Department DH Process

Mentee Nguyen Thanh Dat

DAILY REPORT Mentor
Date
Tran Minh Vuong
04/01/2021
Sheet 1/9
Study Content
UTILITIES

Unit 1100: Steam/ Condensate/ BFW System

1. Process description & Process flow

1.1. Steam
- Following steam headers shall deliver steam o the plant at the following conditions:

Steam Pressure (approx.), kg/cm2g Temperature ,oC

HP steam 44.8 380

MP steam 12.5 270

LP steam 3.4 160

- The Steam System consists of the following systems:

+ DH steam Generation
+ Cracking Furnace Steam Generation H-6601
+ HP Steam distribution system
+ MP Steam distribution system
+ LP Steam distribution system

HP Steam Header

- The main consumers of HP Steam include:

+ Cracked Gas Compressor Turbine J-6801
+ Drier Regeneration Gas Heater E-6807
+ Drier Regeneration Gas Heater E-6304

MP Steam Header

- The incoming steam pressure and temperature is reduced from 44.8 kg/cm2g and 380oC to 12.5
kg/cm2g and 270oC. The de-superheating is carried out by BFW injection at 115oC.
- The main consumers of MP Steam include:
+ DH Reaction Section Unit 6000
 Department DH Process
Mentee Nguyen Thanh Dat
DAILY REPORT Mentor
Date
Tran Minh Vuong
04/01/2021
Sheet 2/9
Study Content
+ Cracking Furnace Unit 6600
+ Wet Air Oxidation Unit

LP Steam Header

- The main consumers of LP Steam (LS) include:

+ Depropanizer Reboiler E-6204A/B
+ Methanol Vaporizer E-1752
+ Deethanizer Reboiler E-6501A/B
+ C4 plus Evaporator E-6206
+ C3+ Hydrogenation Heater E-6506
+ To Wet Air Oxidation Unit
+ To Flare Gas Unit 1700
+ Process Water Stripper T-6702
+ Dryer Evaporator E-6202 ( discontinuous )
+ C2 Hydrogenation Heater E-6910 (discontinuous )
+ Steam tracing, flare system, utility stations
1.2. Condensate System
- Most condensates are collected in separate condensate collection systems, corresponding to the
respective steam pressure. Most condensates are from LP-Steam consumers and collected in the
Condensate Drum D-1151. The condensate from the HP-Steam consumers are collected in the
LP-Condensate Drum D-1154. The blow down from the furnace Steam Drum D-6601 is
collected in the Blow Down Drum I D-1152.

Condensate Collector LP-Condensate Drum D-1134

- The LP-Condensate is collected in LP-condensate header and is routed to D-1134:

+ Drier Regeneration Gas Heater E-6807
+ Drier Regen Gas Heater E-6304

Condensate Drum D-1131

- LP Condensate:
+ Methanol Vaporizer E-1752
+ Dryer Evaporator E-6202
+ Depropanizer Reboiler E-6204A/B
 Department DH Process
Mentee Nguyen Thanh Dat
DAILY REPORT Mentor
Date
Tran Minh Vuong
04/01/2021
Sheet 3/9
Study Content
+ C4+ Evaporator E-6206
+ Deethanizer Reboiler E-6501A/B
+ Condensate from all steam facilities for flushing of equipment/piping
- Cold LP Condensate:
+ C2 Hydrogenation Heater E-6910
+ C3+ Hydrogenation Heater E-6505
- The streams from the above mentioned header along with the condensate from LP Condensate
Drum D-1154 are fed into the D-1151.
- The flash steam of D-1151 is routed to the Condensate Drum Condenser E-1151 A/B where it
is condensed against cooling water and routed back to Condensate Drum D-1151.

Blow Down Drum I D-1152

- Blow down from Steam Drum D-6601 is fed to Blow down Drum I D-1152. The stream is
expanded into the vessel and the flashed steam is sent to LP steam header. That level of vessel
is controlled by LIC11603.

Blow Down Drum D-1153

- Flash steam from the 2-phase stream fed into the vessel is sent to atmosphere and blow down
condensate is sent to battery limit. The condensate is routed to open ditch by gravity and
collected in drainage system.
1.3. Boiler Feed Water System
- Boiler Feed Water is import from OSBL and is used for steam generation, de-superheating in
let-down stations and several tie-ins in the plant where injection of BFW is required.
- Consumers include:
+ Steam generation section of the DH plant
+ Cracking furnace for HP steam generation
+ Injection into the LD Station HP-MP, PK-1152 A/B
+ Injection into the LD Station MP-LP, PK-1153 A/B
+ To Quench Tower T-6701
- Cooled boiler feed water is required for some consumers below:
+ Cracked Gas Compressor C-6801, injection for cooling
+ Cracker Caustic Scrubber II, T-6802 top feed ti back-washing trays
+ DH Caustic Scrubber, T-6301 top feed to back-washing trays.
 Department DH Process
Mentee Nguyen Thanh Dat
DAILY REPORT Mentor
Date
Tran Minh Vuong
04/01/2021
Sheet 4/9
Study Content
Unit 1200: Cooling Water System
1. Cooling Water System
- Temperature of cooled water: approx. 35oC is supplied from B.L and distributed to the
different consumers from the cooling water supply header in the DH and Side Cracker plant.
- Main consumers of cooling water:
+ Dryer Regen Condenser E-6203
+ Depropanizer Condenser E-6205A/B
+ Effluent Compressor Intercooler E-6301A/B
+ Drier Regen Gas Cooler E-6305
+ PSA Feed Compressor Interstage Cooler E-6415A/B
+ PSA Feed Compressor Aftercooler E-6416A/B
+ PSA tail gas Compressor Aftercooler E-6418
+ Deethanizer Condenser E-6502A/B
+ Propylene Condenser E-6505
+ Wash water Cooler E-6702A/B
+ Process water Blowdown Cooler E-6703
+ CGC 1st Stage Intercooler E-6801
+ CGC 2nd Stage Intercooler E-6802
+ CGC 3rd Stage Intercooler E-6803
+ CGC 4th Stage Intercooler E-6804
+ Regeneration Gas Cooler E-6808\
+ Methanol Condenser E-6911
+ Ethylene Cooler 3rd Stage I, E-6915
+ Condensate Drum Condenser E-1151A/B
+ BFW Cooler E-1132
+ E-6002 A-D in DH Reaction Section
+ To Wet Oxidation Unit
- For throttling the cooling water inlet flow to exchangers, hand control valve will be used.
Cooling water is warmed up to max. 43oC
- Additionally, in start-up mode: chemicals is required for reason below:
+ Removing microorganism
+ Surface passivation
+ Cleaning pipes.
 Department DH Process
Mentee Nguyen Thanh Dat
DAILY REPORT Mentor
Date
Tran Minh Vuong
04/01/2021
Sheet 5/9
Study Content
Unit 1300: Plant Water System
1. Treated Boiler Water
- Treated Boiler Water is obtained from BL and distributed inside the DH and Side Cracker plant
via Treated Boiler Water headers to the consumers.
- The pressure of the treated boiler water from B.L is indicated by PI13103 and locally by
PG13104. And the temperature is indicated by TI13102. The Flow of treated boiler feed water
is indicated by FI13101A.
2. Domestic Water
- Domestic Water is obtained from BL and distributed inside the DH and Side Cracker plant via
the domestic water header to the consumers.
- The pressure of the domestic water from battery limit is indicated by PI13203 equipped with
low alarm and locally by PG13204.
Unit 1500: Nitrogen System
- Nitrogen is really important for operation. Especially, when the plant is start-up  Nitrogen is
required.
- Nitrogen is mainly used for:
+ Inertizing, purging or blanketing equipment
+ As backup seal gas for the compressors
+ As regeneration gas for start-up
Unit 1600: Plant-/Instrument-/Decoking Air System

Plant Air System

- Plant Air is used in consumers below:

+ T-6101: Catalyst Regeneration
+ Wet Air Oxidation
- Pressure of the plant air from B.L is indicated by PI16204. The flow of plant air is indicated by
FI16201A and the total flow by FQI16201B.

Instrument Air System

- Instrument Air is produced from the plant air system for controlling. Instrument air must be dry
and free of oil and other contaminations to protect the sensitive equipment consuming
instrument air. Two filter are installed at battery limit to remove any possible dust or particles.
One is in operation and one in standby.
 Department DH Process
Mentee Nguyen Thanh Dat
DAILY REPORT Mentor
Date
Tran Minh Vuong
04/01/2021
Sheet 6/9
Study Content
Decoking Air System

- Decoking of the furnace is required periodically to remove carbonaceous deposits from

cracking coils and quench exchangers. These deposits result from chemical reactions of
reactive compounds in the cracked gas such as acetylenes, dienes, olefins and aromatics.
Periodic removal of coke deposits is required to operate within design temperature and allowed
maximum process pressure drop.
Unit 1700: Flare Blowdown and Slop System
- The purpose of the blow down system is to collect all combustible gases and liquids which are
discharged in case of emergencies, malfunctions, maintenance, start-up and shutdown or plant
upsets. These are then routed to the proicess flare for controlled and safe combustion. The flare
itself is OSBL.
- The blow-down system consists of the following:
+ Warm collecting system
+ Cold collecting system
+ Methanol Vaporization system

Warm Flare System

- The warm flare system is designed to receive all warm and wet gases and liquids within the
Dehydrogenation and Side Cracker. It consists of one common header system for gases and
liquids, a Warm Blow Down Drum D-1751, the main header to the flare area, and Flare Gas
Condensate Pump P-1751A/B.
- The flare gas and flare liquids with temperature above 0°C from different process units of the
Dehydrogenation and Side Cracker are routed via flare header to the Warm Blow Down Drum
D-1751.
- The vapor phase passes up into the main Header and the liquids carried by warm flare gas and
warm flare liquid are knocked out and collected in the warm Blow Down Drum D-1751. The
liquids from Warm Blow Down Drum D-1751 are routed to truck via the Flare Gas Condensate
Pump P-1751 A/B.
- During normal operation of Ethylene Plant, none of the Flare Gas Condensate Pump is in
service, both pumps are in stand-by mode. For maintenance purposes the pumps can be drained
to truck using nitrogen purge.

Cold Flare System

 Department DH Process
Mentee Nguyen Thanh Dat
DAILY REPORT Mentor
Date
Tran Minh Vuong
04/01/2021
Sheet 7/9
Study Content
- The cold flare system is designed to receive all cold and dry gases and liquids within the
Dehydrogenation and side cracker. It consists of a cold gas flare header, a cold liquid flare
header the Dry Blow Down Drum D-1752 with an integrated heating vaporization coil, the
Cold Flare Liquid Vaporizer E-1751 and the Methanol vaporizer E-1752.
- The Cold Flare Gas System is designed to collect relieved streams from pressure controllers
and safety relief valves. The Cold Liquid Flare System is designed to collect liquids from drains
and thermal relief valves.
- Cold liquids and gases, with temperatures below 0°C after expansion to flare system pressure
from the different process units, are collected in separate headers and directed to Cold Blow
Down Drum D-1752. The Blow Down Drum D-1752 is designed to separate the liquid droplets
from the gas flow.
- The liquid collected in Cold Blow Down Drum D-1752 is evaporated against condensing
methanol vapor by integrated Cold Flare Liquid Vaporizer E-1751. The cold liquid which is
collected in D-1752 below the integrated Cold Flare Liquid Vaporizer E-1751, will also be
warmed up and partly vaporized against condensing methanol by additional heating coils which
are installed in the lower part of Cold Blow Down Drum D-1752. The resulting gas escapes to
the flare gas line, whereas the liquid which cannot be evaporated is collected in the boot of
Cold Blow Down Drum D-1752.

Methanol Vaporization System

- Methanol from the methanol system is evaporated in Methanol Vaporizer E-1752 by

condensing LP-steam. The condensate from E-1752 is routed to the LP Condensate system via
steam trap. Pressure and temperature of the methanol vapor depend on the saturation
temperature of the LP-steam. The tube pressure in the methanol vaporizer will be kept by
parallel steam traps.
- The methanol vapor consumers are heating coil in the bottom of the Cold Blow Down Drum D-
1752 and the Cold Liquid Vaporizer E-1751 in which methanol is condensed by vaporizing and
superheating the cold flare liquid. The condensed methanol flows back again to the methanol
vaporizer E-1752 in natural circulation.

Slop System
 Department DH Process
Mentee Nguyen Thanh Dat
DAILY REPORT Mentor
Date
Tran Minh Vuong
04/01/2021
Sheet 8/9
Study Content
- The purpose of the Slop System is to collect liquid hydrocarbons/Caustic from all the
equipment which are taken out of operation and need to be drained for cleaning / maintenance
purpose during normal or during plant shutdown scenario. The various slop systems are:
+ Wash Water and Hydrocarbon Slop system
+ Cracker Caustic Slop system
+ DH Caustic Slop system

Wash Water and Hydrocarbon Slop System

- The Wash Water and Hydrocarbon Slop Drum D-1753 is used for draining of liquid
hydrocarbon and wash water from various units of the Side Cracker. Residues are collected in a
common Header and then routed via gravity to Wash Water and Hydrocarbon Slop Drum D-
1753.
- Normally the liquid collected in Wash Water and Hydrocarbon Slop Drum D-1753 is routed to
the Warm Flare System by using nitrogen purge.

Cracker Caustic Slop System

- The Cracker Caustic Slop Drum D-1754 serves for drainage of caustic contaminated liquids
from the cracker caustic scrubbing and spent caustic treatment systems of the Side Cracker.
- The Cracker Caustic Slop Drum D-1754 serves for drainage of caustic contaminated liquids
from the cracker caustic scrubbing and spent caustic treatment systems of the Side Cracker.

DH Caustic Slop System

- The DH Caustic Slop Drum D-1755 serves for drainage of caustic contaminated liquids from
the DH caustic scrubbing and spent caustic treatment systems of the Dehydrogenation section.
- The liquid from DH Caustic Slop Drum D-1755 is routed to Spent Caustic Tank which is part
of the Wet Air Oxidation Package Unit by using nitrogen purge.
 Department DH Process
Mentee Nguyen Thanh Dat
DAILY REPORT Mentor
Date
Tran Minh Vuong
04/01/2021
Sheet 9/9
Feedback (Questions, Requirements, Opinion, Etc.)