kefem*g 17 0.15 AIBIC 6. | PSLL 2525 | B.L.FGZone-2 | Kg/em?g 17 0.15 7. | PSLL 2535 | B.L.FG Zone-3 | Kg/om’g 17 0.15 8. | TSHH 3410] QT. O/H Temp.| °C 40 65 9. }us 1801 | DCs sD1 Push Button 10.) FSLL 1815 | DIL.Steam | T/hr 3.0 0.95 ABIC to Zone-1 11. | FSLL 1825 | DIL. Steamto | Thr 3.0 0.95 AIBIC Zone-2 12. | FSLL 1835 | DIL. Steamto | Thr 3.0 0.95 ABIC Zone-3 13. | PSHH 1803 | Arch. Draft Press | MM.WC -40 #20 14, | LSLL3002 | V-12Drum | % 50% 10% AIBIC 15. | PSLL.2512 | TC FG Press to | Kg/m’g 17.1 ABIC Zone-1 16. | PSLL 2522 | TC FG Press to | Kg/em?g 7) 0.15 ABIC Zone-2 17. | PSLL 2532 | TC FG Press to | Kg/cm?g 17 0.15 ABIC Zone-3 -56-18. | TSHH 3006] SV HTR 495-500 | 560 AIBIC O/L VHP Temp 19.| US 1802 | Manual SD2 Buttion 20, | B-12 ID Fan H-13 Trip Test Records Sr. |TagNo. | Location Unit Values INo.| Normal___ Set 1. |FSLL1912 | HC Feedto | Téhr (m*/hr) ABIC Zone-1 Ethane 9.1 (6700) | 2.6 (1940) Propane 10.0 (5300) | 3.0 (1585) 2. | FSLL 1922 | HCFeedto — | Tihr (m'~nr) ABIC Zone-2 Ethane 9.1 (6700) | 2.6 (1940) Propane 10.0 (5300)| 3.0 (1585) 3. |FSLL1932 | HC Feedto — | T/ar (m’/hr) AIBIC Zone-3 Ethane 9.1 (6700) } 2.6 (1940) Propane 10.0 (5300) 3.0 (1585) 4. |LSLL3106 | V-13Drum | % 50 20% 5. | PSLL2615 | B.L.FG Zone-I | Kg/em’g 17 0.15 AIBIC 6. | PSLL 2625 | B.LFG Zone-2 | Kg/em’g ua 0.15 AIBIC 7, | PSLL 2635 | B.L.FGZone-3 | Ke/cm’g 09t015 | 0.15 AIBIC 8. | TSHH 3410] Q.T O/H Temp. | °C 40 65 AIBIC 9. |US 1901 | DCS SDI Push Button 10,| FSLL1915 | DIL. Steam — | Thr 3.0 0.95 AIBIC to Zone-1 FSLL 1925 | DIL.Steam — | Thr 3.0 0.95 ‘AIBIC to Zone-2 12. | FSLL 1935 | DIL. Steam — | Thhr 3.0 0.95 AIBIC to Zone-3 13. | PSHH 1903 | Arch. draft press | MM.WC -4.0 20 AIBIC 14.| LSLL3102 | V-13Drum | % 50% 10% AIBIC 15.| PSLL 2612 | TCFG press | Ke/em’g 7 0.15 ABIC to Zone-1 16.| PSLL 2622 | TCFG press | Kg/em’g 17 0.15 AIBIC to Zone-2 17.| PSLL2632 | TCFG press | Kg/em*g 17 0.15 AIBIC to Zone-3 18. | TSHH 3106 | Sup Htr 495-500 | 560 ABIC O/L VHP Temp 19.]} US 1902 | Manual SD2 Buttion 20. | B-13, ID Fan LE -5T-Furnace general maintenance job list : Following jobs are normally attended whenever a furnace goes for long shut down. 1) _ Allblock valves which are listed for gland leaks during normal opera- tion - are offered for gland filling after isolating. 2) All floor burners cleaning and air damper/registers greasing, 3) Radiant box insulation repair 4) _ ID fan preventive maintenance/Damper greasing. 5) All control valves stroke checking and switches trip testing/FT’s cali- bration. 6) COT thermowell rotation and replacement if broken. 7) USX/TLX hydrojetting / USX collection header end flange opening for coke lumps removal 8) Following spots are checked for crack / weld failure by DP test and radiography. a) FDA's take off lines, b) PG-PT take of mixers 3 USX I/L PG lines, c) Coils (particular 3rd and 4th passes) 9) QT side and decoke side MOV operation,checking. 10) All PSVS Calibration 11) Coil support checking 12) Steam drum LG lights/glares attending/replacement. 13) SVHB/V's rousing. 14) FDA sample line decoking/analyser calibration. 15) Decoke NRV flapper checking/leaks attending. 16) 2 analyser calibration. 17) Peep door greasing. 18) CO2 Sample point end flange opening & decoking opening. Furnace general failure spots : 1) Coil failures especially third and fourth pass. 2) FDA take off point. 3) Convection bank mixed preheat outlet. 4) Mixer PG-PT take off point. 5) USX inlet PG-PT take off point. 6) COT thermowells 7) Main BFW egalisation valve. COIL PRESSURE TEST . Coil pressure test is to be carried out after furnace is back from maintenance. All the flanges which were loosened during maintenance period to be thor -58-oughly leak tested. In addition to that the following general points are also to be checked. 1. H/C (Ethane, Propane and LPG) 2nd B/V’s O/L flange and their glands. 2. Bleeder in between two H/C B/V’s to be checked. 3. 3.Nos., of H/C C/V’s, 3 Nos. of Dilution steam C/V’s and 3 Nos., of Decoke steam C/V’s glands. Dilution steam C/V’s and Decoke steam C/V’s bleeders to be checked 3 zones Decoke steam line NRV’s u/s and d/s flanges. Plant air valves and connected flanges. Mixing Drum PG take off flange. Radiant coils inlet venturi flanges. 12 USX’s I/L flanges and O/L flanges. 10. Zone 1 USX collection header both sides flanges and bleeder. 11. Zone 2 USX collection header both sides flanges and bleeder. 12. Zone 3 USX collection header both sides flanges and bleeder. 13. Primary TLX V/L and O/L flanges and connected Exchanger flanges. 14. Sec. TLX W/L and OIL flanges and connected Exchanger flanges. 15. Decoke side MOV U/S flange and MOV gland. 16. Q.T. side MOV U/S PSV UIS flange. 17. QT. side MOY U/S flange and MOV gland. 18. Q.T. side MOV and B/V in between vent/bleeder 1st B/V U/S flange. 19. Purge steam R.O’s of all the point. 20. Purge steam line trap connected flanges which is towards CPP. 21. Purge steam line B/V d/s flange. PONDS STEAM DRUM MAN ENTRY AND IBR TESTING MAN ENTRY Once furnace is brought down, isolate BFW main B/V, (open dis bleeder), Economiser, S-TLX, attemperator, CBD C/V's. Silencer vent will be opened before furnace is brought down and SVH side both the b/v’s and equalising valves are to be shut. Open steam drum vent and open IBD valves, also deblind one of the USX collection header (BFW side) end bleeder and drain water from the system. Once drum is totally empty open the manhole. Put DM water and drain it. Then provide a air hose inside the drum for cooling. BFW and steam systems to be properly isolated for man entry. For IBR test- ing, close all the drains, box up man hole. Take BFW through economiser -59-slowly keeping, vent open, once water starts coming from vent, close vent. GAG ALL THREE SAFETY VALVES BEFORE TAKING WATER INTO DRUM. ‘Then slowly pressurise the drum to 100 Ke/em’s to see any major leakage is there or not, If leaks are there, those are to be attended. If not, depressurise upto 80 kg/em’g. Drum is to be again pressurised in presence of IBR inspecior upto 130 Kg/ cm?g or as required by IBR and all BFW inletvoutlets to be shut ‘The pressure should hold. 2.8.3 PROCEDURE FOR FURNACE DRYOUT "The refractory linings and insulation material can contain considerable quan- tities of water. The presence of water in the lining and refractory impair the efficiency of lining and could lead to localised overheating of the steel shell with subsequent buckling, If the furnace is fixed too hard before the water vaporises, it is essential that water should be dried out from the material on a controlled manner. Moreover, most high temperature cements only gain their full bond strength after a few hours at an elevated temperature, and must be therefore be cured before being subjected to full operating temperature. In USC cracking furnaces, ceramic fibre insulations is used in radiant box and castable refractory bricks are used in convection section. The following jobs should be completed prior to furnace dryout: 1) Checking furnace jnstrumentation interlocks, alarm / trip systems 2) Boiler feed water system to be charged till BIV. 3) Dilution steam system to be charged till main BIV. 4) — Fuel gas system to be charged till main B/V. 5) Instrument air and power are available. 6) Chemical injection in Boiler Feed Water. VHP generation system is available. Step 1 a) — Clean all debris from radiant section and furnace platforms. b) Unlock spring hangers to check cold load. c) FG system to be leak tested with N,. 4) Ensure hydrocarbon and steam coils are thoroughly steam blown be- fore radiant coil inlet. -60-Step 2: Trip test furnace Step 3: Establish level in VHP steam drum. 1) Blind on main BFW line for individual furnace to be removed 2) Steam drum LV/HV bypass HIC to be opened for taking level in steam drum. 3) Close the steam drum vent after sufficient venting and line up SVH to silencer. 4) Commission LIC/FIC loop. Step 4: Start ID fan. SD2 bypass is to be activated for starting ID fan. After starting ID fan and dilution steam flow, $D2 bypass can be normalised. Check manual operation of damper and leave damper open, at minimum stop. Step 5: Bypass low HC feed flow leading to SD1. Ensure that low steam drum level, low fuel gas pressure trip are on line. Step 6: Chatge FG headers a) b) °) Co} Check that all burners individual isolation valves are closed. Close all primary and secondary air registers and peepholes. Prepare checklist for lighting two bumers. Remove the main FG blind for individual furnace. Open all the PCVs for both FG headers for all zones. Manually reset the main trip valve and hold the valve in reset position till downstream header gets pressurised beyond PSLL setting (0.15 KSCG). Individual FG header pressure to be maintained at 1.0 KSCG. SD1 will remain on, Only temp. Controlled header burner will be lighted, Gas test the fire box, after sufficient purging with air only. Light all pilots first. One burner on each wall at opposite ends of the bottom row of wall bumers applying full primary air to ensure burner remains lit in the cold furnace. Use sufficient secondary air to main- tain flame away from the burner block. -61-Step 7: After 4 hours light more burners, keeping the firing rates even and well spread. Slowly raise radiant arch temperature to 180 Degree C at a maximum rate of 10 Degree C per hour. Use low fuel gas header pressure, 0.5 Kg/em2g. Step 8 : Hold radiant arch temperature at 180 Degree C for 72 hours or more. During this period, periodically measure furnace casing temperature at several points. As the drying proceeds the furnace shell temperature increases to about 100°C ing down when moisture is totally evapo- maintain constant and ultimately fé rated from refractory material. Step 9: Prior to rising COT to 280 Degree C, introduce dilution steam and purge steam to the furnace. Ensure that dilution steam is dry before introducing, steam into radiant coil. Blow off condensate when the radiant arch tempera ture reaches 200 Degree C, establish dilution steam flow through the coils. After commissioning dilution steam, SD2 bypass can be reset. Heater efflu- ent will remain routed to decokepot. Step 10: IF THERE IS ANY WATER LEFT OUT IN RADIANT COIL AFTER COIL, HYDROTEST, IT CAN BE REMOVED ONLY BY SLOW EVAPORATION WITH FUEL GAS TEMPERATURE HELD AT 200°C AT RADIANT ARCH. Step 11 BFW economiser outlet temperature is to be maintained well below design temperature by maintaining BFW flow and blowing down from steam drum. Steam drum LIC/FIC to remain in line. Step 12: Increase furnace firing in mirror image, pattern to get 260 Degree C at radi- ant arch at a maximum of 30 Degree C per hour. Hold for 24 hours. Starting from this stage at each subsequent stage inspect : a) _ Fire box to ensure that there i no overheating of the refractory. b) No restriction for movement of radiant coils. ©) — Convection coils are expanding in desired direction and are free to -62-expand, d) All bumers firing equally and evenly. ©) Reduce venting from silencer to generate about 25 Kg/Cm’g pressure on steam drum. Step 13: Increase firing rate and raise radiant arch temperature to 370 Degree C at a maximum rate of 30°C/hr and hold for 24 hours. The steam rate is approxi- mately 60% of decoking steam flow 13.6 MT/hr. Raise steam drum pressure to about 60 Kg/Cm? during this stage Step 14: Add more burners in mirror image pattern to increase radiant arch to 510°C at a maximum of 30 Degree C per hour. Increase steam flow to 90% of decoke steam flow 20.3 MT/hr. Check all the refractory face temperature. For full dryout, the face température should be at 800°C for 24 hours. for full dryout of convection section refractory, the temperature below the stack should be 150°C for 72 hours. Raise steam drum pressure to design when COT is reached 510°C. Step 15 At this stage it may be necessary to start BFW flow through SVH superheat coil via restricting orifice. Check the convection section temperatures, ad- just BFW flow to keep SVH superheat coil temperatures below the design temperatures. Maintain steam drum pressure at 100Kg/Cm*g. Step 16: As temperature are increased during dry out, gradually reduce SVH steam venting rate ensuring all convection section temperatures are within limits. Pressurise the steam drum to 110 Kscg pressure by adjusting venting THROUGH OUT DRYING OPERATION, STEAM WILL REMAIN ROUTED TO ATMOSPHERE ONLY. TO AVOID CONDENSATE CARRY OVER INTO HEADER. “Step 17°: Bring the furnace to hot steam standy conditions. Commission all instru- ments and steam drum LIC, SVH steam TIC, SEC TLX, FIC. loops. -63-Step 18: Reduce excess air used to ensure.even refractory heating and bring the fur- nace to the normal operating mode with excess air below the convection at about 15% Adjust individual primary air registers full open and adjust the secondary registers to give approximately 15% excess air. Test automatic damper adjustment from the fire box pressure system and put it into service. Test steam drum PSV’s. Step 19: If it is planned to open the furnace for inspection, reduce firing rates at a maximum of 50 Decree C per hour (coil outlet temperature) cutting out dilu- tion steam flow at 200°C of radiant arch temperature. Step 20: Carry out pressure survey at hot steam stand by conditions, for future refer- ence Step 21: Regularly observe fire box conditions radiant coil spring hangers conditions. Step 22: ‘The safety valve on steam drum will operate at set pressure of 119.0 and 122.5 KSCG and safety valve on superheat coil outlet will operate at a set pressure of 116 Kscg. Step 23: After testing all three safety valves, the furnaces is to be cooled down at a maximum rate a 50°C per hour. Step 24: Swapping of burners on temp. controlled header / baseload header to be done : 2.8.4. OPERATION OF LD. FAN 1. Check that lubricating oil is made up to right level. 2. Check suction and discharge conditions “e Rotate the machine in rotating direction, and observe that there is no unusual noise and check for free rotation. Start the main motor of the fan -64-10. ll. 12, If unusual noise or vibration is observed immediately stop the motor and investigate Open the damper gradually after normal speed is achieved. It is pro- hibited to run with the damper shut for a Jong time because it increases the inner temperature of the fan and can result in an accident Check that expansion joints are on the allowance for the fan move- ment. The gas temperature is to be increased gradually confirming the ther- mal expansion of casing. ID fan alarm @) An indication will be there on DCS on high bearing temp and high vibration will be there on DCS. This is an emergency alarm which appears even if one of temp or vibration goes high. As soon as alarm appears area operator must ensure that field operator goes to ID fan platform and check for the healthiness, cil level and bearing tempere- ture in TG. The alarm tag point for H-11 is BM-11 ID fan. During the operation record the pressure, capacity, bearing tempere- ture at certain interval. Inspect lube oil at predetermined frequency, and replace deteriorated oil by new one. Check for any abnormal vibration noise and temperature rise of bear- ing Shutdown the motor and close the damper as per requirement speci cations of lube oil supplied is as follows: Note : Type: TURBINE OIL 150 VG 32 Quantity 3.6 liters (twice) Maximum quantity : 0.15 litre (twice) Max. allowable vibration : Below 100 millimicrons. Max. allowable noise level : 85 db Max, bearing temperature : 80°C. The damper operation is handled by actuator, which is supplied with sole- noid, valve. It can operate either in manual or.auto. it Transfer from automatic to manual operation : When the actuator is in auto mode, the air supply valve is open, the solenoid equalising valve is closed and the Hand/Auto transfer handle is in auto. When -65-the application calls for manual operation : 1 Turn the Hand / Auto transfer handle to Hand. 2... Open the solenoid equalising valve. 3. Close the air supply shutoff valve. 4. Move the actuator to the desired position by means of the hand opera tor ratchet handle. Note : The manual operating mechanism is self locking and holds any posi- tion to which it is let. Transfer from manual to Automatic operation When the actuator is in manual mode, the air supply valve is shutoff, the solenoid equalising valve is open and the hand/Auto transfer handle is in hand. When the application calls for automatic operation : 1. Manually position the actuator to the extreme end of travel correspond- ing to solenoid demand. Close the solenoid equalising valve Slowly open the air supply shutoff valve Turn the Hand/auto transfer handle to auto. pe ca After completing the transfer, the actuator is under solenoid control. ID Fan- trip time delay : When SD-2 occurs, 1D fan will trip but the damper will come to min. stop “position only after 10 secs. Flue gas analysis : CO, : 9.44% 0, =: 20% N, : 72.85% HO: 15.71% 2.9 SPECIAL EQUIPMENT : 2.9.1 FURNACES All furnaces has provision to crack ethane/propane separately. Three fur- naces have a provision to crack LPG also as an added flexibility The fur- naces are arranged in pairs mirror image pattern. : -66-Size of furnace 18600 x 3100 x 14890 MM Height of stack 3050 MM 2.9.1.1 Radiant section : Radiant section consists of 24 “W” coils placed vertically. Each coil is of swaged design (increased diameter towards the outlet). Each coil consists of 4 tubes each 36 ft. long through which the hydrocarbon and steam flow down and up, then down and up again. Each tube thus represent one pass. The first two passes of radiant section are made of HP 4 W These two passes are 2.5 ID & 2.75" ID with 5.5 mm thickness. The maximum metal temperature these coils can withstand is 1040°C. The third pass is made up of HP 4 W Mod with a thickness of 7 mm. The maximum temperature for this pass is 1070°C. The last pass is also made of HP alloy (25% Ni & 35% Cr) of 3.25" ID with a wall thickness of 8 mm. The maximum temperature allowed for this pass is 100°C. The return bends at top and bottom are made of 22 mm wall thickness 2.9.1.2 Convection Section Convection section is divided into six banks: a) _ Hydrocarbon preheat sections : This is located below the damper. Hy- drocarbon going to each zone (3 zones in total) gets divided to two passes in downstream of FIC before entering the convection section. A total 6 passes per row will be there. There are 15 rows in this section Each pass is having finned horizontal tubes. The top two are made of 312 TP 304H (SS Material). Other thirteen rows are of A 106 B (Car- bon steel.) The fifteen rows are divided into two banks of 7 rows and 8 rows. between the two banks space is provided for soot blowing. b) BFW Preheat section : This section is located below HC preheat sec- tion. This section consists of 18 rows with 8 tubes per row. All tubes are finned and made of 5 A 106B (carbon steel.) This section. is again divided in two banks each of 9 tows. c) Second Hydrocarbon Preheat Section : This section is immediately below BFW preheat section. This section conSists of 7 rows (6 tubes per row) of finned tubes. The first four rows are made of A0106B (carbon steel) and other three rows are made of A 33% P11. The maxi- mum temperature allowed is 482°C/593°C. In order to protect this sec- tion it is necessary to keep crossover steam on while taking the heater on cracking. -67-4) VHP Steam Preheat’: This section is below second hydrocarbon pre- heat. This bank consists of 5 rows with 8 tubes per each row. The VHP steam gets reheated in first three rows and goes to attemperator it and further preheated in other two rows. All tubes are finned, first three tows are made of 800H and last two rows are made of SA 335P11. ®) HC& Dil Steam preheat Section : This section consists of 4 rows of 6 Passes each. The first row has finned coils made of a 312 TP 304H material. The second row is also having finned coils made of 80H material. Last two rows have base tubes (non finned) made of 800H material. f) Dilution Steam preheat section : This is the last convection section consisting of one row of 6 tubes made of 800 H material. |Description No of No of tubes | finned or Material of Design rows | perrows | base construction | Max. temp2C Convection bank 1 Dil steam 1 6 Base 800H 982 2HC+ Dil st) | 4 6 2 rows base | 800 H 907/890 3 VHP steam | 5 8 finned 3rows-800H |658 2rows-SA- 503 335 PH 4 H.C. 7 6 finned 3 rows-A 593 335 PH 432 4 rows-A 106 B |482 5 BFW 18 8 finned S-A-106B 333 6 H.C. 15 6 finned 13 rows-A 106 B]482 2 rows-A 213 TP 304H 815 2.9.2 USX EXCHANGER This exchanger is proprietary design of Stone & Webster. This is a double Pipe exchanger of special design with special for thermal expansion. Con- tunuous steam purge is provided to keep tube expansion spaces clean, Heat exchanger data sheet is as follows. Furnace Effluent : No. of Shells : 12 Tube side Gas flow rate : 35083 kgs/hr ‘Vapor : 286987 kgs/hr -68-Steam + 8096 kes/hr Inlet conditions pressure: 0.85 KSCG Design 5.0 KSCG Temperature : 848°C: Design 1010°C Outlet conditions : 555°C temperature Max. allowable > 675°C temperature Shell Side : BFW Rate : 408078 kgs/hr Inlet condition Outlet condition Flow rate steam kg/hr 28560 Liquid 428400 399840 Pressure KSCG 112.5 112.5 Design pr. KSCG 120.5 120.5 Temperature °C 318 318 Design temperature °C 335 335 Heat exchanged 8596560 Kcal/hr. (total for 12 shells) Tube Material of construction 21/4 cr - 1 MO. Tube 110 MMOD x 23 MM thick x 12.8 mt. length This equipment is operated till the outlet temperature reaches 600°C. beyond which it has to be decoked. 2.9.3 TRANSFER LINE EXCHANGERS TLX - 1 TLX - 2 Steam is generated in TLX - 1, and BFW is preheated in TLX - 2, as the effluent stream from the USX’s gets cooled. The operating and design condi- tions are as follows: TLX-1 TIX -2 Tube Side: Inlet conditions Gas flow kgs/hr 39258 39258 ‘Vapor 30198 30198 Steam 9060 9060 Pressure KSCG 0.54 0.65, ‘Temperature °C ~ 574 352 Outlet temperature °C 352 191 Maximum Allowable output temp. 455 400 Heat exchanged Kcal/hr 6140000 . -69-* Shell Side : Inlet BFW rate kgs/hr 319734 22242 Inlet temperature °C 318 116 Inlet pressure KSCG 112.5 - Outlet steam flow kgs/hr 21316 ca Outlet BFW rate Kgs/hr 298418 22242 Outlet temperature °C 318 280 Outlet pressure KSCG 112.5 — Design conditions Shell side pressure KSCG 120.5 120.5 ‘Temperature °C 335 335 Tubside pressure KSCG 4.5 45 Temperature °C inlet channel 675 455 Tubes 370 343 Outlet channel 455 343 Tube sheet 425 343 Material of construction tubes 1/2 MO Carbon steel Tube sheet 11/4cr-12 MO Carbon steel Shell Carbon steel Carbon steel 2.9.4 INDUCED DRAFT FAN The ID fan is supplied by DMW corporation, Japan. The model supplied is 9 FKDB-CNM double suction type with roller bearing with continuous lubri- cation air cooled type. 2.9.5 BURNERS : In each furnace there are 144 wall burners and 24 floor burners. 2.9.5.1 Wall Burners : These bumers are supplied by John Zink Co. The burner is air premix type. Primary air registers will be opened as per requirement and secondary air registers will be normally closed. Burner type : PMS Heat release per burner- Normal 290000 kcal/hr. Max. 326000 keal/hr. Min. 180000 keal/hr. Operating pressure : 1.0 KSCG 2.9.5.2 Floor Burners : These burners are also supplied by John Zink Co. The burners are dual type i.e. can be used either on oil or gas. -10-Burner type PSFFG Heat release per burner Normal 690000 Keal/hr. Max. 830000 kcal/hr. Min. 460000 kcal/hr. Operating gas pressure 1.0 KSCG 2.9.6 ON LINE ANALYSERS 2.9.6.1 Tag No. 10-AT 1601/1701/1801/190i The above on line analysers are for 10-H-10, H-11, H-12 and H-13 respec- tively. They are identical and each of them has the following features. No. of streams = 4 (Auto stream selection) Component being analysed = C,H,, C,H, CH, CH,, aH CoH MAPD, C,H, C,H,, (C,H, & C,H, main component.) Range C2H4 —--(0-100% CH, + 0-50% H, = 0-100% CH, = - 0-15% CH, - -0-1% MAPD - -0-1% CH, - -0-1% CGH, - -0-1% Cys = 01% Sample Point Crack gas of Znl Crack gas of Zn2 Crack gas of Zn3 Total furnace effluent Sample State 1. Vapor (0.9 Kg/cm2g/673°C) 2. Vapor (0.9 Kg/em2g / 673°C) 3. Vapor (0.9 Kg/cm2g / 673°C) 4, Vapor (0.9 Kg/cm2g / 673°C) Analyser type = Gas Chromatograph Detector Type = Flame Ionisation Detection Cycle time = 10 minutes (For total analysis) a7Furnace effluent Sampling 1) On Line analyser (FDAS) : Online analyses of furnace effluent is done from all the three zones individually and total effluent analysis from primary TLX inlet, The samples from individual zone collection header outlet and for total analysis from $-TLX are conditioned to atmospheric temperature by cooling with C,R in sample conditioners (FDA's) before being sent to analysers. The conditions are shell and tube type small exchangers in which CAR (Vth stage) is used as cooling medium, For individual furnaces there is separate C,R liquid block valve and vapor block valve. For all the furnaces jump over with block valves are taken from C,R to E-56 Liquid and vapor lines. A purge steam connection is given with a block valve (RO on the u/s of block) to decoke the line whenever required. Note: 1) Before taking furnace on HSS from cracking or when furnace has tripped inform instrument incharge to take FDA's Offline. 2) Don’t isolate 2" sample take off line ever, unless required to avoid choking of the lines. 3) A message appears on draft schematic that “FDAS to be taken off line” Whenever SD1 occurs or hydrocarbon C/V goes zero %. FDA analysis available is wt %. Where as short cut laboratory analysis is given in mole %. Both are to be taken to the same basis (either w% or mole%) for comparison. Yields For Various Cases (Component | Ethane Ethane | Propane | Propane | LPG we%) (65%) (65%) (79%) (90%) (90%) , 36 414 123 Tat 116 CH, 3.06 3.97 18.4 22.68 21.63 CH, 0.297 04 0.27 0.42 0.78 CH, 45.5 512 27.33 32.36 28.23, ICH, 43.2 34.97 6.09 43 1.82 CH, 0 0 0.24 O41 122 CH, 0.96 1.05 144 13.45 174 CH, 061 0.615 17.38 8.86 4.68 CH, 095 1.34 0.16 177 1.92 CH, 0.21 0.21 2.216 2.612 587 n-CH,, 03 03 172 0.67 + 131 -CHyy 0 0 4.85 2.61 3.39 Ct 1.27 1.77 5.32 8.45 10.05 -T2-2.9.6.2 Tag No. 10-AT-2102 ‘This analyser uses the same heater effluent sample conditioner as the above on line analysers but is used for monitoring CO during decoking. No. of streams = 4 Sample state = furnace effluent (0.53 kg/em?g, 232°C) Components being analysed Component Range H, 0-2% CO 0-5% CO, 0-20% Analyser type : Gas chromatography (Thermal conductivity detector). 2.9.6.3 Tag No. 10-AT-2801/2901/3001/3101 This analyser is used for monitoring 02 in the flue gas from stack of furnace Range 2 0-5% (wt) Cycletime : Sec. 2.9.6.4 Tag No. 10-AT-3301 This analyser is used to measure PH of VHP steam header. Sample state = 109 kg/em2g, 510°C 2.9.6.5 Tag No. 10-AT-3302 This analyser is used to measure the conductivity of steam. Sample state = 109 kg/em2g, 510°C 2.9.6.6 Tag No. 10-AT-2802 / 2902 / 3002 / 3102 This analyser is used to monitor stack flue gas CO. Type IR Cycle time: Sssec. Range : 0-100 ppm 2.9.6.1 Tag No. 10-AT-2804 / 2904 / 3004 / 3104 This analyser is used for SOx monitoring in stack flue gas. -T-cycle time : S sec. Range 1 0-150 ppm 2.9.6.8 Tag No. 10-AT-2803 / 2903 / 3003 / 3103 This analyser is used for NOx monitoring in stack flue gas. Type : UV Cycle time —: 5 see. Range : 0-100 ppm -74-3.0 WATER QUENCH TOWER : C-40 3.1 INTRODUCTION The total effluent from the transfer the exchanger is cooled before compres- sion in order to condense the gasoline, Fuel oil, tar and the dilution steam. Final temperatures are held low in order to minimise the compressor horse power and to reduce as far as possible the interstage temperatures to reduce fouling of compressor internal. ion. The water circulation in this tower is very large by virtue of high cooling duty The cooling is achieved in water quench tower by water circul: and efficient scrubbing action of water will remove the major portion of tar and heavy distillate portions. The quench effluent from the bottom of the tower flows to a separate drum and sufficient time is provided for settling of any tar in the bottom and for separation of gasoline which is pumped to gasoline fractionator. The water which remains saturated with oil is then cooled in closed cycle quench water system and recirculated to the quench tower. The part of the quench water is sent for the dilution steam generation system after filtering and stripping of hydrocarbons. The heat recovery in the process heater and reboiler minimise total utilities consumption. 3.2. PROCESS DESCRIPTION ‘The quench water tower is 24.2 meters high and is of variable diameter. The tower is fitted with 18 ripple trays. Which has got low turn down ratio. From Ist tray to 9th tray the tower dia. is 4 meter and from 10th tray to 18th tray the dia is 5 meters. The tower is made of carbon steel. The cracked gas effluent from transfer line exchangers enters as main feed “stream t6 the tower at the bottom. The various other streams joining the quench tower are : 1) CG recycle from third stage discharge drum to load quench tower trays at low through put. 7 2) Water stripper overhead and water stripper feed coalescer top. -15-3) Decanted water from P-38 A/B. 4) — Green oil drain from 10-R-170 A/B/C. 5) Wet flare knock out pump 10-P-231 discharge. 6) DM water make up line. 7) Off gas from HDPE. The quench tower bottom goes to oil-water separator dram 10-V-40 by grav- ity flow. The tar product settled at the column goes to tar drum (10-V-39) from where tar removed to tanker intermittently, In the oil water separator drum 10-V-40 oil overflows over the baffle and is pumped by 10-P-40 A/B to storage as Light fuel oil product, Water separated in this drura is quench water and is circulated by pump 10-P-42 A/B to C-40 bottom. Excess water pumped by P-36 A/B to F-40 A/B to DSG feed. The quench water from column intermediate sump circulated through P-41 AJBIC is divided into two streams. One stream is heated in 10-E-42 A/B against low pressure steam and then used as reboiler medium for deethaniser bottom reboiler (10-E-100) & deethaniser intermediate reboiler (10-E-101) and then sent back to quench tower as primary Q.W. the other stream goes to propylene stripper bottom reboiler 10-E-120 A/B and then to 1) Propane feed / recycle heater No. 2 (10-E-07) 2) Ethane feed/recycle heater No. 2 (10-E-06) 3) Weak caustic heater (10-E-52) 4) _ EMP prefactionator reboiler (10-E-02 A/B) For maintaining level in the sump during up set condition pump discharge taken back to C-40 through level controlled valve LV-3406. QwW. from 10-E-07, 10-E-06 & 10-E-52 cooled in primary Q.W. coolers (10- E-40 A/B) and goes to Q.T. as primary Q.W. Quench water from 10-E-02 A/ B goes to propane feed / recycle vaporiser 10-E-04 and then cooled in sec- ondary quench water coolers 10-E-41 A/B/C and sént to quench tower as secondary quench water. Isolation valves are provided in the Q.W. side of E- 40 A/B and E-41 A/B/C for on-line cleaning purpose. PH meter AI 3401 tapping has been taken from C-40 bottom line to 10-V-40. -76-In initial start up as there is no flow through 10-E-120 A/B, a differential press of 1.5 kg/cm?g is maintained between inlet and outlet of 10-E-120 A/B by PDIC 3401. Similarly a differential press of 1.5 kg/cm?g is maintained across 10-E-06, 10-E-07. 10-E-52 inlet and outlet and by PDIC 3402. The O/ L temperature of Q.W. From 10-E-42 is controlled by TIC 3407 which in- creases or decreases the steam flow to 10-E-42 as per requirement. The pri- mary and Secondary flow to the Q.T. is controlled by FIC 3402 & FIC 3401. The temperature of primary Q.W. is controlled by FIC 3407 which bypasses required amount Q.W. across 10-E-40 A/B. To load the Q.T. in case of low through put required amount of C.G. is recycled and the flow is controlled by FIC 3403. In case of C.G.Machine trip this C/V gets shut and it has to be manually reset in the field. The quench tower pressure is controlled by PIC 3403 which dumps to wet flare. PIC 3403 function as a split range controller and operates two control valves. PV 3403/1 and PV 3403/2 at different output range. PV 3403/1 oper- ates between 4 mA to 12 mA signal and PV 3403/2 operates between 12 mA to 20 mA signal. To avoid creation of vacuum because of sudden depressurisation, a vacuum breaker control is given through PIC 3404 which admits fuel gas to tower. To maintain the PH of Q. Water a provision is given for ammonia injection to the bottom to tower. Nine safety valves (PSV 3401/ A to 1) set at 3.5 kg/em? are installed on column overhead and discharges to wet flare. 3.3. NORMAL OPERATION : Innormal operation with full throughput, two of the three quench water pumps will be running to quench the cracked gases and condensed out most of the steam coming with heater effluent hydrocarbon steam. The bulk of the quench- ing is done in the bottom section (trays 10 to 18) of the tower, Where most of the condensation takes place. At full through put operation the final cooling, to approximately 40°C is achieved in the top section. (trays 1 to 9). At low through put (two furnaces load) during plant start up, the bottom section of the tower will not contribute significantly, since the contacting 11+